Duerkopp Adler 756 A User manual

755 A / 756 A

Service Instructions

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.

IMPORTANT

READ CAREFULLY BEFORE USE

KEEP FOR FUTURE REFERENCE

Table of Contents

Service Instructions 755 A/756 A - 00.0 - 02/2019 1

1 About these instructions ........................................................... 7

1.1 For whom are these instructions intended?.................................. 7

1.2 Representation conventions – symbols and characters ............... 7

1.3 Other documents .......................................................................... 9

1.4 Liability.......................................................................................... 9

2 Safety......................................................................................... 11

2.1 Basic safety instructions ............................................................. 11

2.2 Signal words and symbols used in warnings.............................. 12

3 Working basis ........................................................................... 15

3.1 Gages ......................................................................................... 15

3.2 Locking the machine in place ..................................................... 15

3.3 Swiveling up the machine head.................................................. 16

3.4 Swiveling down the machine head ............................................. 18

3.5 Setting the handwheel scale....................................................... 20

4 Aligning the machine head...................................................... 21

5 Disassembling and assembling the machine head............... 25

5.1 Disassembling the machine head............................................... 25

5.2 Assembling machine head ......................................................... 26

6 Needle bar ................................................................................. 28

6.1 Non-switchable needle bar (class 755)....................................... 28

6.1.1 Aligning the needle bar with the throat plate .............................. 28

6.1.2 Setting the needle bar height...................................................... 32

6.1.3 Changing the needle holder ....................................................... 34

6.1.4 Disassembling the needle bar linkage........................................ 35

6.1.5 Assembling the needle bar linkage............................................. 37

6.2 Switchable needle bar (class 756).............................................. 40

6.2.1 Aligning the needle bars with the throat plate............................. 40

6.2.2 Setting the needle bar height...................................................... 43

6.2.3 Changing the needle holder ....................................................... 44

6.2.4 Disassembling the needle bar linkage........................................ 45

6.2.5 Assembling the needle bar linkage............................................. 48

6.2.6 Disassembling the needle bar linkage........................................ 54

6.2.7 Assembling the needle bar linkage............................................. 58

6.3 Setting the needle transport ....................................................... 62

7 Hook........................................................................................... 64

7.1 Changing the hook ..................................................................... 64

7.2 Setting the loop stroke................................................................ 65

7.3 Setting the distance between hook tips and needles ................. 67

7.4 Setting the needle guard ............................................................ 69

7.5 Setting the bobbin case lifter ...................................................... 71

7.5.1 Setting the timing for opening..................................................... 72

7.5.2 Setting the lifting gap .................................................................. 74

8 Setting the safety clutch .......................................................... 75

8.1 Engaging the safety clutch ......................................................... 75

8.2 Setting the torque ....................................................................... 76

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2 Service Instructions 755 A/756 A - 00.0 - 02/2019

9 Setting the remaining thread monitor..................................... 77

10 Middle knife............................................................................... 78

10.1 Changing the drive motor ........................................................... 78

10.1.1 Disassembling the drive motor ................................................... 78

10.1.2 Assembling the drive motor ........................................................ 80

10.2 Setting the middle knife .............................................................. 81

11 Setting the thread tension spring ........................................... 84

12 Setting the trimming and clamping device

for the needle threads .............................................................. 85

12.1 Testing the function of the trimming and clamping device

for the needle threads................................................................. 86

12.2 Replacing knives and thread-pulling knife .................................. 87

12.3 Setting the thread-pulling knife to a different needle distance.... 90

12.4 Converting the trimming and clamping device............................ 91

13 Setting the trimming and clamping device

for the hook threads................................................................. 92

13.1 Changing the knives ................................................................... 93

13.2 Setting the height of the hook thread trimmer ............................ 94

13.3 Testing the hook thread trimmer................................................. 95

14 Needle thread advancing device............................................. 96

14.1 Adjusting the needle thread quantity .......................................... 96

14.2 Setting the movement of the needle thread advancing device... 97

15 Changing the sewing motor .................................................... 98

16 Setting the folding station plate............................................ 101

17 Folder....................................................................................... 103

17.1 Assembling the folder ............................................................... 103

17.2 Aligning the folder with the needles.......................................... 104

17.3 Aligning the folder with the middle of the pocket opening ........ 105

17.4 Setting the guide plates at the folder ........................................ 107

17.5 Setting the stroke movement for the folder............................... 109

17.6 Setting the folder detection....................................................... 113

18 Transport carriage.................................................................. 115

18.1 Setting the reference position of the transport carriage............ 115

18.2 Setting the front end position of the transport carriage............. 116

18.3 Changing the toothed belt ........................................................ 118

18.4 Setting the toothed belt tension ................................................ 120

19 Transport clamps ................................................................... 123

19.1 Setting the height of the transport clamps ................................ 124

19.2 Changing the transport clamps................................................. 125

19.3 Aligning the transport clamps with the sliding plate edge......... 126

19.4 Setting the distance of the transport clamps

to the folder sole ....................................................................... 127

19.4.1 Setting the distance of the transport clamps

to the folder sole (manually) ..................................................... 128

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Service Instructions 755 A/756 A - 00.0 - 02/2019 3

19.4.2 Setting the distance of the transport clamps to the folder

sole (motorized)........................................................................ 130

19.5 Setting the blowing of the piping strips ..................................... 132

19.6 Setting the transport clamp pressure........................................ 134

19.6.1 Setting the transport clamp pressure manually ........................ 134

19.6.2 Setting the programmable transport clamp pressure................ 135

19.7 Changing the toothed belt of the motorized transport clamp.... 135

20 Automatic corner knife station (straight pocket)................. 137

20.1 Adjusting the corner knives mechanically................................. 137

20.1.1 Setting the initial position of the corner knives ......................... 138

20.1.2 Testing the initial position of the corner knives manually.......... 139

20.2 Testing and adjusting the corner knives electrically ................. 142

20.3 Aligning the corner knife station with the seams....................... 145

20.4 Setting the angle of the corner knife incisions .......................... 146

20.5 Replacing corner knives ........................................................... 147

21 Automatic corner knife station (straight/slanted pocket)... 148

21.1 Adjusting the corner knives mechanically................................. 148

21.1.1 Setting the initial position of the corner knives ......................... 149

21.1.2 Setting the piercers................................................................... 150

21.1.3 Setting the corner knife inclination............................................ 151

21.1.4 Testing the initial position of the corner knives manually.......... 153

21.2 Testing and adjusting the corner knives electrically ................. 156

21.3 Aligning the corner knife station with the seams....................... 160

21.4 Setting the angle of the corner knife incisions .......................... 161

21.5 Replacing corner knives ........................................................... 162

22 Multi-functional corner knife station..................................... 163

22.1 Adjusting the corner knives manually ....................................... 163

22.1.1 Setting the initial position of the corner knives ......................... 164

22.1.2 Setting the piercers................................................................... 165

22.1.3 Setting the corner knife inclination............................................ 166

22.1.4 Testing the initial position of the corner knives manually.......... 167

22.2 Setting the speed and the end position damping

of the corner knives .................................................................. 171

22.2.1 Setting the speed...................................................................... 171

22.2.2 Setting the end position damping ............................................. 172

22.3 Testing and adjusting the corner knives electrically ................. 173

22.4 Aligning the corner knife station with the seams....................... 178

22.5 Setting the angle of the corner knife incisions .......................... 180

22.6 Replacing corner knives ........................................................... 181

22.7 Changing the reference switch on the corner knife support ..... 182

23 Marking lamps ........................................................................ 183

23.1 Setting the stationary marking lamps ....................................... 184

23.2 Setting the programmable marking lamp vertical (optional) ..... 185

24 Light barriers .......................................................................... 187

24.1 Setting the light barrier holder .................................................. 187

24.2 Aligning the light barriers .......................................................... 189

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4 Service Instructions 755 A/756 A - 00.0 - 02/2019

24.3 Setting the correction values for the flap .................................. 196

24.4 Aligning the air nozzles for cleaning the reflecting foils ............ 196

25 Assembling the vacuum unit (optional) ............................... 199

26 Endless zipper feed (optional)............................................... 201

26.1 Threading and activating the zipper ......................................... 201

26.2 Setting the guide rails at the folder ........................................... 204

26.3 Setting the lifting movement of the guide plates....................... 205

26.4 Zipper cutter ............................................................................. 207

26.4.1 Changing the knives ................................................................. 207

26.4.2 Setting the height of the zipper cutter....................................... 209

26.4.3 Setting the position of knife and counter blade......................... 210

26.4.4 Setting the swivel width ............................................................ 211

26.4.5 Setting the swivel speed of the zipper cutter ............................ 212

26.4.6 Setting the end position damping ............................................. 213

26.5 Driver zipper ............................................................................. 215

26.5.1 Setting the distance between the driver zipper

and the needles ........................................................................ 215

26.5.2 Setting the driver zipper limit .................................................... 217

26.5.3 Setting the speed of the driver zipper....................................... 218

26.6 Setting the folder height when the zipper is cut........................ 219

27 Additional equipment............................................................. 221

27.1 Setting the outfeed roller .......................................................... 221

27.2 Tape feeder .............................................................................. 223

27.2.1 Assembling the tape feeder and inserting

the reinforcement strip.............................................................. 223

27.2.2 Setting the height of the tape feeder ........................................ 226

27.2.3 Changing the knives ................................................................. 227

27.2.4 Changing the conveyor belt...................................................... 229

27.3 Setting the downholder............................................................. 232

27.4 Assembling the pocket bag clamp............................................ 235

28 Stacker..................................................................................... 237

28.1 Pincer stacker........................................................................... 237

28.1.1 Assembling the pincer stacker.................................................. 238

28.1.2 Setting the pincer stacker ......................................................... 241

28.1.3 Activating the pincer stacker..................................................... 242

28.2 Throw-over stacker................................................................... 243

28.2.1 Assembling the throw-over stacker........................................... 243

28.2.2 Aligning the throw-over stacker ................................................ 248

28.2.3 Activating the throw-over stacker ............................................. 250

28.2.4 Setting the stacking speed ....................................................... 250

28.2.5 Setting the stack removal ......................................................... 251

28.2.6 Setting the sewing material surface.......................................... 252

28.2.7 Setting the position of the stops ............................................... 253

28.3 Setting the stacker brackets ..................................................... 254

28.3.1 Replacing pneumatic cylinders, pneumatic valve

and coupling rods ..................................................................... 257

28.3.2 Setting the pneumatic switch.................................................... 263

29 Programming .......................................................................... 265

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Service Instructions 755 A/756 A - 00.0 - 02/2019 5

30 Maintenance............................................................................ 437

30.1 Cleaning ................................................................................... 438

30.2 Lubricating ................................................................................ 440

30.2.1 Lubricating the machine head .................................................. 441

30.2.2 Lubricating the hook ................................................................. 442

30.3 Servicing the pneumatic system............................................... 443

30.3.1 Setting the operating pressure ................................................. 443

30.3.2 Draining the water condensation .............................................. 444

30.3.3 Cleaning the filter element........................................................ 445

30.4 Parts list.................................................................................... 446

31 Decommissioning................................................................... 447

32 Disposal................................................................................... 449

33 Troubleshooting ..................................................................... 451

33.1 Customer Service ..................................................................... 451

33.2 Messages of the software......................................................... 451

34 Technical data......................................................................... 469

35 Appendix ................................................................................. 471

35.1 Wiring diagram ......................................................................... 471

35.2 Pneumatic diagram................................................................... 486

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6 Service Instructions 755 A/756 A - 00.0 - 02/2019

About these instructions

Service Instructions 755 A/756 A - 00.0 - 02/2019 7

1 About these instructions

These instructions have been prepared with utmost care. They contain

information and notes intended to ensure long-term and reliable operation.

Should you notice any discrepancies or if you have improvement requests,

then we would be glad to receive your feedback through Customer

Service ( p. 451).

Consider these instructions as part of the product and keep it easily

accessible.

1.1 For whom are these instructions intended?

These instructions are intended for:

• Specialists:

This group has the appropriate technical training for performing

maintenance or repairing malfunctions.

With regard to minimum qualification and other requirements to be met

by personnel, please also follow the chapter Safety ( p. 11).

1.2 Representation conventions – symbols and characters

Various information in these instructions is represented or highlighted by the

following characters in order to facilitate easy and quick understanding:

Proper setting

Specifies proper setting.

Disturbances

Specifies the disturbances that can occur from an incorrect setting.

Cover

Specifies which covers must be disassembled in order to access the

components to be set.

About these instructions

8 Service Instructions 755 A/756 A - 00.0 - 02/2019

Steps to be performed when operating the machine (sewing and

equipping)

Steps to be performed for service, maintenance, and installation

Steps to be performed via the software control panel

The individual steps are numbered:

First step

Second step

The steps must always be followed in the specified order.

Lists are marked by bullet points.

Result of performing an operation

Change to the machine or on the display/control panel.

Important

Special attention must be paid to this point when performing a step.

Information

Additional information, e.g. on alternative operating options.

Order

Specifies the work to be performed before or after a setting.

References

 Reference to another section in these instructions.

Safety Important warnings for the user of the machine are specifically marked.

Since safety is of particular importance, hazard symbols, levels of

danger and their signal words are described separately in the chapter

Safety ( p. 11).

Location

information

If no other clear location information is used in a figure, indications of right

or left are always from the user's point of view.

1.

2.

…

•



About these instructions

Service Instructions 755 A/756 A - 00.0 - 02/2019 9

1.3 Other documents

The machine includes components from other manufacturers. Each

manufacturer has performed a hazard assessment for these purchased

parts and confirmed their design compliance with applicable European

and national regulations. The proper use of the built-in components is

described in the corresponding manufacturer's instructions.

1.4 Liability

All information and notes in these instructions have been compiled in

accordance with the latest technology and the applicable standards and

regulations.

Dürkopp Adler cannot be held liable for any damage resulting from:

• Breakage and damage during transport

• Failure to observe these instructions

• Improper use

• Unauthorized modifications to the machine

• Use of untrained personnel

• Use of unapproved parts

Transport

Dürkopp Adler cannot be held liable for breakage and transport damages.

Inspect the delivery immediately upon receiving it. Report any damage

to the last transport manager. This also applies if the packaging is not

damaged.

Leave machines, equipment and packaging material in the condition in

which they were found when the damage was discovered. This will ensure

any claims against the transport company.

Report all other complaints to Dürkopp Adler immediately after receiving

the product.

About these instructions

10 Service Instructions 755 A/756 A - 00.0 - 02/2019

Safety

Service Instructions 755 A/756 A - 00.0 - 02/2019 11

2 Safety

This chapter contains basic information for your safety. Read the instruc-

tions carefully before setting up or operating the machine. Make sure to

follow the information included in the safety instructions. Failure to do so

can result in serious injury and property damage.

2.1 Basic safety instructions

The machine may only be used as described in these instructions.

These instructions must be available at the machine's location at all times.

Work on live components and equipment is prohibited. Exceptions are

defined in the DIN VDE 0105.

For the following work, switch off the machine at the main switch or

disconnect the power plug:

• Replacing the needle or other sewing tools

• Leaving the workstation

• Performing maintenance work and repairs

• Threading

Missing or faulty parts could impair safety and damage the machine.

Only use original parts from the manufacturer.

Transport Use a lifting carriage or forklift to transport the machine. Raise the machine

max. 20 mm and secure it to prevent it from slipping off.

Setup The connection cable must have a power plug approved in the relevant

country. The power plug may only be assembled to the connection cable

by qualified specialists.

Obligations

of the operator

Follow the country-specific safety and accident prevention regulations and

the legal regulations concerning industrial safety and the protection of the

environment.

All the warnings and safety signs on the machine must always be in

legible condition. Do not remove!

Missing or damaged warnings and safety signs must be replaced

immediately.

Requirements

to be met by

the personnel

Only qualified specialists may:

• Setting up the machine

• Performing maintenance work and repairs

• Performing work on electrical equipment

Only authorized persons may work on the machine and must first have

understood these instructions.

Safety

12 Service Instructions 755 A/756 A - 00.0 - 02/2019

Operation Check the machine during operating for any externally visible damage.

Stop working if you notice any changes to the machine. Report any

changes to your supervisor. Do not use a damaged machine any further.

Safety

equipment

Safety equipment should not be removed or deactivated. If it is essential

to remove or deactivate safety equipment for a repair operation, it must be

assembled and put back into operation immediately afterward.

2.2 Signal words and symbols used in warnings

Warnings in the text are distinguished by color bars. The color scheme is

based on the severity of the danger. Signal words indicate the severity of

the danger.

Signal words Signal words and the hazard they describe:

Symbols The following symbols indicate the type of danger to personnel:

Signal word Meaning

DANGER (with hazard symbol)

If ignored, fatal or serious injury will result

WARNING (with hazard symbol)

If ignored, fatal or serious injury can result

CAUTION (with hazard symbol)

If ignored, moderate or minor injury can result

CAUTION (with hazard symbol)

If ignored, environmental damage can result

NOTICE (without hazard symbol)

If ignored, property damage can result

Symbol Type of danger

General

Electric shock

Safety

Service Instructions 755 A/756 A - 00.0 - 02/2019 13

Examples Examples of the layout of warnings in the text:

 This is what a warning looks like for a hazard that will result in serious

injury or even death if ignored.

 This is what a warning looks like for a hazard that could result in

serious or even fatal injury if ignored.

 This is what a warning looks like for a hazard that could result in

moderate or minor injury if the warning is ignored.

Puncture

Crushing

Environmental damage

Symbol Type of danger

DANGER

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

WARNING

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

CAUTION

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

Safety

14 Service Instructions 755 A/756 A - 00.0 - 02/2019

 This is what a warning looks like for a hazard that could result in

environmental damage if ignored.

 This is what a warning looks like for a hazard that could result in

property damage if ignored.

CAUTION

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

NOTICE

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

Working basis

Service Instructions 755 A/756 A - 00.0 - 02/2019 15

3 Working basis

3.1 Gages

The locking peg (part number 0367 105950) is included with the machine

as a standard tool in the accessory pack. It can be used to peg the

machine head in place at the Loop stroke position or at the Needle at

top dead center position.

3.2 Locking the machine in place

Fig. 1: Locking the machine in place

The arm shaft crank (2) is equipped with a large arresting groove (3)

(5 mm) and a small arresting groove (5) (3 mm).

WARNING

Risk of injury from moving parts!

Crushing possible.

Do not reach into the tabletop cutout when the

machine head is swiveled up.

Switch off the machine before adjusting the

machine head settings.

(1) - Hole

(2) - Arm shaft crank

(3) - large arresting groove

(4) - Locking peg

(5) - small arresting groove

①②③

④

⑤

Working basis

16 Service Instructions 755 A/756 A - 00.0 - 02/2019

The machine head can be pegged into place in the hole (1) using the

locking peg (4).

There are 2 securing positions:

• Position 1: Loop stroke position

• 5 mm end in the large arresting groove (3)

• Setting the loop stroke and needle bar height

• Position 2: Handwheel zero position

• 3 mm end in the small arresting groove (5)

• Setting the handwheel position and checking the top dead center

for the needle bar

3.3 Swiveling up the machine head

The machine head can be swiveled up for maintenance work.

This requires that the transport carriage be in its rear position.

Fig. 2: Swiveling up the machine head (1)

To swivel up the machine head:

1. Pull the handle of the folding station to the left.

2. Swivel the folding station out by 90°.

NOTICE

Property damage may occur!

Possible damage to the light barriers or needle breakage.

Do NOT grab the machine head in the area of the light barriers or

the needles when swiveling it up.

(1) - Locking lever (2) - Fabric sliding plate

①

②

Working basis

Service Instructions 755 A/756 A - 00.0 - 02/2019 17

3. Remove the fabric sliding plate (2).

4. Swivel the locking lever (1) up.

Fig. 3: Swiveling up the machine head (2)

5. Lift and carefully swivel up the machine head.

 The latch (3) locks into place as well.

The space below the stand is accessible for cleaning and setting

operations.

(3) - Latch

③

Working basis

18 Service Instructions 755 A/756 A - 00.0 - 02/2019

3.4 Swiveling down the machine head

Fig. 4: Swiveling down the machine head (1)

To swivel down the machine head:

1. Raise the machine head until the latch (1) disengages.

2. Lower the machine head carefully.

NOTICE

Property damage may occur!

Possible damage to the light barriers or needle breakage.

Do NOT grab the machine head in the area of the light barriers or

the needles when swiveling it down.

(1) - Latch

①

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