DURKOPP ADLER 745-35-10 S Service Instructions Manual
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DURKOPP ADLER 745-35-10 S Service Instructions Manual

DURKOPP ADLER 745-35-10 S Service Instructions Manual

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

  • Page 1 745-35-10 S 745-35-10 A 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 . 69 3.14 Setting the thread advancing device for the needle threads ..72 3.15 Setting the synchronizer ............. 73 3.16 Setting the differential gear............74 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 4 Setting the stroke movement of the folder ........ 138 12.4 Aligning the folder with the needles .......... 141 12.5 Setting the guide plates at the folder ........143 12.6 Setting the folder detection ............145 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 5 Customer Service ..............315 20.2 Messages of the software............315 Technical data................. 327 Appendix ................. 329 22.1 Wiring diagram 745-35-10 S............. 329 22.2 Wiring diagram 745-35-10 A............. 341 22.3 Pneumatic diagram..............363 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 6 Table of Contents 22.4 Pneumatic diagram throw-over stacker ........378 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 7: About These Instructions

    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 com- ponents to be set. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 8 Safety ( p. 7). 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 S/745-35-10 A - 02.0 - 04/2017...

  • 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 10 About these instructions Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 11: Safety

    • set up the machine • perform maintenance work and repairs • perform work on electrical equipment Only authorized persons may work on the machine and must first have understood these instructions. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 13 Safety Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 14 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 15 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 16 Safety Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 17: Machine Head

    The machine head can be pegged into place in the hole (3) using the lock- ing peg. When pegged in this position, the machine head is in the loop stroke position. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 18: Swiveling Up The Machine Head

    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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 19 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 20: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 21: Disassembling The Machine Head

    1. Lift the hood (1) up at the front and the rear to release the lock. 2. Carefully life 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 22 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 23: 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. Adjust the height of the machine head ( p. 129). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 24 7. Swivel the locking lever (3) down. Fig. 11: Assembling machine head (3) ⑦ ⑥ (6) - Hood (7) - Handle 8. Swivel down the folding station and engage the handle of the folding station (7). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 25: 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 adjustment does not require that crank and arm shaft be removed. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 26 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 27 4. Swivel the thread tension plate (5) sideways 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 28 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 29 13. Tighten the fastening screws firmly (Caution: Left-handed thread). 14. Assemble and adjust the needle bar linkage ( p. 38). 15. Assemble the switching cylinder used for the middle knife drive ( p. 61). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 30: Needle Bar Linkage

    To remove the head cover: 1. Loosen the screw (1). 2. Carefully loosen the clamp for the needle thread monitor (3). The needle thread monitor may become damaged. 3. Remove the head cover (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 31 (6) - Thread advancing device To remove the needle bar linkage: 1. Loosen screws (4) and (7). 2. Remove the thread advancing device (6). 3. Loosen the screw (5). 4. Loosen the screw (8). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 32 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 33: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 34 12. Pull the needle bar down and out of the needle bar linkage (4). Caution: This process may cause the three bottom coupling balls (9) to fall out of the ball holes of the needle bar. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 35: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 36: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 37: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 38 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 39 (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. 40). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 40: Assembling The Needle Bar Linkage

    6. Move the adjusting screw (7) up to the stop pin (4) and secure it using the counternut (6).  The adjusting screw (7) regulates the height of the needle bar linkage. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 41 (13) - Thread advancing device 11. Slide the thread advancing device (13) onto pins (15) and (12). 12. Tighten screws (14) and (11). 13. Adjust the thread advancing device (13) ( p. 72). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 42: Setting The Height Of The Needle Bar Linkage

    To set the height of the needle bar linkage: 1. Loosen the screw (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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 43  The distance between 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. Assemble the head cover (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 44: 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. Re-tighten the screws (1). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 45: Changing The Needle Holder

    4. Turn the handwheel to disconnect the needle bar. 5. Continue to turn the handwheel.  The actuated needle bar switches off. 6. Keep turning the handwheel until the needle bar is at bottom dead center. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 46 12. Check how the needle plunges into the needle hole ( p. 42). 13. Check the lateral distance of the needle to the hook ( p. 52). 14. The second needle holder is replaced in the same way as the first needle holder. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 47: Hook

    The exact height of the hook shaft is set using the gage (3) (part number 0244 001001). To adjust the height of the hook shaft: 1. Remove the throat plate. 2. Remove both hooks ( p. 56). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 48 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. 56). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 49: Setting The Gear Clearance Of The Hook Drive

    1. Slightly turn the hook while checking the gear clearance. 2. Loosen the screw (3). 3. Slightly loosen the screw (1). 4. Slightly loosen the clamping screws of the worm wheel (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 50: Setting The Loop Stroke

    Do not check and adjust the loop stroke unless the sewing unit is switched off. Fig. 36: Setting the loop stroke (1) ② ① 0,1 mm (1) - Needle (2) - Hook tip Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 51 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. 18). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 52: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 53 (2) with as little play as possible. 15. Loosen the screw (6). 16. Turn the needle holder (8) to adjust the height of the needle holder. A complete 360° rotation is possible. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 54: Setting The Distance Between Hook Tips And Needles

    ( p. 55). 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 55 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 56 (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. Screw on the throat plate. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 57: Setting The Needle Guard

    4. Adjust the needle guard (5) by turning the eccentric bolt (3). 5. Tighten the screw (4) firmly. 6. Assemble bobbin case bottom parts and hook cover. 7. Assemble the throat plate. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 58: Changing The Hook

    Do not apply force when removing the bobbin case bottom part. 6. Loosen the fastening screw (1) of the hook. 7. Lift off and remove the hook from the hook shaft. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 59: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 60 The rear of the hook must not hit the underside of the bobbin case holding wire while the hook is completing its rotation. Adjust the height of the plate (1) accordingly. 9. Tighten the screw (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 61: Middle Knife

    3. Pull the cover off carefully. 4. Loosen the screws on the eccentric (1). 5. Loosen the motor fastening screws (2). 6. Pull the drive motor (3) out of the eccentric (1) towards the rear. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 62: 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 by connecting the plug between cable harness and motor cable. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 63: Disassembling The Switching Cylinder

    2. Loosen the connection (3) from the cylinder if necessary. 3. Remove the drive motor ( p. 59). 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 64: 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. 60). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 65: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 66 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 67: Setting The Thread Tensioning Spring

    To adjust 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 68: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 69 0.5 mm 1 mm ① ② ③ ④ ⑤ ⑥ (1) - Screw (4) - Screw (rear side) (2) - Screws (5) - Thread-pulling knife (3) - Blade (6) - Knife guard Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 70 (5) is centric between the needles. 2. Adjust the height of the thread-pulling knife such that the dimension between sliding plate and bottom edge of the thread-pulling knife (5) is 27+/- 1 mm. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 71: Setting The Trimming And Clamping Device For The Hook Threads

    The hook thread clamp (2) is located below the throat plate. It opens pneumatically. The hook threads are pulled between the throat plate panel and the open thread clamping plates (5). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 72 5. Adjust the height of the hook thread trimmer (1).  The upper side of the hook thread trimmer (1) and the top side of the throat plate must be in the same plane. 6. Tighten the screw (6). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 73 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 74: 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. Adjust 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 75: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 76: Setting The Differential Gear

    3. Re-tighten the threaded pin (2) of the compensating weight (1). Make sure that the threaded pin (2) points up vertically and that the com- pensating weight (1) is seated in the middle of the bearing bracket (3). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 77: Transport Carriage

    (2) - Switching screw (4) - Stop Proper setting The reference switch (1) determines the rear and, by means of a defini- tively specified path, the front end position of the transport carriage. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 78: 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. Adjust the reference switch in the slotted hole (2) ( p. 92). 3. Re-tighten the upper counternut. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 79: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 80: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 81: Changing The Toothed Belt

    Fig. 66: Changing the toothed belt (1) ① ② (1) - Belt clamp (2) - Screws The toothed belt is split to allow for easy replacement. It is held together by a belt clamp (1). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 82 To remove the old toothed belt: 1. Loosen the screw (4). 2. Remove the hood (3). 3. Remove the screws of the belt clamp (2). 4. Slide the carriage to the side. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 83 (9). 3. Position the belt clamp (1) above the carriage and assemble it using the screws of the belt clamp. 4. Set the toothed belt tension ( p. 82). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 84: Setting The Toothed Belt Tension

    2. Slightly loosen the fastening screws (2) (3x) of the motor bracket. 3. Use the clamping screw (1) to set the toothed belt tension to 60Hz and secure the clamping screw. 4. Re-tighten the fastening screws (2) (3x) of the motor bracket. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 85 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 86 Transport carriage Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 87: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 88: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 89 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 90: Setting The Stroke Height Of The Transport Clamps

    20 mm on the left and the right. To set the stroke height of the transport clamps: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 91 ④ (4) - Screws 3. Loosen the screws (4). 4. Check and set the stroke height of the transport clamps relative to the fabric sliding plate. 5. Tighten the screws (4). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 92: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 93 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. Re-tighten the screw (5). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 94: Setting The Front End Position Of The Transport Clamp

    Set the transport clamp only with utmost caution and with the sewing unit switched on. Fig. 77: Setting the rear end position of the transport clamp ① ② (1) - Reference switch (2) - Rear stop Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 95 5. Correct the rear stop (2) ( p. 78). 6. Switch on the main switch. 7. Make another reference run and check the dimension for the front edge of the transport clamp. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 96: Setting The Blowing Of The Piping Strips

    > Pedal mode press the button ( p. 233). 2. In the menu Program parameters > Program loading process > Blowing mode set mode 2 ( p. 230). 3. Position piping and pocket bag. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 97 9. Loosen the screws and adjust the blast pipes in the flap clamps (3) by turning. 10. Adjust 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 98 Transport clamps Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 99: Corner Knives

    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. Adjust the other knife holders as described above. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 100: Setting The Corner Knife Parameters

    1. Open the menu Service > Machine test and select the menu item Test and adjust corner knife ( p. 256). 2. Press the button. 3. Enter the password: 25483.  The display switches to: Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 101 • 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 102: Checking The Corner Knife Station (745-35-10 A Only, Slanted Pocket)

    Fig. 83: Checking the corner knife station ① ② (1) - Corner knife support (4) - Corner knife (2) - Corner knife (5) - Corner knife (3) - Corner knife (6) - Corner knife support Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 103: Checking The Front Left Corner Knife (745-35-10 A Only)

    To check the front left corner knife: 1. 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 104: Checking The Rear Left Corner Knife (745-35-10 A Only)

    To check the rear left corner knife: 1. 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 105: Aligning The Corner Knife Station With The Seams

    To align the corner knife station with the seams: 1. Iron a piece of Vlieseline onto the workpiece.  This makes the corner knife cuts more visible. 2. Sew a test seam. 3. Check seam and cutting pattern. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 106 1. Swing the corner knife station (4) out completely. 2. Loosen the screws (1). 3. Shift the holder (3). 4. Tighten the screws (1). 5. Swivel the corner knife station back. 6. Correct the distance of the switch (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 107 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 108: Setting The Slant Of The Corner Knife Cuts

    1. Iron a piece of Vlieseline onto the workpiece.  This makes the corner knife cuts more visible. 2. Sew a test seam. 3. Check seam and cutting pattern. 4. Loosen the screw (1). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 109: Replacing Corner Knives

    (5) - Screws of the piercer (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). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 110 6. Tighten the screw (4). 7. Insert the piecer (1) again.  The tip of the blade has to be below the piercer (1). 8. Swivel in the corner knife station. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 111: Marking Lamps

    Marking lamps Marking lamps 7.1 Aligning the laser modules (745-35-10 S) The 745-35-10 S comes standard with 3 laser modules for marking the positioning points. An adjustment template is available under part number 0745 290050. WARNING Risk of injury from laser light! Risk of sustaining eye damage and going blind.
  • Page 112 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. 113) • Observe the maximum sewing area Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 113: Aligning The Laser Modules (745-35-10 A)

    (5) - Marking of the rear positioning point (varies with the setting of the sewing (6) - Edge of the sliding plate (measuring length) line) Sewing length (mm) Spacing A (mm) Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 114 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. 113) • Observe the maximum sewing area Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 115: Setting The Exact Position Of The Laser Marking

    (varies with the setting of the sewing (6) - Edge of the sliding plate (measuring length) line) Fig. 97: Setting the exact position of the laser marking (2) Sewing head Operator Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 116 (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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 117: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 118: Aligning The Light Barriers

    The light barriers are set using 2 templates. Fig. 99: Aligning the light barriers ① ② (1) - Template for straight pockets (2) - Template for slanted pockets Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 119 To set the light barriers, swing out the folding station. Fig. 100: Preparing sewing unit and transport clamps ③ ② ① (1) - Screws (3) - Folding station (2) - Reflecting foils Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 120 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 121 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 adjust them ( p. 86). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 122: Setting The Light Barriers For Automatic Slant Detection

    4. Press the button.  Reference run is carried out. 5. Press the button and select the desired transport clamp position.  The light barriers must be aligned with the transport clamp position. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 123  The template (1) is scanned. The display shows the scanned parameters. The scanned parame- ters are automatically adopted by the control. 15. Press the button.  The flap clamp opens. 16. Remove the template (1). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 124  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 sewing unit. 27. Switch the sewing unit back on. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 125: 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. 105: Setting the light barriers for automatic slant detection (1) ① (1) - Template for straight pockets Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 126 9. Insert the template (1) (straight pocket) such that line (3) points to the left needle and is parallel to the right transport clamp. 10. Press the button.  The flap clamp closes. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 127  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 sewing unit. 21. Switch the sewing unit back on. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 128: 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 output element YC106. 7. Re-tighten the screws (1). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 129: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 130 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 two unused holes on the plate of the ratchet lever (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 131: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 132 1. Remove the hood (3). 2. Loosen counternuts (7) and (8). 3. Turn sleeves (6) and (9) evenly using an Allen key while holding the screws (5) in place. 4. Tighten counternuts (7) and (8). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 133 1. Swivel up the machine head ( p. 16). 2. Loosen the counternut (11). 3. Screw in or loosen the centering nut (12) as necessary. 4. Re-tighten the counternut (11). 5. Swivel down the machine head ( p. 18). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 134 Aligning the machine head Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 135: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 136 Setting fabric sliding plate and vacuum plate Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 137: Folder

    The pin (1) must be seated in the hole of the actuating lever (2). To assemble the folder: 1. Loosen the screw (4). 2. Slide the folder (3) up as far as it will go. 3. Tighten the screw (4). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 138: Aligning The Folder With The Middle Of The Pocket Opening

    100 mm - a - 1/2 x NA = x 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). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 139 (5) - Threaded pin To align the folder with the middle of the pocket opening: 1. Depressurize the machine and press the folder down manually. 2. Slightly loosen the screws (6). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 140: Setting The Stroke Movement Of The Folder

    6 mm when swiveling up before being swung out of the sewing area. When the folder is raised When the folder is raised, there must be some clearance between the guide roller (1) and the highest point of the guide groove (3). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 141 4. If necessary, turn the joint head (5) on the piston rod of the cylinder.  If the folder collides with the swivel arm of the reflected light barriers ( p. 115) when swinging out, the plate cam (2) must be readjusted. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 142 (7) abuts on stop (8) (make sure it snaps into place). 2. Set the spring pressure using the screw (4) in the stop screw (7) so that the folder is pushed back. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 143: Aligning The Folder With The Needles

    To align the position of the folder in relation to the needles: 1. Manually press the folder down all the way. 2. Check the position of the folder sole (3) in relation to the needles and the middle knife (1). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 144 ④ ⑤ (4) - Screw (6) - Screw (5) - Folder 3. Loosen screws (4) and (6). 4. Shift the folder (5) in sewing direction. 5. Tighten screws (4) and (6). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 145: Setting The Guide Plates At The Folder

    To adjust the guide plates at the folder: 1. Lower the folder. 2. Check the position of the guide plates (2) in relation to the needles. 3. Check the spring pressure of the guide plates (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 146 10. Tighten the threaded pin (7). Setting the spring pressure To set the spring pressure: 1. Loosen the screws (5). 2. Adjust the pressure by aligning the leaf springs (3). 3. Tighten the screws (5). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 147: Setting The Folder Detection

    To set the folder detection: 1. Slightly loosen the nuts (1). 2. Set the distance between the switching flag and switches S11 (2) and S12 (3). 3. Re-tighten the nuts (1). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 148 Folder Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 149: Additional Equipment

    The bobbin case retainer (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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 150: Assembling The Waistband Clamp (745-35-10 A Only)

    Fig. 129: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 151 To assemble the waistband clamp: The fully assembled waistband clamp (1) and the needle rib (2) are fixed in the rear fastening threads (3) of the vacuum plate (5) towards the sew- ing machine. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 152: Setting The Outfeed Roller (745-35-10 A Only)

    Setting the height of the transport rollers When lowered, both transport rollers (5) and (7) should rest evenly on the tabletop. To set the height of the transport rollers: 1. Loosen the hexagon screws (6). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 153  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. 253). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 154: 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. 172). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 155 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 156 Additional equipment Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 157: Stacker

    The open stacker tongs should be positioned relative to the tabletop so that the workpiece can be transported without hindrance. To set the position of the stacker tongs relative to the tabletop: 1. Loosen the counternut (2). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 158: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 159: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 160: Setting The Cylinder Speed

    Fig. 138: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 161: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 162: Throw-Over Stacker (745-35-10 A Only)

    (-) = 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 163 Fig. 142: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 164 • 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 165: 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 adjust the switch cam (7) by turning. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 166 Check the optimal switch actuation point by performing stacking operations with workpieces and correct it if necessary. Fig. 146: Setting the throw-over stacker (4) ⑪ ⑩ ⑫ (10) - Switch cam (12) - Cylinder (11) - Switch Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 167 Check the optimal switch actuation point by performing stacking operations with workpieces and correct it if necessary. Fig. 148: Setting the throw-over stacker (6) ⑰ ⑯ (16) - Switch (17) - Switch cam Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 168: Setting The Stacking Speed

    To check the speed of the stacker function, you can trigger a stacker operation by activating valve Y14 ( p. 274). 14.2.4 Activating the stacker You activate the stacker in the Machine config. submenu ( p. 242). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 169: Pressure Supply

    4. Loosen the screw (2) on the pressure monitor (1). If display reads S11-: • Turn the screw (2) clockwise until the display reads S11+. • Slightly turn the screw (2) counterclockwise until the display reads S11- again. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 170: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 171: Programming

     p. 238 1.17 Select flap clamps  p. 243 1.18 Set light barrier scan  p. 256 1.22 Corner knife device (745-35-10 A only)  p. 242 1.23 Set pedal operation Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 172 3.4 External devices  p. 274 3.5 Multi test I/O  p. 282 3.6 Sewing motor test  p. 273 3.7 Error messages  p. 279 RAM test  p. 281 ROM test Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 173 5.1.4.9 Select flap right/left  p. 201 5.1.4.10 Select positioning points  p. 201 5.1.4.11 Set stitch length main seam  p. 205 5.1.4.12 Set flap scan  p. 207 5.1.5 Correction light barrier Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 174  p. 227 5.1.13.2 Vacuum On/Off  p. 227 5.1.13.3 Downholder On/Off  p. 228 5.1.13.4 Select downholder mode (745-35-10 A only)  p. 230 5.1.13.5 Set blowing mode (745-35-10 A only) Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 175  p. 285 8.1 Data transfer to USB  p. 287 8.2 Data transfer from USB 9.0 Init. parameters  p. 289 Initialize machine configuration  p. 289 Initialize global parameters Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 176 Initialize all sequences  p. 289 Initialize RAM 10.0 Maintenance  p. 291 10.3 Display software version  p. 291 10.4 Enter date and time  p. 296 Updating machine software Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 177 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 178  p. 181 Edit seam sequence ④  p. 180 Piece counter ⑤ Display of selected seam pattern • the display changes with the setting of the pocket program (with/without flap). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 179 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 180 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 181 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 182  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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 183 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 184 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 185 The pocket programs will be stored in the seam sequence in the order in which they were added to the seam sequence. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 186 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 187 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 188 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 189  The display switches to Select source of sequence. Fig. 161: Changing the seam sequence template (2) Display of the sequence Selectable content sequences  The destination sequence is grayed out and cannot be selected. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 190 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 191  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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 192 Fig. 165: 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 193 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 194  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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 195 Fig. 169: Activating a pocket program from the seam sequence ① ② (1) - Pocket programs in sequence (2) - selected pocket program Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 196 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 197 Select pocket program  p. 197 Enter name of pocket program  p. 198 Copy pocket program  p. 198 Create seam program  p. 200 Correction light barrier  p. 207 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 198 Program loading process  p. 227 Stacker/smoother/blow-off/roll-off  p. 234 Tape trimming On/Off (745-35-10 A only) Reset seam program 2. Press the desired button.  The user interface for setting the desired item is displayed. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 199 ( p. 181). If the pocket program has already been copied to the selected seam sequence, you can activate it in the seam sequence ( p. 193). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 200  The display switches to Copy pocket program. Fig. 172: Copying a pocket program (1) Symbols Meaning Select source Select destination Save settings To copy a pocket program: 1. Press the button. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 201 Fig. 173: Copying a pocket program (2) 6. Confirm with OK.  The message Copy was successful is displayed. 7. Confirm with OK.  The display switches to the selected seam program. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 202 • slanted • slanted • Set slanted pocket shape seam begin. (1 - 13 mm) Securement seam beginning left/right needle • Stitch condensing OR • Single tack OR • Double tack Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 203 • 100 mm - 450 mm Set stitch length main seam • 1.5 mm - 3.5 mm Set flap scan • Fixed seam length • 1 light barrier • Automatic flap scan left Reset seam program Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 204 Select double tack • Set stitch length for double tack at seam beginning (0.5 - 3.5 mm) • Set number of stitches for double tack at seam beginning (0 - 10) Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 205 ( p. 202). Set securement seam end left needle  The display switches to Securement seam end left needle. Fig. 176: Set securement seam end left needle Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 206 2. Enter the desired value using the numeric keypad.  The user interface for setting the desired item is displayed. Information If the seam pattern is straight, you only have to set the left seam securement. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 207 Set maximum flap length Not available unless Activate flap scan has been selected Activate automatic flap scan left • Light barrier must be activated in the Machine configuration  p. 243 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 208 Fig. 178: Activating the flap (2) ② ① ② ③ (1) - Quick access corner knife correction (3) - Display of flap (2) - Quick access flap correction Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 209 • -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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 210 Fig. 180: 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 211  The user interface for setting the desired item is displayed. Information The default option allows you to switch 8 marking lamps on/off. The system offers the option of assembling 8 additional marking lamps. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 212 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 213 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 214 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.  Confirm with OK. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 215 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 216 Fig. 186: 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 217 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 218 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. 237). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 219 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 220 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. 190: Set corner knife correction seam begin./seam end Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 221 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. 237). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 222 Set length of tape at seam begin. • 0 - 99 mm Set length of tape at seam end • 0 - 99 mm Adjust clamp speed with belt transport • 10 - 100 % Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 223 • Transport up to loading position Set waiting position of transport clamp To set the transport clamp: 1. Press the desired button.  The user interface for setting the desired item is displayed. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 224 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.  Confirm with OK. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 225 • 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.  Confirm with OK. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 226  The display switches to Process of transport clamp. Fig. 195: 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 227 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 set the transport clamp quick adjustment: 1. Press the desired button. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 228 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 229 Right flap clamp closes first Vacuum On/Off Downholder On/Off Select downholder mode (745-35-10 A only) Select blowing mode (745-35-10 A only) Breast welt mode On/Off (745-35-10 A only) Select pedal mode Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 230 Programming Information If vacuum and downholder are activated in the Machine configuration, these functions must be activated / deactivated together in the 745-35-10 S. To program the loading process: 1. Press the desired button.  The user interface for setting the desired item is displayed.
  • Page 231 To select downholder mode: 1. Press the desired button. Information The numbering of the buttons downholder , vacuum and waist- band clamp in the lower half of the display changes with the selected setting. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 232 2: Blowing ON at folding plate 180 mm + blowing ON at flap clamp 1: Blowing ON at flap clamp, blowing ON at folding plate for 180 mm seam path To select blowing mode: 1. Press the desired button. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 233 Programming 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 234 Programming Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 235 • 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 236 • only with active blow-off  p. 238 Set the duration for which the blow-off will be blowing • only with active blow-off  p. 238 • 0 ms - 1000 ms Roll-off On/Off Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 237 • 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.  Confirm with OK. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 238 Test individual machine functions  p. 250 Perform system updates  p. 269 Test machine settings  p. 272 Read/write data to/from a USB key  p. 284 Set basic parameters  p. 289 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 239 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. 204: Machine configuration Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 240 • left flap clamp only • right flap clamp only • left and right flap clamp Set light barrier scan  p. 243 Waistband clamp On/Off (745-35-10 A only) Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 241 • straight or slanted pocket Toolbox configuration  p. 244 Kit Shims On/Off To set the machine configuration: 1. Press the desired button.  The user interface for setting the desired item is displayed. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 242 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 243 Programming Selecting needle distance  The display switches to Select needle distance: Fig. 206: Select needle distance To select the needle distance: 1. Select the desired needle distance. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 244 Operation with 2 pedals: 1. pedal left, 2. pedal right Operation with pedal and knee lever: 1. pedal, 2. knee lever • not active in 745-35-10 S and 745-35-10 A To set the pedal operation: 1. Press the desired button.
  • Page 245 You can configure no more than 2 light barriers at a time. The automatic slant scan (3) is only available for the 745-35-10 A. It is only intended for the left side and for jacket processing. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 246  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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 247 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 248 Set positioning point seam center (100 mm - 300 mm) • Set positioning point seam end (100 mm - 300 mm) Adjust transport clamp  p. 248 Adjust corner knife • Set cutting duration (0 ms - 1000 ms) Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 249 Set counting direction of piece counter UP Set counting direction of piece counter DOWN To set the Global parameters: 1. Press the desired button.  The user interface for setting the desired item is displayed. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 250 • 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 251 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. 294). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 252 Adjust and test corner knife  p. 256 Switch on needle and middle knife • Test sewing motor On/Off • Test middle knife On/Off • Split needle bar slanted pocket On/Off Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 253 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 254 Fig. 215: Set and test hook thread monitor Symbols Meaning Set sensitivity left • 0 - 15 Set sensitivity right • 0 - 15 To test the hook thread monitor: 1. Press the desired button. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 255 Test roll-off speed and duration (On/Off) Test roll-off speed (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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 256 Refer to the  Service Instructions for instructions on how to align the light barriers with the help of templates. To align the light barriers: 1. Press the button.  Reference run is carried out. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 257 Lift pick-up folder/lower pick-up folder depressurized Transport clamp quick adjustment ( p. 225) Open/Close flap clamp Split needle bar On/Off Scan straight flap Scan slanted flap 2. Press the desired button. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 258  The display switches to Adjust corner knife. Fig. 218: Test and adjust corner knife (1), automatic corner knife station Fig. 219: Test and adjust corner knife (2), manual corner knife station Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 259 • 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 260 • 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 261 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 262 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 263 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 264  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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 265 To test the step motor: 1. Press the button.  Reference run is carried out. The following table lists the items that can be set in the Test step motor menu. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 266 If there is a difference between the Encoder and Position values, you can reset the values by carrying out a reference run. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 267 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 268 Fig. 227: 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 Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 269 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 on the control panel while the control panel boots up. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 270 Programming Touch test  The display switches to Touch test. Fig. 229: Touch test The Touch test menu item allows you to draw on the touch screen. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 271 This submenu allows the user to trigger the update of the control again. To perform the update: 1. Press on the screen.  A prompt appears on the display asking if you wish to perform the update. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 272 2. Confirm with OK. Fig. 232: 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 273 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 274 • 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 Test sewing motor Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 275 Error messages  The display switches to Error messages. Fig. 235: Error messages The list contains the last 10 error messages as well as the date and time of the error. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 276 Light barrier for material removal / Cover monitoring Pedal in front Pedal back Light barrier for flap scan Second Light barrier for flap scan S100 reference switch for sewing motor S101 Reference switch transport clamp Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 277 Open needle thread cutter Lower center knife Blow out fluff Open hook thread cutter Close hook thread cutter Close thread tension Lower left transport clamp Lower right transport clamp Lift folder off Lower folder Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 278 Lift left transport clamp Lift right transport clamp Pincer stacker: Stacker bracket swivelled out YC133 Move transport clamp left to the inner side YC134 Move transport clamp right to the inner side Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 279 Blowing on (folding plate) YC140 Needles waistband clamp YC141 Marking lamp YC142 Marking lamp YC143 Marking lamp YC144 Marking lamp YC145 Marking lamp YC146 Marking lamp YC147 Marking lamp YC148 Marking lamp Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 280  The display switches to Internal devices. Fig. 237: Internal devices The area State can display 3 different status messages: • conn = connected • nc = not connected • err = error Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 281 Fig. 238: RAM test (1).  The test result is displayed. Fig. 239: RAM test (2) 1. Press the OK button to confirm.  The display returns to Multi test. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 282 The External devices menu is used to detect errors in CAN devices. External devices have only been fitted on the 745-35-10 A. • Knife block unit (CAN 0) • Transport unit (CAN 1) Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 283 Fig. 241: ROM test (1)  The test result is displayed. ROM error-free OR ROM defective. Fig. 242: ROM test (2) 1. Press the OK button to confirm.  The display returns to Multi test. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 284 • 70 RPM - 3000 RPM Start sewing motor To test the sewing motor: 1. Press the desired button. 2. Enter the desired values using the numeric keypad. 3. Confirm with OK. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 285 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 motor.  The sewing drive starts at the set speed. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 286 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 287  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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 288  When the data has been written to the USB key, the display shows the message Data successfully written: XY. Fig. 246: Data transfer to USB (2) 3. Press OK.  The display returns to USB data transfer. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 289 • 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 290  When the data has been written to the OP7000, the display shows the message Data successfully read: XY. Fig. 248: Data transfer from USB (2) 3. Press the OK button.  The display returns to USB data transfer. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 291 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 292 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 293 Fig. 252: Date and time To enter date and time: 1. Press the Date button. 2. Use the buttons to enter the desired date. 3. Use the buttons to enter the desired time. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 294 Symbols Meaning Language selection User password setup Button beep On/Off To set the user configuration: 1. Press the desired button.  The user interface for setting the desired item is displayed. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 295 Language selection  The display switches to Language selection. Fig. 254: Language selection To select the language: 1. Select the desired language.  The system restarts with the new language setting. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 296 Fig. 255: 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 297 Programming Information After setting up a user password, you can lock the start screen for other operators with a press on the button. Fig. 256: User password setup (2) Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 298 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: Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 299 6. Remove the USB key when prompted to do so.  The machine restarts automatically. The display shows notice 8403: Machine has an outdated program. Should a new program be transmitted? Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 300 Fig. 261: 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. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 301 8. Press CANCEL to cancel the update.  The following warning appears: Fig. 263: Update the machine software (7)  After confirming with OK, you can continue working with the old control software. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 302 Programming Information If the update fails, you can restart it in the Service menu under DAC update ( p. 269). Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 303: 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 slitting device Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 304: Cleaning

    Fig. 264: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 305: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 306: Checking The Oil Level In The Oil Reservoirs

    To top up with oil: 1. Swivel up the machine head ( p. 16). 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 307: Lubricating The Hook

    2. Refill oil through the nipple (1) until the oil level reaches the MAX marking (3). 17.2.2 Lubricating the hook Fig. 267: Lubricating the hook ① ② (1) - Screw (2) - Screw Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 308: Servicing The Pneumatic System

    The operating pressure cannot deviate by more than ± 0.5 bar. Check the operating pressure on a daily basis. Abb. 268: Setting the operating pressure ① ② (1) - Pressure controller (2) - Pressure gage Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 309: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 310: 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 S/745-35-10 A - 02.0 - 04/2017...

  • Page 311: Parts List

    Maintenance 17.4 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 312 Maintenance Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 313: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 314 Decommissioning Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 315: 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 S/745-35-10 A - 02.0 - 04/2017...
  • Page 316 Disposal Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 317: Troubleshooting

    • Replace the sewing motor cable • Sewing motor cable defective 1002 Sewing motor insulation fault • Check motor phase and PE for low-impedance connection • Replace the sewing motor encoder • Replace sewing motor Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 318 • Sewing motor defective • Replace the sewing motor • Control defective • Replace the control 1053 Mains voltage too high Check the mains voltage 1054 Internal short circuit Replace the control Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 319  p. 296 • Replace the control 1342-1344 Error in the reference run • Switch off and on the machine again • Perform software update  p. 296 • Replace the control Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 320 • Step motor transport clamp • Eliminate seizing seized up • Replace the transport clamp step • Faulty step motor transport motor clamp • Replace the control • Control defective Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 321 • Control defective 2401 Step motor error at corner knife, seam begin. • Faulty cable to the reference • Check the reference switch and switch replace, if necessary • Reference switch defective Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 322 Check the mains voltage Temporary mains voltage interruption 3102 Voltage sewing motor: Check the mains voltage Temporary mains voltage interruption 3103 Voltage step motors: Check the mains voltage Temporary mains voltage interruption Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 323 • Inform Dürkopp Adler Service Error code 7000-7999: Error messages displays 7200 Failure in CAN - Module corner • Check cable knife (AC001), no module • Check jumpers recognized at address • Check voltage supply Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 324 Update failed! Should the program be retransmitted? 8408 Information Waiting for RESET by machine. 8409 Information Switch off and on the machine again. 8410 Information Update failed! Should the program be retransmitted? Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 325 Set light barrier for sewing material removal not active removal 9605 Transport clamp moves 9700 Folder not up Correct folder setting 9701 Folder not down Correct folder setting 9702 Folder not vertical Correct folder setting Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 326 Corner knife cut impossible • Increment the pocket length • Use additional equipment short pockets 9800 Middle knife not ready for use Check cable 9810 Smoother not ready for use Check cable Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 327 • 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 again changed Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 328 Troubleshooting Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 329: Technical Data

    [Hz] 50/60 50/60 Operating pressure [bar] Length [mm] 1440 1440 Width [mm] Height [mm] 1200 1200 Weight [kg] approx. 275 approx. 280 Rated power: [kWh] - StandBy >0.1 >0.1 - Operation Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 330 • Step motor technology allows for short cycle times and guarantees a perfectly accurate corner cut. • It contributes to unprecedented pocket quality at a high level of productivity. Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...

  • Page 331: Appendix

    Appendix 22 Appendix 22.1 Wiring diagram 745-35-10 S Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
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  • Page 339 Appendix " Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
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  • Page 343: Wiring Diagram 745-35-10 A

    Appendix 22.2 Wiring diagram 745-35-10 A Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 344 Appendix Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
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  • Page 357 Appendix " Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
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  • Page 365: Pneumatic Diagram

    Appendix 22.3 Pneumatic diagram Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 366 Appendix Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
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  • Page 379 Appendix Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 380 Appendix 22.4 Pneumatic diagram throw-over stacker Service Instructions 745-35-10 S/745-35-10 A - 02.0 - 04/2017...
  • Page 382 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone: +49 (0) 521 925 00 Email: service@duerkopp-adler.com www.duerkopp-adler.com...

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