DURKOPP ADLER 745-35-10 D Service Instructions Manual Download Page 300

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Troubleshooting

298

Service Instructions 745-35-10 D - 00.0 - 10/2017

Error code 2000-2999

: Error messages motors

2101

Step motor transport clamp
timeout reference
• Faulty cable to the reference

switch

• Reference switch defective

• Replace the cable

• Replace the reference switch

2102

Step motor transport clamp
overload
• blocked/sluggish, defective
• Control defective

• Fix blockage
• Check the encoder cable and

replace, if necessary

• Replace step motor

2103

Step motor transport
• Step motor transport clamp

(transport clamp) has step loss

Check seizing of the transport clamp

2121

Transport clamp step motor:
• Encoder plug (Sub-D, 9-pin)

not connected or defective

• Encoder defective

• Check the encoder cable

connection and replace encoder
cable, if necessary

2122

Pulse-wheel search time out

• Check connection cables
• Check step motor for stiff

movement

2130

Step motor card defective

• Perform software update



p. 275

• Replace the step motor card
• Replace control

2152

Step motor transport clamp
excess current

• Replace transport clamp step

motor

• Replace control

2153

Step motor transport clamp
excess voltage

Check mains voltage

2155

Step motor transport clamp
overload
• defective/seized up
• defective
• Control defective

• Fix blockage/sluggishness
• Replace step motor
• Replace control

2156

Step motor transport clamp
overheat
• Step motor transport clamp

seized up

• Faulty step motor transport

clamp

• Control defective

• Eliminate seizing
• Replace transport clamp step

motor

• Replace control

Error code

Symbol

Meaning

Remedial action

Summary of Contents for 745-35-10 D

Page 1: ...745 35 10 D Service Instructions...

Page 2: ...er AG and protected by copyright Any reuse of these contents including extracts is prohibited without the prior written approval of D rkopp Adler AG Copyright D rkopp Adler AG 2017 IMPORTANT READ CARE...

Page 3: ...edle bar linkage 36 3 8 7 Setting the height of the needle bar linkage 38 3 8 8 Aligning the needle bar linkage with the throat plate 40 3 8 9 Changing the needle holder 41 3 9 Hook 43 3 9 1 Setting t...

Page 4: ...the front left corner knife 95 6 3 2 Checking the rear left corner knife 96 6 4 Aligning the corner knife station with the seams 96 6 5 Setting the slant of the corner knife cuts 99 6 6 Replacing cor...

Page 5: ...or 145 16 2 Setting the transport clamp control 146 17 Programming 147 18 Maintenance 281 18 1 Cleaning 282 18 2 Lubricating 283 18 2 1 Checking the oil level in the oil reservoir 284 18 2 2 Lubricati...

Page 6: ...Table of Contents 4 Service Instructions 745 35 10 D 00 0 10 2017...

Page 7: ...instructions intended These instructions are intended for Specialists This group has the appropriate technical training for performing maintenance or repairing malfunctions With regard to minimum qua...

Page 8: ...play control panel Important Special attention must be paid to this point when performing a step Information Additional information e g on alternative operating options Order Specifies the work to be...

Page 9: ...andards and regulations D rkopp Adler cannot be held liable for any damage resulting from Breakage and damage during transport Failure to observe these instructions Improper use Unauthorized modificat...

Page 10: ...About these instructions 8 Service Instructions 745 35 10 D 00 0 10 2017...

Page 11: ...could impair safety and damage the machine Only use original parts from the manufacturer Transport Use a lifting carriage or forklift to transport the machine Raise the machine max 20 mm and secure it...

Page 12: ...used in warnings Warnings in the text are distinguished by color bars The color scheme is based on the severity of the danger Signal words indicate the severity of the danger Signal words Signal words...

Page 13: ...en fatal injury if ignored This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored Puncture Crushing Environmental damage Symbol Type of...

Page 14: ...envi ronmental damage if ignored This is what a warning looks like for a hazard that could result in property damage if ignored CAUTION Type and source of danger Consequences of non compliance Measur...

Page 15: ...Fig 1 Slot in the arm shaft crank The arm shaft crank 2 is fitted with a slot 1 5 mm The machine head can be pegged into place in the hole 3 using the locking peg When pegged in this position the mach...

Page 16: ...hine head 1 To swivel up the machine head 1 Remove the hood 1 To do so lift the hood 1 up at the front to release the lock Carefully life the hood 1 up and off 2 Pull the handle of the folding station...

Page 17: ...chine head 2 5 Raise the fabric sliding plate 4 at the front and swivel it out to the left 6 Lift the machine head in the head cover area 2 and swivel it up carefully The latch 5 locks into place as w...

Page 18: ...wiveling down the machine head 2 To swivel down the machine head 1 Hold the machine head in the head cover area 2 2 Release the latch 5 NOTICE Property damage may occur Needle breakage When swiveling...

Page 19: ...e the machine head prior to repairs or for a quick and easy switch to a different needle distance This requires that the transport carriage be in its rear position Fig 6 Disassembling the machine head...

Page 20: ...5 Swivel the locking lever 3 up 6 Raise the fabric sliding plate 4 at the front and swivel it out to the left 7 Disconnect the electrical and pneumatic connection to the machine head 8 Loosen the gas...

Page 21: ...ool to carefully lift the machine head up and out 3 6 Assembling machine head Fig 9 Assembling machine head 1 To assemble the machine head 1 Useasuitabletooltocarefullyinsertthemachineheadintothemachi...

Page 22: ...ng machine head 2 4 Restore the gas shock absorber connection 5 5 Establish the electrical and pneumatic connection to the machine head 6 Insert the fabric sliding plate 4 7 Swivel the locking lever 3...

Page 23: ...the top dead center of the needle bars mandated by the design of the machine The crank pin has been set precisely by the manufacturer It needs to be re adjusted after the thread lever has been replac...

Page 24: ...e head 22 Service Instructions 745 35 10 D 00 0 10 2017 Removing the head cover Fig 12 Removing the head cover To remove the head cover 1 Loosen the screws 1 2 Remove the head cover 2 1 Screws 2 Head...

Page 25: ...ad tension plate To loosen the thread tension plate 3 Loosen the screws 4 4 Swivel the thread tension plate 5 to the right Disassembling switching cylinder and needle bar linkage Fig 14 Disassembling...

Page 26: ...le the crank pin 1 Loosen the fastening screws Caution Left handed thread 2 Loosen the needle bar connecting rod from the crank pin 8 and pull it off along with the needle cage 3 Turn the handwheel un...

Page 27: ...d lever 11 must be minimal to allow for oiling 9 Tighten the screw 9 10 Tighten the hexagon screws 14 11 Remove the gage 13 12 Turnthehandwheelandcheckthearmshaftforeaseofmovement 12 13 Slip the needl...

Page 28: ...ve the head cover 1 Unscrew the screws 1 2 Carefully loosen the clamp for the needle thread monitor 3 Make sure not to damage the needle thread monitor when doing so 3 Remove the head cover 2 WARNING...

Page 29: ...ing the needle bar linkage Fig 17 Disassembling the needle bar linkage 1 To remove the needle bar linkage 1 Loosen screws 4 and 7 2 Remove the thread advancing device 6 3 Unscrew the screws 5 4 Unscre...

Page 30: ...ting screws 9 to set the needle bar linkage frame to the correct height Important Avoid damage to the oil wick when removing the needle bar Take note of the oil wick position for subsequent reassembly...

Page 31: ...the needle bar linkage Fig 19 Removing a needle bar from the needle bar linkage 1 To remove a needle bar from the needle bar linkage 1 Loosen the clamping screw 1 2 Pull out the bearing bolt 3 3 Pull...

Page 32: ...s 7 The securing halves 7 are seated in the annular slot 6 and become visible by sliding down the clamping ring 16 10 Move the switching block to a position where the two decoupling bars 5 are not act...

Page 33: ...bar To dismantle the needle bar 1 Remove needle bar linkage and needle bar p 26 2 Unscrew the screw 1 3 Unscrew the needle holder 2 4 Unscrew the screw 4 5 Loosen the spring counter bearing 3 Importan...

Page 34: ...d secure the cap nut 12 in such a way that the gap between the lower edge of the taper sleeve 9 and the top edge of the cap nut 12 is 30 5 mm Important Strictly follow this dimension 30 5 mm as it is...

Page 35: ...the spring counter bearing 4 firmly in place with the screw 5 8 Repeatedly press down on the decoupling bar 16 to check whether the linkage can move inside the needle bar 3 with enough free movement...

Page 36: ...es at the top 6 7 Hold the needle bar 4 in position 8 Press the decoupling bar 13 into the needle bar 4 while pulling the crosshead 9 down at the same time The crosshead is halfway down relative to th...

Page 37: ...he safety bolt 14 20 Screw on the guide rail 16 The guide rail 16 prevents a disconnected needle bar from turning Important Do not slide the crosshead 9 down too far when the needle bar linkage is rem...

Page 38: ...clamping screw 8 The needle bar linkage 2 must be close to the support plate 1 but retain its free movement 4 Carefully slide the support plate 1 with the needle bar linkage 2 onto the stop pin 4 5 In...

Page 39: ...ith the throat plate 9 Tighten the screw 5 10 Check the height of the needle bar linkage p 38 and check the lateral alignment with the needle hole p 40 Fig 27 Assembling the needle bar linkage 3 11 Sl...

Page 40: ...tting When the two needle bars are switched on at top dead center the distance between the crosshead 4 and the needle bar linkage 3 must be 0 2 mm To set the height of the needle bar linkage 1 Unscrew...

Page 41: ...screw 7 on the support plate 5 Loosen counternuts 8 and 5 6 Use screws 6 and 9 to set the height of the needle bar linkage The distance between needle bar linkage 3 and crosshead 4 is 0 2 mm 7 Tighten...

Page 42: ...unge into the center of the holes on the throat plate 2 To align the needle bar linkage with the throat plate 1 Insert new needles 2 Slowly turn the handwheel to move the needle bars down 3 Check the...

Page 43: ...er needle bar must be disconnected To change the needle holder 1 Loosen the screw 3 2 Remove the needle from the needle holder 4 3 Use a hex key 1 to press down and hold the switch rod of the needle b...

Page 44: ...4 from the needle bar 9 Screw in a new needle holder 10 Set the height of the needle holder p 47 11 Tighten the screw 3 12 Check how the needle plunges into the needle hole p 40 13 Check the lateral...

Page 45: ...nd the flange surface of the hook shaft 1 must be 17 7 mm The exact height of the hook shaft is set using the gage 3 part number 0244 001001 To set the height of the hook shaft 1 Remove the throat pla...

Page 46: ...s 5 7 Loosen the screws found below the plastic stoppers 5 8 Loosen the screws 7 9 Slide the flange surface of the hook shaft 1 under the measuring sleeve 2 of the gage To do so position a screwdriver...

Page 47: ...gear clearance 2 Loosen the screw 3 3 Loosen the screw 1 4 Loosen the clamping screws of the worm wheel 2 5 Shift the worm wheel 2 in axial direction The distance between the worm wheel 2 and the inn...

Page 48: ...Setting the loop stroke 1 Proper setting The loop stroke is the distance the needle bars travel from bottom dead center to the point where the hook tips 2 are level with the middle of the needle 1 Th...

Page 49: ...n the first screw found below the plastic stoppers 4 10 Remove the locking peg 11 Continue to turn the machine and tighten the second screw 12 Press the plastic stoppers 4 back into the holes 13 Swive...

Page 50: ...l to move the needle bars nearly up to the top dead center 8 Use a hex key 4 to press down and hold the switch rod through the hole 5 9 Continue to turn the handwheel The depressed switch rod switches...

Page 51: ...21 Perform the same setting for the second needle holder 3 9 5 Setting the distance between hook tips and needles Fig 40 Setting the distance between hook tips and needles 1 Proper setting In the loo...

Page 52: ...m shaft crank 4 Check the distance between hook tips and needles Fig 41 Setting the distance between hook tips and needles 2 5 Remove bobbin case top part 7 with bobbin 6 Unscrew the fastening screws...

Page 53: ...into the needle holder as far as it will go 13 Swivel up the machine head 14 Loosen screws 13 and 10 15 Shift the hook support 11 laterally The hook tip should slightly touch but not displace the meas...

Page 54: ...e to push the needle into the path of the hook tip 2 When the hook tip is level with the middle of the needle the distance between the hollow groove of the needle and the hook tip 2 must be 0 1 mm To...

Page 55: ...of the hook 7 Lift off and remove the hook from the hook shaft 8 Slip a new hook onto the hook shaft The position of the hook on the hook shaft is determined by the arrangement of the holes at the bot...

Page 56: ...nd through the slot in the throat plate Proper setting The gap between the edge of the holding lug 7 and the edge of the throat plate cutout must be 0 6 mm to 1 mm to allow the thread to pass through...

Page 57: ...bobbin case holding wire 3 must abut in front of edge 2 5 of the bobbin case top part 6 9 Tighten the screw 2 10 Loosen the screw 8 11 Shift the plate 1 The distance between the holding lug 7 and the...

Page 58: ...ween cable harness and motor cable 2 Loosen the screw 5 of the cover 3 Pull the cover off carefully 4 Loosen the screws on the eccentric 1 5 Unscrew the motor fastening screws 2 6 Pull the drive motor...

Page 59: ...Align the drive motor 3 parallel to the upper shaft and centrally to the middle knife guide 3 Tighten the drive motor 3 with the motor fastening screws 2 4 Tighten the screws on the eccentric 1 5 Care...

Page 60: ...emove the switching cylinder 1 Pull off the pneumatic hose 2 2 Unscrew the connection 3 from the cylinder if necessary 3 Remove the drive motor p 56 4 Loosen the clamping screw 5 between switching cyl...

Page 61: ...g screw 5 between switching cylinder and drive rod 3 Push the drive motor forward and slide the motor shaft into the eccentric 4 4 Tighten the drive motor with the fastening screws 1 5 Tighten the scr...

Page 62: ...middle knife 1 must abut on the stationary knife in the throat plate and exert a slight pressure To set the middle knife to parallel position 1 Turn the middle knife 1 with the eccentric on the drive...

Page 63: ...Tighten the screws 3 5 Loosen screws 7 and 8 6 Move the middle knife holder 6 with the middle knife 1 to the left against the stationary knife in the throat plate The middle knife must abut in parall...

Page 64: ...nge into the sewing material the needles may prick the threads when moving down To check the thread tension slowly turn the handwheel forward while observing the thread tensioning springs at the momen...

Page 65: ...g knife 4 drops down and picks up the needle threads The thread pulling knife shoots up after a preset period of time The needle threads are clamped at the clamping plate 2 and cut off by the knife 3...

Page 66: ...d pulling knife Fig 55 Setting the trimming and clamping device for the needle threads 2 Information The knife 3 will become blunt after a certain service life The blunt knife needs to be removed for...

Page 67: ...and thread pulling knife 3 9 Carry out a cutting and clamping test 10 If necessary use the screw 7 to set the clamping pressure Assembling a complete thread pulling knife To assemble a complete threa...

Page 68: ...read clamp 2 is located below the throat plate It opens pneumatically The hook threads are pulled between the throat plate panel and the open thread clamping plates 5 Close the thread clamping plates...

Page 69: ...tance Fig 58 Setting the trimming and clamping device for the hook threads 2 To set the trimming and clamping device for the hook threads 1 Loosen the screw 7 2 Align the openings of the hook thread t...

Page 70: ...ook tips to the thread clamps 12 If necessary adjust the limit plates 4 accordingly 13 Press the OK button The lower thread clamp closes 14 Regulate the air blast used to clean the hook thread trimmer...

Page 71: ...egins the needles moving downward must not pull the needle threads out of the needle thread clamp at the same time the stitches need to be tight and the thread advancing device must not come into cont...

Page 72: ...rks of the light barrier To set the synchronizer 1 Turn the machine to move it approx 5 mm in front of the Thread lever at top dead center position 2 Loosen the threaded pin 2 3 Turn the cam segment 1...

Page 73: ...1 must point up vertically when the machine head is at the Needles at bottom dead center position To set the differential gear 1 Loosen the threaded pin 2 on the compensating weight 1 2 Set the machin...

Page 74: ...Machine head 72 Service Instructions 745 35 10 D 00 0 10 2017...

Page 75: ...switch 1 determines the rear and by means of a definitively specified path the front end position of the transport carriage The distance between the switching screw 2 and the reference switch 1 must...

Page 76: ...t also requires a correction of the stop 4 1 1 Setting the position of the reference switch in the slotted hole Fig 63 Position of the reference switch in the slotted hole To set the position of the r...

Page 77: ...etween reference switch 1 and switching screw 2 must be 1 mm To set the distance between switching screw and reference switch 1 Loosen the screw on the switching screw 2 2 Set the height of the switch...

Page 78: ...ort carriage 3 To set the stop for the transport carriage 1 Slide the transport carriage 3 back until the surface of the switching screw 2 is positioned at the center below the reference switch 1 2 Lo...

Page 79: ...ed belt Fig 66 Changing the toothed belt 1 The toothed belt is split to allow for easy replacement It is held together by a toothed belt clamp 1 WARNING Risk of injury from moving parts Crushing possi...

Page 80: ...10 2017 Fig 67 Changing the toothed belt 2 Removing the old toothed belt To remove the old toothed belt 1 Unscrew the screws 4 2 Remove the hood 3 3 Remove the screws of the toothed belt clamp 2 4 Sl...

Page 81: ...hine Insert the new toothed belt piece goods minimum length 1 45 meters To insert a new toothed belt 1 Insert the new toothed belt through the bar Make sure that the toothed belt runs correctly over b...

Page 82: ...for pretension measuring devices this app quickly provides useful indications Fig 69 Setting the toothed belt tension To set the toothed belt tension 1 Slide the transport carriage all the way forwar...

Page 83: ...of excess toothed belt tension reduced service life Operating noise possible step losses Consequences of insufficient toothed belt tension no proper tooth meshing between toothed belt teeth and disk...

Page 84: ...Transport carriage 82 Service Instructions 745 35 10 D 00 0 10 2017...

Page 85: ...ned with the middle of the pocket opening The middle of the pocket opening is defined as the center between the two needle holders Use the edge of the sliding plate measuring line 1 to set and check t...

Page 86: ...l as with the edge of the sliding plate 2 To align the transport clamps relative to the auxiliary line 1 Slide the transport clamps 1 into the area of the folder 2 Check if the inner edge of the trans...

Page 87: ...g the stroke height of the transport clamps 1 Proper setting When the flap clamps 1 are closed the raised transport clamps 3 need to pass the machine arm 2 without colliding with it The distance betwe...

Page 88: ...ns 745 35 10 D 00 0 10 2017 Fig 74 Setting the stroke height of the transport clamps 2 3 Loosen the screws 4 4 Check and set the stroke height of the transport clamps 3 relative to the fabric sliding...

Page 89: ...2 0 mm This distance is necessary to ensure both uniform piping strips and unhin dered transport of the sewing material To set the distance of the transport clamps to the folder sole 1 Check the loadi...

Page 90: ...ouble piping stop screw 4 and stop screw 7 respectively serve as a stop for the lever 6 The fine adjustment of the stop screws can be carried out with the knurled nuts 3 4 Loosen the screw 5 5 Dependi...

Page 91: ...rt clamp and folder 5 4 Setting the front end position of the transport clamp Fig 77 Setting the front end position of the transport clamp Proper setting Dimensional check for the front edge of the tr...

Page 92: ...tion as viewed by the user A press of the pedal moves the transport carriage to the front 2 Difference between the reached position and the calculated target position 3 Switch off the machine 4 Correc...

Page 93: ...position To set the initial position of the corner knives 1 Loosen the screw 2 2 Turn the corner knife holders 4 in such a way that the face sides 3 are in front of each other 3 Tighten the screw 2 4...

Page 94: ...meters Fig 79 Setting the corner knife parameters 1 To set the corner knife parameters 1 Open the menu Service Machine test Adjust and test corner knife and press the button p 234 2 Enter the password...

Page 95: ...nife Distance of middle knife incision to seam ends X Value range 99 9 99 9 This value depends on the needle distance and the corresponding corner knife Set corner knife correction seam begin left onl...

Page 96: ...s more visible Sew a test seam Check seam and cutting pattern Repeat the process until the desired result has been achieved To quit the test program press the button or 6 3 Checking the corner knife s...

Page 97: ...value and confirm by pressing OK 5 Check the distance between corner knife support 2 and corner knife support 1 6 3 1 Checking the front left corner knife Fig 83 Checking the front left corner knife T...

Page 98: ...Open the menu Service Machine test and press the button 2 Enter the desired value and confirm by pressing OK 3 Check the distance between corner knife 1 and corner knife 2 6 4 Aligning the corner kni...

Page 99: ...ck seam and cutting pattern Correction of the corner incision at the seam end Fig 86 Aligning the corner knife station with the seams 2 To correct the corner incision at the seam end 1 Swing the corne...

Page 100: ...To correct the corner incision at the seam beginning 1 Loosen the screw 5 2 Adjust the corner knife station with the eccentric 6 3 Tighten the screw 5 4 Sew a test seam 5 Check seam and cutting patter...

Page 101: ...pos sible but must not cut the seam Fig 89 Setting the slant of the corner knife cuts 2 To set the slant of the corner knife cuts 1 Iron a piece of Vlieseline onto the workpiece This makes the corner...

Page 102: ...cing corner knives shown on straight pocket To replace the corner knives 1 Swivel out the corner knife station 2 Remove the piercer 1 for straight pocket only 3 Loosen the screw 4 4 Remove the old cor...

Page 103: ...k of injury from laser light Risk of sustaining eye damage and going blind NEVER look into the laser light source 1 Needles 2 Cutting line 3 Marking of the front positioning point 4 Auxiliary line 5 M...

Page 104: ...ust be 100 mm To align the laser modules 1 Loosen clamping nuts 14 and 15 2 Align distance and angle of the laser module with the cutting line 2 by shifting and turning 3 Tighten clamping nuts 14 and...

Page 105: ...hecking the exact position of the marking lamp 1 Fig 94 Checking the exact position of the marking lamp 2 1 Needles 2 Cutting line 3 Marking of the front positioning point 4 Auxiliary line 5 Middle of...

Page 106: ...e at the marking of the front positioning point 3 Start sewing The seam must start at the chalk line To make a correction align the marking of the front positioning point 3 anew after loosening its ho...

Page 107: ...e the arm snaps securely into place To set the swivel arm 1 Swing out the swivel arm 1 with the light barriers 2 Swing the swivel arm 1 back and check the pressure of the locking screw 3 3 Check the p...

Page 108: ...parallel to the machine head with screw 2 9 Tighten the counternut 2 8 2 Aligning the light barrier To align the light barrier open the service menu and select the menu item Machine test The Machine...

Page 109: ...port clamps Fig 97 Preparing machine and transport clamps To prepare machine and transport clamps 1 Place material below the transport clamps NOTICE Property damage may occur Risk of breakage To set t...

Page 110: ...ED on Reflection present Orange LED off reflection not present Orange LED flashes weak signal re align light barrier or replace reflecting foil Green LED on Switching signal stable Green LED off Clean...

Page 111: ...older onto the sliding plate 4 Pull the transport clamps forward The folder sole is guided under the folding plates 5 Check theswitchingbehavior of thelight barrier withthe folderswiveled in 6 Swing t...

Page 112: ...rvice Instructions 745 35 10 D 00 0 10 2017 Setting the light barrier for the left flap rest Fig 99 Setting the light barrier for the left flap rest 1 Fig 100 Setting the light barrier for the left fl...

Page 113: ...n 6 Press the button The flap clamp opens 7 Press the button The needles are switched on 8 Use the handwheel to turn the needles downward with the direction of rotation until they are approx 2 mm abov...

Page 114: ...15 Remove the template 1 16 Press the button The settings are stored and the display switches to Machine test 17 Slide the transport clamps to the rear by hand 18 Swing in the folding station 19 Swit...

Page 115: ...the reflecting foils while the transport clamp moves to the loading position The transport clamps must be aligned correctly with the folder sole p 87 To align the air nozzles for cleaning the reflecti...

Page 116: ...Light barriers 114 Service Instructions 745 35 10 D 00 0 10 2017...

Page 117: ...he middle of the needle and the outer side of the folding station plate 1 must be 87 mm To set the folding station plate 1 Use a strip or an angle to extend the folding station plate 1 to the sliding...

Page 118: ...means to hammer out the clamping pins 4 Slightly loosen the screws 4 on the plate of the ratchet lever 2 5 Set the distancebetween the extended surfaceof the folding station 5 and the needles of the m...

Page 119: ...e plate 2 of the machine head must be at the same level as the tabletop 1 along its entire length To align the machine head 1 Slide the transport clamps to the rear 2 Raise the sliding plate 4 at the...

Page 120: ...07 Aligning the machine head 3 Machine head rear 1 Remove the hood 3 2 Loosen counternuts 7 and 8 3 Turn sleeves 6 and 9 evenly using a hex key Hold the screws 5 in place while doing so 4 Tighten coun...

Page 121: ...119 Fig 108 Aligning the machine head 4 Machine head front 1 Swivel up the machine head p 14 2 Loosen the counternut 11 3 Tighten or loosen the centering nut 12 as necessary 4 Re tighten the counternu...

Page 122: ...Aligning the machine head 120 Service Instructions 745 35 10 D 00 0 10 2017...

Page 123: ...set fabric sliding plate and vacuum plate 1 Swivel the fabric sliding plate aside 2 Check the height of the vacuum plate in relation to the tabletop 3 Turn the threaded pin 1 Set vacuum plate higher t...

Page 124: ...Setting fabric sliding plate and vacuum plate 122 Service Instructions 745 35 10 D 00 0 10 2017...

Page 125: ...Fig 110 Assembling the folder To assemble the folder 1 Tighten the folder 2 with the screw 1 on the folder mounting plate The folder centers itself while being tightened WARNING Risk of injury from mo...

Page 126: ...n the width of the folder sole 3 This dimension can be used to align the folder with the middle of the pocket opening 2 and parallel to the edge of the sliding plate 1 Deduct piping width a and half o...

Page 127: ...align the folder with the middle of the pocket opening 1 Loosen the screw 4 2 Align the folder 5 parallel to the transport clamp 3 Tighten the screw 4 4 Loosen the screw 6 5 Set the lateral distance b...

Page 128: ...Folder 126 Service Instructions 745 35 10 D 00 0 10 2017...

Page 129: ...check the following setting Folder p 123 13 1 Aligning the positioning device Fig 113 Aligning the positioning device To align the positioning device 1 The positioning device 6 is fastened to the moun...

Page 130: ...crews 2 and 3 13 2 Setting the pattern shift correction Information There will be a design related pattern shift between the breast welt as po sitioned exactly as per the pattern and the turned breast...

Page 131: ...vel in and out rapidly but not abruptly To set the throttle valve 1 Open the menu Service Multi test Multi test I O and select the output YC103 The positioning turning device 4 swivels 2 Check the mot...

Page 132: ...ports the pocket bags to the middle of the pocket opening at the folder The assembly strip moves to the middle of the pocket opening and is in parallel position above the workpiece at a distance of ap...

Page 133: ...such a way that the gripping needle rows plunge into the center of the sponge rubber 3 The pocket bag must not be clamped by the loading angle 1 To set the position of the assembly strip 1 Loosen the...

Page 134: ...e valve Fig 118 Setting the throttle valve Proper setting The feeding motion should allow for a rapid but not abrupt movement To set the throttle valve 1 Set throttle valves 1 and 2 Throttle valve 1 L...

Page 135: ...ker The transport rollers 5 and 7 convey the narrow workpiece to the stacker opening of the throw over stacker Important The transport rollers must be aligned parallel to the tabletop and the middle o...

Page 136: ...a slight pressure on the tabletop 4 Tighten the threaded pin 1 5 Tighten the hexagon screws 6 Setting the throttle valves To set the throttle valves 1 Set the lifting speed at the throttle valve 3 2...

Page 137: ...o set the tape feed 1 Loosen the screws at guides 1 2 and 3 2 Set the guides in such a way that the strip is fed precisely 3 Tighten the screws at guides 1 2 and 3 Setting the tape length The tape len...

Page 138: ...ng the tape feeding and tape cutting device 2 The stops must be set in such a way that enough tape is pulled off for the next pocket To set the tape puller 1 Shift the screw 2 to pull off more tape 2...

Page 139: ...e switch actuation point is advanced or delayed by turning the switch cams towards earlier or later To check the function sequence of the throw over stacker 1 Once the start signal for the stacking pr...

Page 140: ...lamps the sewing material before clamping bracket b 4 is lifted 3 Loosen the screw on switch cam c 3 and turn switch cam c 3 on the axle Switch actuation point later turn counterclockwise Switch actua...

Page 141: ...ch actuation point earlier turn clockwise 8 Valve 3 11 is actuated as soon as throw over bracket d 1 swivels back down Clamping bracket b 4 swivels back Switch cam h 13 operating valve 3 11 must be se...

Page 142: ...d by turning the switch cams towards earlier or later Fig 126 Setting the throw over stacker 2 To set the throw over stacker 1 Start signal Swivel bracket 2 closes 2 The switch 5 is pressed approx 5 m...

Page 143: ...the throw over stacker 3 Clamping bracket 4 opens The switch 8 is pressed when the clamping bracket 4 is at a distance of a 60 80 mm from the swivel bracket 2 4 Loosen the screw and set the switch ca...

Page 144: ...ng the last section of the backward movement Check the optimal switch actuation point with workpieces and correct it if necessary Fig 129 Setting the throw over stacker 5 The throw over bracket 3 swiv...

Page 145: ...und Check the optimal switch actu ation point by performing stacking operations with workpieces and correct it if necessary 15 0 3 Setting the stacking speed The speed of the swiveling movement perfor...

Page 146: ...Throw over stacker 144 Service Instructions 745 35 10 D 00 0 10 2017...

Page 147: ...low pressure level The switching threshold of the pressure monitor is set at 4 7 0 2 bar To set the pressure monitor 1 Pull up the pressure controller 4 and turn it until the pressure level is at 4 7...

Page 148: ...ss of the material To set the transport clamp control 1 Turn the left pressure controller 2 to set the downforce pressure of the transport clamp on the left The default setting is 0 5 Mpa approx 5 bar...

Page 149: ...feeder On Off p 215 Vacuum On Off p 215 1 13 Select stacker smoother p 215 Roll off On Off p 215 Start Bootloader Touchkalibrierung Hauptbildschirm Sequenzen Servicemen Programmparameter Taschenprogra...

Page 150: ...lign light barriers p 232 2 4 Test corner knife p 234 2 4 1 Adjust corner knife p 236 2 5 Switch on needle middle knife p 228 2 6 Test tape feeder p 229 2 7 Machine workflow test p 237 Loading process...

Page 151: ...76 5 1 3 Copy pocket program p 176 5 1 3 1 Select source p 176 5 1 3 2 Select destination p 176 5 1 4 Create a seam program p 178 5 1 4 5 Set securement seam beginning left needle p 181 5 1 4 6 Set se...

Page 152: ...rrection seam end p 194 5 1 10 Automatic tape feeder p 199 5 1 10 2 Set length of tape at seam begin p 199 5 1 10 3 Set length of tape at seam end p 199 5 1 10 4 Set clamp speed while transport p 199...

Page 153: ...nsport clamp p 226 5 2 2 2 Clamp down Time to next action p 226 5 2 2 3 Speed to corner knife position p 226 5 2 2 4 Speed to waiting position p 226 5 2 2 6 Delay till clamp moves to seam begin p 226...

Page 154: ...B p 264 9 0 Init parameters Initialize machine configuration p 266 Initialize global parameters p 266 Initialize all seam programs p 266 Initialize all sequences p 266 Initialize RAM p 266 10 0 Mainte...

Page 155: ...unction with the OP7000 control panel with the user interface in symbolic representation Fig 133 Control panel OP7000 Switching on the machine After the machine has been switched on the control and th...

Page 156: ...elow 1 Pocket programs in sequence 2 Automatic seam sequence 3 Overview of seam sequences 4 Piece counter 5 Seam pattern 6 Positioning points 7 Quick selection corner knife correction 8 Info field 9 T...

Page 157: ...utton 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 Positioning point seam begin Positioning point seam...

Page 158: ...Help text is displayed for every button you press Press the Help button again to deactivate this mode Help is deactivated automatically when the user exits the menu level Home button and Return button...

Page 159: ...ring values using the numeric keypad To enter values using the numeric keypad 1 Enter the desired value 2 Confirm with OK To enter a negative value on the numeric keypad 1 Enter the desired value 2 Pr...

Page 160: ...effect Fig 136 Entering values using the numeric keypad 2 Piece counter Resetting the piece counter To reset the piece counter 1 Press the button briefly The piece counter is reset to 0 Setting initia...

Page 161: ...Overview of sequences Fig 137 Creating or changing a seam sequence 1 1 Selected seam sequence 2 Display of pocket programs in the sequence 3 Scroll down seam sequences 4 Scroll up seam sequences 5 Cop...

Page 162: ...sequence is highlighted with a bold frame and the color orange 1 4 Press the button The display switches to Create sequence via drag drop Fig 138 Creating or changing a seam sequence 2 Call up additio...

Page 163: ...gram is positioned via Drag and Drop the left half of the display will show the seam pattern of the pocket program The pocket programs will be stored in the seam sequence in the order in which they we...

Page 164: ...2 Use Drag and Drop to drag the desired pocket program from the tem plate to an available pocket program slot The display switches to Select program Fig 139 Selecting pocket programs from the seam se...

Page 165: ...rogram slot 1 To create a seam sequence 1 Use Drag and Drop to drag any pocket programs you do not need from the sequence to be created 10 to the trash OR tap on the trash to delete all pocket program...

Page 166: ...other seam sequences The currently selected pocket program is highlighted in orange 3 Select the desired pocket program You can select no more pocket programs than there are available pocket program...

Page 167: ...hanging the seam sequence template 1 To change the seam sequence template 1 Press the S01 button The display switches to Select source of sequence Fig 143 Changing the seam sequence template 2 The des...

Page 168: ...ence The display returns to Create sequence via drag drop Information Cancel the selection by pressing the same sequence again Fig 144 Changing the seam sequence template 3 4 Use Drag and Drop to drag...

Page 169: ...m sequence template 1 to an available pocket program slot OR Press the button to selectthe desired pocketprogram from the list 6 Press the button to save the setting and return to the previous level T...

Page 170: ...uence 1 To enter a name for a seam sequence 1 Press the button S02 S20 depending on which seam sequence you have selected The display switches to a keypad Fig 147 Naming a seam sequence 2 2 Enter the...

Page 171: ...ences Fig 148 Copying a seam sequence 1 2 Select the seam sequence you wish to copy from the list To scroll up and down the list of sequences press the buttons and 3 Press the desired seam sequence Th...

Page 172: ...with a bold frame and the color orange 5 Select the seam sequence you wish to overwrite from the list To scroll up and down the list of sequences press the buttons and OR drag the bar up or down Info...

Page 173: ...he display returns to Overview of sequences Activating a pocket program from the seam sequence You can activate a single pocket program stored in the seam sequence if you wish to sew a specific pocket...

Page 174: ...ys sews using the selected pocket program Activating the automatic seam sequence If the automatic seam sequence is activated the machine will automatically sew the next pocket program in the sequence...

Page 175: ...lable or grayed out it must be set up in the Machine configuration menu p 214 Otherwise the option will be unavail able in this class To configure pocket programs 1 Press the Program parameters button...

Page 176: ...p 186 Marking lamps 1 16 p 188 Sewing head parameters p 189 Middle knife parameters p 192 Corner knife p 194 Automatic tape feeder p 199 Transport clamp p 200 Process of transport clamp p 203 Program...

Page 177: ...pad to set the desired pocket program 1 99 2 Confirm with OK The display switches to the selected pocket program You can configure the selected pocket program as described below Important When you ret...

Page 178: ...ame of the pocket program 2 Confirm with OK The display switches to the selected pocket program Copying a pocket program The display switches to Copy pocket program Fig 154 Copying a pocket program 1...

Page 179: ...n program will be overwritten during the copying process If necessary you will have to make additional adjustments in the software If selecting a destination program that is already used in another se...

Page 180: ...s 745 35 10 D 00 0 10 2017 Creating a seam program The display switches to Create seam program Fig 156 Creating a seam program Press a button to either open another submenu or enter the desired values...

Page 181: ...mm Pocket shape seam begin straight slanted slanted Set slanted pocket shape seam begin 1 13 mm Securement seam beginning left right needle Stitch condensing OR Single tack OR Double tack Flap shape...

Page 182: ...itch condensing OR Single tack OR Double tack Flap left OR Flap right Set positioning point seam begin straight pocket only 100 mm 450 mm Set positioning point seam center straight pocket only 100 mm...

Page 183: ...e numeric keypad 3 Confirm with OK Symbols Meaning Select stitch condensing Set stitch length for stitch condensing at seam beginning 0 5 3 5 mm Set number of stitches for stitch condensing at seam be...

Page 184: ...right needle is adopted Set securement seam beginning right needle Information The settings in subitem Securement seam beginning right needle are adopted automatically from the settings for the Secure...

Page 185: ...tically from the settings for the Securement seam end left needle p 182 Symbols Meaning Select stitch condensing Set stitch length for stitch condensing at seam end 0 5 3 5 mm Set number of stitches f...

Page 186: ...e desired value using the numeric keypad 3 Confirm with OK Symbols Meaning Activate fixed seam length Set sewing length Not available unless Activate sewing length has been selected Activate flap scan...

Page 187: ...et the display will switch from the seam program to the start screen The display shows the flap and the flap scan and corner knife correction can be set via the quick access menu Fig 160 Activating th...

Page 188: ...orrection light barrier Fig 161 Correction light barrier 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 Symbo...

Page 189: ...d The display switches to Correction light barrier seam begin end Fig 162 Set correction light barrier seam begin end Information The arrows in the left half of the display indicate the correction dir...

Page 190: ...6 Fig 163 Activate marking lamps 1 16 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...

Page 191: ...ng the numeric keypad To edit the sewing head parameters 1 Press the desired button The user interface for setting the desired item is displayed Symbols Meaning Set sewing speed 100 RPM 3000 RPM Set s...

Page 192: ...ig 165 Soft start parameters To edit the soft start parameters 1 Press the desired button 2 Enter the desired value using the numeric keypad 3 Confirm with OK Symbols Meaning Soft start On Off Set sof...

Page 193: ...The display switches to Seam securement Fig 166 Set seam securement To set the seam securement 1 Press the desired button 2 Enter the desired value using the numeric keypad 3 Confirm with OK Symbols...

Page 194: ...167 Middle knife parameters To set the middle knife parameters 1 Press the desired button 2 Enter the desired value using the numeric keypad 3 Confirm with OK Symbols Meaning Middle knife On Off Set m...

Page 195: ...e display switches to Set middle knife correction seam begin seam end Fig 168 Set middle knife correction seam begin seam end Information The arrows in the left half of the display indicate the correc...

Page 196: ...r knife Straight pocket Fig 169 Corner knife straight pocket To set the corner knife 1 Press the desired button 2 Enter the desired value using the numeric keypad 3 Confirm with OK Symbols Meaning Cor...

Page 197: ...fe correction seam begin seam end Fig 170 Set corner knife correction seam begin seam end Information The arrows in the left half of the display indicate the correction direction Seam beginning Correc...

Page 198: ...Slanted pocket in the submenu Corner knife setup in the Machine configuration p 214 The display switches to Corner knife Slanted pocket Fig 171 Parameters Corner knife Slanted pocket Symbols Meaning A...

Page 199: ...esired button 2 Enter the desired value using the numeric keypad 3 Confirm with OK Set corner knife correction seam begin seam end Fig 172 Set corner knife correction seam begin seam end Seam end oute...

Page 200: ...he left half of the display indicate the correction direction Seam beginning Correction outward Correction inward Seam end Correction inward Correction outward Corner knife options Without corner knif...

Page 201: ...Automatic tape feeder The display switches to Automatic tape feeder Fig 173 Automatic tape feeder Symbols Meaning Automatic tape feeder On Off Set length of tape at seam begin 0 99 mm Set length of ta...

Page 202: ...nu or enter the desired values directly using the numeric keypad Symbols Meaning Set return speed 10 100 Set insertion speed 10 100 Set softstart for insertion speed Insertion speed fast Insertion spe...

Page 203: ...eturn of transport clamp The display switches to Return of transport clamp Fig 175 Set return of transport clamp To set the transport clamp return 1 Press the desired button 2 Enter the desired value...

Page 204: ...position of transport clamp Fig 176 Set waiting position of transport clamp To set the waiting position of the transport clamp 1 Press the desired button 2 Enter the desired value using the numeric ke...

Page 205: ...2017 203 Process of transport clamp The display switches to Process of transport clamp Fig 177 Process of transport clamp To set the process of the transport clamp 1 Press the desired button The user...

Page 206: ...ay switches to Select transport clamp quick adjustment Fig 178 Select transport clamp quick adjustment To select the transport clamp quick adjustment 1 Press the desired button Symbols Meaning Left in...

Page 207: ...sport clamp To select the process of the transport clamp 1 Press the desired button Symbols Meaning Lower both transport clamps together Lower left transport clamp first Lower right transport clamp fi...

Page 208: ...180 Program loading process Press a button to either open another submenu or enter the desired values directly using the numeric keypad Symbols Meaning Select flap clamps Both flap clamps close togeth...

Page 209: ...ode The display switches to Blowing mode Fig 181 Select blowing mode Symbols Meaning Function off 1 Lower pickup folder 2 Blowing ON at flap clamp folding plate 1 Lower pickup folder 2 Blowing ON at f...

Page 210: ...olding plate flap clamp and lower pickup folder in the lower half of the display changes with the selected setting 1 Blowing ON at flap clamp folding plate 2 Lower pickup folder 1 Lower pickup folder...

Page 211: ...loading position Blow pocket bag and or piping briefly Blow piping already while folder is lowering Mode 4 B F Blow tube in folding plate Lower pickup folder Flap clamps closed Blow tube in flap clam...

Page 212: ...ithout stop Push pedal after each step Vacuum downholder and transport clamp are each triggered with one step during the loading process the sewing process starts after the transport clamps have been...

Page 213: ...et the duration grip stacker signal only with active pincer stacker p 215 0 ms 1000 ms Select earlier clamping time 0 ms 1000 ms Smoother On Off only with active smoother p 215 Set smoother Start afte...

Page 214: ...off and the roll off device 1 Press the desired button 2 Enter the desired value using the numeric keypad 3 Confirm with OK Set roll off time 0 ms 1000 ms Set roll off speed 1 15 Set time after roll o...

Page 215: ...utton The display switches to the Service menu Fig 184 Service menu Button Meaning Configure machine settings p 214 Configure settings for the sewing process p 223 Test individual machine functions p...

Page 216: ...he Machine configuration menu is protected with a password You use this menu to set basic program parameters The password is 25483 The display switches to Machine config Fig 185 Machine configuration...

Page 217: ...tor does not appear in the global parameters p 223 If deactivated the hook thread monitor appears in the global parameters and must be configured manually p 223 Tape feeder On Off Vacuum On Off Select...

Page 218: ...figuration 1 Press the desired button The user interface for setting the desired item is displayed Corner knife device without straight pocket straight pocket slanted pocket Pedal operation p 219 Spli...

Page 219: ...ect the working method and the matching seam length 1 Select the desired working method 1 2 Select the desired maximal seam length 2 3 Restart the machine to activate the selection Information When yo...

Page 220: ...Service Instructions 745 35 10 D 00 0 10 2017 Selecting needle distance The display switches to Select needle distance Fig 187 Select needle distance To select the needle distance 1 Select the desired...

Page 221: ...88 Pedal operation To set the pedal operation 1 Press the desired button Symbol Meaning Operation with 1 pedal Operation with 2 pedals First pedal right Second pedal left Operation with 2 pedals First...

Page 222: ...r scan The display switches to Light barrier scan Fig 189 Light barrier scan To set the light barrier scan 1 Press the desired button Information A light barrier scan is only possible with 1 light bar...

Page 223: ...has been selected for this position yet Depending on the class and method the display will only show the tools available for that class and method To configure the toolbox 1 Press on a blank field to...

Page 224: ...onfiguration 2 Information You can use the button to remove a previously selected tool from the toolbox again Tools already in use are grayed out 2 To navigate up and down the list use the arrow butto...

Page 225: ...password is 25483 Information If an option is not available or grayed out it must be set up in the Machine configuration menu p 214 Otherwise the option will be unavail able in this class The display...

Page 226: ...just transport clamp p 226 Adjust corner knife Set cutting duration 0 ms 1000 ms Corner cut until clamp forward 0 s 1 s set maximum hook thread counter only visible in global parameters if hook thread...

Page 227: ...tem is displayed Special functions Set time for breast welt pocket clamp 0 1000 ms Pick up folder mode before seam start On Off Time Clamp the breast welt pocket automatically 0 800 ms Time Enable poc...

Page 228: ...the desired button 2 Enter the desired value using the numeric keypad 3 Confirm with OK Symbol Meaning Lower transport clamp automatically On Off Set delayed lifting of transport clamp 0 ms 1000 ms S...

Page 229: ...t passwords for the levels listed below on or off The display switches to Set password protection Fig 194 Set password protection To set password protection 1 Press the button in front of the desired...

Page 230: ...display switches to Machine test The display varies with the machine configuration p 214 Fig 195 Machine test Symbol Description USB_Logging p 229 Set and test hook thread monitor p 230 Test roll off...

Page 231: ...2 Load the Log txt file onto a USB key 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...

Page 232: ...1 and 15 If the value is above the minimum value of 8 the display shows an arrow between reflecting head and hook thread bobbin A signal tone will sound at the same time Important If the light barrier...

Page 233: ...roll off device The display switches to Test roll off device Fig 197 Testing roll off device To test the roll off device 1 Press the desired button 2 Enter the desired value using the numeric keypad 3...

Page 234: ...display 1 or 2 light barriers p 220 Refer to the Service Instructions for instructions on how to align the light barriers with the help of templates For information on how to connect the light barrier...

Page 235: ...can be set in the Align light barriers menu item 2 Press the desired button Symbol Meaning Reference Lift pick up folder lower pick up folder depressurized Transport clamp quick adjustment p 204 Open...

Page 236: ...n 1 Press the button Reference run is carried out The following table lists the items that can be set in the Adjust corner knife menu item CAUTION Risk of injury from moving parts Crushing Do NOT reac...

Page 237: ...est corner knife function seam begin right On Off only for configuration Automatic corner knife station Test corner knife function seam beginning only for configuration Manual corner knife station Tes...

Page 238: ...ton 2 Enter the desired value using the numeric keypad 3 Confirm with OK Symbols Meaning Set corner knife correction seam begin 99 9 mm 99 9 mm Set corner knife correction seam end 99 9 mm 99 9 mm Set...

Page 239: ...workflow test Fig 201 Machine workflow test To perform a machine workflow test 1 Press the desired button The user interface for setting the desired item is displayed Symbols Meaning Exit machine test...

Page 240: ...sewing path Information To monitor the transport path of the sewing material we recommend that you reduce the insertion speed prior to the loading process test p 200 To perform a loading process test...

Page 241: ...ches to Test step by step Fig 203 Test step by step To carry out a step by step test 1 Press the Test step by step button 2 Press the pedal after every single work step The step by step test allows yo...

Page 242: ...2017 Cycle time The display switches to Cycle time Fig 204 Cycle time To test the cycle time 1 Sew The display shows the time in ms The cycle time allows you to optimize the machine settings 2 To exit...

Page 243: ...To test the step motor 1 Press the button Reference run is carried out CAUTION Risk of injury from moving parts Crushing possible When you advance the transport clamp the transport clamp will start a...

Page 244: ...ved If there is a difference between the Encoder and Position values you can reset the values by carrying out a reference run Symbol Meaning Adjust clamp speed 10 100 Adjust step motor pos 1 0 517 5 m...

Page 245: ...The display switches to Adjust and test control panel Fig 206 Adjusting and testing control panel To adjust and test the control panel 1 Press the desired button The user interface for setting the des...

Page 246: ...ness and contrast The display switches to Adjust brightness and contrast Fig 207 Adjust brightness and contrast To adjust the brightness of the display 1 Move the controller Increase brightness Slide...

Page 247: ...ess on the places indicated by the green arrow Touch calibration is carried out The display returns to Adjust and test control panel OR 1 Press Cancel Touch calibration is canceled The display returns...

Page 248: ...Programming 246 Service Instructions 745 35 10 D 00 0 10 2017 Touch test The display switches to Touch test Fig 209 Touch test The Touch test menu item allows you to draw on the touch screen...

Page 249: ...booting up the machine will compare the software version of control panel and control If the software versions do not match the system will suggest an update This submenu allows the user to trigger th...

Page 250: ...5 35 10 D 00 0 10 2017 Fig 211 DAC update 2 2 Confirm with OK The update is carried out Fig 212 DAC update 3 Important Do not switch off the machine while the update is in progress The display shows n...

Page 251: ...Fig 213 DAC update 4 The machine restarts automatically 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 th...

Page 252: ...arameters The password is 25483 The display switches to Multi test Fig 214 Multi test Symbols Meaning A press on the button will bring up a list The last 10 error messages Date of the error Time of th...

Page 253: ...the individual tests 1 Press the desired button The user interface for setting the desired item is displayed Error messages The display switches to Error messages Fig 215 Error messages The list cont...

Page 254: ...on by 1 3 Display of the selected input 4 Reduce selection by 1 5 Clear selection 6 Manual test On Off 7 Automatic test On Off 8 Output S1 Needle thread monitor left S2 Needle thread monitor right S3...

Page 255: ...corner knife rear left Y1 Thread cutter top on Y2 Middle knife on Y3 Blow out fluff remaining thread monitor Y4 Open lower thread clamp Y5 Lower thread cutter on Y6 Thread tension on Y7 Lower left tra...

Page 256: ...sitioning device YC105 Lift pocket bag YC106 Feed pocket bag YC107 Clamp breast welt YC108 Correction positioning device YC133 Move transport clamp left to the inner side YC134 Move transport clamp ri...

Page 257: ...nstructions 745 35 10 D 00 0 10 2017 255 Internal devices The display switches to Internal devices Fig 217 Internal devices The area State can display 3 different status messages conn connected nc not...

Page 258: ...10 D 00 0 10 2017 RAM test The RAM test of the control is carried out The progress of the test is indicated by a progress bar Fig 218 RAM test 1 The test result is displayed Fig 219 RAM test 2 1 Confi...

Page 259: ...10 2017 257 External devices The display switches to External devices Fig 220 External devices Information The External devices menu is used to detect errors in CAN devices 0 Step motor card corner kn...

Page 260: ...st The ROM test of the control is carried out The progress of the test is indicated by a progress bar Fig 221 ROM test 1 The test result is displayed ROM error free OR ROM defective Fig 222 ROM test 2...

Page 261: ...Sewing drive test Fig 223 Sewing drive test To test the sewing drive 1 Press the desired button 2 Enter the desired values using the numeric keypad 3 Confirm with OK Symbols Meaning Select needle pos...

Page 262: ...e sewing drive starts at the set speed CAUTION Risk of injury from sharp or moving parts Puncture or crushing possible Do NOT reach into the moving part of the machine NOTICE Property damage may occur...

Page 263: ...fer The display switches to USB data transfer Fig 224 USB data transfer 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 dis...

Page 264: ...USB key 1 Select which data you wish to store on the USB key Current seam program All seam programs and sequences Global parameters Machine config All data The selected option is highlighted in orange...

Page 265: ...dy existing on USB XY Write YES NO Press YES Data on the USB key is overwritten Press NO The display returns to USB data transfer The write process can take between a few seconds and several minutes d...

Page 266: ...he control Current seam program All seam programs All seam programs and sequences Global parameters Machine config NOTICE Property damage may occur The machine will not work if you load data from a wr...

Page 267: ...the OP7000 Information You can cancel the USB data transfer with a press on the button The write process can take between a few seconds and several minutes depending on which write option has been sel...

Page 268: ...ill be lost Program parameters will be reset to the factory default settings Initialize global parameters All stored data will be lost Global parameters will be reset to the factory default settings I...

Page 269: ...ng Service Instructions 745 35 10 D 00 0 10 2017 267 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 initi...

Page 270: ...switches to Maintenance Fig 229 Maintenance To edit the parameters in the Maintenance menu item 1 Press the desired button The user interface for setting the desired item is displayed Symbols Meaning...

Page 271: ...ersion To display the software version 1 Press the Software version button The display shows the current software version You will need this information when contacting the DA service depart ment for...

Page 272: ...amming 270 Service Instructions 745 35 10 D 00 0 10 2017 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...

Page 273: ...configuration The display switches to User config Fig 232 User configuration To set the user configuration 1 Press the desired button The user interface for setting the desired item is displayed Symbo...

Page 274: ...tructions 745 35 10 D 00 0 10 2017 Language selection The display switches to Language selection Fig 233 Language selection To select the language 1 Select the desired language The system restarts wit...

Page 275: ...word already exists you need to enter this password before you can create a new user password To activate password protection you need to restart the machine When the machine starts up you will be pro...

Page 276: ...ming 274 Service Instructions 745 35 10 D 00 0 10 2017 Information After setting up a user password you can lock the start screen for other operators with a press on the button Fig 235 User password s...

Page 277: ...second step a software update is performed for the control DAC comfort To perform an update of the machine software 1 Download the update file from D rkopp Adler s website The file is named for examp...

Page 278: ...ate the machine software 3 The update will take approx 2 minutes Important Do not switch off the machine while the update is in progress 6 Remove the USB key when prompted to do so The machine restart...

Page 279: ...7 277 Fig 239 Update the machine software 4 8 Confirm with OK The update is carried out Fig 240 Update the machine software 5 Important Do not switch off the machine while the update is in progress Th...

Page 280: ...The machine restarts automatically After restarting the machine loads the start screen and is ready for operation OR 9 Press CANCEL to cancel the update The following warning appears Fig 242 Update th...

Page 281: ...Programming Service Instructions 745 35 10 D 00 0 10 2017 279 Information If the update fails you can restart it in the service menu under DAC update p 247...

Page 282: ...Programming 280 Service Instructions 745 35 10 D 00 0 10 2017...

Page 283: ...from moving parts Crushing possible Prior to any maintenance work switch off the machine or set the machine to threading mode Work to be carried out Operating hours 8 40 160 500 Machine head Remove f...

Page 284: ...that the particles do not fly close to people Make sure no particles fly into the oil pan NOTICE Property damage from soiling Lint and thread remnants can impair the operation of the machine Clean th...

Page 285: ...ty with the following specifications Viscosity at 40 C 10 mm s Flash point 150 C CAUTION Risk of injury from contact with oil Oil can cause a rash if it comes into contact with skin Avoid skin contact...

Page 286: ...d for lubricating the machine head Fig 244 Lubricating 1 Proper setting The oil level must not raise above the MAX marking 3 or drop below the MIN marking 2 To top off the oil 1 Swivel up the machine...

Page 287: ...245 Lubricating 2 Proper setting The oil level must not be higher than the MAX marking To top off the oil 1 Swivel up the machine head p 14 2 Refill oil through the nipple 1 until the oil level reach...

Page 288: ...8 3 Servicing the pneumatic system 18 3 1 Setting the operating pressure Proper setting Refer to the Technical data p 307 chapter for the permissible operating pressure The operating pressure cannot d...

Page 289: ...mulates in the water separator 2 of the pressure controller Proper setting Water condensation must not rise up to the level of the filter element 1 Check the water level in the water separator 2 on a...

Page 290: ...n the water condensation p 287 3 Loosen the water separator 2 4 Loosen the filter element 1 5 Blow out the filter element 1 using the compressed air gun 6 Wash out the filter tray using benzine 7 Tigh...

Page 291: ...Maintenance Service Instructions 745 35 10 D 00 0 10 2017 289 18 4 Parts list A parts list can be ordered from D rkopp Adler Or visit our website for further information at www duerkopp adler com...

Page 292: ...Maintenance 290 Service Instructions 745 35 10 D 00 0 10 2017...

Page 293: ...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 WARNING Risk of injury from a lack of care Serious injur...

Page 294: ...Decommissioning 292 Service Instructions 745 35 10 D 00 0 10 2017...

Page 295: ...cable national regulations 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 dispos...

Page 296: ...Disposal 294 Service Instructions 745 35 10 D 00 0 10 2017...

Page 297: ...rvice if an error occurs that is not described here Do not attempt to correct the error yourself Error code Symbol Meaning Remedial action Error code 0 1999 Error messages sewing motor control 1000 En...

Page 298: ...he sewing machine 1008 Fault in sewing motor encoder Replace encoder 1010 Cable to sewing motor reference switch defective Reference switch defective Replace cable Replace reference switch part number...

Page 299: ...motor cable Replace encoder Replace sewing motor Replace control 1203 Sewing motor Position not reached Check mechanical changes to the machine e g thread cutting setting toothed belt tension Check p...

Page 300: ...coder defective Check the encoder cable connection and replace encoder cable if necessary 2122 Pulse wheel search time out Check connection cables Check step motor for stiff movement 2130 Step motor c...

Page 301: ...ctive Control defective Fix blockage sluggishness Replace step motor Replace control 2256 Step motor corner knife Overheat seized up defective Control defective Eliminate seizing Replace step motor co...

Page 302: ...ges displays 3010 Control 100V voltage error Check connections Replace control 3011 Control 100V voltage error Check connections Replace control 3012 Control Voltage error 100V I2T Switch off and on t...

Page 303: ...d air 3123 Oil level too low Top off the oil p 283 3210 Thread broken left Thread broken right Insert thread 3220 Empty bobbin left Empty bobbin right Changing the bobbin 3522 Error Command Interprete...

Page 304: ...re in CAN Module corner knife AC001 excess temperature at step motor output stage Check cable Check jumpers Check voltage supply Check output stage Check motors 7209 Failure in CAN Module corner knife...

Page 305: ...ogram be retransmitted 8408 Information Waiting for RESET by machine 8409 Information Switch off and on the machine again 8410 Information Update failed Should the program be retransmitted 8411 Inform...

Page 306: ...folder setting 9702 Folder not vertical Correct folder setting 9703 Folder not slanted Correct folder setting 9704 Folder not on the pipe table Correct folder setting 9707 Scissors not down Correct t...

Page 307: ...e insert a larger flap 9730 Corner knife cut impossible Increment the pocket length Use additional equipment short pockets 9800 Middle knife not ready for use Check cable 9810 Smoother not ready for u...

Page 308: ...Troubleshooting 306 Service Instructions 745 35 10 D 00 0 10 2017...

Page 309: ...d switch actuation points can be programmed Thread cutter for needle threads and hook threads Needle thread monitor Hook thread monitor Technical data Unit 745 35 10 D Type of stitches 301 Double lock...

Page 310: ...transferred via a USB port on the control panel Tabletop The tabletop has been prepared for vacuum supply It can be equipped with a device to accommodate an in house vacuum system in order to allow f...

Page 311: ...Service Instructions 745 35 10 D 00 0 10 2017 309 23 Appendix Wiring diagram 0 1 2 2 3 0 4 5 6 0 4 5 0 7 3 8 8 4 3 9 8 3 3 9 8 6 9 4 A 0 A 0 B C D E 0 F F 1 0 0 0 0 1 0 GH I 8 G I G I 9 9 9 9 9 J 4KK...

Page 312: ...1 1 8 H 8 1 8 6G 8 1 4 1H 1H 1H 1H H 61 1H 1 H 4 6G H 6G H 6G H 6G H 1 1 1H 1H 1H 1H 1 1H 1 H 4 6G H 6G H 6G H 6G H 4 1H 1H 1H 1H GH 61 1H 1 H 4 6G H 6G H 6G H 6G H 1 1 1H 1H 1H 1H 1 1H 1 H 4 6G H 6G...

Page 313: ...311 0 1 1 2 3 4 5 6 6 7 8 4 9 4 6 1 4 6 6 6 9 3 9 3 4 6 6 6 6 9 4 4 76 1 6 4 76 6 4 6 1 6 6 6 9 6 6 6 6 4 80 8 3 4 4 76 1 6 4 76 6 4 6 1 6 6 6 9 6 6 6 6 30 4 3 76 1 4 6 76 6 4 4 4 6 6 9 9 9 9 9 9 6 6...

Page 314: ...Appendix 312 Service Instructions 745 35 10 D 00 0 10 2017 0 12 3 4 5 6 1 1 4 2 1 1 0 7 2 1 8 9 7 2 14 7 7 12 4 1...

Page 315: ...00 0 10 2017 313 0 1 0 2 3 4 5 6 0 10 0 7 7 8 0 7 7 8 0 0 7 7 8 7 7 8 9 9 5 0 0 7 20 6 2 1 0 6 2 5 1 2 02 8 0 1 0 3 4 0 0 0 0 10 0 7 6 1 0 7 6 1 0 0 7 6 1 7 6 1 2 2 45 0 0 0 A 6 45 0 A 6 6 1 0 A 6 A...

Page 316: ...Appendix 314 Service Instructions 745 35 10 D 00 0 10 2017 0 1 2 1 2 34 1 5 6 5 78 1 92 1 1 1 1 34 1 5 5 34 1 34 1 34 1 5 34 1 0 4 A A B A A A A A A 6 0 6 0 A A A C C A 1 1 1 1 1 1 1 1 1 1 1 1 1...

Page 317: ...D 00 0 10 2017 315 0 123 4 3 560 1 7 1 7 8 7 8 7 19 6 19 6 6 8 6 8 6 9 0 9 3 9 A A A A B 9 9 C 4 C 4 B16 C 4 C 4 B16 A A A 0 0 1 7 40 0 0 1 7 40 0 8 7 0 8 7 9 9 A A A A 9 9 9 9 9 6 9 9 6 9 9 9 9 9 0...

Page 318: ...1 2 6 2 26 0 1 7 2 7 8 6 9 0 1 7 2 7 5 26 9 0 1 7 7 8 6 0 1 7 7 5 26 1 5 2 3 9 9 9 9 9 9 9 6 6 6 6 6 6 6 9 6 9 9 9 9 9 9 A 9 6 A A A A A A A 2 2 2 8 2 1 2 8 9 B 2 2 9 B 2 2 9 C A A A A A 9 9 9 0 1 0...

Page 319: ...ce Instructions 745 35 10 D 00 0 10 2017 317 0 0 0 0 1 233 1 233 4 4 4 5 6 7 2 7 7 233 7 8 7 53 9 9 0 3 6 6 6 6 6 6 6 6 6 6 4 0 0 0 0 0 0 0 0 0 0 0 0 A 6 3 7 3 7 3 33 6 3 3 3 6 3 3 7 3 3 3 6 7 6 6 6 0...

Page 320: ...tions 745 35 10 D 00 0 10 2017 0 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 3 2 45 67 2 33 8 2 2 2 9 2 9 2 3 9 2 3 9 2 3 9 2 3 9 2 3 2 2 2 2 2 2 2 2 2 2 2 2 3 3 9 3 9 3 3 3 A B C B C B C B C B C 3 4 3 7 3 3 3 3 3...

Page 321: ...0 511 2 10 6 72 4 8 7 3 8 2 10 4 3 9 4 2 10 9 4 2 4 2 4 4 4 4 4 4 3 01 4 3 1 3 7 8 3 4 A B C D C D C D C D C D C D C D C D C D C D C D C D C D C D C D C D 3 3 1 1 3 9 1 1 1 1 1 1 1 1 1 1 1 1 1 3 9 71...

Page 322: ...ns 745 35 10 D 00 0 10 2017 01 2 34 2 5 3 6 5 7 8 2 7 9 6 6 9 6 10 9 2 2 9 2 2 2 2 6 01 2 6 9 1 6 3 5 7 7 6 2 9A 9A 9A 9A 9A 9A 9A 9A 9A 9A 9A 9A 6 6 1 1 6 8 11 6 8 31 5 6 8 31 5 8 7 7 7 1 2 6 1 2 6 1...

Page 323: ...0 511 2 10 6 72 4 8 7 3 8 2 10 4 3 9 4 2 10 9 4 2 4 2 4 4 4 4 4 4 3 01 4 3 1 3 7 8 3 4 A B C D C D C D C D C D C D C D C D C D C D C D C D C D C D C D C D 3 3 1 1 3 9 1 1 1 1 1 1 1 1 1 1 1 1 1 3 9 71...

Page 324: ...Appendix 322 Service Instructions 745 35 10 D 00 0 10 2017 0 1 2 3 4 5 4 6 2 2 7 8 9 72 72 72 72 72 72 72 4 4 4 4 4 4 4 7 4 4...

Page 325: ...0 10 2017 323 0 0 0 0 0 0 0 0 0 0 1231 12456 6 783 9 0 0 0 8 0 0 0 0 8 0 0 1 8 1 8 1 1 3 6 A B A B A B A B 8 2 A B 1 8 2 C 9 312 C 9 312 312 266 1 312 266 1 C 9 C 9 8 2 8 2 8 2 A B 1 8 2 8 2 8 2 A B...

Page 326: ...Appendix 324 Service Instructions 745 35 10 D 00 0 10 2017 01 1 23 4 3 3 5 6 7 8 3 9 8 6 1 8 5 6 5 5 6 5 5 5 3 3 A 4 A 4 115 115 A 4 A 4 3 3 5 3 3 3 3 6 B C C 8...

Page 327: ...01 01 01 01 01 01 2 3 4 5 5 6 3 0 7 3 1 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 59 5 7A 7A 7A 7A 7A 7A 7A 7A 1 1 1 1 1 1 1 1 8 9 8 9 3 3 1 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9...

Page 328: ...7 8 9 4 9 2 2 2 2 4 9 2 2 2 2 6 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 6 0 6 0 6 6 0 6 0 6 0 6 0 60 0 0 6 6 6 6 6 6 0 0 6 6 6 0 60 6 0 0 6 0 6 0 6 6 0 6 60 0 6 6 0 6 0 0 6 6 0 6 0 6 6 0 6 0 6 0 6 0 6...

Page 329: ...ce Instructions 745 35 10 D 00 0 10 2017 327 01 2 3 4 5 6 6 6 6 6 6 7 3 3 28 0 0 9 8 9 3 6 6 6 6 0 0 3 6 6 6 6 3 3 3 4 3 5 9 9 5 4 3 5 5 5 5 90 6 3 6 3 3 3 3 3 0 0 90 5 0 5 0 0 5 5 0 90 0 90 0 90 0 90...

Page 330: ...tions 745 35 10 D 00 0 10 2017 0 1 0 2 0 3 4 4 0 5 6 6 7 8 9 2 9 9 9 9 9 9 4 6 4 0 4 AB AB C0 8 C0 8 AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB 0 0 D 0 4 D 0 4 D 0 4 00 4 0 4 0...

Page 331: ...10 2017 329 0 0 0 0 1 2 3 3 1 45 6 6 7 7 8 9 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 5 5 5 7 1 3 7 1 3 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 0 3 0 3 0 3 0 3 0 3 0 3 0 3 1 3 1...

Page 332: ...nstructions 745 35 10 D 00 0 10 2017 0 1 2 1 2 3 4 5 6 6 7 8 9 7 7 6 6 8 8 8 8 8 8 8 8 6 6 8 8 8 8 8 8 8 8 6 9 9 9 9 9 9 9 9 6 6 9 9 9 9 9 9 9 9 6 7 3 1 2 1 2 1 2 A A 3 6 6 B1 2 6 8 B 8 B 8 B 8 B 8 B...

Page 333: ...Appendix Service Instructions 745 35 10 D 00 0 10 2017 331 0 01 2 3 4 4 52 0 0 6 2 78 0 0 9 9 60 60 0 0 0 0 0 0 9 9 60 60 4 7 7 7 7 4 5...

Page 334: ...Appendix 332 Service Instructions 745 35 10 D 00 0 10 2017 0 1 1 2 3 0 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 4 7 4 5 5 5 5 5 5 5 5 8 6 8 6 1 1 1 1 1 79 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 5...

Page 335: ...Appendix Service Instructions 745 35 10 D 00 0 10 2017 333 0 0 1 2 3 2 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 4 7 4 5 5 5 5 5 5 5 5 8 6 8 6 0 0 0 0 0 79 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 5...

Page 336: ...Appendix 334 Service Instructions 745 35 10 D 00 0 10 2017 01 2 2 3 4 5 1 6758 6758 6758 6758 2 2 5 9 9 2 2 6758 6758 6758 6758 9 2 9 AB...

Page 337: ......

Page 338: ...Germany Phone 49 0 521 925 00 Email service duerkopp adler com www duerkopp adler com Subject to design changes Part of the machines shown with additional equipment Printed in Germany D rkopp Adler AG...

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