Duerkopp Adler 745-35 User manual

745-35

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.

Table of Contents

Service Instructions 745-35 - 01.0 - 09/2015

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 .......................................................................6

1.4 Liability.......................................................................................6

1.4.1 Transport ...................................................................................7

1.4.2 Proper use .................................................................................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

Gauges .................................................................................... 13

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

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

3.4 Removing/installing the machine head....................................17

3.5 Adjusting the crank pin at the arm shaft...................................20

3.6 Needle bar linkage...................................................................24

3.6.1 Removing the needle bar linkage............................................24

3.6.2 Removing the needle bar from the linkage..............................27

3.6.3 Dismantling the needle bar......................................................29

3.6.4 Assembling the needle bar ......................................................30

3.6.5 Installing needle bar and needle bar linkage ...........................31

3.6.6 Installing the needle bar linkage..............................................34

3.6.7 Needle bar linkage, height check and adjustment...................36

3.6.8 Aligning the needle bar linkage with the throat plate...............38

3.6.9 Changing the needle holder.....................................................39

3.7 Hook ........................................................................................41

3.7.1 Checking and adjusting the height of the hook shaft...............41

3.7.2 Hook drive, check and adjustment of gear clearance..............42

3.7.3 Checking and adjusting the loop stroke...................................44

3.7.4 Needle holder, height check and adjustment...........................46

3.7.5 Hook tips, setting the distance to the needles .........................48

3.7.6 Checking and adjusting the needle guard................................51

3.7.7 Changing the hook...................................................................52

3.7.8 Checking and adjusting the bobbin case holding wire.............53

3.8 Center knife .............................................................................55

3.8.1 Removing/installing the drive motor.........................................55

3.8.2 Removing/installing the switching cylinder...............................57

3.8.3 Adjusting the knife ...................................................................58

3.9 Adjusting the thread controller spring......................................60

3.10 Trimming and clamping device for the needle threads............61

3.10.1 Performing a function check....................................................61

3.10.2 Replacing knife and thread-pulling knife..................................63

3.11 Trimming and clamping device for the hook threads...............65

3.12 Adjusting the thread advancing device for the needle threads 67

3.13 Setting the synchronizer..........................................................68

3.14 Oil lubrication...........................................................................69

3.14.1 Hook lubrication.......................................................................71

3.15 Adjusting the differential gear..................................................72

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Service Instructions 745-35 - 01.0 - 09/2015

2

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

4.1 Checking and adjusting the rear end position..........................73

4.1.1 Checking and adjusting the position of the reference switch...74

4.1.2 Adjusting the distance between switching screw and reference

switch.......................................................................................75

4.1.3 Adjusting the transport carriage stop.......................................76

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

4.3 Adjusting the belt tension.........................................................80

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

5.1 Aligning transport clamps and folder........................................83

5.2 Aligning the transport clamp with the sliding plate edge..........84

5.3 Checking and adjusting the stroke height of the transport

clamps .....................................................................................86

5.4 Adjusting the distance of the transport clamps to the

folder sole................................................................................88

5.5 Adjusting the front end position of the transport clamp............90

5.6 Blowing the piping strips..........................................................92

6 Corner knives.........................................................................95

6.1 Presetting knives for corner incision........................................95

6.2 Adjusting the corner knife station to the seams.......................96

6.3 Adjusting the slant of the corner knife cuts..............................99

6.4 Replacing the corner knives...................................................100

7 Laser markings ....................................................................101

7.1 Method A ...............................................................................101

7.2 Method B ...............................................................................103

8 Light barriers........................................................................107

8.1 Adjusting the swivel arm........................................................107

8.2 Adjusting the light barrier for flaps.........................................108

8.3 Aligning the air nozzles for cleaning the reflected foil............108

9 Folding station plate............................................................111

10 Aligning the machine head.................................................113

11 Adjusting fabric sliding plate and vacuum plate.............. 123

12 Folder (method A)................................................................125

12.1 Installing and removing the folder..........................................125

12.2 Aligning the folder with the middle of the pocket opening......126

12.3 Adjusting the lifting motion of the folder.................................128

12.4 Aligning the folder with the needles.......................................131

12.5 Adjusting the guide plates at the folder..................................133

12.6 Ensuring folder detection.......................................................135

13 Folder (method B and F) .....................................................137

13.1 Attaching the folder - method B and F...................................137

13.2 Alignment with the middle of the pocket opening...................138

13.3 Checking the position between needles and center knife......140

13.4 Adjusting guide plates using spring-loaded downholders......142

13.5 Checking and adjusting the lifting motion of the folder ..........144

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Service Instructions 745-35 - 01.0 - 09/2015

3

13.6 Presetting the mounting plate for the pick-up folder..............145

13.7 Aligning the pick-up folder......................................................148

13.7.1 Aligning the folder sole with the middle of the

pocket opening ......................................................................148

13.7.2 Adjusting the height of the pick-up folder with the folder....... 150

13.7.3 Adjusting the position of the pick-up folder in

sewing direction.....................................................................150

13.8 Adjusting the guide plates at the pick-up folder.....................152

13.9 Adjusting the stop screw for the pick-up folder......................153

13.10 Checking and adjusting pick-up folder detection ...................154

14 Infeed device (method B and F)..........................................157

14.1 General information ...............................................................157

14.2 Changing the toothed belt......................................................157

14.2.1 Changing the front toothed belt .............................................157

14.2.2 Changing the rear toothed belt..............................................158

14.3 Adjusting the belt tension (method B)....................................160

14.4 Setting the basic position of the swivel arms (method B)...... 161

14.5 Aligning and adjusting the flap clamps (method B)................163

14.5.1 Aligning the flap clamps with the sliding plate edge...............163

14.5.2 Aligning the flap clamp lifting device......................................165

14.5.3 Aligning the flap clamps with the pick-up folder.....................166

14.5.4 Adjusting the flap clamps to the rest table.............................168

14.6 Flap turning device (method F)..............................................170

14.6.1 Changing the toothed belt......................................................170

14.6.2 Setting the basic position of the turning device......................173

14.6.3 Aligning the flap turning device..............................................174

14.6.4 Adjusting the flap transfer position.........................................176

14.6.5 Swiveling the flap turning device to the loading area.............178

14.6.6 Adjusting the movable flap clamps........................................179

14.7 Sewing test according to pattern............................................180

14.8 Error elimination.....................................................................182

15 Device for cutting the piping ends automatically.............187

15.1 Adjusting the piping cutter to the pick-up folder.....................187

15.2 Adjusting the height of the rest table......................................189

15.3 Adjusting the piping strip deflector.........................................190

15.4 Replacing the piping knives...................................................191

15.5 Checking the rear end position of the piping knife.................192

15.6 Checking and adjusting the knife carrier................................194

15.7 Checking and adjusting the toothed belt tension...................195

15.8 Changing the toothed belt......................................................197

16 Positioning device (method D)...........................................199

16.1 General information ...............................................................199

16.2 Aligning the folder..................................................................199

16.3 Aligning the positioning device...............................................200

16.4 Adjusting the pattern shift correction......................................201

16.5 Adjusting the throttle valve.....................................................202

16.6 Pocket bag feed.....................................................................203

16.6.1 Adjusting the loading position................................................203

16.6.2 Adjusting the position of the assembly strip...........................204

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Service Instructions 745-35 - 01.0 - 09/2015

4

16.6.3 Adjusting the throttle valve.....................................................205

17 Adjusting the additional equipment...................................207

17.1 Downholder and pocket bag clamp........................................207

17.2 Waistband clamp ...................................................................209

17.3 Throw-over stacker................................................................211

17.3.1 Checking the function sequence............................................211

17.3.2 Adjusting the throw-over stacker............................................214

17.3.3 Adjusting the stacker speed...................................................217

17.3.4 Activating the stacker.............................................................217

17.3.5 Switching on the stacker........................................................217

17.3.6 Throw-over stacker - pneumatics diagram.............................218

17.3.7 Throw-over stacker - troubleshooting ....................................219

17.4 Outfeed roller.........................................................................221

17.5 Tape for infeed and cutting device.........................................223

17.6 Parts set - pocket bag on the flap..........................................225

17.6.1 Aligning the flap clamps.........................................................225

17.6.2 Adjusting the guide plates at folder and pick-up folder..........225

17.6.3 Adjustment of the transport clamps.......................................226

17.6.4 Adjusting the light barrier position..........................................227

17.6.5 Program Aligning the light barrier..........................................228

17.6.6 Parameter: Setting pocket bag/Blowing of pipings................228

17.6.7 Mode: Pocket bag on flap......................................................228

18 Pressure supply...................................................................229

18.1 Adjusting the pressure monitor..............................................229

18.2 Adjusting the transport clamp control.....................................230

19 Maintenance.........................................................................231

19.1 Checking the oil level.............................................................232

19.2 Lubricating the hook ..............................................................232

19.3 Customer Service ..................................................................232

About these instructions

Service Instructions 745-35 - 01.0 - 09/2015 5

1 About these instructions

These instructions for the 745-35 have been prepared with utmost care.

They contain information and notes in order to ensure long-term and reli-

able operation.

Please contact us if you find any discrepancies or have any suggestions,



19.3 Customer Service, p. 232.

Consider the instructions part of the product and store it in a place where

they are readily available. Be sure to read these instructions completely

before using the product for the first time. Only give the product to some-

one else along with the instructions.

These instructions describe the intended use and the setup of the 745-35.

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 qualifications and other requirements to be met

by the personnel, please also observe  2 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

Indicates proper setting.

Malfunctions

Specifies the faults that can occur due to an incorrect setting.

Cover

Specifies which covers have to be removed in order to access the compo-

nents to be set.

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:

About these instructions

6 Service Instructions 745-35 - 01.0 - 09/2015

1. First step

2. Second step

The sequence of the steps must always be followed.

Lists are identified by bullet points.

Result of performing an operation

Change on 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.

Sequence

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

References

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

Safety Important warnings for the machine users are specially designated. Since

safety is of particular importance, hazard symbols, levels of danger and

their signal words are described separately in  2 Safety, p. 9.

Orientation If the figure is unclear, indications of right or left are always from the user's

point of view.

1.3 Other documents

The machine includes components from other manufacturers. Each man-

ufacturer has performed a hazard assessment for these purchased parts

and confirmed their design compliance with applicable European and na-

tional regulations. The proper use of these components is described in

each manufacturer's instructions.

1.4 Liability

All information in these instructions was compiled with consideration to the

state of the art, and applicable standards and regulations.

The manufacturer cannot be held liable for damages resulting from:

• Breakage and damage during transport

• Failure to observe these instructions

1.

2.

•



About these instructions

Service Instructions 745-35 - 01.0 - 09/2015 7

• Improper use

• Unauthorized modifications to the machine

• Use of untrained personnel

• Use of unapproved replacement parts

1.4.1 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 applies even if the packaging is

undamaged.

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.

1.4.2 Proper use

The 745-35 is intended for sewing light to moderately heavy material. Light

to moderately heavy material requires a needle strength of 80-110 Nm.

The machine is intended only for use with dry sewing material. The mate-

rial must not contain any hard objects.

The seam must be completed with a needle thread that satisfies the re-

quirements of the specific application at hand.

The 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 DIN EN 60204-31.

Only authorized persons may work on the machine.

The manufacturer cannot be held liable for damages resulting from im-

proper use.

WARNING

Danger due to electric shock, crushing and

punctures!

Improper use can result in injury.

Follow all information given in the instructions.

About these instructions

8 Service Instructions 745-35 - 01.0 - 09/2015

NOTICE

Damage to the machine in case of non-compliance!

Improper use can result in property damage.

Follow all information given in the instructions.

Safety

Service Instructions 745-35 - 01.0 - 09/2015 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 this section. 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.

The instructions should be available at the machine's location at all times.

Work on live components and equipment is prohibited. Exceptions are de-

fined in the 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

• Threading

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

Make sure you only use original replacement parts from the manufacturer.

Transport Use a sturdy lifting carriage or stacker for transporting the machine. Raise

the machine max. 20 mm and secure it against slipping off.

Setup The power cable must have a plug authorized for the country in which the

machine is being used. The power plug may only be connected to the

power cable by qualified specialists.

Obligations

of the operator

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 should be

replaced immediately.

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 first have understood these instructions.

Safety

10 Service Instructions 745-35 - 01.0 - 09/2015

Operation Inspect the machine while in use for any externally visible damage. Stop

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

your supervisor. A damaged machine must no longer be used.

Safety

equipment

Safety equipment should not be removed or deactivated. If this cannot be

avoided for a repair operation, the safety equipment must be refitted and

put back into service immediately afterwards.

2.2 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 indicate the se-

verity of the danger.

Signal words Signal words and the hazard that they describe:

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

Signal word Meaning

DANGER (with hazard symbol)

If ignored, death or serious injury will result

WARNING (with hazard symbol)

If ignored, death or serious injury can result

CAUTION (with hazard symbol)

If ignored, moderate or light injury can result

NOTICE (without hazard symbol)

If ignored, property damage can result

Symbol Type of danger

General

Electric shock

Pointed objects

Crushing

Environmental damage

Safety

Service Instructions 745-35 - 01.0 - 09/2015 11

Examples Examples of the layout of the 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 seri-

ous injury or even death 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.

 This is a warning note for a hazard that could result in environmental

damage if ignored.

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.

CAUTION

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

Safety

12 Service Instructions 745-35 - 01.0 - 09/2015

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

property damage if ignored.

NOTICE

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

Machine head

Service Instructions 745-35 - 01.0 - 09/2015 13

3 Machine head

3.1 Gauges

The gauges listed below allow you to precisely set and check the sewing

unit.

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

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

loop stroke position.

Gauges

3.2 Groove in the arm shaft crank

(1) - Groove in the arm shaft crank

The arm shaft crank (2) is fitted with a groove (1) that is 5 mm wide.

Setting gage Part no. Use

Locking peg 0211 000700 Loop stroke position

Gauge 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

Gauge 0246 002591 Crank pin to arm shaft

(1) - Groove

(2) - Arm shaft crank

(3) - Hole

①②③

Machine head

14 Service Instructions 745-35 - 01.0 - 09/2015

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

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

stroke position.

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. 1: Swiveling the machine head up/down I

Swiveling up the machine head

1. Remove the hood (1). To do so, lift the hood up at the front and the

rear to release the lock. Carefully life the hood up and off.

WARNING

Caution: Risk of injury!

Do not swivel up the machine head unless the main

switch is switched off.

WARNING

Risk of crushing by moving parts!

Do not reach into the table top cutout when the

machine head is swiveled up.

(1) - Hood

①

Machine head

Service Instructions 745-35 - 01.0 - 09/2015 15

Fig. 2: Swiveling machine head up/down II

2. Pull the handle of the folding station (2) up and swivel the folding station

out by 90°.

Fig. 3: Swiveling machine head up/down III

3. Swivel the locking lever (3) up.

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

5. Lift the machine head in the head cover area (5) and swivel up carefully.

The latch (6) locks into place as well. The space below the machine

table is accessible for cleaning.

(2) - Handle of the folding station

(3) - Locking lever

(4) - Sliding plate

(5) - Head cover

②

③

④⑤

Machine head

16 Service Instructions 745-35 - 01.0 - 09/2015

Fig. 4: Swiveling machine head up/down IV

Swiveling down the machine head

1. Hold the machine head in the head cover area (5).

2. Release the latch (6).

3. Swivel down the machine head carefully.

4. Insert the fabric sliding plate (4).

5. Swivel the locking lever (3) down.

6. Carefully swivel down the folding station and engage the handle of the

folding station (2).

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

(6) - Latch

⑥

NOTICE

Property damage may occur

When swiveling down the depressurized machine: Manually move

the plunger to the upper position! Otherwise, the needle may collide

with the plunger and break off.

Machine head

Service Instructions 745-35 - 01.0 - 09/2015 17

3.4 Removing/installing the machine head

It is possible to remove the machine head for repairs. This requires that

the transport carriage be in its rear position.

Fig. 5: Installing/removing the machine head I

Removing the machine head

1. Remove the hood (1). To do so, lift the hood up at the front and the

rear to release the lock. Carefully life the hood (1) up and off.

Fig. 6: Installing/removing the machine head II

WARNING

Caution: Risk of injury!

Do not remove and install the machine head unless

the main switch is switched off.

(1) - Hood

①

(2) - Handle of the folding station

②

Machine head

18 Service Instructions 745-35 - 01.0 - 09/2015

2. Pull the handle of the folding station (2) up and swivel the folding station

out by 90°.

Fig. 7: Installing/removing the machine head III

3. Swivel the locking lever (3) up.

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

5. Disconnect the electrical and pneumatic connection to the machine

head.

Fig. 8: Installing/removing the machine head II

6. Loosen the gas shock absorber connection (5) at the top.

(3) - Locking lever (4) - Fabric sliding plate

(5) - Gas shock absorber connection

③

④

⑤

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Duerkopp Adler 745-35 User manual

Duerkopp Adler 745-35 User manual

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