Page 1 745-35-10 B 745-35-10 F Operating 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
4.19.6 Blow-out device (745-35-10 B only) ........... 48 4.19.7 Bundle clamp (745-35-10 B only) ..........48 4.19.8 Automatic incision device for piping ends........50 4.19.9 Feeding devices for flaps and pocket bags ........ 52 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 4 Table of Contents 4.19.10 Shaped guide Lining loop triangle ..........53 4.19.11 Pocket bag on flap (745-35-10 B only) ........54 4.19.12 Zipper feeders (745-35-10 B only)..........57 4.20 Sewing ..................58 4.20.1 Start sewing ................58 4.20.2 Working method B ..............59 4.20.3 Working method F ..............
Page 5: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 6 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 7: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 8 About these instructions Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 9: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 10: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 11 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 12 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 13: Machine Description
Fig. 1: Components of the machine 745-35-10 B ⑥ ⑤ ① ② ④ ③ (1) - Workpiece boxes (4) - Winder (2) - Stacker (5) - Control panel OP7000 (3) - Pedal (6) - Reel stand Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 14: Components Of The Machine 745-35-10 F
① ⑤ ② ④ ③ (1) - Workpiece boxes (5) - Winder (2) - Stacker (6) - Control panel OP7000 (3) - Turning device (7) - Reel stand (4) - Pedal Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 15: Proper Use
DIN EN 60204-31. Only authorized persons may work on the machine. Dürkopp Adler cannot be held liable for damages resulting from improper use. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 16: Declaration Of Conformity
Machine description 3.4 Declaration of Conformity The machine complies with European regulations ensuring health, safety, and environmental protection as specified in the declaration of conformity or in the declaration of incorporation. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 17: Operation
Fig. 3: Switching on the machine To switch on the machine: 1. Turn the main switch from position 0 to position I.  The machine starts up. The control panel starts up. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 18: Swiveling The Folding Station To The Side
2. Swivel the entire folding station (1) including folder to the right. Information If the machine is switched on, a safety message will be shown on the display of the control panel: Info 9002  The sewing area is freely accessible. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 19: Locking The Folding Station In Place
(1) - Locking mechanism (2) - Folding station To lock the folding station in place: 1. Swivel down the folding station (2). 2. Lock the folding station in place inside the locking mechanism (1). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 20: Inserting/Changing The Needles
1. Swivel the folding station to the side ( p. 16).  The needles are freely accessible. 2. Loosen the screws (3) and pull the needles down and out of the needle holders (1). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 21: Threading The Needle Thread
1. Swivel the folding station to the side ( p. 16). 2. Fit the thread reel on the reel stand (1). 3. Feed the thread from the thread reel through the holes (2). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 22 1. Swivel the folding station to the side ( p. 16). 2. Fit the thread reel on the reel stand (1). 3. Feed the thread from the thread reel through the holes (2). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 23 12. Feed the needle thread through the guide (5). 13. Feed the needle thread through the needle thread monitor (7). 14. Feed the needle thread through the guide (6). 15. Feed the needle thread into the right needle. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 24: Winding The Hook Thread
5. Feed the hook thread counterclockwise through the hook thread tensioner (2). 6. Wind some of the hook thread counterclockwise into the front and rear reserve grooves of the bobbin (4). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 25: Changing The Bobbins
 The bobbin case retainer (2) will be lifted as well. 5. Remove the bobbin case upper section (1) together with the empty bobbin. 6. Remove the empty bobbin from the bobbin case upper section (1). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 26: Thread Tension
If the tension of needle thread and hook thread is identical, the thread interlacing lies in the middle of the sewing material. Set the needle thread tension so that the desired seam pattern is achieved with the lowest possible tension. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 27: Setting The Needle Thread Tension
To set the needle thread tension: 1. Set the needle thread tension using the knurled nuts (1) and (2). • Increase the tension: turn clockwise • Reduce the tension: turn counterclockwise Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 28: Setting The Hook Thread Tension
1. Set the tension of the leaf spring (3) using the adjusting screw (2). • Increase the tension: turn clockwise • Reduce the tension: turn counterclockwise  With the bobbin inserted and the hook thread threaded, a uniform and easy pull-off must be assured. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 29: Sliding Back The Hood And Removing The Fabric Sliding Plate
Fig. 16: Sliding back the hood and removing the fabric sliding plate (1) ① ② (1) - Hood (2) - Screw To slide back the hood: 1. Switch off the machine. 2. Loosen the screw (2) on the hood (1). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 30 2. Lift the fabric sliding plate (3) in the area of the tabletop recess (4) and swing it out to the left. 3. Lift the fabric sliding plate completely at the pin (5). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 31: Swiveling Up The Machine Head
To do so, lift the hood (1) up at the front to release the lock. 2. Carefully lift the hood (1) up and off. 3. Swivel the folding station to the side ( p. 16). 4. Swivel the locking lever (3) up. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 32 6. Lift the machine head in the head cover area (2) and swivel it up carefully.  The latch (5) latches into place. The space under the stand is now accessible. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 33: Swiveling Down The Machine Head
(5) - Latch To swivel down the machine head: 1. Hold the machine head in the head cover area (2). 2. Release the latch (5). 3. Swivel down the machine head carefully. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 34: Remaining Thread Monitor
Cleaning the remaining thread monitor CAUTION Risk of injury from sharp and moving parts! Puncture or crushing possible. Do not clean the remaining thread monitor unless the machine is switched off. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 35: Stacker Control
The transport carriage is not returned until the workpiece has been moved out correctly. Important For a secure function of the stacking control clean the lens of the reflected light barrier with a soft cloth once a day. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 36: Corner Knife Station
4.15.1 Swiveling the corner knife station for straight pockets in and out Fig. 24: Swiveling the corner knife station for straight pockets in and out ① (1) - Corner knife station Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 37: Swiveling The Corner Knife Station For Slanted Pockets In And Out
1. Swivel the corner knife station (1) to the left.  The knives are accessible for setup and service work. 2. Swivel down and engage the corner knife station under the sewing unit. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 38: Adjust Corner Knife
5. Set the angle at the other pair of knives accordingly. 6. Swivel in the corner knife station. Setting the height of the corner knives The height of the corner knives cannot be adjusted. The knives always cut through completely. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 39: Setting The Reference Position
 The current step of the positioning sequence or the sewing cycle is stopped immediately. The display shows the message Error 9601 2. Press the pedal back again.  The transport carriage moves out of the loading area. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 40: Flap And Piping Projection
Fig. 29: Setting the sewing depth of the flap (1) ① ② (1) - Flap stop (2) - Hexagon bolt To set the sewing depth of the flap: 1. Remove the flap stop (1). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 41 20 mm beyond seam beginning and seam end. The length of the piping strip is calculated as follows: Piping strip length = sewing length + 2 x 20 mm Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 42: Folder Monitor
None of the sensors is active Faulty transport clamp setup If the sewing program launches with a faulty transport clamp setup, the dis- play shows, for example, the following message: Info 9014 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 43: Additional Equipment
• Minimum distance: 200 mm from the middle of the pocket opening to the edge of the workpiece The rolling speed and the duty cycle are set at the OP7000 control panel. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 44: Tape Feeder And Automatic Cutter
3. Insert the adapter (3) into a new tape roll on the left and the right. 4. Slip the adjusting ring (2) back onto the shaft. 5. Tighten the screw (1). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 45 7. Remove the fabric sliding plate (8) ( p. 27). 8. Press the slide (10) to the rear and lift off the cover (9). 9. Press the button.  The tape brake is released, and the reinforcement strip advances continuously. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 46  The reinforcement strip (6) is cut to the correct length. Information The tape projection at seam beginning and seam end can be set in the Program parameters menu item ( p. 124). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 47: Vacuum Device
3. Switch on the vacuum in the Program parameters menu item ( p. 131). Setting the vacuum intensity Fig. 38: Setting the vacuum intensity ① ② (1) - Screw (2) - Slide Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 48: Waistband Clamp (745-35-10 B Only)
5. Press the left pedal forwards.  Downholder (1) and waistband clamp (3) lower and clamp the hind trousers in their position. 6. Smooth out the clamped hind trousers laterally and to the front. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 49: Downholder And Pocket Bag Clamp
3. Press the left pedal forwards.  The downholder (1) lowers and clamps the hind trousers in their position. 4. Smooth out the clamped hind trousers laterally and to the front. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 50: Blow-Out Device (745-35-10 B Only)
After sewing they are removed with the roll-off device or the blow- out device and descend while being held by the bundle clamp. Information A smoother device can be used to optimize the bundle array (special man- ufacturing, available on request). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 51 (1) lower. The transport rollers (1) convey the hind trousers part out of the sewing unit. The hind trousers part will then dangle from the bundle clamp (3). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 52: Automatic Incision Device For Piping Ends
Pocket length Fixed cutting length of the piping knife Cutting length within the pocket length Ü Cut-open piping projection 30 mm with seam length of 180 20 mm with seam length 200 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 53 Positioning a single pipe To position a single pipe: 1. Position the piping strip at the front or rear stop (2). 2. Position the piping strip at the center stop (3). 3. Start sewing. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 54: Feeding Devices For Flaps And Pocket Bags
 The clamp of the left feeding device (1) closes. 8. Press the left pedal forward.  The clamps of feeding devices (1) and (2) swivel into the loading area and feed the flap or additional parts automatically. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 55: Shaped Guide Lining Loop Triangle
Make sure the lining loop triangle (7) cannot slip. 4. Press the left pedal.  The pocket bag (6) and the lining loop triangle (7) are fed. The sewing process starts. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 56: Pocket Bag On Flap (745-35-10 B Only)
(1) - Rear marking lamps (2) - Rear flap stop 4. Set one of the rear marking lamps (1) and the rear flap stop (2) to the longest flap length to be sewn. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 57 Make sure the flap (3) does not slip. 8. Release the right pedal.  The left flap clamp (4) closes. 9. Press the right pedal back and keep it there.  The right flap clamp (7) opens. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 58 17. Press the left pedal forward.  The sewing process starts. During the feeding process air is blown on the pocket bag (6), allowing it to slide more easily into the pick-up folder (9). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 59: Zipper Feeders (745-35-10 B Only)
2. Apply custom positioning marks on the rest table. 3. Push the zipper (1) into the guide bar (2) up to the positioning mark. 4. If required, position and feed a pocket bag. 5. Start sewing. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 60: Sewing
This section describes how to adjust and align the positioning aids (e.g. positioning marks, marking lamps, stops, etc.). Positioning and starting sewing process This item includes a list of the individual positioning steps illustrated by typical examples. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 61: Working Method B
(1) - Dart (5) - Light spot (2) - Right jacket front part (6) - Light spot (3) - Left jacket front part (7) - Light spot (4) - Light spot Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 62 9. Position the right jacket front part (2) with the dart (1) at the light spot (6). 10. Align the pocket incision at the center knife incision (lengthwise line of the light spot). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 63 Depending on the selected pedal mode ( p. 137), the loading process is completed either using inching operation or automatically. With a press on the button on the start screen, the previously picked- up piping strip can be released again. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 64 To align the hind trousers symmetrically (positioning method a): 1. Align the light spot (10) such that it lines up exactly on top of the dart. The front light spot (1) can be shifted towards the user. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 65 • Symmetrical positioning: set the stop (7) lower in the sewing area • Set the stops for the positioning of the piping (11) in such a way that the piping (11) is symmetrical to the light spot (10). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 66  The vacuum is switched on. 14. Press the left pedal forward.  The piping (11) is cut and picked up. The transport carriage moves to the loading position. The transport clamps are lowered. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 67 • First pedal tap: The folding plates open, and the pick-up folder swivels back to its initial position • Second pedal tap: The transport clamps lift • Third pedal tap: The transport carriage returns to its waiting position Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 68: Working Method F
(3) - Left jacket front part (7) - Light spot (4) - Light spot To sew a jacket front part: 1. Position the left jacket front part (3) at the rear light spot (4). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 69 9. Align the pocket incision at the light spot (5) (knife incision). 10. If additionally equipped with a vacuum device: press the left pedal forward.  The vacuum is switched on. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 70 The flap clamp (14) seizes the flap (15) and clamps it. The piping strip is cut and picked up by the pick-up folder (16). The transport carriage moves to the loading position. The transport clamps are lowered. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 71 Depending on the selected pedal mode ( p. 137), the loading process is completed either using inching operation or automatically. With a press on the button on the start screen, the previously picked- up piping strip can be released again. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 72 Operation Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 73: Programming
1.3 Select needle distance  p. 143 Hook thread monitor On/Off  p. 143 Automatic flap feeder On/Off  p. 143 Tape feeder On/Off  p. 143 Vacuum On/Off  p. 143 Downholder On/Off Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 74  p. 171 2.9 Adjust and test control panel  p. 175 2.10 Test piping knife  p. 157 2.12 Test pick-up folder 3.0 Multi test  p. 188 3.3 Internal devices Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 75 5.1.4.7 Set securement seam end left needle  p. 108 5.1.4.8 Set securement seam end right needle  p. 105 5.1.4.9 Select flap right/left  p. 105 5.1.4.10 Select positioning points Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 76  p. 127 5.1.11.5 Waiting position of transport clamp  p. 128 5.1.12 Process of transport clamp  p. 129 5.1.12.1 Transport clamp quick adjustment  p. 130 5.1.12.2 Process of transport clamp Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 77 5.2.1.2 Set positioning point seam center  p. 152 5.2.1.3 Set positioning point seam end  p. 153 5.2.2 Adjust transport clamp  p. 154 5.2.2.2 Clamp down: Time to next action Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 78 Initialize all seam programs  p. 199 Initialize all sequences  p. 199 Initialize RAM 10.0 Maintenance  p. 202 10.3 Display software version  p. 202 10.4 Enter date and time Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 79 Programming Option/described Menu item in chap. Internal information (password-protected) (for DA staff only)  p. 208 Update machine software Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 80 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 81  p. 84 Edit seam sequence ④  p. 83 Piece counter ⑤ Display of selected seam pattern • the display changes with the setting of the pocket program (with/without flap). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 82 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 83 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 84 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 85  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 86 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 87 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 88 The pocket programs will be stored in the seam sequence in the order in which they were added to the seam sequence. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 89 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 90 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 91 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 92  The display switches to Select source of sequence. Fig. 69: Changing the seam sequence template (2) Selectable Display of the sequence sequences content  The destination sequence is grayed out and cannot be selected. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 93 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 94  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 95 Fig. 73: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 96 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 97  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 98 Fig. 77: Activating a pocket program from the seam sequence ① ② (1) - Pocket programs in sequence (2) - selected pocket program Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 99 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 100 Fig. 79: Program parameters Symbols Meaning Select pocket program  p. 100 Enter name of pocket program  p. 101 Copy pocket program  p. 101 Create or change seam program  p. 103 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 101 Patterned goods • Plain goods Piping knife  p. 140 Reset seam program to default values 2. Press the desired button.  The user interface for setting the desired item is displayed. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 102 ( p. 84). If the pocket program has already been copied to the selected seam sequence, you can activate it in the seam sequence ( p. 96). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 103 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 104 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 105  The display switches to Create seam program. Fig. 82: Creating a seam program Press a button to either open another submenu or enter the desired values directly using the numeric keypad. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 106 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) Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 107 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 108 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 109 Securement seam beginning left needle ( p. 106). Set securement seam end left needle  The display switches to Securement seam end left needle. Fig. 84: Set securement seam end left needle Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 110 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. 107). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 111 • Light barrier must be activated in the machine configuration  p. 142 To activate the flap: 1. Press the desired button. 2. Enter the desired value using the numeric keypad. 3. Confirm with OK. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 112 Fig. 86: Activating the flap (2) ② ① ② ③ (1) - Quick access corner knife (2) - Quick access flap correction correction (3) - Display of flap Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 113 • -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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 114 Fig. 88: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 115 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 116 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 117 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 118 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 119 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 120 Fig. 94: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 121 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 122 Fig. 96: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 123 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 124 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. 98: Set corner knife correction seam begin./seam end Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 125 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. 142). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 126 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 % Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 127 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 128 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 129 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 130  The display switches to Process of transport clamp. Fig. 103: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 131 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 132 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 133 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 134 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 135 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 136 Select blowing mode  The display switches to Blowing mode. Fig. 108: Select blowing mode Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 137 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 138 Programming Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 139 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 140 • only with active blow-off  p. 143 Set the duration for which the blow-off will be blowing • only with active blow-off  p. 143 • 0 ms - 1000 ms Roll-off On/Off Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 141 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 142 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 143 Test individual machine functions  p. 156 Perform system updates  p. 177 Test machine settings  p. 180 Read/write data to/from a USB key  p. 194 Set basic parameters  p. 199 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 144 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. 113: Machine configuration Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 145 • 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 146 Split needle bar On/Off Toolbox configuration  p. 149 Kit Shims On/Off To set the machine configuration: 1. Press the desired button.  The user interface for setting the desired item is displayed. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 147 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 148 Programming Selecting needle distance  The display switches to Select needle distance: Fig. 115: Select needle distance To select the needle distance: 1. Select the desired needle distance. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 149 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 150 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 151  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 152 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 153  The display switches to Global parameters. Fig. 120: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 154 • Pedal forward: open left; pedal back: open right Transport clamp quick adjustment • without bypass • bypass left • bypass right • bypass left and right Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 155 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. 121: Adjust transport clamp Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 156 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 157 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. 206). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 158 Adjust and test corner knife  p. 162 Switch on needle and middle knife • Test sewing motor On/Off • Test middle knife On/Off • Test split needle bar slanted pocket On/Off Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 159 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 160 Fig. 124: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 161 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 162 For information on how to connect the light barriers, see the wiring diagram included in the Appendix ( p. 257). To test the light barriers: 1. Press the button.  Reference run is carried out. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 163 Lift pick-up folder/lower pick-up folder depressurized Transport clamp quick adjustment  p. 129 Open/Close flap clamp Split needle bar On/Off Scan straight flap Scan slanted flap 2. Press the desired button. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 164 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 165 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 166 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 167 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 168 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 169 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 170  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 171  The display switches to Test step motor. Fig. 133: Test step motor To test the step motor: 1. Press the button.  Reference run is carried out. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 172 If there is a difference between the Encoder and Position values, you can reset the values by carrying out a reference run. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 173 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 174 Fig. 135: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 175 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 176 Programming Touch test  The display switches to Touch test. Fig. 137: Touch test The Touch test menu item allows you to draw on the touch screen. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 177 • 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 178 Fig. 139: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 179 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 180  The update is carried out. Fig. 142: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 181 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 182 • 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 183 Error messages  The display switches to Error messages. Fig. 145: Error messages The list contains the last 10 error messages as well as the date and time of each error. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 184 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 185 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 186 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 187 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 188 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 189 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 190  The display switches to Internal devices. Fig. 147: Internal devices The area State can display 3 different status messages: • conn = connected • nc = not connected • err = error Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 191 Fig. 148: RAM test (1).  The test result is displayed. Fig. 149: RAM test (2) 1. Confirm with OK.  The display returns to Multi test. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 192 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) Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 193 Fig. 151: ROM test (1)  The test result is displayed. ROM error-free OR ROM defective. Fig. 152: ROM test (2) 1. Press the OK button to confirm.  The display returns to Multi test. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 194 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 195 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 196 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 197  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 198  When the data has been written to the USB key, the display shows the message Data successfully written: XY. Fig. 156: Data transfer to USB (2) 3. Press OK.  The display returns to USB data transfer. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 199 • 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 200  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 201 • 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 202 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 203 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 204  The display shows the current software version. You will need this information when contacting the DA service depart- ment for assistance. Fig. 160: Software version Date and time Fig. 161: Date and time Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 205 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 206 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 207 Language selection  The display switches to Language selection. Fig. 163: Language selection To select the language: 1. Select the desired language.  The system restarts with the new language setting. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 208 Fig. 164: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 209 Programming Information After setting up a user password, you can lock the start screen for other operators with a press on the button. Fig. 165: User password setup (2) Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 210 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: Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 211  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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 212 Fig. 170: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 213 9. Press CANCEL to cancel the update.  The following warning appears: Fig. 172: Update the machine software (7)  After confirming with OK, you can continue working with the old control software. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 214 Programming Information If the update fails, you can restart it in the service menu under DAC update ( p. 177). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 215: Maintenance
Removing lint and thread remnants  Clean the lenses of the light barriers  Clean the piping incision device  Checking the water level  Topping off the oil  Check the pneumatic system Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 216: Cleaning
Fig. 173: Cleaning ① ② ③ ④ ⑤ ⑥ (1) - Light barrier (4) - Light barrier (2) - Hook (5) - Vacuum valve (3) - Hook (6) - Filter ring Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 217 1. Loosen the screws (3) and remove the stop (2) completely. 2. Use a compressed air gun to clean the area around the cutting unit (1) and around the transport belt. 3. Assemble the stop again (2). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 218: Lubricating
• Flash point: 150 °C You can order the lubricating oil from our sales offices using the following part numbers: Container Part no. 250 ml 9047 000011 9047 000012 9047 000013 9047 000014 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 219: Lubricating The Machine Head
The oil level must not be higher than the maximum level marking (3). Fig. 176: Lubricating the hook ① ② ① ② ③ (1) - Oil filler opening (3) - Maximum level marking (2) - Oil reservoir Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 220: Servicing The Pneumatic System
Check the operating pressure on a daily basis. Fig. 177: Setting the operating pressure ① ② (1) - Pressure controller (2) - Pressure gage To set the operating pressure: 1. Pull the pressure controller (1) up. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 221: Draining The Water Condensation
3. Loosen the drain screw (3) completely. 4. Allow water to drain into the collection tray. 5. Tighten the drain screw (3). 6. Connect the machine to the compressed air supply. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 222: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 223: Parts List
Maintenance 6.4 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 224 Maintenance Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 225: Setup
If you wish to transport the sewing unit to a different location, you have to attach the transport locks again. When removing/fitting the transport locks, also observe the information given in the supplementary sheet included with the machine. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 226: Setting Up The Machine
(2) and screw in the stand feet (2). 2. When transport is complete, loosen the stand feet (2) until the casters (1) lift off the ground. 3. Tighten the nuts (3). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 227: Assembling And Connecting The Pedal
For convenience, the parts are only named on one side. However, the same mapping applies on the other side of the pedal. Information The pedals can be set in height, angle of inclination and lateral position. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 228 3. Tighten screws (2) and screws (1) at the pedals’ desired angle of inclination. To set the lateral position of the pedals: 1. Loosen the screws (4) (4x). 2. Shift the pedal laterally on the stand bar. 3. Tighten the screws (4). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 229: Setting The Working Height
(measured to the upper edge of the tabletop). The sewing unit has been set to the lowest working height of 797 mm at the factory. Fig. 183: Setting the working height ① ① (1) - Screws Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 230: Assembling The Machine Parts Removed For Shipping
1. Insert the reel stand (3) into the hole (1) in the tabletop and assemble it with the nut below the tabletop. 2. Mount and align the reel plate (2) and the unwinder arms (4) as shown in the figure. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 231: Assembling The Control Panel
7.6.3 Assembling winder and tray Fig. 186: Assembling winder and tray ① ② ③ ⑥ ④ ⑤ (1) - Winder (4) - Arm (2) - Arm (5) - Bracket (3) - Tray (6) - Holder Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 232: Assembling The Cylinder For The Pick-Up Folder Stroke
4. Loosen the screws (1) and move the mounting plate for the pick-up folder along the entire length of the cylinder stroke.  The cylinder retainer aligns itself. 5. Tighten the screws (1). 6. Check ease of movement again. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 233: Assembling The Workpiece Boxes (Optional)
2. Align the height of the workpiece boxes. 3. Tighten the screws on the clamping pieces (1). 4. Loosen the clamping lever (2). 5. Align the workpiece boxes with the sewing station. 6. Tighten the clamping lever (2). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 234: Mounting The Table Extensions (Additional Equipment)
2. Slightly fasten the mounting bracket (4) to the striker (2) using the screws (3) (4x). 3. Align the table extension (5) with the height of the tabletop. 4. Tighten the screws (3). Storage table (large) Fig. 190: Storage table (large) Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 235 Storage table (small) Fig. 191: Storage table (small) To mount the storage table (small): The fastening of the small storage table is identical to the fastening of the slanted table above. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 236: Electrical Connection
To connect the winder: 1. Insert the plug of the winder into the socket (1) below the tabletop. 2. Secure the plug with a union nut. 3. Fit the equipotential bonding (2). Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 237: Pneumatic Connection
Ensure that the machine is only used when the operating pressure is set correctly. Proper setting Refer to the Technical data ( p. 255) chapter for the permissible operating pressure. The operating pressure cannot deviate by more than ± 0.5 bar. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 238: Connection To The In-House Vacuum System
The motor winding becomes damaged. When mounting the vacuum device (side-channel blower), you MUST replace the sealing ring (2) (black) with a filter ring (white). The filter ring is included in the accessory pack. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 239: Performing A Test Run
2. Replace the sealing ring (2) with the filter ring included in the accessory pack. 7.10 Performing a test run When setup is complete, perform a test run to check the functionality of the machine. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 240 Setup Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 241: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 242 Decommissioning Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 243: 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. Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 244 Disposal Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 245: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 246 • 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 247  p. 208 • Replace the control 1342-1344 Error in the reference run • Switch off and on the machine again • Perform software update  p. 208 • Replace the control Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 248 • Step motor transport clamp • Eliminate seizing seized up • Replace the transport clamp step • Faulty step motor transport motor clamp • Replace the control • Control defective Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 249 - mains voltage too high 2355 Stroke position step motor overload • blocked/sluggish • Fix blockage/sluggishness • defective • Replace the step motor • Control defective • Replace the control Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 250 • Replace the control 3030 Sewing motor: Phase error • Test sewing motor phases (R=2.8 OHM, high impedance to PE) • Replace the encoder • Replace the sewing motor • Replace the control Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 251 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 the control Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 252 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 253 Manually turn the handwheel to the upper position of the thread lever (top dead center) 9007 Test the loading process Resuming the process after pushing the start pedal Insert tape  p. 42 9013 Tape missing Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 254 • Check flap size maximum sewing area (behind • Insert the flap correctly the rear positioning point) 9723 Fluff at the flap beginning • Insert flaps with smooth edges • Check reflecting foil Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 255 • 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 256 Troubleshooting Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 257: 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 258 • 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 Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 259: Appendix
Appendix 12 Appendix Wiring diagram Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 260 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 261 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 262 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 263 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 264 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 265 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 266 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 267 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 268 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 269 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 270 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 271 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 272 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 273 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 274 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 275 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 276 Appendix " Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 277 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 278 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 279 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 280 Appendix " Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 281 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 282 Appendix " Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 283 Appendix " Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 284 Appendix Operating Instructions 745-35-10 B/745-35-10 F - 00.0 - 04/2017...
Page 286 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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