Duerkopp Adler 745-35-10 User manual

745-35-10 B

745-35-10 F

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 745-35-10 B/745-35-10 F - 00.0 - 10/2017 1

1 About these instructions ...........................................................5

1.1 For whom are these instructions intended?..................................5

1.2 Representation conventions – symbols and characters...............5

1.3 Other documents..........................................................................7

1.4 Liability..........................................................................................7

2 Safety...........................................................................................9

2.1 Basic safety instructions...............................................................9

2.2 Signal words and symbols used in warnings..............................10

3 Machine head............................................................................13

3.1 Gages.........................................................................................13

3.2 Slot in the arm shaft crank..........................................................13

3.3 Swiveling up the machine head..................................................14

3.4 Swiveling down the machine head.............................................16

3.5 Disassembling the machine head...............................................17

3.6 Assembling machine head .........................................................19

3.7 Assembling the crank pin at the arm shaft .................................21

3.8 Needle bar linkage......................................................................26

3.8.1 Disassembling the needle bar linkage........................................26

3.8.2 Removing a needle bar from the needle bar linkage..................29

3.8.3 Dismantling the needle bar.........................................................31

3.8.4 Assembling the needle bar.........................................................32

3.8.5 Assembling needle bars into the needle bar linkage..................33

3.8.6 Assembling the needle bar linkage.............................................36

3.8.7 Setting the height of the needle bar linkage...............................38

3.8.8 Aligning the needle bar linkage with the throat plate..................40

3.8.9 Changing the needle holder .......................................................41

3.9 Hook ...........................................................................................43

3.9.1 Setting the height of the hook shaft............................................43

3.9.2 Setting the gear clearance of the hook drive..............................45

3.9.3 Setting the loop stroke................................................................46

3.9.4 Setting the needle holder height.................................................48

3.9.5 Setting the distance between hook tips and needles .................50

3.9.6 Setting the needle guard ............................................................53

3.9.7 Changing the hook .....................................................................54

3.9.8 Setting the bobbin case holding wire..........................................55

3.10 Middle knife ................................................................................57

3.10.1 Disassembling the drive motor ...................................................57

3.10.2 Assembling the drive motor........................................................58

3.10.3 Disassembling the switching cylinder.........................................59

3.10.4 Assembling the switching cylinder..............................................60

3.10.5 Setting the middle knife..............................................................61

3.11 Setting the thread tension spring................................................63

3.12 Setting the trimming and clamping device

for the needle threads.................................................................64

3.13 Setting the trimming and clamping device for the hook threads...... 67

3.14 Setting the thread advancing device for the needle threads ......70

3.15 Setting the synchronizer.............................................................71

3.16 Setting the differential gear.........................................................72

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2 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

4 Transport carriage....................................................................73

4.1 Rear end position of the transport carriage................................73

4.1.1 Setting the position of the reference switch in the slotted hole........ 74

4.1.2 Setting the distance between switching screw

and reference switch ..................................................................75

4.1.3 Setting the transport carriage stop .............................................76

4.2 Changing the toothed belt ..........................................................77

4.3 Setting the toothed belt tension..................................................80

5 Transport clamps .....................................................................83

5.1 Aligning the transport clamps with the sliding plate edge...........84

5.2 Setting the transport clamp stroke height...................................86

5.3 Setting the distance of the transport clamps to the folder sole......88

5.4 Setting the front end position of the transport clamp..................90

5.5 Setting the blowing of the piping strips.......................................92

6 Corner knife ..............................................................................95

6.1 Setting the initial position of the corner knives ...........................95

6.2 Setting the corner knife parameters ...........................................96

6.3 Checking the corner knife station...............................................98

6.3.1 Checking the front left corner knife.............................................99

6.3.2 Checking the rear left corner knife............................................100

6.4 Aligning the corner knife station with the seams.......................100

6.5 Setting the slant of the corner knife cuts ..................................103

6.6 Replacing corner knives ...........................................................104

7 Aligning the marking lamps...................................................107

8 Light barriers ..........................................................................111

8.1 Setting the swivel arm ..............................................................111

8.2 Aligning the light barriers..........................................................112

8.2.1 Setting the light barriers for automatic slant detection..............116

8.2.2 Setting the light barriers for the left and the right flap rest........119

8.3 Setting the light barrier for the flap ...........................................122

8.4 Aligning the air nozzles for cleaning the reflecting foils............122

9 Setting the folding station plate............................................123

10 Aligning the machine head....................................................125

11 Setting fabric sliding plate and vacuum plate .....................129

12 Folder.......................................................................................131

12.1 Assembling the folder...............................................................131

12.2 Aligning the folder with the middle of the pocket opening ........132

12.3 Setting guide plates using spring-loaded downholders............134

12.4 Presetting the mounting plate for the pick-up folder.................136

12.5 Aligning the pick-up folder........................................................138

12.5.1 Aligning the pick-up folder sole with the middle

of the pocket opening...............................................................138

12.5.2 Aligning the pick-up folder height with the folder......................140

12.5.3 Setting the pick-up folder position in sewing direction..............141

12.6 Setting the guide plates at the pick-up folder ...........................142

12.7 Setting the stop screw for the pick-up folder ............................143

12.8 Setting the pick-up folder detection..........................................144

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Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017 3

13 Feeding device........................................................................145

13.1 Changing the toothed belt ........................................................145

13.1.1 Changing the front toothed belt................................................146

13.1.2 Changing the rear toothed belt.................................................147

13.2 Setting the toothed belt tension (745-35-10 B).........................148

13.2.1 Setting the front toothed belt tension........................................149

13.2.2 Setting the rear toothed belt tension.........................................150

13.3 Setting the initial position of the swivel arms (745-35-10 B)..... 150

13.4 Flap clamps (745-35-10 B).......................................................153

13.4.1 Aligning the flap clamps with the sliding plate edge.................153

13.4.2 Setting the flap clamp lifting device..........................................154

13.4.3 Aligning the flap clamps with the pick-up folder........................155

13.4.4 Setting the flap clamps to the flap rest table.............................157

13.5 Flap turning device (745-35-10 F) ............................................159

13.5.1 Changing the lower toothed belt...............................................160

13.5.2 Changing the upper toothed belt..............................................161

13.5.3 Setting the initial position of the flap turning device..................162

13.5.4 Aligning the flap turning device.................................................165

13.5.5 Setting the flap transfer position...............................................166

13.5.6 Setting the swivel range of the flap turning device...................168

13.5.7 Setting the movable flap clamp ................................................169

13.6 Performing a sewing test according to pattern .........................170

13.7 Making corrections to the settings............................................171

13.7.1 Correction: Flap sewn in too deep............................................171

13.7.2 Correction: Flap not sewn in deep enough...............................172

13.7.3 Correction: Flap fed obliquely...................................................173

13.7.4 Correction: Flap is sewn in shifted to the right..........................174

13.7.5 Correction: Flap is sewn in shifted to the left............................175

14 Piping cutter............................................................................177

14.1 Setting the piping cutter to the pick-up folder...........................177

14.2 Aligning the height of the rest table..........................................179

14.3 Setting the piping strip deflector...............................................180

14.4 Replacing the piping knives......................................................181

14.5 Checking the rear end position of the piping knives.................182

14.6 Setting the knife carrier.............................................................184

14.7 Setting the toothed belt tension................................................185

14.8 Changing the toothed belt ........................................................186

15 Additional equipment.............................................................189

15.1 Setting downholder and pocket bag clamp...............................189

15.2 Assembling the waistband clamp (745-35-10 B only)...............190

15.3 Setting the outfeed roller ..........................................................192

15.4 Setting the tape feeding and tape cutting device......................194

15.5 Pocket bag on flap (745-35-10 B only).....................................196

15.5.1 Aligning the flap clamps............................................................196

15.5.2 Setting the guide plates at folder and pick-up folder ................196

15.5.3 Setting the transport clamps.....................................................197

15.5.4 Setting the light barrier position................................................199

15.5.5 Aligning the light barriers..........................................................200

15.5.6 Setting blowing mode...............................................................200

15.5.7 Setting transport clamp mode...................................................200

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4 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

16 Stacker.....................................................................................201

16.1 Pincer stacker...........................................................................201

16.1.1 Setting the position of the stacker tongs

relative to the tabletop..............................................................201

16.1.2 Setting the height of the stacker tongs.....................................202

16.1.3 Setting the position of the stacker tongs and closing the tongs..... 203

16.1.4 Setting the cylinder speed........................................................204

16.1.5 Setting the tray position............................................................204

16.1.6 Swiveling the stacker to the side..............................................205

16.2 Throw-over stacker...................................................................206

16.2.1 Checking the function sequence ..............................................206

16.2.2 Setting the throw-over stacker..................................................209

16.2.3 Setting the stacking speed .......................................................212

16.2.4 Activating the stacker ...............................................................212

17 Pressure supply......................................................................213

17.1 Setting the pressure monitor ....................................................213

17.2 Setting the transport clamp control...........................................214

18 Programming ..........................................................................215

19 Maintenance............................................................................357

19.1 Cleaning ...................................................................................358

19.2 Lubricating................................................................................359

19.2.1 Top off the oil reservoir.............................................................360

19.2.2 Lubricating the hook.................................................................361

19.3 Servicing the pneumatic system...............................................362

19.3.1 Setting the operating pressure .................................................362

19.3.2 Draining the water condensation..............................................363

19.3.3 Cleaning the filter element........................................................364

19.4 Parts list....................................................................................365

20 Decommissioning...................................................................367

21 Disposal...................................................................................369

22 Troubleshooting .....................................................................371

22.1 Customer Service.....................................................................371

22.2 Messages of the software.........................................................371

23 Technical data.........................................................................383

24 Appendix .................................................................................385

About these instructions

Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017 5

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. 371).

Consider the instructions part of the product and store them in a place

where they are readily available.

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. 9).

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

6 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

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. 9).

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 745-35-10 B/745-35-10 F - 00.0 - 10/2017 7

1.3 Other documents

The machine includes components from other manufacturers. Each manu-

facturer 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

8 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

Safety

Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017 9

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 connecting cable must have a power plug approved in the relevant

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

10 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

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 745-35-10 B/745-35-10 F - 00.0 - 10/2017 11

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

12 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

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

ronmental 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.

Machine head

Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017 13

3 Machine head

3.1 Gages

The gages listed below allow you to precisely set and check the machine.

The locking peg is included with the machine as a standard tool in the

accessory pack. It can be used to peg the machine head into place in the

loop stroke position.

Gages

3.2 Slot in the arm shaft crank

FIg. 1: Slot in the arm shaft crank

The arm shaft crank (2) is fitted with a slot (1) (5 mm).

The machine head can be pegged into place in the hole (3) using the

locking peg. When pegged in this position, the machine head is in the loop

stroke position.

Setting gage Part number Use

Locking peg 0211 000700 Loop stroke position

Gage 0244 001001 Hook shaft height

Measuring bridge 0212 004942 Needle holder height

Measuring pin 0216 001070 Needle holder height

Setting peg 0244 001014 Hook side clearance

Gage 0246 002591 Crank pin to arm shaft

(1) - Slot

(2) - Arm shaft crank

(3) - Hole

①②③

Machine head

14 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

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. Remove the hood (1).

To do so, lift the hood (1) up at the front to release the lock. Carefully life

the hood (1) up and off.

2. Pull the handle of the folding station up.

3. Swivel the folding station out by 90°.

4. Swivel the locking lever (3) up.

WARNING

Risk of injury from moving parts!

Crushing possible.

Do not reach into the tabletop cutout when the

machine head is swiveled up.

(1) - Hood

(2) - Head cover

(3) - Locking lever

①

②

③

Machine head

Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017 15

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

5. Raise the fabric sliding plate (4) at the front and swivel it out to the left.

6. Lift the machine head in the head cover area (2) and swivel it up

carefully.

 The latch (5) locks into place as well.

The space below the stand is accessible for cleaning.

(4) - Fabric sliding plate (5) - Latch

④⑤

Machine head

16 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

3.4 Swiveling down the machine head

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

FIg. 5: Swiveling down the machine head (2)

To swivel down the machine head:

1. Hold the machine head in the head cover area (2).

2. Release the latch (5).

NOTICE

Property damage may occur!

Needle breakage.

When swiveling down the depressurized machine, manually move

the folder to the upper position.

(1) - Hood

(2) - Head cover

(3) - Locking lever

(4) - Fabric sliding plate (5) - Latch

①

②

③

④⑤

Machine head

Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017 17

3. Swivel down the machine head carefully.

4. Insert the fabric sliding plate (4).

5. Swivel the locking lever (3) down.

6. Swivel down the folding station and latch it using the locking lever (3).

7. Replace and re-engage the hood (1).

3.5 Disassembling the machine head

It is possible to remove the machine head prior to repairs or for a quick and

easy switch to a different needle distance. This requires that the transport

carriage be in its rear position.

FIg. 6: Disassembling the machine head (1)

To remove the machine head:

1. Lift the hood (1) up at the front and the rear to release the lock.

2. Carefully lift the hood (1) up and off.

3. Pull the handle of the folding station (2) up.

4. Swivel the folding station out by 90°.

WARNING

Risk of injury!

Crushing possible.

Switch off the machine before disassembling the

machine head.

(1) - Hood (2) - Handle

①

②

Machine head

18 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017

FIg. 7: Disassembling the machine head (2)

5. Swivel the locking lever (3) up.

6. Raise the fabric sliding plate (4) at the front and swivel it out to the left.

7. Disconnect the electrical and pneumatic connection to the machine

head.

8. Loosen the gas shock absorber connection (5).

(3) - Locking lever

(4) - Fabric sliding plate

(5) - Gas shock absorber connection

③

④

⑤

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Duerkopp Adler 745-35-10 User manual

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