Duerkopp Adler 745-22 Service Instructions Manual
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Duerkopp Adler 745-22 Service Instructions Manual

Duerkopp Adler 745-22 Service Instructions Manual

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Contents
Part 3: Service Instructions Cl. 745-22; -23; -24
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.
Transport Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Forward End Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Rear End Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
Timing Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5
Changing the Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
Stroke Movement of the Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
3.3
Position of the Folder to the Needles and the Center Knife . . . . . . . . . . . . . . . . . . . .
3.4
Guide Plates on the Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.
Clearance of the Transport Clamps to the Folder sole . . . . . . . . . . . . . . . . . . . . .
4.1
Manual Adjustment of the Transport Clamps (745-22) . . . . . . . . . . . . . . . . . . . . . . .
4.2
5.
Marker Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.
Knife Brackets for Cutting the Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
Adjusting the Position of the Corner Incisions . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
6.3
Changing the Corner Knives (745-22 and 745-23) . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
Changing the Corner Knives (745-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.
Adjusting the Piping Reverser (745-23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.
Cloth Slider Plate and Support Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.
Stroke Height of the Transport Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
Clearance of the flap clamps to the slider plate . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.
Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.
Machine Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1
Crank Pin on the Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2
Needle Bar Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.3 Turning the Needle Bars on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.4 Assembling and Removing the Needle Bar Link . . . . . . . . . . . . . . . . . . . . . . . . . .
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Summary of Contents for Duerkopp Adler 745-22

  • Page 1: Table Of Contents

    Home Contents Page: Part 3: Service Instructions Cl. 745-22; -23; -24 General ..........Transport Carriage .
  • Page 2 Contents Page: 11.3 Hook Shaft Height ......... . 11.4 Tooth Play of the Hook Drive .

  • Page 3: General

    1. General These Service Instructions describe the adjustments on the sewing unit in a practical order. Attention! The various setting positions are interdependent. It is therefore essential that the individual settings be made in the order described. ATTENTION ! The tasks described in these Service Instructions may only be conducted by skilled personnel or appropriately trained persons! Danger of Breakage ! Before starting the sewing unit again after disassembly first conduct...
  • Page 4 Setting gauges The following setting gauges are available on request: Subclass Setting gauges Order no. Application 745-22; -23; -24 Gauge 0246 002591 Crank pin to the arm shaft Gauge 0244 001001 Hook shaft height Arresting pin 0211 000700 Looping stroke setting Measuring bridge 0212 004942 Needle holder height Measuring pin 0216 001070 Needle holder height...

  • Page 5: Transport Carriage

    2. Transport Carriage The advance of the transport carriage occurs via a step motor. Caution Risk of Injury ! Do not reach into the area of moving machine parts. 2.1 Rollers The transport carriage is guided on the extension pipes 2 by ball sleeves on the left and by rollers on the right.

  • Page 6: Forward End Position

    2.2 Forward End Position The switch b2 determines the forward end position of the transport carriage. In this position the clearance from the forward edges of the forward-lying needles to the forward edges 2 of the transport clamps must be 306 mm. This corresponds to a clearance of 15 mm from the forward edges 2 of the transport clamps to the H-light marker 1 (see sketch).

  • Page 7: Rear End Position

    2.3 Rear End Position The switch b1 determines the rear end position of the transport carriage. Set switch b1 so that in the rear end position there is still a clearance of 5 mm between the damper discs 1 and the transport carriage 2. The surface 4 on the transport carriage must open the pneumatic valve 3 when running into the rear end position.

  • Page 8: Timing Belt Tension

    2.4 Timing Belt Tension At the middle of the belt section S the timing belt must bend in 13 mm under the test load FV = 500g. Consequences of too high timing belt tension: – Reduced life – Running noises Consequences of too low timing belt tension: –...

  • Page 9: Changing The Timing Belt

    2.5 Changing the Timing Belt To simplify changing, the timing belt is split. It is held together by the timing belt clamp 1. Caution Risk of Injury ! Turn the main switch off. Change the timing belt only with the main switch turned off. Remove the old timing belt –...

  • Page 10: Folder

    3. Folder For the unimpaired transport of the material and a flawless fabrication of the pocket opening, the folding and cutting tools, as well as the marker lights, must be aligned to the center of the pocket opening. The incision of the center knife is seen as the center of the pocket opening.

  • Page 11: Stroke Movement Of The Folder

    3.1 Stroke Movement of the Folder Caution Risk of Injury ! Turn the main switch off. Set the stroke movement of the folder only with the main switch turned off. With the folder raised: There must be a safety clearance of 3 mm between the lever 13 and the bottom of the curve piece 12.
  • Page 12 – Loosen clamping screw 14. – Turn the folder slightly on the axle 15. There must be a uniform clearance between the folder sole and the cloth slider plate along the whole length. – Tighten clamping screw 14 and nut 10. –...

  • Page 13: Aligning The Folder To The Center Of The Pocket Opening

    3.2 Aligning the Folder to the Center of the Pocket Opening When properly mounted the folder can be aligned from the measurement line 17 to the center of the pocket opening. Dependent on the width of the folder sole 19 the dimension x can be established.

  • Page 14: Position Of The Folder To The Needles And The Center Knife

    3.3 Position of the Folder to the Needles and the Center Knife With a properly mounted folder the following positions must be attained: – In the most forward position the needles must enter the needle holes of the folder sole unhindered (without being deflected). –...

  • Page 15: Guide Plates On The Folder

    3.4 Guide Plates on the Folder With the needle bar link in the most forward position the edges 2 of the guide plates must extend approx. 1 mm to the rear beyond the needles. The leaf springs 1 hold the guide plates down on the folder sole with a slight pressure.

  • Page 16: Clearance Of The Transport Clamps To The Folder Sole

    4. Clearance of the Transport Clamps to the Folder Sole There must be a certain clearance between the outer edges 2 of the folder sole and the inner edges 1 of the transport clamps. By medium weight cloth for ready-made clothes it must be e.g. 1 to 1.5 mm. The clearance is necessary in order to assure uniform piping widths on both sides and an unhindered transport of the material.

  • Page 18: Pneumatic Quick Clamp Adjustment (745-23)

    4.2 Pneumatic Quick Clamp Adjustment (745-23) With the 745-23 the left transport clamp has the pneumatic quick clamp adjustment as standard equipment. When changing the the folder between single and dual piping the left transport clamp correctly sets itself automatically. The clearance between the outer edges 2 of the folder sole and the inner edges 1 of the lowered transport clamps is dertermined as follows:...

  • Page 20: Marker Lights

    5. Marker Lights The light markers 2 and 4 limit the sewing area. Alternatively a 3rd marker light, available on request, can be attached (Order no. 793 022068). The multiple masks built into the lamp optics make possible the following application: –...
  • Page 21 Aligning the light markers All light markers must be aligned to the cutting line (center of the pocket opening 5). The clearance between the lengthwise lines of the H-light markers and the measurement line 6 must be 125 mm. – Loosen the clamping screws 8 of the lamp holder 12 slightly.
  • Page 22 Check the exact position of the light markers Light marker 2 (seam beginning): – Set the " " key on the front panel of the control unit to "Positioning point-forward". The LED above the key is lit. – Designate the desired seam beginning with a chalk mark on the sewing piece.

  • Page 23: Knife Brackets For Cutting The Corners

    6. Knife Brackets for the Cutting of the Corners Caution Risk of Injury ! Do not reach into the area of the corner knives. The rapidly rising corner knives can cause serious cuts. Presetting: The clearance between the cutting edges of the corner knives in the knife bracket "seam end"...

  • Page 24: Adjusting The Position Of The Corner Incisions

    6.1 Adjusting the Position of the Corner Incisions – Call up the longest sewing distance (e.g. 150 mm) with the L1 key on the front panel of the control unit. – Conduct a trial seam. It is useful to first iron a piece of nonwoven fleece onto the sewing piece.
  • Page 25 745-22: 745-23: 745-24:...
  • Page 26 Adjusting the scale With the 745-22 and 745-23 the scale 7 with the dimension corresponding to the sewing distance (in the example 150 mm) must lie congruent to the edge 6 of the knife bracket 2 ("seam beginning"). – Loosen screw 9 slightly. –...
  • Page 27 745-22: 745-23: 745-24:...

  • Page 28: Adjusting The Knife Brackets For Bias Corner Incisions (745-24)

    6.2 Adjusting the Knife Brackets for Bias Corner Incisions (745-24) Caution Risk of Injury ! Turn the main switch off. Adjust the knife brackets for bias corner incisions only with the main switch turned off. Do not reach into the area of the corner knives. The rapidly rising corner knives can cause serious injuries through cuts.
  • Page 29 – Turn the awl rod 13 and knife rods 21 accordingly. – Tighten the clamping screws 23 and 33 again. – Check the ease of movement of the knife rods 21 and the awl rod 13. – Attach the block 18 at the "seam beginning" knife bracket again. It is then essential to set the base position of the position plate 28.

  • Page 30: Changing The Corner Knives (745-22 And 745-23)

    6.3 Changing the Corner Knives (745-22 and 745-23) Blunt corner knives are to be replaced with the knife set in the accessories pack. Please find the order numbers for the corner knife sets in Chapter 1 of these Service Instructions. Caution Risk of Injury ! Turn the main switch off.

  • Page 31: Changing The Corner Knives (745-24)

    6.4 Changing the Corner Knives (745-24) Blunt corner knives are to be replaced with the knife set in the accessories pack. Please find the order numbers for the corner knife sets in Chapter 1 of these Service Instructions. Caution Risk of Injury ! Turn the main switch off.

  • Page 32: Adjusting The Piping Reverser (745-23)

    7. Adjusting the Piping Reverser (745-23) The corner cutting device of the 745-23 is additionally equipped with a piping reverser. The piping reverser pulls the sewn-on piping strip with corner incisions (only dual piping) onto the other side of the material. ca.
  • Page 33 Height of the extended piping reverser With fully extended piping reversers the clearance between their upper edge and the cloth slider plate must be approx. 115 mm. – Loosen lock nut 4. – Set the height of the extended piping reverser by turning the rod 3. Thereby align the reversing tools of the piping reverser parallel to the pocket opening.

  • Page 34: Cloth Slider Plate And Support Plate

    8. Setting the Cloth Slider Plate and Support Plate The cloth slider plate 1 is to be so aligned that its cutout has the same clearance to both sides of the needle plate elevation. The support plate 6 must be at one level with the base plate of the machine head.

  • Page 35: Stroke Height Of The Transport Clamps

    9. Stroke Height of the Transport Clamps With the flap clamps (optional equipment) closed the raised transport clamps must pass the machine arm without hitting. With the 745-22 and 745-24 the clearance between the forward edges 1 of the raised transport clamps and the cloth slider plate 2 must be approx.

  • Page 36: Clearance Of The Flap Clamps To The Slider Plate

    9.1 Clearance of the flap clamps to the slider plate If the sewing unit is equipment with flap clamps 0791 011161 (clamp left) and/or 0792 011162 (clamp right), the clearance of the flap clamps to the cloth slider plate should be 40 mm. 1: Flap clamp 2: Slider plate 3: Transport clamp...
  • Page 37 1st needle position: Needle low position The 1st needle position triggers the swing timing of the needle bar link for the seam bartacking at the seam beginning and the seam end. The light screen 3 determines the precise swing timing through its position.

  • Page 38: Machine Head

    11. Machine Head 11.1 Crank Pin on the Arm Shaft The clearance of the eccentric crank pin 1 to the arm shaft 4 determines the size of the needle bar stroke and thus the upper dead center of the needle bars. The crank pin 1 is precisely set at the factory! After a replcement of the thread lever the crank pin 1 must be reset.
  • Page 39 – Insert gauge 13 with its pegs into the accepting holes 6. – Turn the crank pin 1 so that it catches in the recess in the gauge. – Press the crank pin 1. The thread lever 5 must be set tight except for a lubrication gap. –...

  • Page 40: Needle Bar Link

    11.2 Needle Bar Link For securing the seams the seam beginning and the seam end are made with stitch condensation and seam bartacking (slewing the needle bar link) or only stitch condensation. – Turn seam bartacking on and off by pressing the " "...
  • Page 41 – Step back on the left pedal. The transport carriage runs into its rear end position. Caution Risk of Injury ! Turn the main switch off. Set the slewing movement of the needle bar link only with the main switch turned off. –...

  • Page 42: Setting The Needle Bar Link To The Needle Bars

    11.2.2 Setting the Needle Bar Link to the Needle Bars For a sure turning on and off of the needle bars the needle bar link must be precisely set to the needle bars. The setting is made with gauge 3 (Order no. 246 000919). Caution Risk of Injury ! Turn the main switch off.

  • Page 44: Turning The Needle Bars On

    11.2.3 Turning on the Needle Bars With cylinder 6 not operated the needle bars are turned off and arrested in the high position. The extending piston rod of the cylinder 6 operates the latch 3. The coupling-in of the needle bars occurs at that moment in which the crosshead reaches its upper dead center.
  • Page 45 – Turn the handwheel until the swing lever 9 has reached its furthest swing to the back (in the direction of the arrow). – Turn the swing lever 9 on the shaft 11 so that the shoulder 10 of the latch is still just pushed off of the stopper 1. –...

  • Page 46: Assembling And Removing The Needle Bar Link

    11.2.4 Removing and Attaching the Needle Bar Link Caution Risk of Injury ! Turn the main switch off. Remove or attach the needle bar link only with the main switch turned off. Removing the needle bar link – Loosen screws 8 and 11. –...
  • Page 47 – Loosen clamping screw 4 slightly. – Pull out the bearing bolt 3. – Remove the holder plate 6 from the needle bar link 15. Attaching the needle bar link – Mount the needle bar link 15 with bearing bolt 3 on holder plate 6. –...

  • Page 48: Hook Shaft Height

    11.3 Hook Shaft Height The clearance between the needle plate support 4 and the shoulder 1 of the hook shaft must be 17.7 mm. The precise height of the hook shaft is set with the gauge 3 (Order no. 244 001001). Caution Risk of Injury ! Turn the main switch off.

  • Page 49: Tooth Play Of The Hook Drive

    11.4 Tooth Play of the Hook Drive The tooth play between worm and worm wheel should be as little as possible. Ease of movement must, however, remain assured. After every adjustment of the hook drive in axial direction the tooth play must be reset.

  • Page 50: Looping Stroke

    11.5 Looping Stroke The looping stroke is the path of the needle bars from lower dead center up to the point at which the hook points lie at the center of the needle. The looping stroke is 2 mm. It is set with the arresting pin 4 (Order no. 0211 000700). Caution Risk of Injury ! Turn the main switch off.

  • Page 51: Height Of The Needle Holders

    11.6 Height of the Needle Holders For setting the needle holders 5 the needle 7 must lie above the center of the the needle hole and in the looping stroke position. The clearance from the upper edge of the eye of the needle to the hook point 8 must be 1.5 mm in this position (see sketch).
  • Page 52 Caution Risk of Injury ! Danger of cuts! When working on the needle holders 5 do not reach into the area of the center knife 9. – Press under the needle holder 5 of the needle bar to be turned off. At the same time turn the handwheel backwards.

  • Page 53: Clearance Of The Hook Points To The Needles

    11.7 Clearance of the Hook Points to the Needles The clearance of the hook points to the needles must be 0.1 mm. It is precisely set at the factory with setting pin 5 (Order no. 244 001014). The set clearance makes possible the working with needles with the needle thickness Nm 90 to Nm 110.
  • Page 54 – Loosen screw 8. – Set the needle guard 7 back by turning the eccentric bolts 6. – Remove the needle from the needle holder. – Push the setting pin 5 into the needle holder up to the stop. – Tilt the machine head to the back.

  • Page 55: Needle Guard

    11.8 Needle Guard The needle guard 2 prevents a deflecting of the needle 4 into the path the hook point 5. Before the hook point 5 reaches the needle the tip of the needle must touch on the needle guard 2. The needle should not be allowed to be pressed into the path of the hook point 5.

  • Page 56: Changing The Hook

    11.9 Changing the Hook Caution Risk of Injury ! Turn the main switch off. Change the hook only with the main switch turned off. – Remove the needle plate 7 after loosening the mounting screws. – Remove the top of the bobbin case 6 with bobbin. –...

  • Page 57: Bobbin Case Holding Wire

    11.10 Bobbin Case Holding Wire Function The bobbin case holding wire 1 holds the top of the bobbin case and the bottom in a certain position counter to the turning movement of the hook. The needle thread loop guided around hook is pulled between the sprung holding wire 1 and the edge 2 of the top of the bobbin case.
  • Page 58 13 mm Caution Risk of Injury ! Turn the main switch off. Set the bobbin case holding wire only with the main switch turned off. – Loosen clamping screw 3 slightly. – Set the holding wire 1. The holding wire 1 must extend 13 mm out of plate 5. –...

  • Page 59: Aligning The Light Barriers Of The Remaining Thread Monitor

    11.11 Aligning the Light Barriers of the Remaining Thread Monitor The light barrier mountings 3 and 6 are set at the factory so that a sufficient safety clearance of 5-6 mm to the moving hooks is provided. The alignment of the reflecting light barriers occurs in program P51. ATTENTION ! The remaining thread monitor is only activated when the value for the underthread counter is set to "0000"...

  • Page 60: Center Knife

    11.12 Center Knife Caution Risk of Injury ! Turn the main switch off. Set the center knife only with the main switch turned off. Position of the center knife in the lower dead center The forward edge 4 of the movable knife 3 must lie 1 mm above the cutting edge of the fixed knife in the lower dead center.
  • Page 61 Center knife movement The center knife must move counter to the needle bars. When the needles are in their lower dead center the knife bar drive lever 1 must be in the upper dead center. – Tilt the machine head to the back. –...
  • Page 62 Knife bar drive lever – Remove the cylinder with swing lever for the thread puller after loosening the mounting screws. – Remove the head cover after loosening the mounting screws. – Move the knife bar drive lever 8 into its lower dead center by turning the handwheel.
  • Page 63 – Move the knife bar bridge 5 into its lower dead center by turning the handwheel. Prerequisite: The piston rod of the operating cylinder 9 must have caught in the groove 4. – Check the ease of movement of the knife bar bridge 5 on the link frame.

  • Page 64: Thread Controller Springs

    11.13 Thread Controller Springs Base setting The thread controller springs must hold the needle threads taut until the tip of the needles enter the material. If the needle threads are already loose when the needles enter there is a danger that the needles will stitch into the threads during their downward movement.

  • Page 65: Trimming And Clamping Device For The Needle Threads

    11.14 Trimming and Clamping Device for the Needle Threads Function – After the seam end and during pulling forward of the thread the long stroke of the cylinder 1 is switched on. The thread catcher 5 lowers and takes up the needle threads. –...

  • Page 66: Trimming And Clamping Device For The Underthreads

    11.15 Trimming and Clamping Device for the Underthreads Function – After the seam end and during the pulling forward of the thread the underthreads are pulled through the thread grooves in the needle plate into the opened underthread shears 1 and underthread clamp 2.
  • Page 67 Caution Risk of Injury ! Turn the main switch off. Set the trimming and clamping device for the underthreads only with the main switch turned off. – Loosen screw 7. – Align the openings in the underthread shears 1 centered to the thread grooves of the needle plate.

  • Page 68: Thread Puller For The Needle Threads

    11.16 Thread Puller for the Needle Threads The thread puller 4 pulls a set quantity of needle thread forward out of the opened thread tension. The quantity of needle thread pulled forward must be large enough to meet the following conditions: –...

  • Page 69: Winder

    11.17 Winder The winding procedure must shut off automatically when the bobbin is filled to within approx. 0.5 mm of the bobbin edge. Caution Risk of Injury ! Turn the main switch off. Set the bobbin capacity only with the main switch turned off. Correcting the bobbin capacity –...

  • Page 70: Changing The Needle Holders

    11.18 Changing the Needle Holder – Step back on the left pedal. The transport carriage runs into its rear end position. Caution Risk of Injury! Turn the main switch off. Change the needle holder only with the main switch turned off. –...
  • Page 71 – Loosen screw 2. – Screw needle holder 3 out of the needle bar. – Screw a new needle holder into the needle bar. – Set the height of the needle holder 3 (see Chapter 11.6). – Tighten screw 2. –...

  • Page 72: Setting The Optional Equipment

    12. Setting the Optional Equipment 12.1 Draw-off Device and Bundle Clamp The draw-off device 4 (Order no. 0794 000701) conveys the finished sewing piece out of the machine so that it hangs down on the bundle clamp 6 (Order no. 0794 002201). Caution Risk of Injury ! Turn the main switch off.

  • Page 73: Length-Controlled Feed And Trimming Device For Reinforcement Strips

    12.2 Length-controlled Feed and Trimming Device for Reinforcement Strips Caution Risk of Injury ! Turn the main switch off. Set the feed and trimming device only with the main switch turned off. – Tilt the machine head to the back. Setting the advance speed The transport roller must advance the reinforcement strips quickly.

  • Page 74: Holder, Pocket Bag And Waistband Clamp

    12.3 Holder, Pocket Bag and Waistband Clamp With this device fullness occuring in the area of the pocket openings because of darts is securely held and smoothed. The device consists of the following components: – Holder 6 – Clamping plate 3 for pocket bag pieces –...
  • Page 75 Setting the waistband clamp 4 – Loosen screws 7 on the waistband clamp 4. – By alignment of the waistband clamp 4 establish how much of the waistband is to be engaged. – Tighten screws 7. – Tilt the machine head to the back. –...

  • Page 76: Reflecting Light Barrier For Flap Scanning (745-22 And 745-24)

    12.4 Reflecting Light Barrier for Flap Scanning (745-22 and 745-24) The recognition of the seam beginning and seam end occurs via the reflecting light barrier b44 when sewing with flap. Presetting: – Set the correction values for seam beginning (NA) and seam end (NE) to the median value 50 (no correction) (see Short Description Microcontrol).
  • Page 77 – Conduct a sewing trial. The seam beginning and seam end must lie symmetric to the flap. The first stitch should lie in front of and the last stitch behind the flap edge (see illustration a). – Loosen screws 7 at joint picture b) or c). –...

  • Page 78: Throw-Over Stacker

    12.5 Throw-over Stacker The following base settings of the throw-over stacker were made at the factory. They are to be corrected only in exceptional cases. Caution Risk of Injury ! Before all setting work turn the main switch off and disconnect the throw-over stacker from the compressed air supply.

This manual is also suitable for:

745-24745-23

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