DURKOPP ADLER 745-35-10 F Service Instructions Manual
  1. Manuals
  2. Brands
  3. DURKOPP ADLER Manuals
  4. Sewing Machine
  5. 745-35-10 F
  6. Service instructions manual
DURKOPP ADLER 745-35-10 F Service Instructions Manual

DURKOPP ADLER 745-35-10 F Service Instructions Manual

Hide thumbs Also See for 745-35-10 F:
1
2
Table Of Contents
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
Table of Contents

Advertisement

Quick Links

Download this manual
745-35-10 B
745-35-10 F
Service Instructions

Advertisement

Table of Contents
loading

Related Manuals for DURKOPP ADLER 745-35-10 F

Summary of Contents for DURKOPP ADLER 745-35-10 F

  • Page 1 745-35-10 B 745-35-10 F Service Instructions...
  • Page 2 IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE 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 2017...

  • Page 3: Table Of Contents

    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 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 4 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 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 5 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 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 6 19.3.3 Cleaning the filter element ............364 19.4 Parts list ..................365 Decommissioning..............367 Disposal................... 369 Troubleshooting ..............371 22.1 Customer Service ..............371 22.2 Messages of the software............371 Technical data................. 383 Appendix ................. 385 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 7: About These Instructions

    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. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 8 Safety ( p. 9). If no other clear location information is used in a figure, indications of right Location information or left are always from the user's point of view. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 9: Other Documents

    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. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 10 About these instructions Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 11: Safety

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

  • Page 12: Signal Words And Symbols Used In Warnings

    If ignored, environmental damage can result NOTICE (without hazard symbol) If ignored, property damage can result The following symbols indicate the type of danger to personnel: Symbols Symbol Type of danger General Electric shock Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 13 Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 14 Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in property damage if ignored. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 15: Machine Head

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

  • Page 16: Swiveling Up The Machine Head

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

  • Page 18: Swiveling Down The Machine Head

    ⑤ (4) - Fabric sliding plate (5) - Latch To swivel down the machine head: 1. Hold the machine head in the head cover area (2). 2. Release the latch (5). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 19: Disassembling 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°. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 20 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). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 21: Assembling Machine Head

    1. Use a suitable tool to carefully insert the machine head into the machine head cutout. 2. Use the screws (1) and (2) to tighten the machine head. 3. Align the height of the machine head ( p. 125). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 22 4. Restore the gas shock absorber connection (5). 5. Establish the electrical and pneumatic connection to the machine head. 6. Insert the fabric sliding plate (4). 7. Swivel the locking lever (3) down. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 23: Assembling The Crank Pin At The Arm Shaft

    Important The crank pin is re-adjusted with the help of a gage (part number 0246 002591). The setting does not require that crank and arm shaft be removed. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 24 FIg. 12: Removing the head cover ① ② ① (1) - Screws (2) - Head cover To remove the head cover: 1. Loosen the screws (1). 2. Remove the head cover (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 25 2. Swivel the thread tension plate (5) to the right. Disassembling switching cylinder and needle bar linkage FIg. 14: Disassembling switching cylinder and needle bar linkage ⑥ ⑦ (6) - Switching cylinder (7) - Needle bar linkage Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 26 3. Turn the handwheel until the hexagon screws (14) are facing down.  In this position, the screws are accessible. 4. Loosen the hexagon screws (14). 5. Loosen the screw (9). The screw can be accessed through the hole (3) (figure above). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 27 14. Tighten the fastening screws firmly (Caution: Left-handed thread). 15. Assemble and set the needle bar linkage ( p. 36). 16. Assemble the switching cylinder used for the middle knife drive ( p. 59). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 28: Needle Bar Linkage

    1. Unscrew the screws (1). 2. Carefully loosen the clamp for the needle thread monitor (3). Make sure not to damage the needle thread monitor when doing so. 3. Remove the head cover (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 29 (6) - Thread advancing device To remove the needle bar linkage: 1. Loosen screws (4) and (7). 2. Remove the thread advancing device (6). 3. Unscrew the screws (5). 4. Unscrew the screw (8). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 30 7. Carefully pull the support plate (13) with the needle bar linkage (12) off the stop pin (11). Pulling off the plate is made easier by slightly turning it back and forth. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 31: Removing A Needle Bar From The Needle Bar Linkage

    To remove a needle bar from the needle bar linkage: 1. Loosen the clamping screw (1). 2. Pull out the bearing bolt (3). 3. Pull the support plate (2) off the needle bar linkage. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 32 11. Slowly slide the crosshead (13) up the needle bar until the three top coupling balls (8) pop out. Important Make sure not to lose the coupling balls. The coupling balls are spring-loaded. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 33: Dismantling The Needle Bar

    Ø 4 mm pin that you insert into the needle bar from the bottom. 6. Remove the parts housed in the needle bar one at a time from the bottom. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 34: Assembling The Needle Bar

    (12) is 30.5 mm Important Strictly follow this dimension (30.5 mm) as it is necessary for allowing the coupling to exert the retaining force required for needle penetration. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 35: Assembling Needle Bars Into The Needle Bar Linkage

    (13) - Decoupling bar (7) - Coupling balls (3x) To assemble the needle bars into the needle bar linkage: 1. Insert the needle bar (4) into the needle bar linkage (1) from the bottom. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 36 13. Screw in the needle holder (11). 14. Tighten the screw (12). 15. Turn the needle bar (4) until the front faces of both needle holders (11) are in the same plane. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 37 (5), (see fig. above), may pop out inadvertently. Information The exact height of the needle in relation to the hook must be set after the installation of the needle bar linkage in accordance with ( p. 38). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 38: Assembling The Needle Bar Linkage

    4. Carefully slide the support plate (1) with the needle bar linkage (2) onto the stop pin (4). 5. Insert and slightly tighten the fastening screw (5). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 39 ( p. 40). FIg. 27: Assembling the needle bar linkage (3) ⑪ ⑮ ⑫ ⑭ ⑬ (11) - Screw (14) - Screw (12) - Pin (15) - Pin (13) - Thread advancing device Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 40: Setting The Height Of The Needle Bar Linkage

    To set the height of the needle bar linkage: 1. Unscrew the screws (1). 2. Remove the head cover (2). 3. Verify that the distance between crosshead (4) and needle bar linkage (3) is 0.2 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 41  The distance between needle bar linkage (3) and crosshead (4) is 0.2 mm. 7. Tighten counternuts (8) and (5). 8. Tighten the screw (7) on the support plate. 9. Place the head cover (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 42: Aligning The Needle Bar Linkage With The Throat Plate

    3. Check the position of the needles inside the needle hole. 4. Loosen the screws (1). 5. Shift the needle bar linkage laterally until the needles are at the center of the needle holes. 6. Tighten the screws (1). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 43: Changing The Needle Holder

    3. Use a hex key (1) to press down and hold the switch rod of the needle bar. 4. Turn the handwheel to disconnect the needle bar. 5. Continue to turn the handwheel.  The actuated needle bar switches off. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 44 12. Check how the needle plunges into the needle hole ( p. 40). 13. Check the lateral distance of the needle to the hook ( p. 50). 14. Replace the second needle holder in the same way as the first needle holder. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 45: Hook

    The exact height of the hook shaft is set using the gage (3) (part number 0244 001001). To set the height of the hook shaft: 1. Remove the throat plate. 2. Remove both hooks ( p. 54). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 46 11. Slide the sleeve (6) against the hook shaft as far as it will go. 12. Tighten the screws (7) on the surfaces of the sleeve (6). 13. Re-assemble hook and throat plate ( p. 54). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 47: Setting The Gear Clearance Of The Hook Drive

    To set the gear clearance of the hook drive: 1. Slightly turn the hook while checking the gear clearance. 2. Loosen the screw (3). 3. Loosen the screw (1). 4. Loosen the clamping screws of the worm wheel (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 48: Setting The Loop Stroke

    Risk of injury from moving parts! Crushing possible. Switch off the machine before setting the loop stroke. FIg. 36: Setting the loop stroke (1) ② ① 0,1 mm (1) - Needle (2) - Hook tip Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 49 10. Remove the locking peg. 11. Continue to turn the machine and tighten the second screw. 12. Press the plastic stoppers (4) back into the holes. 13. Swivel down the machine head ( p. 16). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 50: Setting The Needle Holder Height

    3. Insert the locking peg through the hole in the machine arm.  The locking peg must engage in the slot of the arm shaft crank. 4. Check the position of the needles to the hook tips. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 51  It should be possible to slide the measuring bridge under the measur- ing pin (2) with as little play as possible. 15. Unscrew the screw (6). 16. Turn the needle holder (8) to adjust its height. A complete 360° rotation is possible. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 52: Setting The Distance Between Hook Tips And Needles

    ( p. 53). The distance between the hook tips and the needles is set using a setting peg (3) (part number 0244 001014). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 53 8. Take the bobbin case bottom part (4) out of the hook. To do so, slightly turn the handwheel back and forth. Important Do not apply force when removing the bobbin case bottom part (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 54 (12) of the setting peg (3). 16. Tighten the screws (13). 17. Tighten the screws (10). 18. Assemble bobbin case bottom parts and hook cover. 19. Insert the throat plate. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 55: Setting The Needle Guard

    4. Set the needle guard (5). To do so, turn the eccentric bolt (3). 5. Tighten the screw (4). 6. Assemble bobbin case bottom parts and hook cover. 7. Insert the throat plate. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 56: Changing The Hook

    Do not apply force when removing the bobbin case bottom part. 6. Unscrew the fastening screw (1) of the hook. 7. Lift off and remove the hook from the hook shaft. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 57: Setting The Bobbin Case Holding Wire

    (6) - Bobbin case top part (2) - Screw (7) - Holding lug (3) - Bobbin case holding wire (8) - Screw (4) - Edge 1 (9) - Clamping screw (5) - Edge 2 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 58 The rear of the hook must not hit the underside of the bobbin case holding wire while the hook is completing its rotation. Set the height of the plate accordingly. 9. Tighten the screw (2). 10. Loosen the screw (8). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 59: Middle Knife

    3. Pull the cover off carefully. 4. Loosen the screws on the eccentric (1). 5. Unscrew the motor fastening screws (2). 6. Pull the drive motor (3) out of the eccentric (1) towards the rear. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 60: Assembling The Drive Motor

    5. Carefully fit the cover. 6. Tighten the screw (5) of the cover. 7. Establish the electrical connection on the motor. To do so, the plug between cable harness and motor cable. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 61: Disassembling The Switching Cylinder

    2. Unscrew the connection (3) from the cylinder if necessary. 3. Remove the drive motor ( p. 57). 4. Loosen the clamping screw (5) between switching cylinder and drive rod. 5. Pull the switching cylinder up and out. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 62: Assembling The Switching Cylinder

    5. Tighten the screws on the eccentric (4). 6. Screw the pneumatic connection (3) into the cylinder if necessary. 7. Slip on the pneumatic hose (2). 8. Assemble the drive motor ( p. 58). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 63: Setting The Middle Knife

    3. Turn the middle knife drive rod (5).  The middle knife is in parallel / slight cutting position in relation to the knife in the throat plate. 4. Tighten the screw (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 64 7. Tighten screws (7) and (8). 8. Carry out a cutting test. 9. To correct the position of the middle knife, slightly turn the middle knife drive rod (5) counterclockwise until it is in cutting position. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 65: Setting The Thread Tension Spring

    To set the thread tension: 1. Loosen the screw (1). 2. Turn the socket (2). • Increase the thread tension: turn clockwise • Reduce the thread tension: turn counterclockwise 3. Tighten the screw (1). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 66: Setting The Trimming And Clamping Device For The Needle Threads

    (3). This sets the knife automatically to the cutting position. FIg. 54: Setting the trimming and clamping device for the needle threads (2) ⑤ (5) - Pneumatic switch Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 67 1 mm ① ② ③ ④ ⑤ ⑥ (1) - Screw (4) - Screw (rear side) (2) - Screws (5) - Needle thread catcher (3) - Knife (6) - Knife guard Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 68 2. Set the height of the needle thread catcher such that the dimension between the sliding plate and the bottom edge of the needle thread catcher (5) is 27+/- 1 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 69: Setting The Trimming And Clamping Device For The Hook Threads

    After reaching the end of the seam, the hook threads are pulled into the open hook thread trimmer (1) and the hook thread clamp (2) through the thread grooves in the throat plate. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 70 2. Align the openings of the hook thread trimmer (1) with the center of the thread grooves in the throat plate. 3. Tighten the screw (7). 4. Loosen the screw (6). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 71 The throttle valve is located at the blast pipe. Important The air blast must not interfere with the stitch formation. Lightweight sewn products (e.g. lining fabrics) must not be blown upward on the throat plate. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 72: Setting The Thread Advancing Device For The Needle Threads

    To set the thread advancing device for the needle threads: 1. Loosen the counternut (1). 2. Set the stop width of the thread advancing device (3) by turning the stop screw (2). 3. Tighten the counternut (1). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 73: Setting The Synchronizer

    3. Turn the cam segment (1) such that the offset edge of the cam segment (1) is at the center between the forks of the light barrier. 4. Tighten the threaded pin (2). 5. Check the positioning after cutting. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 74: Setting The Differential Gear

    3. Tighten the threaded pin (2) on the compensating weight (1). Make sure that the threaded pin (2) points up vertically and that the compensating weight (1) is seated in the middle of the bearing bracket (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 75: Transport Carriage

    The reference switch (1) determines the rear and, by means of a definitively specified path, the front end position of the transport carriage. The distance between the switching screw (2) and the reference switch (1) must range between 0.5 mm and 1 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 76: Setting The Position Of The Reference Switch In The Slotted Hole

    To set the position of the reference switch in the slotted hole: 1. Loosen the upper counternut at the reference switch (1). 2. Set the reference switch in the slotted hole (2) ( p. 90). 3. Re-tighten the upper counternut. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 77: Setting The Distance Between Switching Screw And Reference Switch

    3. Tighten the counternut. 4. Slide the transport carriage (3) all the way back. 5. Verify that the distance between reference switch (1) and screw (2) is 0.5 - 1 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 78: Setting The Transport Carriage Stop

    2. Loosen the counternut on the stop (4). 3. Move the stop (4) up to the transport carriage until it is at a distance of 2 mm. 4. Tighten the counternut on the stop (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 79: Changing The Toothed Belt

    Fig. 66: Changing the toothed belt (1) ① ② (1) - Toothed belt clamp (2) - Screws The toothed belt is split to allow for easy replacement. It is held together by a toothed belt clamp (1). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 80 To remove the old toothed belt: 1. Unscrew the screws (4). 2. Remove the hood (3). 3. Remove the screws of the toothed belt clamp (2). 4. Slide the carriage to the side. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 81 3. Position the toothed belt clamp (1) above the carriage and assemble it using the screws of the toothed belt clamp (1). 4. Set the toothed belt tension ( p. 80). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 82: Setting The Toothed Belt Tension

    2. Slightly loosen the fastening screws (2) of the motor bracket. 3. Use the clamping screw (1) to set the toothed belt tension to 60Hz and secure the clamping screw. 4. Tighten the fastening screws (2) of the motor bracket. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 83 Consequences of insufficient toothed belt tension • no proper tooth meshing between toothed belt teeth and disk toothing • Skipping of teeth under load • uneven stitch lengths • possible step losses Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 84 Transport carriage Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 85: Transport Clamps

    Use the edge of the sliding plate (measuring line) (1) to set and check the folding and cutting tools. The sliding plate edge (1) runs parallel to the feed mechanism at a distance of 100 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 86: Aligning The Transport Clamps With The Sliding Plate Edge

    1. Slide the transport clamps (1) into the area of the pick-up folder. 2. Check if the inner edge of the transport clamp and the edge of the sliding plate (2) are parallel to each other. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 87 4. Set the transport clamps (1) in parallel position using the hexagon screws (3) (SW 2). • Turn the hexagon screws (3) clockwise or counterclockwise until reaching the parallel position. 5. Tighten the tightening screws (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 88: Setting The Transport Clamp Stroke Height

    20 mm on the left and the right. To set the transport clamp stroke height: 1. Slide the transport carriage under the machine arm (3). 2. Check the stroke height of the two transport clamps. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 89 FIg. 74: Setting the transport clamp stroke height (2) ④ (4) - Screws 3. Loosen the screws (4). 4. Set the transport clamp stroke height relative to the fabric sliding plate. 5. Tighten the screws (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 90: Setting The Distance Of The Transport Clamps To The Folder Sole

    (2) and the inner edges of the transport clamps (1). The distance for moderately heavy clothing fabric must be approx. 1.0 mm to 1.5 mm. This distance is necessary to ensure both uniform piping strips and unhin- dered transport of the sewing material. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 91 4. Loosen the screw (5). 5. Depending on the application at hand, slide the lever (6) in front of stop screw (4) or stop screw (7). 6. Tighten the screw (5). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 92: Setting The Front End Position Of The Transport Clamp

    Set the transport clamps only with utmost caution and with the machine switched on. FIg. 77: Setting the front end position of the transport clamp ① ② (1) - Reference switch (2) - Rear stop Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 93 6. Correct the rear stop (2) ( p. 76). 7. Switch on the machine. 8. Make another reference run and check the dimension for the front edge of the transport clamp. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 94: Setting The Blowing Of The Piping Strips

    > Select pedal mode and press the button ( p. 281). 2. Open the menu Program parameters > Program loading process > Select blowing mode and select Mode 2 ( p. 278). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 95 9. Loosen the screws and set the blow tubes in the flap clamps (3) by turning. 10. Set the compressed air at the throttle valve (5). 11. Tighten the screws. 12. Press the left pedal.  The sewing process starts. 13. Check the feeding process. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 96 Transport clamps Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 97: Corner Knife

    2. Turn the corner knife holders (4) in such a way that the face sides (3) are in front of each other. 3. Tighten the screw (2). 4. Set the other knife holders as described above. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 98: Setting The Corner Knife Parameters

    1. Open the menu Service > Machine test > Adjust and test corner knife and press the button ( p. 306). 2. Enter the password: 25483.  The display switches to: Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 99 • only for configuration: Automatic corner knife station • Value range: -13 - 13 • The knife supports (1) and (4) must be parallel to one another Fig. 82: Setting the corner knife parameters (3) Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 100: Checking The Corner Knife Station

    Cutting injuries may be sustained. Do NOT reach into the area of the corner knives. Fig. 83: Checking the corner knife station ① ② (1) - Corner knife support (2) - Corner knife support Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 101: Checking The Front Left Corner Knife

    1. Open the menu Service > Machine test and press the button 2. Enter the desired value and confirm by pressing OK. 3. Check the distance between corner knife (1) and corner knife (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 102: Checking The Rear Left Corner Knife

    Risk of injury from sharp parts! Cutting injuries may be sustained. Set the corner knife station only when the machine is switched off. Fig. 86: Aligning the corner knife station with the seams (1) Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 103 2. Loosen the screws (1). 3. Shift the holder (3). 4. Tighten the screws (1). 5. Swivel the corner knife station (4) back. 6. Correct the distance of the switch (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 104 1. Loosen the screw (5). 2. Adjust the corner knife station with the eccentric (6). 3. Tighten the screw (5). 4. Sew a test seam. 5. Check seam and cutting pattern. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 105: Setting The Slant Of The Corner Knife Cuts

     This makes the corner knife cuts more visible. 2. Sew a test seam. 3. Check seam and cutting pattern. 4. Loosen the screw (1). 5. Set the corner knife holder (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 106: Replacing Corner Knives

    (3) - Corner knife holder To replace the corner knives: 1. Swivel out the corner knife station. 2. Remove the piercer (1) (for straight pocket only). 3. Loosen the screw (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 107 6. Tighten the screw (4). 7. Insert the piecer (1) again.  The tip of the knives has to be below the piercer (1). 8. Swivel in the corner knife station. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 108 Corner knife Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 109: Aligning The Marking Lamps

    (3) - Marking of the front positioning point (7) - Marking of the rear positioning point (4) - Auxiliary line (8) - Edge of sliding plate Method Sewing length (mm) Spacing A (mm) 200* 200* Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 110 After adjusting the laser modules, make sure to follow the steps listed below: • Check the markings and their alignment relative to the middle of the pocket ( p. 109) • Observe the maximum sewing area Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 111 (7) - Marking of the rear positioning point (4) - Auxiliary line (8) - Edge of sliding plate Fig. 95: Checking the exact position of the marking lamp (2) Sewing head Operator Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 112 (5). • Start sewing. The seam must start at the chalk line. • To make a correction, align the marking of the rear positioning point (5) anew after loosening its holders. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 113: Light Barriers

    2. Swing the swivel arm (1) back and check the pressure of the locking screw (3). 3. Check the position of the swivel arm (1) in relation to the machine head. 4. Loosen the counternut (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 114: Aligning The Light Barriers

    The light barriers are set using 2 templates. Fig. 97: Aligning the light barriers ① ② (1) - Template for straight pockets (2) - Template for slanted pockets Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 115 To set the light barriers, swing out the folding station. Fig. 98: Preparing machine and transport clamps ③ ② ① (1) - Screws (3) - Folding station (2) - Reflecting foils Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 116 9. Align the light barriers on the reflecting foils (2). 10. Tighten the screws (1). 11. Slide the transport clamps to the rear and to the front position and check the alignment of the light barriers. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 117 7. Remove the strips of adhesive tape from the reflecting foils. Information If the light barriers fail to switch at seam beginning and seam end, check if the transport clamps are parallel and set them ( p. 84). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 118: Setting The Light Barriers For Automatic Slant Detection

    5. Press the button and select the desired transport clamp position.  The light barriers must be aligned with the transport clamp position. 6. Press the button.  The flap clamp opens. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 119  The flap clamp opens. 16. Remove the template (1). 17. Insert the template (2) (slanted pocket) such that line (6) points to the left needle and is parallel to the right transport clamp. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 120  The settings are stored, and the display switches to Machine test. 24. Slide the transport clamps to the rear by hand. 25. Swing in the folding station. 26. Switch off the machine. 27. Switch on the machine again. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 121: Setting The Light Barriers For The Left And The Right Flap Rest

    Do not reach into the travel path of the transport clamps. The folding station must be swung out. Fig. 103: Setting the light barriers for the left and the right flap rest (1) ① (1) - Template for straight pockets Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 122 2 mm above the sewing material. 9. Insert the template (1) (straight pocket) such that line (3) points to the left needle and is parallel to the right transport clamp. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 123  The settings are stored, and the display switches to Machine test. 18. Slide the transport clamps to the rear by hand. 19. Swing in the folding station. 20. Switch off the machine. 21. Switch on the machine again. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 124: Setting The Light Barrier For The Flap

    5. Turn the air nozzle holder in such a way that the air stream hits the reflecting foil. Do NOT shift the light barrier position. 6. Select the output YC106. 7. Tighten the screws (1). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 125: Setting The Folding Station Plate

    To set the folding station plate: 1. Use a strip or an angle to extend the folding station plate (1) to the sliding plate surface. 2. Check the distance to the needle. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 126 7. Re-attach the plate of the ratchet lever (2) to the support pipe (3) using pins. For this purpose, use new clamping pins and the 2 unused holes of the 4 holes on the plate of the ratchet lever (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 127: Aligning The Machine Head

    1. Slide the transport clamps to the rear. 2. Raise the sliding plate (4) at the front and swivel it out to the left. 3. Check the height of the base plate (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 128 2. Loosen counternuts (7) and (8). 3. Turn sleeves (6) and (9) evenly using a hex key. Hold the screws (5) in place while doing so. 4. Tighten counternuts (7) and (8). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 129 1. Swivel up the machine head ( p. 14). 2. Loosen the counternut (11). 3. Tighten or loosen the centering nut (12) as necessary. 4. Tighten the counternut (11). 5. Swivel down the machine head ( p. 16). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 130 Aligning the machine head Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 131: Setting Fabric Sliding Plate And Vacuum Plate

    2. Check the height of the vacuum plate in relation to the tabletop. 3. Turn the threaded pin (1). • Set vacuum plate higher: turn clockwise • Set vacuum plate lower: turn counterclockwise 4. Readjust the supporting screws (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 132 Setting fabric sliding plate and vacuum plate Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 133: Folder

    2. Pull out the folder (2). 3. Check if the hole of the holding pin (1) points towards the screw (3). 4. Insert the folder (2) again. 5. Tighten the screw (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 134: Aligning The Folder With The Middle Of The Pocket Opening

    100 mm - 5 mm - 1/2 x 12 mm = 89 mm Check the distance of the folder sole (3) to the edge of the sliding plate (1). Dimension A 10.5 11.5 13.5 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 135  The folder sole (3) ascends by 0.5 mm along a length of 100 mm, starting from the sewing area. This facilitates the feed of the sewing material. 7. Tighten the screw (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 136: Setting Guide Plates Using Spring-Loaded Downholders

    2. Turn the threaded pin in nut (10) to set the height of the guide plates. 3. Tighten the nuts (10). 4. Loosen the screw (9). 5. Set the stop (8).  The stop prevents the downholders from colliding with the needles in raised position. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 137 To set the spring pressure of the additional downholder: 1. Loosen the screw (3). 2. Shift the screw (3). • more pressure: shift downward • less pressure: shift upward 3. Tighten the screw (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 138: Presetting The Mounting Plate For The Pick-Up Folder

    To check the position of the mounting plate for the pick-up folder: 1. Pull off the hose coupling (5). 2. Loosen the clamping screw (6). 3. Remove the pick-up folder (7). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 139 1. Loosen the screws (12). 2. Shift the mounting plate for the pick-up folder in sewing direction. Important Make sure that the angle (3) abuts on the face side (2). 3. Tighten the screws (12). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 140: Aligning The Pick-Up Folder

    To align the pick-up folder sole with the middle of the pocket opening: 1. Push the pick-up folder (1) up as far as it will go. 2. Tighten the screw (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 141 As an aid you can use a ruler positioned at the sole of the folder. The soles of folder and pick-up folder need to be exactly in alignment. 9. Tighten screws (2) and (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 142: Aligning The Pick-Up Folder Height With The Folder

    1. Turn the threaded pin (1). 2. Check if both soles are flush at the connecting surface (2). To do so, look at the soles from the side. 3. Readjust if necessary. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 143: Setting The Pick-Up Folder Position In Sewing Direction

    To set the position of the pick-up folder in sewing direction: 1. Loosen the screws (1). 2. Shift the lowered pick-up folder in sewing direction.  The distance between pick-up folder and folder is 0.5 mm. 3. Tighten the screws (1). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 144: Setting The Guide Plates At The Pick-Up Folder

    4. Set the guide plate distance to 0.3 - 0.5 mm. 5. Tighten the nuts (3). 6. Set the 2nd guide plate in the same way. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 145: Setting The Stop Screw For The Pick-Up Folder

    - the stop screw abuts on the stop (3). Make sure the stop snaps into place. 4. Set the spring pressure using the screw (1) so that the folder is pushed back. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 146: Setting The Pick-Up Folder Detection

    To set the pick-up folder detection: 1. Loosen the screws (3). 2. Set the distance between the switching flag and switches S11 (1) and S12 (2). 3. Tighten the screws (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 147: Feeding Device

    • Feeding device right, sewing length 180 and 220 mm 13.1 Changing the toothed belt WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before changing the toothed belt. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 148: Changing The Front Toothed Belt

    7. Turn the eccentric (2) in such a way that the toothed belt is under tension. 8. Tighten the screw (3). Information It must still be possible to easily rotate the toothed belt. 9. Connect the connection hoses (1) again. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 149: Changing The Rear Toothed Belt

    5. Slide the piston rod (5) into the cylinder (7). 6. Swing the cylinder (7) upward. 7. Swing the folding station out. Fig. 130: Changing the rear toothed belt (2) ⑩ ⑪ (10) - Adjusting ring (11) - Locking ring Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 150: Setting The Toothed Belt Tension (745-35-10 B)

    Disturbance Faults due to excessively high toothed belt tension: • reduced service life of the toothed belt • Non-uniform cylinder motion • Reduced slippage of the eccentric bush Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 151: Setting The Front Toothed Belt Tension

    To set the front toothed belt tension: 1. Loosen the screw (1). 2. Turn the eccentric (2). 3. Tighten the screw (1). Important It must still be possible to easily rotate the toothed belt. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 152: Setting The Rear Toothed Belt Tension

    5.0 mm ① ② ③ ④ ⑤ ⑥ 0.5 - 2.0 mm (1) - Arm (4) - Arm (2) - Swivel arm (5) - Shank (3) - Swivel arm (6) - Shank Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 153 1. Loosen the screw (7). 2. Turn the swivel arms (2) and (3) to the horizontal position. 3. Tighten the screw (7). Important Make sure the toothed belt wheel has no lateral play. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 154 To set the shanks: 1. Loosen the screws (8). 2. Set shanks (5) and (6). 3. Tighten the screws (8). Important The movement must be smooth, but there must not be any lateral play. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 155: Flap Clamps (745-35-10 B)

    Fig. 137: Aligning the flap clamps with the sliding plate edge (2) ⑧ ⑨ ① (1) - Flap clamp (9) - Screws (8) - Flap clamp transport clamp Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 156: Setting The Flap Clamp Lifting Device

    The flap clamp lifting device lifts the flap clamps (2) before they are swiveled out so that they can pass over the closed flap clamps (1) without hindrance. To set the flap clamp lifting device: 1. Lower the flap clamp. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 157: Aligning The Flap Clamps With The Pick-Up Folder

    To align the flap clamps with the pick-up folder: 1. Open the menu Service > Multi test > Multi test I/O and select the output YC105 ( p. 324).  The flap feeders swivel in. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 158 Fig. 140: Aligning the flap clamps with the pick-up folder (2) ⑤ ⑥ (5) - Counternut (6) - Piston rod To set the flap clamp sideways: 1. Loosen the counternut (5). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 159: Setting The Flap Clamps To The Flap Rest Table

    The flap rest table must be set such that the stationary flap clamp (1) is flush and parallel to the flap rest table (2). The distance between flap clamp (1) and flap rest table is 8 - 12 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 160 3. Tighten the nut (9). Setting the flap rest table Fig. 143: Setting the flap clamps to the flap rest table (3) ⑬ ⑪ ⑫ (11) - Screw (13) - Screws (12) - Bar Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 161: Flap Turning Device (745-35-10 F)

    Switch off the machine before you set the flap turning device. The flap turning device 745-35-10 F is a supplement to the feeding device of the 745-35-10 B. The feeding device must be set precisely to allow the flap turning device to function properly.

  • Page 162: Changing The Lower Toothed Belt

    While doing so, remove the toothed belt (2) from the toothed belt wheel (1). Placing a new toothed belt Fig. 145: Changing the lower toothed belt (2) ⑤ ⑥ (5) - Cylinder (6) - Threaded pins Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 163: Changing The Upper Toothed Belt

    1. Place a new toothed belt onto the toothed belt wheel (4). 2. Insert the toothed belt wheel (1) with levers and axial disks into the lever (3). 3. Slip on the axial disks. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 164: Setting The Initial Position Of The Flap Turning Device

    ② (1) - Cylinder (2) - Threaded pins To set the initial position: 1. Loosen the threaded pins (2). 2. Turn the cylinder (1) clockwise until reaching a value of 63°. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 165 (4) - Screw (6) - Lever (5) - Needle sleeve (7) - Toothed belt wheel To set the position of the lever in relation to the axles: 1. Loosen the screw (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 166 2. Set the screw (9) to 16.5 mm. 3. Tighten the counternut. 4. Loosen the counternut from screw (8). 5. Set the screw (8) to 14 mm. 6. Tighten the counternut. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 167: Aligning The Flap Turning Device

    1. Loosen screws (6), (1) and (2). 2. Use screws (3), (4) and (5) to align the stationary and the movable flaps parallel to the edge of the sliding plate. 3. Tighten screws (6), (1) and (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 168: Setting The Flap Transfer Position

    2. Turn the screw (1) in such a way that the stationary flap clamp (5) is positioned 20 ± 3 mm below the rest table (3). 3. Tighten the counternut (2) Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 169 ⑥ ⑤ ④ (4) - Flap clamp : Flap turning device 745-35-10 F (5) - Flap clamp : Feeding device 745-35-10 B and (6) - Sleeve 745-35-10 F (7) - Nut Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 170: Setting The Swivel Range Of The Flap Turning Device

    3. Tighten the screw (2). 4. Use screw (4) and counternut (3) to make the fine adjustment.  The distance between the flap clamp and the fabric sliding plate is approx. 1 - 3 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 171: Setting The Movable Flap Clamp

    4. If necessary, align the flap clamp parallel to the fabric in the longitudinal direction. 13.5.7 Setting the movable flap clamp Fig. 158: Setting the movable flap clamp ① ② ③ (1) - Screw (3) - Movable flap clamp (2) - Stationary flap clamp Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 172: Performing A Sewing Test According To Pattern

    (2) - Pocket opening line Sample calculation Na 1/2 Flap cut Flap depth Needle width * 0.5 Pocket opening line PL1 = PT - NA 1/2 PL1 = 60 - 5 = 55 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 173: Making Corrections To The Settings

    13.7.1 Correction: Flap sewn in too deep Fig. 160: Correction: Flap sewn in too deep ③ ① ② (1) - Screw (3) - Clamp of flap turning device (2) - Counternut Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 174: Correction: Flap Not Sewn In Deep Enough

    ③ ① ② (1) - Screw (3) - Clamp of flap turning device (2) - Counternut Proper setting The clamp of the flap turning device must be moved to the right. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 175: Correction: Flap Fed Obliquely

    1. Loosen screws (3), (4) and (5). 2. Loosen screws (1) and (2). 3. Align the flap clamp. 4. Tighten screws (1) and (2). 5. Tighten screws (3), (4) and (5). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 176: Correction: Flap Is Sewn In Shifted To The Right

    1. Loosen screws (5), (3) and (4). 2. Tighten the screw (1).  The gap is increased. 3. Tighten screws (5), (3) and (4). 4. Check the setting and readjust it if necessary. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 177: Correction: Flap Is Sewn In Shifted To The Left

    1. Loosen screws (5), (3) and (4). 2. Tighten the screws (2).  The gap is increased. 3. Tighten screws (5), (3) and (4). 4. Check the setting and readjust it if necessary. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 178 Feeding device Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 179: Piping Cutter

    When completing their cut, the piping knives must run in the center groove of the pick-up folder. The pick-up folder tracks between both centering pins when lowered on the piping cutter. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 180  The rest table is parallel to the sole of the pick-up folder (1). 6. Turn the threaded pins (6) until the pick-up folder (1) tracks between the centering pins (2). 7. Tighten screws (5) and (7). 8. Tighten the counternut (4). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 181: Aligning The Height Of The Rest Table

    2. Check the inclination of the rest table (2) and correct it if necessary. 3. Loosen the screw (3). 4. Align the piping cutter parallel (II) to the sole of the pick-up folder (1) in sewing direction. 5. Tighten the screw (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 182: Setting The Piping Strip Deflector

    5 mm parallel to the pick-up folder sole. To set the piping strip deflector: 1. Loosen the screws (2). 2. Set the piping strip deflector (1). 3. Tighten the screws (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 183: Replacing The Piping Knives

    12. Tighten the screws (1). 13. Assemble the pick-up folder. 14. Connect the machine to the compressed air supply. 15. Check the rear end position of the piping knives ( p. 182). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 184: Checking The Rear End Position Of The Piping Knives

    Check the rear end position of the piping knives after replacing the piping knives. • Check the play of the guide roller in the guide in case of pressurized cylinders  The piping knife point has a play of 0.2 - 0.5 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 185 9. Check the play of the piping knife point and readjust it if necessary.  The piping knife point has a play of 0.2 - 0.5 mm. 10. Assemble the cover (4). 11. Tighten the screws (5). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 186: Setting The Knife Carrier

    5. Press on the pin (2). 6. Tighten the threaded pin (3). 7. Check if the knife carrier (1) can move freely and does not have too much play; readjust if necessary. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 187: Setting The Toothed Belt Tension

    2. Remove the single pipe stop (2). 3. Use a spring balance to pull the lower belt against the upper one through the opening in the rest table. 4. Loosen the screws (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 188: Changing The Toothed Belt

    7. Insert the single pipe stop (2). 8. Tighten the screws (1). 14.8 Changing the toothed belt Fig. 176: Changing the toothed belt (1) ① ② (1) - Screws (2) - Single pipe stop Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 189 7. Fit a new toothed belt. 8. Insert the idler (6). 9. Tighten the screw (5). 10. Insert the clamping plate and tighten the screws (4). 11. Set the toothed belt tension ( p. 185). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 190 Piping cutter Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 191: Additional Equipment

    The downholder (2) is aligned such that it moves down close to the folder on the right / left as well as close to the front in the area of the sewing start. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 192: Assembling The Waistband Clamp (745-35-10 B Only)

    Fig. 179: Assembling the waistband clamp (1) ④ ③ ① ① ② (1) - Waistband clamp (3) - Fastening thread - rear (2) - Fastening thread - front (4) - Needle rib Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 193 To assemble the waistband clamp: The fully assembled waistband clamp (1) and the needle rib (2) are fixed in the front fastening threads (3) of the vacuum plate (5) towards the sewing machine. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 194: Setting The Outfeed Roller

    The transport rollers must be aligned parallel to the tabletop and the middle of the pocket opening. Setting the height of the transport rollers When lowered, both transport rollers (5) and (7) should rest evenly on the tabletop. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 195  The lowering speed should allow for a rapid, but not abrupt movement. Setting roller speed and duty cycle The rolling speed and the duty cycle of the transport rollers are set at the OP7000 control panel ( p. 282). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 196: Setting The Tape Feeding And Tape Cutting Device

    2. Set the guides in such a way that the strip is fed precisely. 3. Tighten the screws at guides (1), (2) and (3). Setting the tape length The tape length is set at the OP7000 control panel ( p. 268). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 197 To set the tape puller: 1. Shift the screw (2) to pull off more tape. 2. Set the throttle valves so as to avoid any after-run of the roller. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 198: Pocket Bag On Flap (745-35-10 B Only)

    (6) - Nuts Order First, check the following settings: • Position of the folder guide plate ( p. 142) • Guide plate height • Spring pressure • Lateral position to the needle Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 199: Setting The Transport Clamps

    2. Loosen the threaded pin (1). 3. Turn the blow tube (2).  The direction of the blown air is set in such a way that the pocket bag runs safely into the folder. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 200 10 mm outward ( p. 90). 7. Set the stroke of the raised left transport clamp ( p. 86).  The default stroke height is 20 mm. The stroke height must not exceed 15 mm. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 201: Setting The Light Barrier Position

     The pick-up folder lowers down on the sliding plate. 10. Pull the transport clamps forward and check the light barrier for proper operation. 11. Turn the holder (3) to set the light barrier. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 202: Aligning The Light Barriers

    > Select blowing mode and select Mode 5 ( p. 278). 15.5.7 Setting transport clamp mode To set transport clamp mode: 1. Open the menu Global parameters > Transport clamp quick adjustment and press the button Bypass left Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 203: Stacker

    To set the position of the stacker tongs relative to the tabletop: 1. Loosen the counternut (2). 2. Screw in or loosen the piston rod of the cylinder (1). 3. Tighten the counternut (2). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 204: Setting The Height Of The Stacker Tongs

    2. Manually push the stacker tongs (3) forward until the tongs close. 3. Tighten the clamping lever (1). 4. Loosen the clamping lever (1) so that you can slide the stacker tongs in both directions on the axle (2) as well. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 205: Setting The Position Of The Stacker Tongs And Closing The Tongs

    3. Tighten the nut (2). Information When creating the pocket program, you can determine the Position of the transport clamp after sewing and adjust the position of the stacker tongs. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 206: Setting The Cylinder Speed

    Fig. 192: Setting the tray position ① ④ ② ③ (1) - Stacking bracket (3) - Locking lever (2) - Clamping lever (4) - Storage table Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 207: Swiveling The Stacker To The Side

    3. Swivel the stacker back to its position after completing the setting operations. 4. Tighten the quick release (2). 5. You can use the locking plate (1) to align the stacker parallel to the machine. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 208: Throw-Over Stacker

    (-) = earlier or (+) = later. To check the function sequence of the throw-over stacker: 1. Once the start signal for the stacking process has been given, swivel bracket a (5) moves down. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 209 Fig. 196: Checking the function sequence (3) ⑩ ⑬ ⑪ ⑫ ⑩ ⑪ (10) - Valve 5 (12) - Switch cam g (11) - Valve 3 (13) - Switch cam h Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 210 • Switch actuation point later (+): turn counterclockwise • Switch actuation point earlier (-): turn clockwise  The stacking process is complete as soon as swivel bracket a (5) has moved back to its original position. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 211: Setting The Throw-Over Stacker

    1. Start signal: Swivel bracket (2) closes. 2. The switch (5) is pressed approx. 5 mm before the stacking bracket (1) is reached. 3. Loosen the screw (6) and set the switch cam (7) by turning. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 212 (4) during the last section of the backward movement. Check the optimal switch actuation point by performing stacking operations with workpieces and correct it if necessary. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 213 (4) during the last section of the backward movement. Check the optimal switch actuation point by performing stacking operations with workpieces and correct it if necessary. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 214: Setting The Stacking Speed

    Multi test > Multi test I/O and select the output Y14 ( p. 326). 16.2.4 Activating the stacker You activate the stacker in the menu Service > Machin config. ( p. 286). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 215: Pressure Supply

    • Turn the screw (2) clockwise until the display reads S11+ • Slightly turn the screw (2) counterclockwise until the display reads S11- again If display reads S11+: • Turn the screw (2) counterclockwise until the display reads S11- Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 216: Setting The Transport Clamp Control

    The default setting is 0.5 Mpa = approx. 5 bar. • Increase pressure: turn counterclockwise • Reduce pressure: turn clockwise Important The safe transport of the sewing material needs to be ensured at all times. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 217: Programming

    1.3 Select needle distance  p. 287 Hook thread monitor On/Off  p. 287 Automatic flap feeder On/Off  p. 287 Tape feeder On/Off  p. 287 Vacuum On/Off  p. 287 Downholder On/Off Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 218  p. 315 2.9 Adjust and test control panel  p. 319 2.10 Test piping knife  p. 301 2.12 Test pick-up folder 3.0 Multi test  p. 332 3.3 Internal devices Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 219  p. 251 5.1.4.7 Set securement seam end left needle  p. 252 5.1.4.8 Set securement seam end right needle  p. 249 5.1.4.9 Select flap right/left  p. 249 5.1.4.10 Select positioning points Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 220  p. 271 5.1.11.5 Waiting position of transport clamp  p. 272 5.1.12 Process of transport clamp  p. 273 5.1.12.1 Transport clamp quick adjustment  p. 274 5.1.12.2 Process of transport clamp Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 221 5.2.1.2 Set positioning point seam center  p. 296 5.2.1.3 Set positioning point seam end  p. 297 5.2.2 Adjust transport clamp  p. 298 5.2.2.2 Clamp down: Time to next action Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 222 Initialize all seam programs  p. 343 Initialize all sequences  p. 343 Initialize RAM 10.0 Maintenance  p. 346 10.3 Display software version  p. 346 10.4 Enter date and time Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 223 Programming Option/described Menu item in chap. Internal information (password-protected) (for DA staff only)  p. 352 Update machine software Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 224 The user must enable the machine for use after the display of the welcome message goes out. Follow the instructions shown on the display for this purpose: To switch on the machine: 1. Press the pedal.  The control panel is enabled. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 225 ③  p. 228 Edit seam sequence ④  p. 227 Piece counter ⑤ Display of selected seam pattern • the display changes with the setting of the pocket program (with/without flap). Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 226 2. Press the desired button for which you wish to display a Help text.  The selected button and a Help text are displayed. 3. Press on the Help text.  The Help text disappears. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 227 Function Home button • saves the settings in the menu • Return to the start screen Return button • saves the settings in the menu • Return to next higher menu level Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 228 To enter a negative value on the numeric keypad: 1. Enter the desired value. 2. Press the +/- button.  The value is given a - sign and becomes negative. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 229  The display switches to Edit mode. 2. Use the numeric keypad to set the desired number of pieces (0-10000). 3. Confirm with OK.  The display returns to the start screen. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 230 Varies with the programming Selected seam sequence ② Varies with the programming Display of pocket programs assigned to the seam sequence ③ Call up additional seam sequences • In steps of 5 Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 231 Fig. 210: Creating or changing a seam sequence (2) ⑨ ⑬ ⑩ ⑪ ⑫ (9) - Seam sequence template (12) - Help (10) - Seam sequence to be created (13) - Delete pocket program (11) - Available pocket program slot Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 232 The pocket programs will be stored in the seam sequence in the order in which they were added to the seam sequence. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 233 Important The preset program is copied to the selected pocket program slot, deleting the previous program. 5. Select additional preset programs as described above and add them to the sequence. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 234 OR tap on the trash to delete all pocket programs.  The pocket programs are deleted from the sequence. 2. Press the button (1).  The display switches to Select program. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 235 The order in which they are selected corresponds to the order of the programs in the seam sequence.  To scroll up and down the list of pocket programs, press the buttons Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 236  The display switches to Select source of sequence. Fig. 215: Changing the seam sequence template (2) Selectable Display of the sequence sequences content  The destination sequence is grayed out and cannot be selected. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 237 4. Use Drag and Drop to drag any pocket programs you do not need from the sequence to be created (3) to the trash OR tap on the trash to delete all pocket programs.  The pocket programs are deleted from the sequence. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 238  The display returns to Overview of sequences. 7. Press the button to save the setting and return to the start screen.  You can start sewing with the new seam sequence right away. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 239  The display switches to a keypad. Fig. 219: Naming a seam sequence (2) 2. Enter the desired sequence name. You can enter up to 18 characters. Every sequence must be given a name. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 240 3. Press the desired seam sequence.  The selected seam sequence is highlighted with a bold frame and the color orange (1). 4. Press the button.  The display switches to Copy sequence. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 241  To scroll up and down the list of sequences, press the buttons OR drag the bar up or down. Information Cancel the selection by pressing the same sequence again. 6. Press the desired seam sequence.  The display shows an info field. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 242 Fig. 223: Activating a pocket program from the seam sequence ① ② (1) - Pocket programs in sequence (2) - selected pocket program Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 243 Fig. 224: Activating the automatic seam sequence To activate the automatic seam sequence: 1. Press the button.  The start screen shows arrows between the seam sequences. The arrows indicate that the automatic seam sequence has been activated. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 244 Fig. 225: Program parameters Symbols Meaning Select pocket program  p. 244 Enter name of pocket program  p. 245 Copy pocket program  p. 245 Create or change seam program  p. 247 Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 245 Patterned goods • Plain goods Piping knife  p. 284 Reset seam program to default values 2. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 246 ( p. 228). If the pocket program has already been copied to the selected seam sequence, you can activate it in the seam sequence ( p. 240). Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 247 Select source • Select the pocket program you wish to copy Select destination • Select the pocket program you wish to overwrite Save settings To copy a pocket program: 1. Press the button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 248 Fig. 227: Copying a pocket program (2) 6. Confirm with OK.  The selected pocket program is copied. The message Copy was successful is displayed. 7. Confirm with OK.  The display switches to the selected seam program. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 249  The display switches to Create seam program. Fig. 228: Creating a seam program Press a button to either open another submenu or enter the desired values directly using the numeric keypad. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 250 • Set slanted flap shape seam end (1 - 13 mm) Pocket shape seam end • straight • slanted • slanted • Set slanted pocket shape seam end (1 - 13 mm) Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 251 • 1 light barrier • Automatic flap scan left Reset seam program To create a seam program: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 252 Set number of stitches for double tack at seam beginning (0 - 10) To set the securement of the left seam beginning: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 253 Securement seam beginning left needle ( p. 250). Set securement seam end left needle  The display switches to Securement seam end left needle. Fig. 230: Set securement seam end left needle Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 254 Set securement seam end right needle Information The settings in subitem Securement seam end right needle are adopted automatically from the settings for the Securement seam end left needle ( p. 251). Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 255 • Light barrier must be activated in the machine configuration  p. 286 To activate the flap: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 256 Fig. 232: Activating the flap (2) ② ① ② ③ (1) - Quick access corner knife (2) - Quick access flap correction correction (3) - Display of flap Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 257 • -20 mm - 20 mm To make a correction to the light barrier: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 258 Fig. 234: Set correction light barrier seam begin./end Information The arrows in the left half of the display indicate the correction direction: Seam beginning Correction outward Correction inward Seam end Correction outward Correction inward Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 259 To activate marking lamps 1 - 16: 1. Press the button of the desired marking lamp.  The marking lamp is (de)activated. Information The default option allows you to switch 4 marking lamps on/off. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 260 Set seam securement • R.p.m seam begin. • R.p.m seam end To edit the sewing head parameters: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 261 Number of stitches for loosening the needle thread clamp • 1 - 20 To edit the soft start parameters: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 262 Set r.p.m. seam end • 100 RPM - 1500 RPM To set the seam securement: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 263 Set speed middle knife • 100 RPM - 3000 RPM To set the middle knife parameters: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 264 Fig. 240: Set middle knife correction seam begin./seam end Information The arrows in the left half of the display indicate the correction direction: Seam beginning Correction outward Correction inward Seam end Correction inward Correction outward Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 265 Set corner knife correction seam end • -9.9 mm - 9.9 mm To set the corner knife: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 266 Fig. 242: Set corner knife correction seam begin./seam end Information The arrows in the left half of the display indicate the correction direction: Seam beginning Correction outward Correction inward Seam end Correction inward Correction outward Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 267 Corner knife seam begin. left On/Off Corner knife seam begin. right On/Off Correction seam begin. left • -9.9 mm - 9.9 mm Correction seam begin. right • -9.9 mm - 9.9 mm Seam end outer left On/Off Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 268 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Set corner knife correction seam begin./seam end Fig. 244: Set corner knife correction seam begin./seam end Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 269 Seam beginning Correction outward Correction inward Seam end Correction inward Correction outward Corner knife options (Without corner knife, Straight pocket, Straight/Slanted pocket) must be set in the Machine configuration ( p. 286). Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 270 Set length of tape at seam begin. • 0 - 99 mm Set length of tape at seam end • 0 - 99 mm Set clamp speed while transport • 10 - 100 % Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 271 Insertion speed middle • Insertion speed slow Set return of transport clamp • Without transport • Transport up to stacking position • Transport up to loading position Set waiting position of transport clamp Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 272 1 mm - 100 mm Activate transport up to loading position To set the transport clamp return: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 273 • 1 mm - 515 mm To set the waiting position of the transport clamp: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 274  The display switches to Process of transport clamp. Fig. 249: Process of transport clamp To set the process of the transport clamp: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 275 Left in, right in (double pipe) Left out, right in (single pipe left) Left in, right out (single pipe right) Left out, right out To select the transport clamp quick adjustment: 1. Press the desired button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 276 Depressurize both transport clamps together Lower left transport clamp first, depressurize right transport clamp Lower right transport clamp first, depressurize left transport clamp To select the process of the transport clamp: 1. Press the desired button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 277 Left flap clamp closes first • Right flap clamp closes first Vacuum On/Off Downholder On/Off (745-35-10 B only) Select downholder mode (745-35-10 B only) Waistband clamp On/Off (745-35-10 B only) Select blowing mode Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 278 1. Press the desired button.  The user interface for setting the desired item is displayed. Information If vacuum and downholder are activated in the Machine configuration, these functions must be activated / deactivated together. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 279 1: Downholder + waistband clamp 2: Vacuum 1: Downholder + vacuum 2: Waistband clamp 1: Downholder 2: Vacuum 3: Waistband clamp 1: Downholder + vacuum Waistband clamp off 1: Downholder 2: Waistband clamp 3: Vacuum Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 280 , vacuum and waist- band clamp in the lower half of the display changes with the selected setting. Select blowing mode  The display switches to Blowing mode. Fig. 254: Select blowing mode Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 281 To select blowing mode: 1. Press the desired button. Information The numbering of the buttons folding plate , flap clamp lower pickup folder in the lower half of the display changes with the selected setting. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 282 Programming Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 283 • The flap clamps can be opened or closed again after the transport clamps have been triggered, and the sewing process can be started. To select pedal mode: 1. Press the desired button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 284 • only with active blow-off  p. 287 Set the duration for which the blow-off will be blowing • only with active blow-off  p. 287 • 0 ms - 1000 ms Roll-off On/Off Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 285 • 0 ms - 1000 ms To set the stacker, the smoother, the blow-off, and the roll-off device: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 286 Set depth of piping knife incision at seam begin. • 0 - 150 mm Set depth of piping knife incision at seam end 0 - 150 mm Additional drive at seam begin. On/Off Additional drive at seam end On/Off Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 287 Test individual machine functions  p. 300 Perform system updates  p. 321 Test machine settings  p. 324 Read/write data to/from a USB key  p. 338 Set basic parameters  p. 343 Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 288 The Machine configuration menu is protected with a password. You use this menu to adjust basic machine parameters. The password is 25483.  The display switches to Machine config. Fig. 259: Machine configuration Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 289 Select stacker/pincer stacker/smoother/blow-off • Stacker Off • Throw-over stacker • Pincer stacker • Smoother • Blow-off Incise piping strip ends • without • incise on the left • incise on the right Roll-off On/Off Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 290 Split needle bar On/Off Toolbox configuration  p. 293 Kit Shims On/Off To set the machine configuration: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 291 3. Restart the machine to activate the selection. Information When you switch to another class, tools that are not available for the selected class may be removed from the toolbox on the start screen. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 292 Programming Selecting needle distance  The display switches to Select needle distance: Fig. 261: Select needle distance To select the needle distance: 1. Select the desired needle distance. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 293 Operation with pedal and knee lever • First pedal • Second knee lever • not active in 745-35-10 B and 745-35-10 F To set the pedal operation: 1. Press the desired button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 294 1. Press the desired button.  The settings for the left and the right light barrier can be configured separately. Information You can configure no more than 2 light barriers at a time. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 295  The display switches to an overview of the possible tools. Tools that have already been selected are highlighted in gray. The display will only show the tools available for the selected class. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 296 Tools already in use are grayed out. 2. To navigate up and down the list, use the arrow buttons 3. Press the selected tool to select it.  The display returns to Machine config. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 297  The display switches to Global parameters. Fig. 266: Global parameters Press a button to either open another submenu, enter the desired values directly using the numeric keypad or select the desired options directly Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 298 • open both clamps simultaneously • Pedal forward: open left; pedal back: open right Transport clamp quick adjustment • without bypass • bypass left • bypass right • bypass left and right Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 299 1. Press the desired button.  The user interface for setting the desired item is displayed. Adjust transport clamp  The display switches to Adjust transport clamp. Fig. 267: Adjust transport clamp Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 300 • Return transport delayed • 0 ms - 1000 ms To set the transport clamp: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 301 To set password protection: 1. Press the button in front of the desired area to enable or disable password protection. Information Locking the screen requires that you assign a user password ( p. 350). Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 302 Adjust and test corner knife  p. 306 Switch on needle and middle knife • Test sewing motor On/Off • Test middle knife On/Off • Test split needle bar slanted pocket On/Off Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 303 3. Plug the USB key with the Log.txt file into the USB port. 4. Confirm with OK.  USB_Logging automatically writes all status messages of the OPO7000 to the Log.txt file until the machine is switched off. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 304 Fig. 270: Set and test hook thread monitor Symbols Meaning Set sensitivity left • 0 - 15 Set sensitivity right • 0 - 15 To set the hook thread monitor: 1. Press the desired button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 305 • 0 ms - 1000 ms Start roll-off test Roll-off On/Off To test the roll-off device: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 306 For information on how to connect the light barriers, see the wiring diagram included in the Appendix ( p. 385). To test the light barriers: 1. Press the button.  Reference run is carried out. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 307 Reference Lift pick-up folder/lower pick-up folder depressurized Transport clamp quick adjustment  p. 273 Open/Close flap clamp Split needle bar On/Off Scan straight flap Scan slanted flap 2. Press the desired button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 308 Meaning Adjust corner knife Adjust corner knife distance • 0 - 220 mm Adjust knife block seam begin. left • -13 - +13 mm • only for configuration: Automatic corner knife station Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 309 • only for configuration: Automatic corner knife station Test corner knife function of all corner knives On/Off 2. Press the desired button. 3. Enter the desired value using the numeric keypad. 4. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 310 Set corner knife correction seam end left • only for configuration: Automatic corner knife station To adjust the corner knives: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 311 Loading process test, test loading process step by step Test step by step Display cycle time To perform a machine workflow test: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 312  The display shows the message 5. Press the right pedal.  The loading process is completed without sewing by performing pedal strokes. 6. To exit the test: access the menu again and press the OFF button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 313 2. Press the pedal after every single work step.  The step by step test allows you to test the machine workflow. 3. To exit the test: access the menu again and press the OFF button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 314  The display shows the time in ms. The cycle time allows you to optimize the machine settings. 2. To exit the test: access the menu again and press the OFF button. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 315 Do not place any objects in the movement area of the transport clamp.  The display switches to Test step motor. Fig. 279: Test step motor To test the step motor: 1. Press the button.  Reference run is carried out. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 316 If there is a difference between the Encoder and Position values, you can reset the values by carrying out a reference run. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 317 Meaning Adjust brightness and contrast Touch calibration Touch test To adjust and test the control panel: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 318 Fig. 281: Adjust brightness and contrast To adjust the brightness of the display: 1. Move the controller. • Increase brightness: Slide the controller to the right • Reduce brightness: Slide the controller to the left Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 319 The display returns to Adjust and test control panel. Information Another option is to perform the touch calibration using the boot loader. To do so, press your finger on the control panel while the control panel boots up. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 320 Programming Touch test  The display switches to Touch test. Fig. 283: Touch test The Touch test menu item allows you to draw on the touch screen. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 321 • 0 - 120 mm Test trimming process of both piping knives On/Off • Caution! The piping knives move and cut! Knife seam begin. On/Off Knife seam end On/Off Reference Switch step motor current-free On/Off Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 322 Fig. 285: Adjusting piping knife Symbol Meaning Enter piping knife offset value • -5.0 - 5.0 To adjust the piping knives: 1. Enter the desired value using the numeric keypad. 2. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 323 This submenu allows the user to trigger the update of the control again. To perform an update: 1. Press on the screen.  A prompt appears on the display asking if you wish to perform the update. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 324  The update is carried out. Fig. 288: DAC update (3) Important Do not switch off the machine while the update is in progress!  The display shows notice 8408: Waiting for Reset by machine. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 325 After restarting, the machine loads the start screen and is ready for operation. The progress of the update is indicated by a progress bar. When the update is complete, the control panel will perform a restart. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 326 • Time of the error Test inputs and outputs Display of the internal devices Test the working memory RAM Display of the external devices Test the read-only memory ROM Sewing drive test Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 327  The user interface for setting the desired item is displayed. Error messages  The display switches to Error messages. Fig. 291: Error messages The list contains the last 10 error messages as well as the date and time of each error. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 328 Folder down Folding station swiveled in Corner knife swiveled in Sewing material removed/cover monitor Pedal left, forward Pedal left, backward Pedal right, forward Pedal right, backward Clamp adjustment right Clamp adjustment left Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 329 Programming Pressure monitor Flap scan 1 Flap scan 2 Tape control Flap scan 3 (inactive in 745-35-10 B and 745-35-10 F) S100 Sewing motor reference S101 Ref. transport unit S102 Ref. knife block seam beginning SC001 Reference switch corner knife front left...
  • Page 330 Lift folder off Lower folder Close folding plates Open left flap clamp Open right flap clamp Stacker on/stacker tongs forward Needle left on Needle right on Solve tape Close tape cutter Open waistband clamp Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 331 YC137 Lower downholder YC138 Blowing on (flap clamp) YC139 Blowing on (folding plate) YC140 Needles waistband clamp YC141 Marking lamp YC142 Marking lamp YC143 Marking lamp YC144 Marking lamp YC145 Marking lamp Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 332 Stacker bracket swivelled out Corner knife up seam begin. left Corner knife up seam end left Corner knife up seam begin. right Corner knife up seam end right YC101 Spread the needles Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 333 Blowing on (folding plate) YC140 Swivel the flap turning device YC141 Marking lamp YC142 Marking lamp YC143 Marking lamp YC144 Marking lamp YC145 Marking lamp YC146 Marking lamp YC147 Marking lamp YC148 Marking lamp Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 334  The display switches to Internal devices. Fig. 293: Internal devices The area State can display 3 different status messages: • conn = connected • nc = not connected • err = error Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 335 Fig. 294: RAM test (1).  The test result is displayed. Fig. 295: RAM test (2) 1. Confirm with OK.  The display returns to Multi test. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 336 The External devices menu is used to detect errors in CAN devices. • 0: Step motor card corner knife station (option: slanted corner knife) • 1: I/O card • 2: Step motor card piping incision device (option: piping incision device) Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 337 Fig. 297: ROM test (1)  The test result is displayed. ROM error-free OR ROM defective. Fig. 298: ROM test (2) 1. Press the OK button to confirm.  The display returns to Multi test. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 338 • 70 RPM - 3000 RPM Start sewing drive To test the sewing drive: 1. Press the desired button. 2. Enter the desired values using the numeric keypad. 3. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 339 Do NOT reach into the moving part of the machine. NOTICE Property damage may occur! Jamming of the machine. Unthread the needle thread before starting the sewing drive.  The sewing drive starts at the set speed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 340 Read data from the USB key To read and write data to and from the USB key: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 341  The software checks the USB key. The selected option is written to the USB key. Depending on the amount of data selected, the process may take anywhere from a few seconds to approx. 2 minutes. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 342  When the data has been written to the USB key, the display shows the message Data successfully written: XY. Fig. 302: Data transfer to USB (2) 3. Press OK.  The display returns to USB data transfer. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 343 • All seam programs and sequences • Global parameters • Machine config. 2. Press the button to confirm.  The software checks the USB key. The selected option is written to the OP7000. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 344  When the data has been written to the OP7000, the display shows the message Data successfully read: XY. 3. Press OK.  The display returns to USB data transfer. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 345 • All stored sequences will be lost • All sequences will be reset to the factory default settings Initialize RAM • All stored data will be lost • All settings will be reset to the factory default settings Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 346 Programming To initialize the parameters: 1. Press the desired button. 2. Press OK to reset the values to their factory settings. 3. Press Cancel to cancel the initialization. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 347 Enter date and time for DA service staff only To edit the parameters in the Maintenance menu item: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 348  The display shows the current software version. You will need this information when contacting the DA service depart- ment for assistance. Fig. 306: Software version Date and time Fig. 307: Date and time Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 349 Programming To enter date and time: 1. Press the Date button. 2. Use the numeric keypad to enter the desired date. 3. Use the numeric keypad to enter the desired time. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 350 Fig. 308: User configuration Symbols Meaning Language selection Set user password Button beep On/Off To set the user configuration: 1. Press the desired button.  The user interface for setting the desired item is displayed. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 351 Programming Language selection  The display switches to Language selection. Fig. 309: Language selection To select the language: 1. Select the desired language.  The system restarts with the new language setting. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 352 Fig. 310: User password setup (1) To set up a user password: 1. Enter the desired 4-digit PIN. 2. Confirm with OK. 3. Re-enter the password (password check) 4. Confirm with OK. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 353 Programming Information After setting up a user password, you can lock the start screen for other operators with a press on the button. Fig. 311: User password setup (2) Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 354 Fig. 312: Update the machine software (1) 3. Switch off the machine and wait for approx. 15 seconds. 4. Connect the Dürkopp Adler USB key to the OP7000. 5. Restart the machine.  The OP7000 boot loader appears: Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 355  The machine restarts automatically. The display shows notice 8403: Machine has an outdated program. Should a new program be transmitted? 7. If the machine fails to restart: Switch off and on the machine again. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 356  The update is carried out. Fig. 316: Update the machine software (5) Important Do not switch off the machine while the update is in progress!  The display shows notice 8408: Waiting for Reset by machine. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 357 9. Press CANCEL to cancel the update.  The following warning appears: Fig. 318: Update the machine software (7)  After confirming with OK, you can continue working with the old control software. Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 358 Programming Information If the update fails, you can restart it in the service menu under DAC update ( p. 321). Serviceanleitung 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 359: Maintenance

     Check the tightness of the system Drive unit and transport carriage  Check state and tension of the toothed belts Additional equipment  Clean (blow out) the automatic piping cutter Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 360: Cleaning

    Fig. 319: Cleaning ① ② ③ ④ ⑤ ⑥ (1) - Light barrier (4) - Light barrier (2) - Hook (5) - Vacuum valve (3) - Hook (6) - Filter ring Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 361: Lubricating

    For topping off the oil reservoir, use only lubricating oil DA 10 or oil of equivalent quality with the following specifications: • Viscosity at 40 °C: 10 mm²/s • Flash point: 150 °C Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 362: Top Off The Oil Reservoir

    To top off the oil: 1. Swivel up the machine head ( p. 14). 2. Refill oil through the hole (4) in the inspection glass until the oil level reaches the Max marking (3). Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 363: Lubricating The Hook

    2. Refill oil through the nipple (1) until the oil level reaches the MAX marking (3). 19.2.2 Lubricating the hook Fig. 322: Lubricating the hook ① ② (1) - Screw (2) - Screw Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 364: Servicing The Pneumatic System

    The operating pressure cannot deviate by more than ± 0.5 bar. Check the operating pressure on a daily basis. Fig. 323: Setting the operating pressure ① ② (1) - Pressure controller (2) - Pressure gage Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 365: Draining The Water Condensation

    (2) - Water separator To drain water condensation: 1. Disconnect the machine from the compressed air supply. 2. Place the collection tray under the drain screw (3). 3. Loosen the drain screw (3) completely. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 366: Cleaning The Filter Element

    6. Wash out the filter tray using benzine. 7. Tighten the filter element (1). 8. Tighten the water separator (2). 9. Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 367: Parts List

    Maintenance 19.4 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 368 Maintenance Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 369: Decommissioning

    5. Cover the control panel to protect it from soiling. 6. Cover the control to protect it from soiling. 7. Cover the entire machine if possible to protect it from contamination and damage. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 370 Decommissioning Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 371: Disposal

    When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials. Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 372 Disposal Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 373: Troubleshooting

    • Replace sewing motor cable • Sewing motor cable defective 1002 Sewing motor insulation fault • Check motor phase and PE for low-impedance connection • Replace sewing motor encoder • Replace sewing motor Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 374 • Replace sewing motor • Sewing motor cable defective • Replace control • Sewing motor defective • Control defective 1053 Mains voltage too high Check mains voltage 1054 Internal short circuit Replace control Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 375 • Perform software update  p. 352 • Replace control 1342-1344 Error in the reference run • Switch off and on the machine again • Perform software update  p. 352 • Replace control Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 376 Step motor transport clamp overheat • Step motor transport clamp • Eliminate seizing seized up • Faulty step motor transport • Replace the transport clamp step clamp motor • Control defective • Replace control Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 377 • Control defective • Replace control 2356 Step motor tape feeder • Overheat • seized up • defective • Eliminate seizing • Control defective • Replace step motor tape feeder • Replace control Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 378 • Check connections • Replace control 3030 Sewing motor: Phase error • Test sewing motor phases (R=2.8 OHM, high impedance to PE) • Replace encoder • Replace sewing motor • Replace control Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 379 Wrong USB key Replace USB key • USB key incompatible with OP7000 • Capacity of USB key too large Error code 6000-6999: Error messages displays 6351 Control error (I2C) Replace control Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 380 Check output cable and output plug unit (AC101), outputs overload/ short circuit 7219 Failure in CAN - Module transport Check jumpers/DIP switch unit (AC101), wrong module recognized at address 7260 General error CAN modules Check cable Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 381 Resuming the process after pushing the start pedal 9013 Tape missing Insert tape 9014 Position of transport clamp Correct position of transport doesn't match the installed die clamp in the seam parameters  p. 272 Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 382 • Check flap size maximum sewing area (behind • Insert flap correctly the rear positioning point) 9723 Fluff at the flap beginning • Insert flaps with smooth edges • Check reflecting foil Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 383 • Set pocket sequences 9902 Defective pocket programs • Initialize pocket programs again (Checksum error) • Set pocket programs 9999 Machine configuration has been Switch off and on the machine changed again Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 384 Troubleshooting Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 385: Technical Data

    • Large vertical hooks • Externally powered middle knife; speed and switch actuation points can be programmed • Thread cutter for needle threads and hook threads • needle thread monitors • Hook thread monitor Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 386 • For method B and method F, five and eight markings lamps, respectively, have been incorporated into the basic sewing unit Light barrier • Light barrier for flap length scanning External winder • Separately motorized winder Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...

  • Page 387: Appendix

    Appendix 24 Appendix Wiring diagram Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 388 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 389 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 390 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 391 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 392 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 393 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 394 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 395 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 396 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 397 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 398 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 399 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 400 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 401 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 402 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 403 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 404 Appendix " Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 405 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 406 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 407 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 408 Appendix " Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 409 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 410 Appendix " Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 411 Appendix " Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 412 Appendix Service Instructions 745-35-10 B/745-35-10 F - 00.0 - 10/2017...
  • Page 414 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone: +49 (0) 521 925 00 Email: service@duerkopp-adler.com www.duerkopp-adler.com...

This manual is also suitable for:

745-35-10 b

Table of Contents