H868
Operating Manual
All rights reserved.
Property of Dürkopp Adler AG and protected by copyright. Any reuse
of these contents, including extracts, is prohibited without the prior
written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG - 2013
Table of contents
Operating manual H868 Version 00.0 - 07/2013 1
1 About this manual...............................................................................3
1.1 Area of applicability ...............................................................................3
1.2 Target group..........................................................................................3
1.3 Symbols and characters used...............................................................4
1.4 Other documents...................................................................................4
1.5 Liability...................................................................................................5
1.6 Transportation .......................................................................................5
1.7 Intended use..........................................................................................5
2 Performance description....................................................................7
2.1 Features ................................................................................................7
2.2 Declaration of conformity (CE) ..............................................................8
2.3 Additional equipment.............................................................................8
2.4 Technical data.......................................................................................9
3 Safety instructions............................................................................11
3.1 Basic safety instructions......................................................................11
3.2 Signal words and symbols used in warnings.......................................12
4 Device description.............................................................................15
5 Operation............................................................................................17
5.1 Switching the power supply on and off................................................17
5.2 Inserting and replacing the needle ......................................................18
5.3 Threading in the needle thread............................................................19
5.4 Inserting and winding on the hook thread............................................22
5.5 Replacing the hook thread bobbin.......................................................25
5.6 Adjusting the thread tension................................................................26
5.6.1 Adjusting the needle thread tension....................................................27
5.6.2 Adjusting the hook thread tension.......................................................28
5.7 Setting the thread regulator.................................................................29
5.8 Lifting the sewing feet..........................................................................30
5.9 Locking the sewing feet in the upper position......................................30
5.10 Sewing foot pressure...........................................................................31
5.11 Sewing foot stroke...............................................................................32
5.12 Stitch length.........................................................................................34
5.13 Setting quick functions at the keypad..................................................36
5.14 Sewing.................................................................................................39
5.15 Maintenance........................................................................................40
5.15.1 Cleaning the machine..........................................................................41
5.15.2 Checking the oil level...........................................................................42
5.15.3 Checking the pneumatic system..........................................................44
5.16 Customer service.................................................................................46
6 Set-up .................................................................................................47
Table of contents
Operating manual H868 Version 00.0 - 07/20132
6.1 Checking the scope of delivery............................................................47
6.2 Removing the transport securing devices ...........................................49
6.3 Fitting the frame components..............................................................49
6.4 Fitting the pedal...................................................................................50
6.5 Completing the table plate...................................................................50
6.6 Fastening the table plate to the frame.................................................52
6.7 Fitting the controller.............................................................................53
6.8 Fitting the setpoint device....................................................................54
6.9 Inserting the machine upper section....................................................55
6.10 Fitting the oil extraction line.................................................................56
6.11 Fitting the knee lever...........................................................................57
6.11.1 Fitting the electric knee lever...............................................................57
6.11.2 Fitting the mechanical knee lever........................................................58
6.12 Fitting the control panel.......................................................................59
6.13 Electrical connection............................................................................61
6.13.1 Fitting the sewing lamp........................................................................61
6.13.2 Fitting and connecting the sewing lamp transformer...........................62
6.13.3 Connecting the direct drive..................................................................64
6.14 Pneumatic connection.........................................................................64
6.14.1 Fitting the maintenance unit ................................................................64
6.14.2 Setting the operating pressure ............................................................66
6.15 Lubrication...........................................................................................67
6.16 Sewing test..........................................................................................69
7 Decommissioning..............................................................................71
8 Disposal..............................................................................................73
9 Appendix............................................................................................75
About this manual
Operating manual H868 Version 00.0 - 07/2013 3
1 About this manual
This operating manual for the special sewing machine H868 was
compiled with the utmost care. It contains information and notes
in order to make long-term and reliable operation possible.
Should you notice any discrepancies or if you have improvement
requests, then we would be glad to receive your feedback,
Section 5.16 Customer service.
Please regard the operating manual as part of the product and
keep it in a safe place where it can be easily accessed. Read the
operating manual completely prior to using the unit for the first
time. Only pass the product on to third parties together with the
operating manual.
1.1 Area of applicability
This manual describes the intended use and the set-up of the
special sewing machine H868.
1.2 Target group
The operating manual is intended for:
• Operating personnel:
This group of employees has been trained in operating the
machine and can access the operating manual. Specifically
Section 5 Operation is important for this group of
employees.
• Specialized staff:
This group of employees has the appropriate technical training
allowing them to perform maintenance on the sewing unit or to
repair faults. Specifically Section 6 Set-up is important for
this specialized staff. Service instructions are supplied
separately.
With regard to minimum qualification and other requirements to
be met by the personnel, please also observe Section 3 Safety
instructions.
About this manual
Operating manual H868 Version 00.0 - 07/20134
1.3 Symbols and characters used
Different information is depicted or highlighted in this operating
manual by the following characters for easier and quicker
understanding:
Safety Important warnings for the user of the sewing machine are
specifically marked. Because safety constitutes an area of major
importance, hazard symbols, levels of risk, and their signal words
are described separately in Section 3 Safety instructions.
Location
information
Information on where something is positioned using the terms
"right" or "left" must always be regarded from the operator's
point of view if the figure gives no other obvious indication for
determining the location.
1.4 Other documents
The device contains built-in components from other manufactur-
ers. The respective manufacturers have carried out hazard as-
sessments for these purchased parts and confirmed compliance
of the design with the applicable European and national regula-
tions. The intended use of the built-in components is described in
the corresponding manuals of the manufacturers.
Symbol/character Meaning
• Lists are identified by bullet points.
1.
2.
Instructions are numbered and have to
be performed in the specified order.
References to further information in this
operating manual or other documents
are identified by this symbol.
About this manual
Operating manual H868 Version 00.0 - 07/2013 5
1.5 Liability
All information and notes in this operating manual have been
compiled in accordance with the latest technology and the
applicable standards and regulations.
The manufacturer accepts no liability for any damage due to:
• Breakage and transport
• Failure to observe the operating manual
• Improper use
• Unauthorized modifications to the machine
• The deployment of untrained personnel
• Using spare parts not approved
1.6 Transportation
Dürkopp Adler cannot be held liable for any damage during
transport. Check the delivered product immediately after receiving
it. Report any damage to the last transport manager. This also
applies if the packaging is not damaged.
Keep the machines, devices, and packaging material in the
condition they were at the time the damage was identified. That
secures any claims towards the transport company.
Report all other complaints to Dürkopp Adler immediately after
receiving the product.
1.7 Intended use
The Dürkopp Adler H868 is for intended for sewing moderately
heavy to heavy material. Moderately heavy material requires
needles strengths of 140 – 180 Nm, heavy material requires
needles strengths of 180 - 250 Nm.
The machine is only intended for processing dry material.
The material must contain no hard objects.
The sewing machine is intended for industrial use.
The machine may only be set up and operated in dry conditions
on well-maintained premises. If the machine is operated on
premises that are not dry and well-maintained, then further
measures may be required which must be compatible with
EN 60204-31:1999.
Only authorized/trained persons may work on the machine.
About this manual
Operating manual H868 Version 00.0 - 07/20136
The manufacturer will not be held liable for damage resulting from
improper use.
Danger due to high voltage, crushing and sharp
objects.
Improper use can result in injuries.
Please follow all instructions in the manual.
WARNING
Improper use could result in material damage.
Please follow all instructions in the manual.
ATTENTION
Performance description
Operating manual H868 Version 00.0 - 07/2013 7
2 Performance description
The Dürkopp Adler special sewing machine H868 is equipped with
an extra-large 3XL hook with a 40 mm bobbin diameter.
The clearance under the sewing feet when lifted is max. 25 mm.
The subclasses have a DC drive with a reversing mechanism,
required in order to position the needle above the feet.
The special sewing machine positions the needle at the end of
the seam and has an electropneumatic foot lifter above the sewing
pedal.
A safety snap-on coupling prevents any misadjustment or damage
to the hook in the event of a thread jamming.
Automatic wick lubrication with an oil level indicator at the column
eases lubrication of the machine and hook.
The special sewing machine is equipped with a 6-key keypad. An
additional switch is located in easy reach of the sewer and can be
assigned 6 functions.
Possible operating functions:
• Manual sewing in reverse
• Needle up / down
• Call up the start or end strip or bartack suppression
• Second stitch length
• Switchable thread tension
• Lower the middle stop
2.1 Features
Upper part of the machine
• Single-needle column double lockstitch version
• Double-needle column double lockstitch version
Performance description
Operating manual H868 Version 00.0 - 07/20138
2.2 Declaration of conformity (CE)
The machine complies with the European regulations specified in
the declaration of conformity or in the installation declaration.
2.3 Additional equipment
A flexible system of additional equipment allows optimal, low-cost
equipping of the special sewing machine to suit the respective
application.
= Standard equipment
= Optional expansion
Order number Additional equipment
H868-
190361
H868-
290361
0868 590014 Residual-thread monitor for the hook thread, 3XL
hook, 1-needle machines
0868 590024 Residual-thread monitor for the hook thread, 3XL
hook, 2-needle machines
0867 490010 Operating panel bracket
9822 510003 Halogen sewing lamp for upper sewing machine
section
9880 867100 Sewing lamp attachment set
0798 500088 Sewing lamp transformer for halogen sewing
lamp
9880 867103 1-diode sewing lamp with attachments
9880 867118 Integrated diode sewing lamp
9850 001089 Power supply unit for integrated sewing lamp and
1-diode sewing lamp
0797 003031 Pneumatic connection package for connecting
frames with maintenance unit
N800 080007 Rollers and straight stop
Performance description
Operating manual H868 Version 00.0 - 07/2013 9
2.4 Technical data
N800 080033 Swiveling end stop, with stop, roller and seam
middle guide
N800 005650 Seam center guide from front, pneumatically
switched
9835 901005 Memo dongle, external memory, for data
transmission with DA Classic control
0867 590984 Thread clamp with thread wiper function (FK kit)
9081 300001 Tool set for M-type
0867 590684 Electronic handwheel
MG55 400364 Frame set for motor, attached to the upper
section, table plate 1060 x 600 mm with pedal
(MG 55-3)
Order number Additional equipment
H868-
190361
H868-
290361
Technical data
H868-
190361
H868-
290361
Length/width/height [mm] 650/280/690
Weight without/with direct drive [kg] 72 74
stitch type Lockstitch 301
Hook type Vertical, oversize (3XL)
Number of needles 1 2
Needle system 328 (794 and 7x23 are possible
after conversion)
Maximum needle strength [Nm] 250
Sewing thread thickness 8/3, braided thread 1.2 mm
Stitch length, forwards / backwards [mm] 12 / 12
Number of adjustable stitch lengths 2
Maximum number of stitches 1800
Performance description
Operating manual H868 Version 00.0 - 07/201310
Number of stitches on delivery 1600
Stitch quantity reduction for stitch lengths of 6 – 12 mm 1200
Stitch quantity reduction for strokes of
1 – 3 mm
1800
Reduction of the number of stitches with stroke exceeding
4 mm
1500
Reduction of the number of stitches with stroke exceeding
6 mm
1200
Reduction of the number of stitches with stroke exceeding
9 mm
1000
Maximum stroke height (only with reversing mechanism) 25
Maximum sewing foot stroke 9
Positive operating pressure [bar] 6
Air consumption [NL] 0.7
Rated voltage [V/Hz] 1x230 V - 50/60 Hz
Rated power [kVA] 375 W
Technical data
H868-
190361
H868-
290361
Safety instructions
Operating manual H868 Version 00.0 - 07/2013 11
3 Safety instructions
This section contains basic instructions for your safety. Read the
instructions carefully before setting up, programming, maintaining,
or operating the machine. Make sure to follow the information
included in the safety instructions. Failure to do this can result in
serious injury and damage to the machine.
3.1 Basic safety instructions
The machine may only be used as described in this manual.
The operating manual must be available at the machine's location
at all times.
Work on live components and equipment is prohibited. Exceptions
are defined in the specifications in DIN VDE 0105.
For the following work, the machine must be disconnected from
the power supply using the main switch or by disconnecting the
power plug:
Replacing the needle or other sewing tools
Leaving the workplace
Performing maintenance work and repairs
Incorrect or faulty spare parts can impair safety
and damage the machine. Therefore only use original spare parts
from the manufacturer.
Feed Use a sturdy lifting carriage or forklift for transporting the machine.
Raise the machine max. 20 mm and secure it against slipping off.
Set-up The connecting cable must have a power plug approved in the
specific country. The power plug may only be connected to the
power cable by a qualified specialist.
Operator's
obligations
Observe the country specific safety and accident prevention
regulations and the legal regulations concerning industrial safety
and the protection of the environment.
All warnings and safety signs on the machine must always be in
legible condition and may not be removed. Missing or damaged
labels must be replaced immediately.
Safety instructions
Operating manual H868 Version 00.0 - 07/201312
Requirements to
be met by the
personnel
The machine may only be set up by qualified specialists.
Maintenance work and repairs may only be carried out by qualified
specialists.
Work on electrical equipment may only be carried out by qualified
specialists.
Only authorized persons may work on the machine. Every person
who works on the machine must have read the operating manual
first.
Operation Inspect the machine while in use for any externally visible damage.
Interrupt your work if you notice any changes to the machine.
Report any changes to your supervisor. A damaged machine may
not be used any more.
Safety
equipment
Safety equipment may not be removed or put out of service. If this
cannot be avoided for a repair operation, the safety equipment
must be refitted and put back into service immediately afterwards.
3.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color
scheme is oriented towards the severity of the danger. Signal
words specify the severity of a danger:
Signal words Signal words and the endangerment that they describe:
Symbols In the case of dangers to personnel, the following symbols indicate
the type of hazard:
Signal word Endangerment
DANGER Resulting in death or serious injury.
WARNING Death or serious injury possible.
CAUTION Moderate to minor injuries possible.
ATTENTION Damage possible.
Symbol Type of danger
General danger
Safety instructions
Operating manual H868 Version 00.0 - 07/2013 13
Examples Examples of the layout of the safety instructions in the text:
Danger due to electric shock
Danger due to sharp objects
Danger due to crushing
Symbol Type of danger
Type and source of the danger
Consequences in the event of noncompliance
Measures for avoiding the danger
This is what a hazard note looks like for a hazard
that will result in serious injury or even death if not
complied with.
DANGER
Type and source of the danger
Consequences in the event of noncompliance
Measures for avoiding the danger
This is what a hazard note looks like for a hazard
that could result in serious injury or even death if
not complied with.
WARNING
Type and source of the danger
Consequences in the event of noncompliance
Measures for avoiding the danger
This is what a hazard note looks like for a hazard
that could result in moderate or minor injury if not
complied with.
CAUTION
Safety instructions
Operating manual H868 Version 00.0 - 07/201314
Type and source of the danger
Consequences in the event of noncompliance
Measures for avoiding the danger
This is what a hazard note looks like for a hazard that
could result in material damage if not complied with.
ATTENTION
Type and source of the danger
Consequences in the event of noncompliance
Measures for avoiding the danger
This is what an hazard note looks like for a hazard
that could result in environmental damage if not
complied with.
ATTENTION
Device description
Operating manual H868 Version 00.0 - 07/2013 15
4 Device description
Figure 1: Product overview
(1) - Unwinding bracket with thread
reel holder
(2) - Handwheel
(3) - Bobbin winder for the hook
thread
(4) - Oil level indicator
(5) - Adjusting wheels for the stitch
length
(6) - Stitch adjustment lever
(7) - Hook
(8) - Sewing foot with needle
(9) - Keypad on the machine arm
(10) - Thread tensions
(11) - Adjusting wheel for the sewing
foot pressure
(12) - Adjusting wheels for the
sewing foot stroke
2
3
4
5
6
7
8
9
10
11
12
1
Device description
Operating manual H868 Version 00.0 - 07/201316
Operation
Operating manual H868 Version 00.0 - 07/2013 17
5 Operation
5.1 Switching the power supply on and off
The lower main switch (2) on the control regulates the power
supply.
Figure 2: Switching the power supply on and off
To switch on the power:
• Press the main switch (2) down to position I.
The indicator lamps (3) and (4) light up.
To switch off the power:
• Press the main switch (2) up to position 0.
The indicator lamps (3) and (4) go out.
(1) - Switch for the sewing lamp
(2) - Main power supply switch
(3) - Indicator lamp on the controller
(4) - Indicator lamp on the keypad for quick functions
4
1
3
2
Operation
Operating manual H868 Version 00.0 - 07/201318
5.2 Inserting and replacing the needle
Figure 3: Inserting and replacing the needle
1. Turn the handwheel back until the needle bar (1) reaches the
upper end position.
2. Loosen the needle screw (2).
3. Pull the needle out towards the bottom.
4. Insert the new needle.
5. Align the needle in such a way that the groove (4) faces the
hook (3).
6. Tighten the needle screw (2).
2-needle
machines
Note on 2-needle machines:
The procedure for the second needle of 2-needle machines is
identical.
• Align the needles in such a way that the grooves face away
from each other. Each groove then faces the hook that
belongs to this needle.
Risk of injury by the needle point and moving
parts
Switch off the sewing machine before replacing the
needle.
Do not touch the needle point.
WARNING
(1) - Needle bar
(2) - Needle screw
(3) - Hook
(4) - Groove
1
3
2
4
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