745 - 35 A Operating Manual
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Table of Contents 1 About this operating manual ..................................................... 3 1.1 1.2 1.3 1.4 1.5 1.5.1 1.5.2 Scope of application of the operating manual............................... 3 For whom is this operating manual?............................................. 3 Representational conventions – Symbols and characters............ 4 Other documents .......................................................................... 4 Liability..........................................
Table of Contents 2 5.17.3 5.18 5.18.1 5.18.2 5.18.3 5.18.4 5.18.5 5.18.6 5.18.7 5.18.8 5.19 5.19.1 5.19.2 Folder monitoring........................................................................ 63 Functions and operation of the optional equipment.................... 65 Downholder and pocket bag clamp ............................................ 65 Waistband clamp ........................................................................ 66 Stacker.........................................................
About this operating manual 1 About this operating manual The operating manual for the 745-35 sewing unit was compiled with the utmost care. It contains information and notes in order to make long-term and reliable operation possible. Should you notice any discrepancies or if you have improvement requests, then we would be glad to receive your feedback, Chapter 6.10 Customer service. Please regard the operating manual as part of the product and keep it in a safe place where it can be easily accessed.
About this operating manual 1.3 Representational conventions – Symbols and characters Different information is depicted or highlighted in this operating manual by the following characters for easier and quicker understanding: Symbol/character • Meaning Lists are identified by bullet points. 1. Instructions are numbered and have to be performed in the specified order. 2. References to further information in this operating manual or other documents are identified by this symbol.
About this operating manual 1.5.1 Transportation Dürkopp Adler cannot be held liable for any damage during transport. Check the delivered product immediately after receiving it. Report any damage to the last transport manager. This also applies if the packaging is not damaged. Keep the machines, devices and packaging material in the condition they were at the time when the damage was identified. That secures any claims towards the transport company.
About this operating manual 6 Operating manual 745-35 A Version 01.
Performance description 2 Performance description The Dürkopp Adler 745-35 is a sewing unit for the automatic runstitching of piped, flap and welt pocket openings with rectangular pocket corners. The piping strips and additional parts are fed manually. 2.
Performance description 2.2 Declaration of conformity The machine complies with the European regulations specified in the declaration of conformity or in the installation declaration. 2.3 Optional equipment By means of a flexible system of optional equipment the sewing unit can be equipped optimally and economically corresponding to the respective application. = Standard equipment F D B (slanted pocket) B (straight pocket) A (slanted pocket) Optional equipment S (Speed) Order No.
F D B (slanted pocket) B (straight pocket) A (slanted pocket) Optional equipment A (straight pocket) Order No. S (Speed) Performance description 0745 517734 Automatic feeding, on the left 180-220 mm (with flap 180200 mm) Automatic feeding of the flap and the additional parts. Can be extended with zipper feed 0745 597774 and 0745 597794. 0745 517744 Automatic feeding, on the right 180-220 mm (with flap 180200 mm) Automatic feeding of the flap and the additional parts.
0745 597774 Zipper feed, on the left In conjunction with feeding device 0745 517734 For cut-to-length zippers, without slider, total width 24 mm, chain width approx. 4 mm, chain inside with ready-made pockets. 0745 597784 Zipper feed, to the right In conjunction with feeding device 0745 517744 For cut-to-length zippers, without slider, total width 24 mm, chain width approx. 4 mm, chain outside with ready-made pockets.
F D B (slanted pocket) B (straight pocket) A (slanted pocket) Optional equipment A (straight pocket) Order No. S (Speed) Performance description Light barriers 0745 598154 Light barrier 2nd Light barrier for Speedpocket 0745 598284 Kit Light barrier Additional light barrier for the 745-35 A with the production of jackets and trousers for the switchable flap detection to the left and to the right and when equipped with a slanted knife carrier also for automatic flap angle detection.
F D B (slanted pocket) B (straight pocket) A (slanted pocket) Optional equipment S (Speed) Order No. A (straight pocket) Performance description 0745 597894 Kit: Pocket bag clamp for small pocket bags & for front positioning point 0745 598134 Sewing light with transformer 0745 598164 Kit: Piping blow-on device for the 745-35 A For the blowing on of the piping with large piping projections.
Performance description 2.4 Subclasses In the following chapters the characteristics of the individual subclasses of the machine will be highlighted. 2.4.1 745-35 S Basic sewing unit for the runstitiching of rectangular piped pockets. The piping strips and additional parts are fed manually. Pocket length 20-200 mm (with flap max. 180 mm) In order to complete the unit a sewing equipment is to be selected. The setting of the corner knives with regard to the pocket length is done manually.
Performance description Large graphic color display BF1CE with decimal key pad and function keys. The user interface can be adapted by the user according to the functions needed. All pocket parameters are freely programmable. Any selected icon is additionally described in an info line available on each window. 2.4.3 745-35 B Sewing unit for the automatic runstitching of piped, flap and welt pocket openings with, depending on the selected kit, slanted or rectangular pocket corners.
Performance description Large graphic color display BF1CE with decimal key pad and function keys. The user interface can be adapted by the user according to the functions needed. All pocket parameters are freely programmable. Any selected icon is additionally described in an info line available on each window. The 12 mm equipment E2116 is part of the subclass 2.4.
Performance description 2.5 Technical data Technical data 745-35 S Sewing stitch type 301/Double lockstitch Number of needles 2 Needle system 2134-85 Needle size [Nm] 80-110 Number of stitches (programmable) [min-1] Number of stitches on delivery [min-1] 2750 Stitch length (programmable) [mm] 0.5-3 Stitch length at delivery [mm] 2.
Safety instructions 3 Safety instructions This section contains basic instructions for your safety. Read the instructions carefully before setting up or operating the machine. Make sure to follow the information included in the safety instructions. Failure to do this can result in serious injury and damage to the machine. 3.1 Basic safety instructions The machine may only be used as described in this operating manual. The operating manual must be available at the machine's location at all times.
Safety instructions Requirements to The machine may only be set up by qualified specialists. be met by the personnel Maintenance work and repairs may only be carried out by qualified specialists. Work on electrical equipment may only be carried out by qualified specialists. Only authorized persons may work on the machine. Every person who works on the machine must have read the operating manual first. Operation Inspect the machine while in use for any externally visible damage.
Safety instructions Symbols In the case of dangers to personnel, the following symbols indicate the type of hazard: Symbol Type of danger General danger Danger due to electric shock Danger due to sharp objects Danger due to crushing Examples Examples of the layout of the warnings in the text: DANGER Type and source of the danger Consequences in the event of noncompliance Measures for avoiding the danger This is what a warning looks like for a hazard that will result in serious injury or even death i
Safety instructions CAUTION Type and source of the danger Consequences in the event of noncompliance 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 not complied with. CAUTION Type and source of the danger Measures for avoiding the danger This is what a warning looks like for a hazard that could result in environmental damage if not complied with.
Machine description 745-35 4 Machine description 745-35 The Dürkopp-Adler 745-35 is a sewing unit for the automatic runstitching of piped, flap and welt pocket openings with rectangular or slanted pocket corners. Depending on the working method different feeding devices, corner knife stations and optional equipments are used. The correct operating principle involves a sequence of different steps and requires precise knowledge of all operating controls. 4.
Machine description 745-35 4.2 Software description The software and all its setting possibilities are explained in detail in the Programming Instructions. The Programming Instructions are available together with the Service Instructions. At this point only a short overview of the operating terminal with its keys and corresponding functions is added.
Machine description 745-35 Key/key group RST key Operating manual 745-35 A Version 01.0 - 07/2013 Function • Quit the machine program. • Stop the currently executed program.
Machine description 745-35 24 Operating manual 745-35 A Version 01.
Operating 5 Operating The Dürkopp-Adler 745-35 is a sewing unit for the automatic runstitching of piped, flap and welt pocket openings with rectangular or slanted pocket corners. Fault-free operation is necessary in order to achieve a good sewing result. To achieve this, all relevant operations on the 745-35 will be explained below. 5.1 Swing the folding station aside For operations at the sewing point (threading the needle threads, needle change etc.
Operating Swinging the folding station back ATTENTION Material damage! After being swung back the folding station must click into lock (1). • Swinging the folding station back Fig.4: Folding station engaged ཱ (2) - Knob/lock 5.2 Pushing the covering hood back and removing the fabric sliding sheets WARNING Caution: Danger of injury! Turn the main switch off. Push the covering hood back and remove the fabric sliding sheet ONLY with the sewing unit switched off.
Operating Fig.5: Pushing the covering hood (1) - Covering hood Pushing the covering hood back • Push the covering hood 1 to the left. The feeding clamps are accessible. • Push the covering hood 1 to the right again until you hear it snapping in. Note: With the sewing unit switched on, a safety message appears on the screen of the control panel when the covering hood has been pushed back.
Operating For complete removing (for maintenance work and adjustments): • Lift off the fabric sliding sheet at the pin (4). Fig.7: Completely removing the fabric sliding sheet ཱི (4) - Pin 5.3 Tilting the machine head up For maintenance work the machine head can be tilted up.For this purpose the transport carriage must be in its rear end position. WARNING Caution: Danger of injury! Turn the main switch off. Fig.
Operating Fig.9: Tilting the machine head up II ི ཱི ུ (3) - Locking lever (4) - Face cover (5) - Fabric sliding sheet Tilting the machine head up • Remove the covering hood (1). For this purpose lift the covering hood at the front so that the catch is released. Carefully lift the covering hood upwards. • Swing the folding station (2) out by 90°. • Swivel the locking lever (3) up. • Lift the left fabric sliding sheet (5) at the front and swing it to the left.
Operating Swinging the machine head back ATTENTION Material damage! Keep a firm hold of the machine head until it is completely tilted up. • Hold the machine head in the area of head cover (4). • Release latch (6). • Swing the machine head back carefully. Fig.10: Releasing the latch ཱུ (6) - Latch • Insert the fabric sliding sheet. • Swivel the locking lever (3) down. • Swing the folding station (2) back and let its locking lever click in. • Put on the covering hood (1) and let it snap in again. 5.
Operating High sewing security and good sewability are achieved with the following core threads: • Two-ply polyester endless polyester core-spun (e.g. Epic Poly-Poly, Rasant x, Saba C,...) • Two-ply polyester endless cotton core-spun (e.g. Frikka, Koban, Rasant,...) If these threads are not available, the polyester fiber or cotton threads listed in the table can also be sewn.
Operating Changing the needles Fig.11: Changing the needles ཱི ཱ ུ ི (1) - Needle holder (2) - Screw (3) - Center knife (4) - Needle scarf left needle (5) - Needle scarf right needle WARNING Caution: Risk of injury! Turn the main switch off. Change the needles only with the main switch switched off. Never reach into the area of the center knife (3) when changing the needles. NEVER reach into the area of moving parts. • Swing the folding station aside ( chapter 5.1). The needles are freely accessible.
Operating ATTENTION Material damage! After changing to another needle size the needle protection on the hook has to be readjusted (see Service Instructions). Note: The 745-35 is delivered as a standard with needles of the size Nm 100. 5.5 Threading in the needle thread WARNING Caution: Danger of injury! Turn the main switch off. Thread the needle threads only with the sewing unit switched off. The threading of the needle threads is done as shown in the illustrations below.
Operating Fig.13: Threading in the needle thread ླྀ ི ཹ ཱི ེ ུ ཻ ཱུ ོ ྲྀ ཽ ཷ ཾ ཿ (3) - Thread lever (4) - Thread puller (5) - Guide (6) - Needle thread monitor (7) - Needle thread monitor (8) - Guide (9) - Drill-hole in support plate (10) - Needle thread tension (11) - Guide (12) - Needle thread tension (13) - Guide (14) - Thread tensioning spring (15) - Thread tensioning spring (16) - Drill-hole in the support Left needle • Fit the thread reel on the thread reel holder.
Operating Right needle • Fit the thread reel on the thread reel holder. • Thread the thread from the thread reel through the drill-hole (1) of the thread reel holder. • Guide the thread through guide (2). • Guide the thread through the drill-hole in the support plate (9). • Guide the thread through the tension disc of the needle thread tension (10). • Guide the thread through the guides (11) and (13). • Guide the thread through the thread controller spring (15).
Operating 5.6 Winding on the bobbin thread A separate winder makes it possible to wind up the bobbin threads without interfering the sewing process. Fig.14: Winding on the bobbin thread ཱ ི ཱི ུ (1) - Drill-hole in the unwinder arm (2) - Bobbin thread tension (3) - Bobbin retainer (4) - Guide (5) - Reflecting surface • Remove remaining thread from the bobbin hubs before winding. • Put the thread reel on the thread reel holder. • Thread the thread through the drill-hole (1) of the unwinding arm.
Operating The winder starts. After reaching the set bobbin filling level the winder shuts off automatically. For the setting of the bobbin filling level, Service Instructions. 5.7 Residual thread monitor: The residual thread monitor monitors the left and right hook thread bobbin with the infrared reflected light barriers (1) and (2). Fig.
Operating WARNING Caution: Danger of injury! Turn the main switch off. Clean the lenses of the light barrier only with the sewing unit switched off. • Turn the main switch off. • Clean the lenses of the light barrier with a soft cloth after every bobbin change. • Turn the main switch on. • Start a new sewing cycle. 5.8 Changing the bobbins ATTENTION Material damage! Turn the main switch off before changing the bobbin. • After a certain number of seams the hook thread quantity on the bobbin is used up.
Operating Fig.18: Removing the bobbin ཱ (1) - Upper part bobbin case (2) - Bobbin case flap Swing the folding station aside. Removing the empty bobbin • Turn the main switch off • Swing the folding station aside. • Lift the fabric sliding sheet and swing it to the left ( chapter 5.2). • Lift the upper part of the bobbin case (1). The bobbin case flap (2) is lifted at the same time. • Remove the upper part of the bobbin case together with the empty bobbin.
Operating • Pull about 4 cm of thread out of the bobbin case. When pulling the thread out, the bobbin should turn in the direction indicated by the arrow (opposite the hook's rotation). • Insert the upper part of the bobbin case (1) with the full bobbin in the lower part of the bobbin case. • Close the bobbin case flap (2). ATTENTION Material damage! For a trouble-free function of the residual thread monitor, clean the lenses of the light barriers after each bobbin change with a soft cloth.
Operating Setting brake spring: At a position stop of the machine head the brake spring avoids an overtravel of the hook thread bobbin. • Set the brake spring (4) by adjusting its position. The brake power is set correctly when the brake spring (4) projects beyond the surface (3) by approx. 1 mm. • When setting the tension spring (6) the brake power is to be taken into account. Setting the tension spring: • Start by setting the tension of the leaf spring (6) at the adjusting screw (5) to the minimum.
Operating 5.10 Stacking control The reflected light barrier (1) monitors the stacking and blowing-out of the sewn workpiece. The transport carriage does not return before the workpiece has been correctly moved out. Fig.21: Stacking control ཱ (1) - Reflected light barrier (2) - Reflecting sheet • If the workpiece is not moved out correctly, the light beam between the reflected light barrier (1) and the reflecting sheet (2) remains interrupted. A restart is not possible.
Operating 5.11 Corner knife station rectangular pocket corners The 745-35 is equipped with a corner knife station. Fig.22: Corner knife station 745_35 5.11.1 Swinging the corner knife station out / in WARNING Caution: Danger of injury! Turn the main switch off. Swing out the corner knife station only with the sewing unit switched off. Fig.
Operating accessible for adjusting and servicing. Swiveling the corner knife station in • Swing the corner knife station (1) back under the sewing unit and make sure it locks. ATTENTION Material damage! The corner knife station must audibly lock when being pushed in. 5.12 Corner knife station slanted pocket corners The setting of the corner knives with regard to the pocket length is programmable and is effected via a step motor.
Operating Fig.24: Swinging the corner knife station (1) - Corner knife station Swiveling the corner knife station out Swing out the corner knife station (1) to the left. The knives are accessible for adjusting and servicing. Swiveling the corner knife station in Swing the corner knife station (1) back under the sewing unit and make sure it locks. ATTENTION Material damage! The corner knife station must audibly lock when being pushed in.
Operating 5.13 Setting the corner knife WARNING Caution: Danger of injury! Turn the main switch off. Set the corner knife station only with the sewing unit switched off. Swinging out the corner knife station Fig.26: Setting the corner knife rectangular corners ཱ slanted corners ི ཱི (1) - Knife carrier (2) - Screw ཱ ི ཱི (3) - Knife carrier (4) - Screw Setting the angle of the corner knife station The angle of the corner knife is set by twisting the knife carriers (1) and (3).
Operating Fig.27: Cut sketch Rectangular pocket corners: The right and the left corner knife incision are parallel Slanted pocket corners: The left corner knife incision is displaced of +/- 13 mm in relation to the incision on the right side 5.14 Reference position, Starting the sewing cycle, Quick stop Reference position The reference position is necessary to reach a defined initial position. • Turn the main switch on. The control is initialized. • The DÜRKOPP ADLER logo briefly appears on the screen.
Operating Starting the sewing cycle • Step forward on the pedal (745-35 A). respectively • Step back on the left pedal (745-35 B, 745-35 F, 745-35 D) By actuating the left pedal several times, the various steps of the positioning procedure are triggered successively. The individual steps depend on the working method (A, B, F, D) and the equipment of the sewing unit (see chapter 2.16). • For positioning corrections: Step back on the pedal resp. on the left pedal.
Operating 5.15 Flap and Piping Projection To ensure an unimpeded passage of the workpieces at the folder or pickup folder station, the maximum projections of piping, flap and material thickness must not be exceeded. Check the maximum admissible width of the piping strips for the different sewing equipments (E-no.) in the Equipment Sheets of the 745-35. Fig.30: Flap and Piping Projection D E ཱ ཱི ུ ཱུ ི 1$ (1) - Folder (2) - Flap projection max.
Operating Fig.31: Sew-in depth of the flap ཷ ྲྀ (7) - Hexagonal bolt (8) - Stop 5.16 Piping strip length The piping strip length must be dimensioned in a way that it projects approx. 20 mm beyond the seam beginning and seam end. This piping strip length is calculated as follows: Piping strip length = sewing length + 2 x 20 mm 50 Operating manual 745-35 A Version 01.
Operating 5.17 Working method A A short explanation of the machine's working method will follow: Working method A Explanation Piped pockets, manual positioning of the piping strips, flaps and other add-on parts The working method is described on the following pages. The description is structured as follows: Positioning points This item indicates the positioning points for the different workpieces (e.g. left and right parts).
Operating 5.17.1 Working method A (Production of trousers) Possible processing variants • Front trousers pockets with underlaid pocket bag. • Hind trousers pockets with or without flap, with underlaid pocket bag. • Hind trousers pockets with or without flap, with automatically fed reinforcement strip. Positioning method Example: Hind trousers without flap, with pocket bag positioned underneath 1st step: • Select the pocket program at the control panel.
Operating Fig.33: 2rd step method A ི ཱུ ཱི ུ (3) - Fabric downholder (4) - Waistband clamp (5) - Rear positioning point (6) - Markings 3rd step: • Touch the pedal, respectively the left pedal. The transport clamps move to the front and lower on the workpiece. • Position the piping strip (8) on the feeding clamps flush with the front edges (9). A detailed description of the alignment of the different types of piping on the feeding clamp follows. See “Positioning of piping strips”.
Operating Positioning the piping strip Double piping: • Position the piping strip centered on the feeding clamps and flush with the front edges. Fig.35: Double piping Single piping (left) with separately positioned facing (right): • Position the piped pocket on the left feeding clamp flush with the cutting line. • Position the facing on the right feeding clamp. For this positioning method the optional equipment "Flap clamp, right" is required.
Operating Single piping left with grown-on facing Position the piping strip at stop (3) on the left folding plate. Fig.37: Simple piping left ི ATTENTION Material damage! With grown-on facing the right folding plate must not close. Pull off the hose coupling at the right feeding clamp.
Operating Sewing without Shaped guide for flap light barrier Fig.38: Flap ཱ (1) - Flap clamp (2) - Unmachined part The unmachined part (2) is delivered with the flap clamp (1). It has to be machined as a shaped guide to fit the used flap. ATTENTION Material damage! The flap length has to correspond to the desired length of the pocket opening.
Operating Fig.39: Production of trousers ི ཱི ུ ུ ཱུ (3) - Right hind trousers part (4) - Positioning marks (5) - Light spot (6) - Positioning marks Sewing with light When sewing in flaps the seam beginning and seam end are recognized barrier by the light barrier. Positioning the flap The positioning marks (6) on the folder limit the sewing area for the attaching of flaps. • Always position the flaps within the marked area.
Operating Correction of seam beginning and seam end The correction of seam beginning (NA) and seam end (NE) when sewing with light barrier occurs in the pocket correction program, further explanations Programming Instructions. 5.17.2 Working method A (Production of jackets) Piped pockets, manual positioning of piping strip, flaps and other add-on parts Loading positions for left or right jacket front parts • Position the left jacket front parts at the rear positioning point (light spot (4)).
Operating Laser markings: • When positioning at the light spot (6), the distance between breast dart (1) and flap edge (2) will always be identical. Fig.41: Positioning aids ཹ ྲྀ ླྀ ུ (5) - Stop (7) - Stop (9) - Flap (10) - Stop Stops for the manual flap feed: • Adjust the stops (7) and (5) on the folder as to the light spots (8) and (3). ATTENTION If the flap (9) is positioned outside the dotted lines (of the sewing area), the function sequence will be interrupted.
Operating WARNING Caution: Danger of injury! Do not reach into the working area of the positioning device when triggering the individual steps of the positioning process. Feeding and starting the sewing process Fig.42: Positioning aids ཹ ླྀ ཷ ྲྀ ཱུ ུ (1) - Breast dart (2) - Flap edge (3) - Light spot (4) - Stop (5) - Light spot ཱ ི ཱི (6) - Stop (7) - Light spot (8) - Light spot (9) - Flap (10) - Side seam 1. Position the jacket front part on the fabric sliding sheet.
Operating Fig.43: Positioning aid ེ (11) - Pocket incision a) Plain goods: Left jacket front parts: Position the jacket front part with breast dart (1) at the light spot (5). Right jacket front parts: Position the jacket front part with breast dart (1) at the light spot (8). b) Patterned goods: Mark the flap edge (2) on the jacket according to the pattern. Left jacket front parts: Position the jacket front part with the marking on light spot (3).
Operating Fig.44: Positioning aid ཻ ོ (12) - Piping strip (13) - Front edges 5. Position the piping strip (12) on the feeding clamps. Left jacket front parts: Position the piping strip (12) flush at the front edges (13). Right jacket front parts: Position the piping strip approx. 20 mm behind the light spot (7). Fig.45: Positioning ླྀ ཱུ ཽ ཾ ྀ ཱི ཿ (4) - Stop (6) - Stop (9) - Flap (14) - Stop (15) - Flap clamp (16) - Folder (17) - Flap clamp 6. Step forward on the pedal. The folder (16) lowers. 7.
Operating Position the flap (9) at the rear stop (4) of the folder (16). Right jacket front parts: Position the flap (9) at the front stop (6) of the folder (16). 8. Step forward on the pedal. Flap clamp (15) closes. 9. Step forward on the pedal. Flap clamp (17) closes. The sewing cycle starts. ATTENTION Material damage! The steps 8 and 9 are dependent on the closing order of the flap clamps set in the pocket parameters and programming instructions. 5.17.
Operating Correction • Step back on the left pedal.The error message is canceled. • Select another program or alter the setting in the program. Setting With single piping left The sensor S 7 is active. The outer position of the left clamp must be set. With single piping right The sensor S 8 is active. The outer position of the right clamp must be set. With double piping None of the sensors is active. 64 Operating manual 745-35 A Version 01.
Operating 5.18 Functions and operation of the optional equipment This chapter describes the function and the operating of the most important optional equipment. 5.18.1 Downholder and pocket bag clamp With these equipment hind trousers and pocket bags are safely held when smoothing out the fullness caused by the dart. The devices consist of the following components: • Downholder (2) • Pocket bag clamp (1) Fig.
Operating 5.18.2 Waistband clamp The waistband clamp retains the upper edge of the workpiece and thus allows for an optimal smoothing out of the fullness in hind trousers. The waistband clamp is often used in conjunction with the downholder and the pocket bag clamp. Fig.48: Holding devices ཱ (1) - Pocket bag clamp (2) - Downholder ི (3) - Waistband clamp WARNING Caution: Danger of injury! Do not reach under downholder (2) and waistband clamp (3) during the positioning process.
Operating 5.18.3 Stacker The nipper stacker or the throw-over stacker can both be deployed at the 745-35. Both stacker are inserted in the seat (1) shown below and locked (2) in place. Fig.49: Stacker seat ཱ (1) - Seat for stacker (2) - Lock Nipper stacker With the nipper stacker the finished workpieces from the sewing unit are deposited on the rack. Activate the stacker: • Activate the nipper stacker via the control panel in the menu "Machine parameters", Programming Instructions.
Operating • The stacker shackle (1) swings to the back and pulls the workpiece off the table. • Set the movement of the stacker shackle (1) with the throttles so that it moves smoothly without jerk. • The stacker grip (2) opens. • The workpiece is deposited on top of the stacker board (3). The stacker board hight has to be set in a way that allows for a safe depositing of the workpiece. • The stacker shackle (1) swings to the front. Fig.
Operating Throw-over The finished workpieces are stacked on the throw-over stacker. stacker The stacked and clamped workpieces can be removed when actuating the foot switch. The throw-over stacker is driven by a trigger and controlled automatically. Activate the stacker: • Activate the throw-over stacker via the control panel in the menu "Machine parameters", Programming Instructions. The parameter signals to the control unit that the sewing unit is equipped with a throw-over stacker.
Operating Fig.52: Throw-over stacker swung-out ཱ ི ཱི ུ ཱུ (1) - Smoother (2) - Clamping pipe (3) - Clamping pipe (4) - Stacked goods stand (5) - Holder (6) - Foot pedal • During the sewing cycle the material runs into the opening between the stacked goods stand (4) and the clamping pipe (3). • After the incision of the corners and the lifting of the feed clamps, the stacking process is triggered by a control pulse. The clamping pipe (3) and the smoother (1) swivel against the stacked goods stand (4).
Operating 5.18.4 Roll-off device The stacker extension is used in conjunction with the throw-over stacker. The transport rollers (1) convey the workpiece into the stacker opening. This is necessary for all workpieces positioned in transverse direction or for those which are too short for being seized by the throw-over stacker (e.g. when sewing linings of inside pockets).
Operating Function Fig.53: Transport rollers of the stacker (1) - Transport rollers • With the lifting of the feeding clamps after the sewing and cutting sequence, the transport rollers (1) lower. • The transport rollers (1) convey the small workpiece into the stacker opening. • The stacking process follows. 5.18.5 Blow-out device The blow-out device (1) is used in conjunction with the bundle clamp. The blower pipe conveys the workpiece out of the sewing area. Fig.
Operating Note: The blower pipe continues blowing until the light barrier at the stapler control is free. 5.18.6 Bundle clamp The bundle clamp including the positioning table are suitable for the production of trousers. The bundle are deposited on the table and stuck in the bundle clamp. After sewing they are removed with the smoother or the blow-out device and descend while being held by the bundle clamp.
Operating Function and operation • Step the foot switch (4) down and hold it down.The bundle clamp (3) opens. The bundle clamp (3) opens. • Insert the hind trousers parts into the bundle clamp (3). • Release the foot switch. The bundle clamp (3) closes. • Deposit the clamped hind trousers parts on the table extension (2). • With the lifting of the feeding clamps after the sewing and cutting sequence, the transport rollers (1) lower.
Operating Fig.57: Tape feed in detail (depicted without tape roll) ཱི ཱ ི (1) - Screw (2) - Setting ring (3) - Adapter (inside) (4) - Wire bow Fig.58: Setting ཷ (8) - Fabric sliding sheet (9) - Cover ླྀ ཹ (10) - Damper slide • Loosen screw (1) and pull off the setting ring (2) from the shaft. • Remove the empty tape roll including the adapter (3). • Insert the adapter (3) into a new tape roll on both sides (right and left).
Operating • Press the “F4” key. The tape brake is released and the reinforcement strip advances continuously. • Insert the reinforcement strip into the feeding device according to the sketch. • Transport the reinforcement strip approx. 20 mm on the fabric sliding sheet for the first working cycle. • Swivel the fabric sliding sheet (8) back again. • Press the “F4” key. The reinforcement strip is cut to the correct length. Function and operation Fig.
Operating 5.18.8 Vacuum device The vacuum device is required for an accurate positioning of the workpieces, if no in-house vacuum unit is available. Fig.60: Vacuum device (1) - Switch (2) - Knurled nut ཱ ི (3) - Damper slide Switching the vacuum device on • Activate the vacuum device at the control panel in the menu item “Machine parameters”. • Turn on switch (1) at the control box of the vacuum device. • Activate the vacuum at the control panel in the menu item “Pocket parameters”.
Operating 5.19 Maintenance WARNING Caution: Danger of injury! Turn the main switch off. The maintenance of the sewing machine must only be done when the machine is switched off. 5.19.1 Cleaning A clean sewing unit protects from malfunctions! Clean and check daily: Fig.61: Cleaning ཱ (1) - Light barrier (2) - Hook (3) - Hook ི ཱི ུ ཱུ (4) - Light barrier (5) - Vacuum valve (6) - Filter ring • Clean the area around the hooks 2 and 3 with the compressed air gun.
Operating Clean and check daily: Fig.62: Cleaning (1) - Water separator ཱ (2) - Drain screw • Check the water level in the pressure regulator. The water level must not reach the filter element. After screwing in the drain screw (2) blow the water with pressure out of the water separator (1). The filter element separates dirt and condensed water. After a certain time of operation wash the dirty filter tray and the filter element with benzine and blow clean with the compressed air gun.
Operating Check and clean weekly Sewing units with automatic piping incision • Loosen screw (3) and remove the stop (2). • Clean the surroundings of the cutting unit (1) and the transport belt with an air gun. • Mount the stop again. Fig.63: Cleaning (1) - Cutting unit (2) - Stop 80 ཱ ི (3) - Screws Operating manual 745-35 A Version 01.
Operating 5.19.2 Weekly lubrication WARNING Caution: Danger of injury! Oil can cause skin rashes. Avoid a longer skin contact with the oil. After contact wash yourself thoroughly. ATTENTION Risk of environmental damage The handling and disposal of mineral oils is subject to legal regulations. Deliver used oil to an authorized collecting station. Protect your environment. Do not spill any oil.
Operating Checking the oil level in the oil reservoir for the lubrication of the hook Fig.65: Oil reservoir hook lubrication (1) - Nipple ཱ ཱ (2) - Oil reservoir • Tilt the machine head up ( chapter 5.3). • Fill up the oil reservoir (2) through the nipple (1) up to the marking “max”. 82 Operating manual 745-35 A Version 01.
Installation 6 Installation In the following, the steps are listed in chronological order. The structure of the chapter is oriented towards this sequence. The manufacturer will not be held liable for damage resulting from improper use. WARNING Danger of injury due to insufficient technical knowledge During the installation of the machine, insufficient technical knowledge can lead to serious injuries. The machine should be installed ONLY by trained personnel.
Installation 6.2 Installing the sewing unit 6.2.1 Transportation . CAUTION Risk of injury due to incorrect transportation! Do NOT lift the sewing unit at the table tops. ALWAYS use an elevating platform truck or a forklift truck. CAUTION Risk of injury due to unstable footing! Before commissioning the sewing unit screw out the stand feet until a secure footing is achieved. Lifting the sewing unit • Only with an elevating platform truck or a forklift. Stand Fig.
Installation Stand For in-house transport the stand can be equipped with four castors. with castors Fig. 67: Stand with castors ཱ (1) - Nuts (2) - Stand feet (3) - Castors ི Rolling the sewing unit (optional) • For transport purpose unfasten the nuts (1) of the stand feet (2) and screw them in. • After transport secure the sewing unit by turning the stand feet (2) out until the castors lift off the ground (3). • Tighten the nuts (1). 6.2.
Installation 6.2.3 Setting the working height The working height is adjustable between 797 and 1138 mm (measured to the upper edge of the table plate). The sewing unit is set to the lowest working height of 797 mm at delivery. CAUTION Be careful when loosening the attachment screws. The sewing unit may keel over when the tubular feet of the frame are pulled out. Fig. 68: Setting the working height (1) - Screws Set the height of the sewing unit by pulling equally the tubular feet of the frame.
Installation 6.2.4 Connecting the foot pedal Fig. 69: Connection foot pedal ཱ ི ཱི (1) - Socket (2) - Plug (3) - Grounding clip (4) - Oil can holder • Insert the plug (2) of the foot pedal into the socket (1) on the stand. • Put the grounding clip (3) around the cable and fix the oil can holder (4). Operating manual 745-35 A Version 01.
Installation 6.2.5 Adjusting the foot pedals For convenience the parts are only named on one side. But the same mapping is valid for the other side of the pedal. Fig. 70: Adjusting the foot pedals with an adjustable stand ཱ ི ཱི (1) - Screws (2) - Slotted hole (3) - Screws (4) - Screws The foot pedals can be adjusted in height, angle of inclination and lateral position. Setting the height • Loosen the four screws (1) and shift them in the slotted hole (2).
Installation 6.3 Attaching the machine parts removed for shipping 6.3.1 Thread reel holder Fig. 71: Attaching the thread reel holder ཱ ི ཱི (1) - Unwinder arms (2) - Thread reel holder (3) - Reel plate (4) - Drill-hole • Insert the thread reel holder (2) in the drill-hole (4) of the table top and fasten it with a nut underneath the table top. • Mount and align the reel plate (3) and the unwinding arms (1) as shown in the illustration. Operating manual 745-35 A Version 01.
Installation 6.3.2 Fastening the control panel and the bobbin winder The holder for the control panel and the external winder is fixed on the right side of the machine head (seen from the operator's view) Fig. 72: Fastening the control panel and winder ཱ ི (1) - Winder (2) - Screw (3) - Pin (4) - Control panel ཱིུ ཱུ ྲྀ ཷ (5) - Ground cable (6) - Nut (7) - Centering mandrel (8) - Screw • Fasten the control panel (4) onto the centering mandrel (7) for the folder station with nut (6).
Installation 6.3.3 Table extensions (optional equipment) Storage table small, slanted Fig. 73: Table extension ཱ ི ཱི ུ (1) - Table extension (2) - Mounting bracket (3) - Screws (4) - Striker (5) - Stand brace • Insert the striker (4) into the stand brace (5). • Slightly fasten the mounting bracket (2) using the four screws (3) with the striker (4). • Align the table extension (1) to the height of the table top and tighten the four screws (3).
Installation Storage table (small) The fastening of the small storage table is identical to the fastening of the slanted table above. Fig. 75: Attachment table extension 92 Operating manual 745-35 A Version 01.
Installation 6.4 Electrical connection DANGER Risk of injury due to electric power! Unprotected contact with electric power can cause dangerous injuries to life and limb. All work on the electrical equipment may ONLY be carried out by qualified electricians or other appropriately trained persons. ALWAYS disconnect the power plug before carrying out work at the electrical equipment. 6.4.1 Connecting the control panel DACIII Fig.
Installation 6.4.2 Connecting a separate winder Fig. 77: Connection separate winder (1) - Plug X412 ཱ (2) - Equipotential bonding • Insert the plug of the bobbin winder into the socket (1) underneath the table top and secure with a cap nut. • Connect the potential compensation cable (2). 94 Operating manual 745-35 A Version 01.
Installation 6.5 Pneumatic connection For the operation of the pneumatic components the sewing unit has to be supplied with anhydrous compressed air. ATTENTION! Material damage! For a trouble-free function of the pneumatic control procedures the compressed air supply must operate as follows: Even at the moment of the highest air consumption, the minimum operating pressure must not drop below 6 bar. In case of a too high loss of pressure: • Increase the compressor output.
Installation 6.5.1 Connecting the maintenance unit for compressed air • Connect the connection hose (1) to the slide valve (2) and the compressed air line by means of a hose coupling ¼ “. Setting the operating pressure • The operating pressure amounts to 6 bar. It can be read off at the manometer (3). • To adjust the operating pressure pull up and turn handle (4).
Installation 6.6 Connection to the in-house vacuum unit Note: In case there is no in-house vacuum unit available, the vacuum device hat to be ordered in addition. The connection procedure is explained in the supplementary instructions. ATTENTION! Material damage! When mounting the vacuum device (side-channel blower) it is absolutely necessary to exchange the joint ring (3) (black) at the connection valve against a filter ring (white) (included in the accessories). Fig.
Installation 6.7 Oil lubrication WARNING Caution: Danger of injury! Oil can cause skin rashes. Avoid a longer skin contact with the oil. After contact wash yourself thoroughly. ATTENTION Risk of environmental damage The handling and disposal of mineral oils is subject to legal regulations. Deliver used oil to an authorized collecting station. Protect your environment. Do not spill any oil.
Installation Oil reservoir for the hook lubrication Fig. 81: Oil reservoir for the hook lubrication ཱ (1) - Nipple ཱ (2) - Oil reservoir • Tilt the machine head up ( chapter 5.3). • Fill the oil reservoir (2) with oil up to the “max.” through nipple (1). marking through nipple (1) (see sketch). Operating manual 745-35 A Version 01.
Installation 6.8 Putting into operation After completion of the installation work a sewing test should be made. • Plug in the mains plug. DANGER Risk of injury due to pointed items and glare Switch off the main switch before threading in the needle and hook thread. Do not look into the light source. • Threading the needle thread ( chapter 5.5). • Threading the hook thread ( chapter 5.6) • Turn on the main switch. The control unit is initialized. • Step back on the left pedal. Reference run is started.
Installation 6.9 Installation of the software 6.9.1 General information Loading a specific sewing Loading a specific sewing software in the DACIII control unit is possible with the help of the “Programmed Dongle”. The “Programmed Dongle” has a label indicating the class and software version. Such a loading (booting) may be used in order to provide several DACIII control unit with a sewing software (first installation) or to install a newer machine software (update).
Installation 6.9.2 Loading the program ATTENTION! Material damage! During the loading process do not remove the dongle and do not switch off the machine (otherwise you will destroy the software). Fig. 82: Connecting the dongle ཱ (1) - Plug X110 (2) - Dongle • Turn off the main switch. • Insert the dongle (2) into the port X110 (TEST-Interface) (1) of the control unit. • Turn on the main switch. The Software will be loaded. The loading process takes less than 60 seconds.
Installation 6.9.3 Dongle-Update via Internet ATTENTION! Material damage! When transferring the machine software onto the dongle, it will first be deleted (formatted). The programs (sequences, parameters) saved on the dongle will then be deleted. If still needed, please make a backup of the files into a computer (desktop, notebook). The required software “Dongle Copy” is available in the “Download Area”. Dongles can be updated by means of Internet.
Installation 104 Operating manual 745-35 A Version 01.
Decommissioning 7 Decommissioning In order to remove the machine from service for a longer period or definitely, some operations have to be carried out. WARNUNG Risk of injury due lacking of care When decommissioning the machine, a lack of care or expertise can lead to serious injuries. Clean the machine ONLY when it is switched off. Avoid skin contact with oil rests. ONLY trained personnel may disconnect the machine. How to decommission the machine: 1. Switch off the main switch. 2.
Decommissioning 106 Operating manual 745-35 A Version 01.
Disposal 8 Disposal The machine must not be disposed of in the normal household waste. The machine must be disposed of in an appropriate and correct manner according to the national regulations. ATTENTION Risk of environmental damage due to incorrect oil disposal. Incorrect disposal of old oil can result in severe environmental damage. ALWAYS observe the legally prescribed regulations for disposal of oil.
Disposal 108 Operating manual 745-35 A Version 01.
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Original Instructions - 0791 745301 EN - 01.0 - 07/2013 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.
