DURKOPP ADLER 745-34 - Operating instructions

745 - 34 Speedpocket
Sewing unit for runstitching
of rectangular piped pockets
Operating Instructions
Installation Instructions
Service Instructions
Instructions for programming DAC
Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
06/2007 Rev. index: 02.0 Printed in Federal Republic of Germany 0791 745171
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All rights reserved.
Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner,
even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.
Copyright © Dürkopp Adler AG - 2007

Foreword
This instruction manual is intended to help the user to become familiar
with the machine and take advantage of its application possibilities in
accordance with the recommendations.
The instruction manual contains important information on how to
operate the machine securely, properly and economically. Observation
of the instructions eliminates danger, reduces costs for repair and
down-times, and increases the reliability and life of the machine.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the machine/sewing
unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
–Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
–Service (maintenance, inspection, repair) and/or
–Transport.
The user also has to assure that only authorized personnel work on the
machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

General safety instructions
The non-observance of the following safety instructions can cause
bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the
instruction book and operated by persons with appropriate training.
2. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot, needle
plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as
the entire sewing unit is found to comply with EC directives.
13. The line cord should be equipped with a country-specific mains
plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).
It is absolutely necessary to respect the safety
instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.

Index Page:
Part 3: Service Instructions 745-34 Speedpocket
1. General notes................................................ 3
1.1 Gauges .................................................... 4
1.2 Grooveinthearmshaftcrank ...................................... 5
2. Sewing machine head
2.1 Raising the sewing machine head .................................... 6
2.2 Removing / Installing the sewing machine head............................ 8
2.3 Crankpinatthearmshaft......................................... 10
2.4 Needle bar linkage ............................................. 13
2.4.1 Removing the needle bar linkage .................................... 13
2.4.2 Removing a needle bar from the linkage ................................ 15
2.4.3 Disassembly of the needle bar ...................................... 16
2.4.4 Assembly of a needle bar ......................................... 16
2.4.5 Installation of the needle bars in the needle bar linkage ....................... 17
2.4.6 Installation of the needle bar linkage .................................. 19
2.4.7 Height of the needle bar linkage ..................................... 21
2.4.8 Aligning the needle bar linkage to the throat plate .......................... 22
2.4.9 Exchanging the needle holder ...................................... 23
2.5 Hook...................................................... 24
2.5.1 Hookshaftheight.............................................. 24
2.5.2 Adjusting the gear clearance of the hook drive ............................ 25
2.5.3 Looping stroke................................................ 26
2.5.4 Height of the needle holders ....................................... 27
2.5.5 Distance between hook tips and needles ................................ 29
2.5.6 Needle protection .............................................. 31
2.5.7 Exchanging the hook ............................................ 32
2.5.8 Bobbin case holding wire ......................................... 33
2.6 Centerknife................................................. 35
2.6.1 Removing / Installing the driving motor ................................. 35
2.6.2 Removing / Installing the switching cylinder .............................. 36
2.6.3 Adjustingtheknife ............................................. 37
2.7 Threadcontrollerspring.......................................... 39
2.8 Trimming and clamping device for the needle threads ........................ 40
2.8.1 Function ................................................... 40
2.8.2 Exchanging knife and thread catcher .................................. 41
2.9 Trimming and clamping device for the hook threads ......................... 43
2.10 Thread puller for the needle threads................................... 46
2.11 Synchronizer................................................. 47
2.12 Oillubrication................................................ 48
2.12.1 Hooklubrication............................................... 49
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Index Page:
3. Transport carriage
3.1 Rearendposition.............................................. 51
3.1.1 Positionofthelimitswitchintheslottedhole ............................. 53
3.1.2 Distancebetweenswitchingscrewandlimitswitch.......................... 53
3.1.3 Stopguidefortransportcarriage..................................... 53
3.2 Changing the toothed belt ........................................ 54
3.3 Adjustingthebelttension......................................... 55
4. Feeding clamps
4.1 Measuring line for aligning the feeding clamps and the folder ................... 56
4.2 Aligning the feeding clamps as to the auxiliary line .......................... 57
4.3 Feeding clamp stroke ........................................... 58
4.4 Distance between the feeding clamps and the folder sole ...................... 59
4.5 Front end position of the feeding clamp................................. 60
5. Knives for corner incision
5.1 Presetting .................................................. 61
5.2 Aligningthecornerknifestationastotheseams........................... 62
5.3 Adjustingtheslantofthecornerincisions............................... 64
5.4 Exchanging the corner knives ...................................... 65
6. Laser markings............................................... 66
6.1 Aligningthemarkings ........................................... 67
7. Reflected light barriers for flap scanning
7.1 Swivelarm.................................................. 68
7.2 Aligningthelightbarriers ......................................... 69
8. Aligning the folding station plate as to the measuring line ................... 70
9. Positioning the sewing machine head as to the table top .................... 71
10. Folder
10.1 Proper fastening............................................... 72
10.2 Aligning the folder as to the middle of the pocket opening...................... 73
10.3 Liftingmotionofthefolder......................................... 74
10.4 Position of the folder to the needles ................................... 76
10.5 Guideplatesatthefolder......................................... 77
11. Stacker
11.1 Positionofthepincerstothetabletop ................................. 78
11.2 Heightofthepincer............................................. 78
11.3 Positionandclosingofthepincers.................................... 79
11.4 Cylinder speed ............................................... 80
11.5 Positionoftherestplate.......................................... 80
11.6 Swivellingthestackeraside........................................ 81
12. Exchange the control unit ........................................ 81

1. General notes
The service instruction manual on hand describes the setting of the
sewing unit 745-34 in an appropriate sequence.
ATTENTION !
Some of the setting positions are interdependent.
Therefore it is absolutely necessary to carry out the individual settings
following the described order.
The operations described in the service instructions must only
be executed by qualified staff and correspondingly instructed persons
respectively!
Danger of breakage !
Before the sewing unit is put into operation again after having been
disassembled the necessary adjustments have to be carried out
according to the service instructions.
Before any adjusting operations of parts involved in the stitch
formation are made:
–Insert a new needle without any damage.
Caution: Danger of injury !
Before repair, converting and maintenance work is done:
–Switch the main switch off and disconnect the sewing unit from the
pneumatic supply system.
Exception:
Adjusting operations carried out with the help of test or setting
programs.
Adjusting operations and function tests when the sewing unit is
running
–Carry out adjusting operations and function tests of the running
sewing unit
only under observation of all safety measures and with utmost
caution.
Adjusting operations in the needle zone
–Parts which can lead to injuries have to be removed before carrying
out the adjusting operations.
Exception:
The parts are absolutely necessary for the adjusting operations.
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1.1 Gauges
The gauges listed below allow a precise setting and testing of the
sewing unit.
The locking peg 1 belongs to the standard accessories of the sewing
unit. It serves to stake out the position A(looping stroke).
The setting gauges marked with *) are available on inquiry.
Position Setting gauge Order No. Use
1 Locking peg 0211 000700 Looping stroke position
2 *) Gauge 0246 002591 Crank pin to arm shaft
3 *) Gauge 0244 001001 Height of hook shaft
4 *) Measuring bridge 0212 004942 Height of needle holder
5 *) Measuring pin 0216 001070 Height of needle holder
6 *) Adjusting pin 0244 001014 Lateral hook distance
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1.2 Groove in the arm shaft crank
The arm shaft crank 1 is provided with a groove 2 (5 mm).
The machine head can be staked out with the locking peg through
drill-hole 3.
Now the machine head is in looping stroke position
(position A).
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2. Sewing machine head
2.1 Raising the sewing machine head
For maintenance work the machine head can be raised.
For this purpose the transport carriage must be in its rear position.
Caution: Danger of injury !
Switchthemainswitchoff.
Raise the machine head only with the main switch switched off.
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Raising the machine head
–Remove the covering cap 1.
For this purpose lift the covering cap at the front and at the back so
that the arrest is released. Lift the covering cap carefully.
–Swivel the folding station 3 out by 90°.
–Swing the locking peg 4 upwards.
–Lift the fabric sliding sheet 6 at the front and swing it to the left.
–Lift the machine head in the area of head cover 5 and raise it
carefully.
Pawl 2 snaps in additionally.
The area underneath the machine table is accessible for cleaning.
Caution: Danger of injury !
Do not reach into the table top cutout when the machine head is
raised.
Swinging the machine head back
–Hold the machine head in the area of head cover 5.
–Release pawl 2.
–Swing the machine head back carefully.
Attention: Danger of breakage!
Hold the machine head tight until it finally rests on.
–Insert the fabric sliding sheet
–Swivel the locking lever 4 downwards.
–Swing the folding station 3 back carefully and let it catch in the
locking lever.
–Put on the covering cap 1 and let it snap in again.
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2.2 Removing / Installing the sewing machine head
For repair work or an easier change to another needle distance the
machine head can be removed.
For this purpose the transport carriage must be in its rear position.
Caution: Danger of injury!
Switch the main switch off and disconnect from the pneumatic net.
Remove and install the machine head only with the main switch
switched off.
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Removing the machine head
–Remove the covering cap 1.
For this purpose lift the covering cap at the front and at the back so
that the arrest is released. Lift the covering cap carefully.
–Swivel the folding station 3 out by 90°.
–Swing the locking lever 4 upwards.
–Lift the fabric sliding sheet 6 at the front and swing it to the left.
–Pull off plug 7 from the circuit board.
–Pull off the main pneumatic hose 11 from the solenoid valve
block 10.
–Loosen the gas shock absorber connection 2.
–Unscrew screws 8 and 9.
–Pull off the plug from the motor at the control cabinet and
disconnect the plug connection from the proximity switch.
–Lift out the machine head carefully with an appropriate auxiliary
tool.
Installing the machine head
–Carefully insert the machine head into the cutout for the head with
an appropriate auxiliary tool.
–Screw the machine head tight with the screws 8 and 9.
–Re-establish the gas shock absorber connection 2.
–Connect the pneumatic hose 11 to the solenoid valve block 10.
–Put plug 7 on the circuit board again.
–Insert the fabric sliding sheet.
–Swing the locking lever 4 downwards.
–Swing the folding station 3 back and let it catch.
–Put on the covering cap 1 and let it snap in.
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2.3 Crank pin at the arm shaft
The distance between the eccentric crank pin 1 and the arm shaft 4
determines the needle bar stroke and thus the upper dead centre of
the needle bars.
ATTENTION !
The crank pin 1 has been precisely set by the manufacturer!
After exchanging the thread lever the crank pin 1 has to be readjusted.
The adjustment of the crank pin 1 is done with the gauge 7
(Order No. 0246 002591).
It is not necessary to remove crank and arm shaft for the adjustment.
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Caution: Danger of injury !
Switchthemainswitchoff.
Adjust the crank pin only with the main switch switched off.
–Remove the head cover 9 after loosening the fastening screws 8.
–Swivel the thread tension plate 10 sideways after loosening the
fastening screws 11.
–Remove the needle bar linkage 12 (see chapter 2.4.1).
–Remove the switching cylinder 13 for the center knife drive
(see chapter 2.6.2).
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–Detach the needle bar tie rod from the crank pin 1 after unscrewing
its fastening screws (ATTENTION left-hand thread) and pull it off
with the needle cage.
–Turn the handwheel until the Allen screws 2 point downward.
In this position the screws are accessible.
–Loosen the Allen screws 2.
–Loosen the support bolt 3.
The screw is accessible through drill-hole 13.
–Put the pivots of gauge 7 in the insertion bores 6.
–Turn the crank pin 1 in such a way that it reaches in the cutout of
the gauge.
–Press the crank pin 1 on.
The thread lever 5 must have a minimum axial backlash for the
lubrication.
–Tighten Allen screws 2 and support bolt 3.
–Remove gauge 7.
–Turn the handwheel and check the free movement of the upper
shaft.
–Put the needle bar tie rod with the needle cage on the crank pin 1
and tighten the fastening screws. (ATTENTION left-hand thread).
–Mount and adjust the needle bar linkage (see chapter 2.4.1).
–Mount the switching cylinder for the center knife drive
(see chapter 2.6.2).
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2.4 Needle bar linkage
2.4.1 Removing the needle bar linkage
Caution: Danger of injury!
Switchthemainswitchoff.
Remove the needle bar linkage only with the sewing unit switched off.
–Unscrew the screws 1 and take off the head cover 2.
–Loosen the screws 3 and 5 and pull off the thread puller 4.
–Unscrew screws 7.
–Unscrew screw 6.
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–Loosen the counternut 12.
–Loosen the adjusting screw 13 a bit.
ATTENTION !
Do not loosen both adjusting screws 13.
With the two adjusting screws 13 the correct height of the linkage
frame has been set by the manufacturer.
ATTENTION !
Avoid damage to the oil wick when taking off the needle bar.
Note the position of the oil wick for the subsequent assembly.
–Carefully remove the support plate 9 with the needle bar linkage 10
from the stop pin 11.
This is facilitated by slight turning motions.
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2.4.2 Removing a needle bar from the linkage
–Loosen the clamping screw 1.
–Pull out the bearing bolt 2
–Pull off the support plate 3 from the needle bar linkage.
–Unscrew the screws 8 and 10.
–Remove the guide rail 9.
–Actuate both decoupling bars 15 and push the yoke 7 downwards
to half the needle bar stroke.
–Unscrew the safety bolt 6 of the clamping ring 4 as well as the
fastening screw 5 located below.
–Remove the two securing halves 14. They are located in the
annular slot 13 and become visible after pushing down the
clamping ring 4.
–Shift the switching block in such a way that the two decoupling
bars 15 are not actuated.
–Shift the yoke 7 slowly up the needle bar until the three upper
coupling balls 12 come out.
ATTENTION !Take care that the balls do not get lost - they are
under spring pressure.
–Pull the needle bar downward out of the linkage 16.
ATTENTION !The three lower balls 11 can drop out of the ball
holes of the needle bar.
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2.4.3 Disassembly of a needle bar
–Remove the linkage 16 and the needle bar as described
under 2.4.1.
–Screw off the screw 1 and unscrew the needle holder 2.
–Unscrew the screw 15 and loosen the spring counter bearing 16.
ATTENTION !The spring counter bearing is under spring pressure.
Before loosening the screw 15 support the spring counter bearing
withapinÆ4 mm inserted in the needle bar from below.
–Take off the parts located in the needle bar one after the other from
below.
2.4.4 Assembly of a needle bar
–Screw the locking screw 3 tightly into the needle bar.
–Pre-assemble the lower coupling bar 17 in the sequence as per the
illustration opposite.
–Tighten nut 9 and counter-rotate the acorn nut 8 in such a way that
there is a distance of 30.5 mm between the lower edge of taper
socket 11 and the top edge of acorn nut 8.
Note
This dimension has to be observed in any case so that the
retaining force of the coupling necessary for the needle penetration
is achieved.
–Put spring 5 and bush 6 on the thinner shaft extension of the
decoupling bar 4.
–Push the thicker shaft extension of the decoupling bar 4 into the
needle bar 18 from below until it emerges on top of locking screw 3.
–Push the following parts into the needle bar: first the conical bolt 7
with the cylindrical part showing upwards, then the pre-assembled
coupling bar 17 and finally spring 13 with spring 14 as well as
spring counter bearing 16.
–Screw the spring counter bearing 16 tight by means of screw 15.
–Press down the decoupling bar 4 repeatedly and check whether the
bars inside the needle bar are movable freely and flexibly.
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