Pfaff 3822-2/42 Instruction Manual
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Pfaff 3822-2/42 Instruction Manual

Pfaff 3822-2/42 Instruction Manual

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3822
-2/42
-2/44

Instruction Manual

This instruction manual applies to machines from the
following serial numbers onwards:
# 2719930
296-12-18 592/002
Betriebsanleitung engl. 01.06

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Summary of Contents for Pfaff 3822-2/42

  • Page 1: Instruction Manual

    3822 -2/42 -2/44 Instruction Manual This instruction manual applies to machines from the following serial numbers onwards: # 2719930 296-12-18 592/002 Betriebsanleitung engl. 01.06...
  • Page 2 This instruction manual applies to all versions and subclasses listed under "Specifications". Reprinting, copying or translation of PFAFF instruction manuals, whether in whole or in part, is not permitted without our prior permission and not without written indication of the source.

  • Page 3: Table Of Contents

    Index Contents ................. Chapter - Page Safety ........................... 1 - 1 Directives ........................1 - 1 General notes on safety ....................1 - 1 Safety symbols ......................1 - 2 Important points for the user ..................1 - 2 Operating and specialist personnel ................1 - 3 .05.01 Operating personnel ......................
  • Page 4 Index Contents ................. Chapter - Page Preparation ........................9 - 1 Inserting the needle ...................... 9 - 1 Winding the bobbin thread, adjusting the thread tension ..........9 - 2 Removing/inserting the bobbin case ................9 - 3 Threading the bobbin case, adjusting the thread tension ..........9 - 3 Oberfaden einfädeln ......................
  • Page 5 Index Contents ................. Chapter - Page Control and adjustment aids ..................13 - 2 Adjusting the basic machine ..................13 - 3 05.01 Basic position of the machine ..................13 - 3 05.02 Preliminary adjustment of the needle height ............... 13 - 4 05.03 Needle in needle-hole centre..................
  • Page 6 Tension release of needle thread ................13 - 44 06.14 Attaching and removing the thread trimming unit ............13 - 45 Adjusting the edge trimming device on the PFAFF 3822-2/42 ........13 - 46 07.01 Knife stroke ......................... 13 - 46 07.02...

  • Page 7: Safety

    Safety Safety Regulations This machine is constructed in accordance with the European regulations indicated in the conformity and manufacturer's declarations. In addition to this instruction manual, please also observe all generally accepted, statutory and other legal requirements, including those of the user's country, and the applicable pol- lution control regulations! The valid regulations of the regional social insurance society for occupational accidents or other supervisory authorities are to be strictly adhered to!

  • Page 8: Safety Symbols

    The user must ensure that none of the safety devices are removed nor put out of work- ing order. The user must ensure that only authorized persons operate and work on the machine. For further information please refer to your PFAFF agency. 1 - 2...

  • Page 9: Danger

    Safety Notes for operating and technical staff Operating staff .05.01 Operating staff are the persons responsible for setting up, operating and cleaning the mach- ine and for removing any disturbances in the sewing area. The operating staff are obliged to observe the following points, and must: always observe the notes on safety in this instruction manual! avoid using any working methods which adversely effect the safety of the machine! avoid wearing loose-fitting clothing or jewelry such as necklaces or rings!

  • Page 10: Danger Warnings

    Safety Danger warnings A working area of 1 m must be kept free both in front of and behind the mach- ine, so that easy access is possible at all times. Never put your hands in the sewing area during sewing! Danger of injury by the needle! While setting or adjusting the machine do not leave any objects on the table nor in the needle plate area! Objects may be trapped or slung out of the mach-ine!

  • Page 11: Proper Use

    Proper use Proper use The PFAFF 3822-2/42, -2/44 are integrated workplaces for run-stitching and trimming the edges of jackets, coats and costumes. Machine type Equipment PFAFF 3822-2/42 Edge trimmer and touch-screen control panel PFAFF 3822-2/44 Edge trimmer for feathered trimming and touch-screen control...

  • Page 12: Specifications

    Fuse protection: .................... 1 x 16 A, inert Working air pressure: ....................6 bar Air consumption : ......40 l/work cycle (on the Pfaff 3801-3/07 and the PFAFF 3801-3/071) Noise data: Emission sound pressure level at the workplace with a sewing speed of 2400 spm: ..............L <...

  • Page 13: Disposal Of Machine

    Disposal of Machine Disposal of Machine Proper disposal of the machine is the responsibility of the customer. The materials used for the machine are steel, aluminium, brass and various plastic mat- erials. The electrical equipment comprises plastic materials and copper. The machine is to be disposed of according to the locally valid pollution control regula- tions;...

  • Page 14: Transportation, Packing And Storage

    Transportation, packing and storage Transportation, packing and storage Transportation to customer's premises All machines are delivered completely packed. Transportation inside the customer's premises The manufacturer cannot be made liable for transportation inside the customer's premises nor to other operating locations. It must be ensured that the machines are only transported in an upright position.

  • Page 15: Explanation Of Symbols

    Explanation of symbols Explanation of symbols In this instruction manual, work to be carried out or important information is accentuated by symbols. These symbols have the following meanings: Note, information Cleaning, care Lubrication Maintenance, repairs, adjustment, service work (only to be carried out by technical staff) 6 - 1...

  • Page 16: Controls

    Controls Controls Main switch The machine is switched on or off by turning main switch 1. Fig. 7 - 01 Pedal 0 = Neutral position +1 = Lower presser foot +2 = Sewing -1 = Raise presser foot -2 = Trim threads Fig.

  • Page 17: Presser Bar Lifter

    Controls Presser bar lifter The presser foot is raised by turning lever 1. Fig. 7 - 03 Knee Switch Manual sewing: By operating knee switch 1 it is possible to alternate between two pre-set amounts of fullness. Programmed sewing: By operating knee switch 1 the amounts of fullness are changed according to the program selected.

  • Page 18: Left Knee Switch

    Controls Left knee switch By operating knee switch 1 1 1 1 1 , the knife for feathered trimming can be switched on or off. Fig. 7 - 05 Control panel The current operating conditions are displayed on control panel 1. Operation takes place in a constant dialogue between the control unit and the operator.

  • Page 19: Keyboard

    Controls Keyboard The keyboard 1 is used for the quick operation of the machine during sewing and when selecting the fullness. With the corresponding LED of the 20 keys, active key functions are displayed (Function active = LED lit). Stitch condensation The stitch condensation is switched on and off by pressing a key.

  • Page 20: Mounting And Commissioning The Machine

    Mounting and commissioning the machine Mounting and commissioning the machine The machine must only be mounted and commissioned by qualified personnel! All relevant safety regulations are to be observed! If the machine is delivered without a table, you must make sure that the frame and the table top which you intend to use can hold the weight of the machine and the motor.

  • Page 21: Tightening The V-Belt

    Mounting and commissioning the machine Tightening the V-belt .01.02 Fit the V-belt. Loosen nut 1 and tighten the V-belt by turning motor mounting 2. Tighten nut 1. 109-020 Fig. 8 - 02 Fitting the top V-belt guard .01.03 Fasten bottom section of V-belt guard 1 with screws 2.

  • Page 22: Mounting The Bottom V-Belt Guard

    Mounting and commissioning the machine Mounting the bottom V-belt guard .01.04 Fig. 8 - 04 109-071 Loosen screws 2 and adjust belt guard support 1 so that the motor pulley and V-belt run freely. Tighten screws 2. Fasten belt guard 3 with screw 4. Fitting the synchronizer .01.05 Insert position stop 1 in the machine...

  • Page 23: Connecting The Plug-In Connections And Earth Cables

    Mounting and commissioning the machine Connecting the plug-in connections and earth cables .01.06 Fig. 8 - 06 Connect all plugs as labelled in the control box 1. Screw the earth cable from the sewing head to earth point A. Connect earth point C and earth point A with an earth cable. Screw the earth cable from main switch 3 to earth point A.

  • Page 24: Fitting The Reel Stand

    Mounting and commissioning the machine Fitting the reel stand .01.07 Fit the reel stand as shown in Fig. 8 - 07. Afterwards insert the stand in the hole in the table top and secure it with nuts pro- vided. Fig. 8 - 07 8 - 5...

  • Page 25: Commissioning

    Mounting and commissioning the machine 8.02 Commissioning Before the machine is commissioned, stopper 1 must be removed! Clean the machine thoroughly and then check the oil level (see Chapter 12 Care and Maintenance). Check the machine, in particular the electrical leads, for any damage. Have specialists check, whether the machine can be operated with the available mains connection.

  • Page 26: Preparation

    Preparation Preparation All regulations and instructions in this Instruction Manual are to be observed! Special attention is to be paid to the safety regulations! All preparation work is only to be carried out by appropriately trained personnel. Before all preparation work, the machine is to be separated from the electricity supply by removing the plug from the mains or switching off the On/Off switch! Inserting the needle Switch off the machine!

  • Page 27: Winding The Bobbin Thread, Adjusting The Thread Tension

    Preparation Winding the bobbin thread, adjusting the thread tension Fig. 09 - 02 Place the empty bobbin 1 onto the bobbin winder spindle 2. Thread the thread in accordance with Fig. 09-02 and wind it a few times around bobbin 1 in a clockwise direction.

  • Page 28: Removing/Inserting The Bobbin Case

    Preparation Removing/inserting the bobbin case Switch off the machine! Danger of injury if the machine is started accidentally! Removing the bobbin case. Lift clip 1 and remove bobbin case 2. Inserting the bobbin case: Insert bobbin case 1 until you feel it click into place.
  • Page 29 Preparation Threading the needle thread Switch off the machine! Danger of injury if the machine is started accidentally! Thread the needle thread in accordance with Fig. 09-05. Fig. 09 - 05 Adjusting the needle-thread tension Adjust the needle-thread tension by turning milled screw 1.

  • Page 30: Selecting The Program Number

    Preparation Selecting the program number Switch on the machine. Call up the program number input menu. Select the desired program number. Confirm the selection and quit the selection menu. The sewing method is determined by the program number selected, see Chapter 10 Sewing.

  • Page 31: Inputting Fullness

    Preparation Inputting fullness Switch on the machine. Call up the program number input menu. Select program number "0". Confirm the selection and quit the selection menu. Enter the desired value with the appropriate arrow keys. Fig. 9 - 07 If necessary, allocate the current fullness amount to one of the number keys (0-12) on the keyboard.

  • Page 32: Entering / Altering The Code Number

    Preparation Entering / altering the code number Switch on the machine. Call up the input mode. Select parameter "800". Select the code number input menu. Enter the code number on the number keys (factory code setting is "3800"). 9 - 7...
  • Page 33 Call up the code number input menu and enter the desired code number. Take over the new code number. Conclude input. Do not forget the code! Without the appropriate code, the protected functions cannot be called up! Help is then only possible through PFAFF service staff. 9 - 8...

  • Page 34: Adjusting The Control Panel

    Preparation Adjusting the control panel Switch on the machine. Call up the input mode. Select the service menu. Select control panel functions. Change the display contrast. Switch the key tone off or on. Never reduce the display contrast to the extent, that the display can no longer be read! 9 - 9...

  • Page 35: Sewing

    Sewing Sewing In the sewing mode all relevant settings for the sewing operation are displayed on the screen and can be altered with the corresponding functions. In the sewing mode a difference is made between manual sewing, sewing with fixed programs and programmed sewing.
  • Page 36 Sewing Seam end Opens the menu for entering the functions at the end of the seam, see Chapter 10.01.01 Entering the seam start and seam end functions in the manual sewing mode. Material type These functions are used for selecting the type of material, see Chapter 10.01.02 Selecting the material type.

  • Page 37: Entering The Seam Start And Seam End In Manual Sewing Mode

    Sewing Entering the seam start and seam end in manual sewing mode .01.01 After calling up the appropriate function, the menu for entering the placement stitch function appears. To begin with the condensed stitches function is not activated. If necessary, switch off the condensed stitches function If necessary, switch on the placement stitch function and alter the value for the placement stitch (using the number panel or arrow keys).

  • Page 38: Selecting The Material Type

    Sewing Selecting the material type .01.02 To achieve equal results (fullness amounts) when sewing different materials, in the manual sewing mode and when working with fixed programs, it is possible to choose between 3 different types of material at any time: Light materials Medium materials Heavy materials...

  • Page 39: Sewing With Fixed Programs

    Sewing Sewing with fixed programs Fixed programs are stored under the program numbers 1 1 1 1 1 and 2 2 2 2 2 . The fixed programs are used for the quick and easy production of seams with different amounts of fullness.
  • Page 40 Sewing Material type These functions are used to select the material type, see 10.01.02 Selecting the material type. Needle raised Moves the needle to its highest position Needle position raised When this function is activated, the needle moves to its highest position after sewing stops. Thread trimming - - - - - when the function is activated, enables thread trimming with the pedal function (optional).

  • Page 41: Programmed Sewing

    Sewing Programmed sewing With the program numbers 3 – 49 it is possible to call up previously programmed seams. In programmed sewing all seam sections for pre-gathering a sleeve are set in one seam pro- gram. The information about the seam program, such as program number, number of programmed seam sections, programmed comments is displayed.
  • Page 42 Sewing Current seam This function is used to select and display the current sleeve seam (right/left). Automatic seam change When this function is activated, the machine changes automatically from the right to left sleeve seam. Material type These functions are used to select the material type, see 10.01.02 Selecting the material type.

  • Page 43: Program Interruption

    Sewing Program interruption .03.01 With the "program interruption" function the programmed seam sequence is interrupted (e.g. if the thread breaks). Interrupt program sequence. If necessary, tact forwards or backwards through the sections of the seam program. If necessary, change the values and carry out the other functions as in manual sewing, see Chapter 10.01 Manual sewing.

  • Page 44: Input

    Input Input In the input mode the functions parameter input, information, creating/adjusting a sewing program, teach-in, program administration and service are available. Switch on the machine. Call up the input mode. Explanation of the functions Sewing mode Quit the input mode and call up the sewing mode. Parameter selection Select the hundred and unit figures of the desired parameters, see Chapter 13.09.02 Example of a parameter input.

  • Page 45: Seam Program Input

    Input Seam program input Seam programs can be created by entering parameters in the "Creating/adjusting a seam program" function, or by sewing a sample with the "Teach in" function. Irrespective of which function is being used, first of all it is necessary to select the program number and the basic settings of the seam program, which is to be sewn.
  • Page 46 Input Set the seam type (by pressing the appropriate symbol several times until the appropriate seam type is displayed). Description of the symbols: Sewing program with left and right seam, beginning with the right seam. Sewing program with left seam only. Sewing program with right seam only.

  • Page 47: Seam Program Input With The "Creating/Adjusting A Program" Function

    Input Seam program input with the "Creating/adjusting a program" function .01.02 With this function the seam program is entered by entering or changing the appropriate values on the control panel. This type of seam program input is particularly suitable for adjusting existing seam programs.
  • Page 48 Input If necessary, use the keyboard to switch on the condensed stitches function for the current seam section, see Chapter 7.07 Keyboard. If necessary switch on the reverse sewing function for the current seam section using the keyboard, see Chapter 7.07 Keyboard. If necessary, insert the seam section.

  • Page 49: Entering The Actual And Required Length Of The Seam Section

    Input Entering the actual and required length of the seam section .01.03 After the corresponding function has been called up, the menu for entering the seam length values (in mm) of the current seam section appears. After the input of the values for the actual and required length, the number of stitches and the fullness amount are calculated.

  • Page 50: Seam Program Input With The "Creating/Adjusting A Program" Function

    Input Seam program input with the "Creating/adjusting a program" function .01.04 With this function the seam program is entered by sewing a sample. A new program is always created, i.e. if an existing program is selected, this will be overwritten. Switch on the machine.
  • Page 51 Input After sewing starts, the following displays and functions are shown on the screen. By pressing Enter the seam section end is defined by stitch counting. By operating the pedal in position "-2", the seam section is ended by pedal operation, see Chapter 7.02 Pedal.

  • Page 52: Entering The Functions At The Beginning Of The Seam During Seam Programming

    Input Entering the functions at the beginning of the seam during seam programming .01.05 After the appropriate function has been called up, the menu for entering the value of the placement stitch appears. To begin with the condensed stitches function is not activated. If necessary, switch off the condensed stitches function.

  • Page 53: Entering The Functions At The End Of Seam Section During Seam Programming

    Input Entering the functions at the end of seam section during seam programming .01.06 After the appropriate function has been called up, the menu for entering the functions and values for the end of the seam section without condensed stitches appears. If necessary, switch off the condensed stitches function.
  • Page 54 Input Conclude the input and change to programmed sewing. It is not possible to set every combination of functions. All the activated functions are shown as inverse symbols. 11 - 11...

  • Page 55: Examples Of How To Create A Seam Program

    Input Examples of how to create a seam program Example of a seam program input with the "creating/adjusting a program" .02.01 function The seam program to be created for a jacket front part should have 6 seam sections and be stored under the program number "4" with the comment "PROG". Seam area 1 Number of stitches: 40 Fullness: -25...
  • Page 56 Input Switch on the machine. Call up the input mode. Call up the "creating/adjusting a seam program" function and enter program number "4". Set the seam type (right seam) by pressing until the appropriate symbol appears. Call up the menu for comment input. Enter the comment "PROG"...
  • Page 57 Input Conclude the input of the end of the seam section. Change to the input of the second seam section. Enter the value "0" for the fullness. Call up the menu for entering the functions at the end of the seam section. Switch on the function for changing to the next seam section with the knee switch.
  • Page 58 Input Call up the menu for entering the required/actual length of the seam section. Gather bottom material ply (fullness < 0). Enter the value "103" for the actual length. Enter the value "95" for the required length. Conclude the input of the required/actual length. The number of stitches ("37") and the value for the fullness ("70") are calculated from the values entered.
  • Page 59 Input Change to the input of the fourth seam section. Enter the value "0" for the fullness. Call up the menu for entering the end of the seam section. Switch on the function for changing to the next seam section with the knee switch. Conclude the input of the end of the seam section.
  • Page 60 Input Activate the "end of program" function. Conclude the seam program input and change to programmed sewing 11 - 17...

  • Page 61: Example Of A Seam Program Input Using The "Teach-In" Function

    Input Example of a seam program input using the "teach-in" function .02.02 The seam program to be created for a jacket front part should have 6 seam sections and be stored under the program number "11" with the comment "TEACH". Seam area 1 Learn number of stitches Fullness: -25...
  • Page 62 Input Switch on the machine. Call up the input mode. Call up the "teach-in" function and enter program number "11". Set the seam type (only left seam) by pressing until the appropriate symbol appears. Call up the menu for comment input. Enter the comment "TEACH"...
  • Page 63 Input Change to the input of the second seam section. Enter the value "0" for the fullness. Call up the menu for entering the end of the seam section. Switch on the function for changing to the next seam section by knee switch. Conclude the input of the end of the seam section Use the pedal function to sew the second seam section.
  • Page 64 Input Enter the value "0" for the fullness. Call up the menu for entering the end of the seam section. Switch on the function for changing to the next seam section by knee switch. Conclude the input of the end of the seam section Use the pedal function to sew the fourth seam section.

  • Page 65: Seam Program Administration

    Input Seam program administration In the program administration the seam programs deposited in the machine memory are displayed and can be deleted or copied. Switch on the machine. Call up the input mode. Call up program administration. Explanation of the functions Input mode Calls up the basic display for the input mode.

  • Page 66: Care And Maintenance

    Care and Maintenance Care and Maintenance Clean hook compartment ........daily, several times if in continuous use Clean the entire machine ................once a week Check the oil level ..................once a month Lubricate the articulated joints of the top feed ..........once a week Check/adjust the air pressure ..............

  • Page 67: Oil Level Of The Machine

    10.00 mm²/s at 40ºC and a density of 0.847 g/ cm³ at 15ºC. We recommend PFAFF sewing machine oil, part no. 280-1-120 105. Fig. 12 - 02 Cleaning/lubricating the top feed joints Once a week or after the machine has...

  • Page 68: Checking/Adjusting The Air Pressure

    Care and Maintenance Checking/adjusting the air pressure Before operating the machine, always check the air pressure on gauge1. Gauge 1 must show a pressure of 6 bar. If necessary adjust to this reading. To do so, pull knob 2 upwards and turn it so that the gauge shows a pressure of 6 bar.

  • Page 69: Adjustment

    Screws, nuts indicated in brackets ( ) are fastenings for machine parts, which must be loosened before adjustment and tightened again afterwards. On the PFAFF 3822 no c-clamps may be attached to the needle bar as this would damage the special coating on the needle bar.

  • Page 70: Control And Adjustment Aids

    Adjustment Control and adjustment aids By marking the holes 1 and 3 - 6 with the adjustment pin (ø 5 mm), the desired needle bar positions can be fixed exactly. Fig. 13 - 01 Turn the balance wheel until the needle bar is approximately in the desired position. Insert the adjustment pin into the appropriate hole and apply pressure.

  • Page 71: Adjusting The Basic Machine

    Adjustment Adjusting the basic machine Basic position of the machine .05.01 Switch on the machine. Call up the input mode. Call up parameter "301". By turning the balance wheel, position the needle point flush to the stop edge of the needle plate.

  • Page 72: Preliminary Adjustment Of The Needle Height

    Adjustment Preliminary adjustment of the needle height .05.02 Requirement With the needle bar at b.d.c. the distance between bottom edge of the needle bar and the needle plate must be16.5 mm. 16,5 mm Fig. 13 - 02 Adjust needle bar 1 (screws 2) according to the requirement. 13 - 4...

  • Page 73: Needle In Needle-Hole Centre

    Adjustment Needle in needle-hole centre .05.03 Requirement The needle should enter the needle hole exactly in the centre. Fig. 13 - 03 Position the needle directly over the needle hole. Loosen screws 1, 2 and 3. Adjust the needle bar frame 4 both crosswise and in the direction of sewing according to the requirement and tighten screw 2 slightly and screw 3.

  • Page 74: Neutral Position Of The Bottom Feed Dog

    Adjustment Neutral position of the bottom feed dog .05.04 Requirement With the stitch length set at "0" there should be no feeding motion of the bottom feed dog when the balance wheel is turned. 45° 54-044 Fig. 13 - 04 Loosen screw 1 (nut 2).

  • Page 75: Feeding Motion Of The Bottom Feed Dog

    Adjustment Feeding motion of the bottom feed dog .05.05 Requirement With the maximum stitch length set and the needle bar positioned 0.6 mm past t.d.c. (adjustment hole 1), the bottom feed dog should not move when the reverse feed key is operated.

  • Page 76: Lifting Motion Of The Bottom Feed Dog

    Adjustment Lifting motion of the bottom feed dog .05.06 Requirement 1. With the needle bar set 0.6 past t.d.c. (adjustment hole 1) and the stitch length set at "0", the bottom feed dog should be at the top of its stroke. 2.

  • Page 77: Height Of The Bottom Feed Dog

    Adjustment Height of the bottom feed dog .05.07 Requirement When the needle bar is at 0.6 past t.d.c. (adjustment hole 1) and the stitch length is set at "0", 1. The bottom feed dog should be in the centre of the needle plate cutout, as seen from the side and in the direction of feed.

  • Page 78: Clearance Between Presser Foot And Needle Plate

    Adjustment Clearance between presser foot and needle plate .05.08 Requirement When hand lever 1 is raised there should be a clearance of 5 mm between the presser foot and the needle plate. Fig. 13 - 08 With the hand lever lower the presser foot onto the needle plate. Loosen the adjustment screw for the presser foot presser (reduce pressure) Push out bolt 1 (screw 2) and remove connection element 3 from the yoke of lever 4.

  • Page 79: Stop In Relation To The Presser Foot

    Adjustment Stop in relation to the presser foot .05.09 Requirement When adjustment foot 1 (part no. 61-111 639-20) is resting on the needle plate, stop 4 should be touching screw 2 2 2 2 2 49-028a Fig. 13 - 09 Remove presser foot.

  • Page 80: Top Feed Driving And Connecting Lever

    Adjustment Top feed driving and connecting lever .05.10 Requirement 1. All moving parts of the top feed should move freely without play. 2. The top feed must not touch the presser foot. Fig. 13 - 10 Lower the presser foot with the hand lever. Swing connection element 1 into the yoke of lever 2, insert bolt 3 and tighten screw 4 (make sure that the parts move freely, if necessary adjust lever 2).

  • Page 81: Neutral Position Of The Top Feed Dog

    Adjustment Neutral position of the top feed dog .05.11 Requirement When the stitch length is set at "0" and with the adjustment gauge 4 fitted, there should be no feeding motion of the top feed dog. 54-033 Fig. 13 - 11 The stitch length limitation (screw 1 in Chapter 13.05.04 Neutral position of the bottom feed dog) must be deactivated.

  • Page 82: Feeding Motion Of The Top Feed Dog

    Adjustment Feeding motion of the top feed dog .05.12 Requirement When the needle bar is positioned 0.6 mm past t.d.c (adjustment hole 1) and the maximum stitch length is set, lever 3 should not move when the feed reverse key is operated.

  • Page 83: Front Linkage Rod To Top Feed Drive

    Adjustment Front linkage rod to top feed drive .05.13 Requirement With the needle bar positioned 0.6 past t.d.c. (adjustment hole 1), there must be a distance of approx. 16.5 mm between the eye of the linkage rod 2 and machine case 3. 16,5 mm Fig.

  • Page 84: Top Feed Stroke

    Adjustment Top feed stroke .05.14 Requirement With the stitch length set at "3" and the adjustment gauge 12 fitted, at its t.d.c. the top feed dog 2 should be 2 mm from the needle plate. 54-033 49-029 Fig. 13 - 14 Lower the presser foot 1 onto the needle plate.

  • Page 85: Lifting Motion Of The Top Feed Dog

    Adjustment Lifting motion of the top feed dog .05.15 Requirement When the stitch length is set at "4" and with adjustment gauge 3 fitted, the top feed dog should rest on the ascending bottom feed dog, when this reaches the top edge of the needle plate.

  • Page 86: Stitch Length Adjustment

    Adjustment Stitch length adjustment .05.16 Requirement When set at "3" the stitch length must be the same size when sewing forwards or in reverse. Fig. 13 - 16 Loosen screw 2. Adjust bush 1 according to the requirement. Take care that the eccentricity of bush 1 is in the lower range.

  • Page 87: Stitch Length Limitation

    Adjustment Stitch length limitation .05.17 Requirement 1. The bottom stroke of rocking bar 6 should be set so that the maximum stitch length is 2.7 mm..2. The top stroke of rocking bar 6 should be set so that the stitch length is 2.7 mm when the feed reverse key is pressed down as far as possible.

  • Page 88: Basic Setting Of The Differential Adjustment Device

    Adjustment Basic setting of the differential adjustment device .05.18 Requirement With the fullness set at "0", the stitch length at "2.7" and the adjustment gauge 5 fitted, the roller 2 should be touching pressure sleeve 4. 54-034 Fig. 13 - 18 Switch on the machine.

  • Page 89: Eccentric Hook Shaft Bearing And Hook-To-Needle Clearance

    Adjustment Eccentric hook shaft bearing and hook-to-needle clearance .05.19 Requirement 1. The slot in bearing 3 (see arrow) must be visible from below and there should be a slight but still noticeable amount of backlash between gears 5 and 7. 2.

  • Page 90: Needle Bar Rise, Readjustment Of The Needle Height And Bobbin Case Position Stop

    Adjustment Needle bar rise, readjustment of the needle height and bobbin case position stop .05.20 Requirement With the stitch length set at "0" and the needle bar positioned 1.8 mm past b.d.c. (adjustment hole 4) 1. The point of the hook should be in centre of the needle and the top edge of the needle eye should be 0.8 mm below the hook point.

  • Page 91: Bobbin Opener Height

    Adjustment Bobbin opener height .05.21 Requirement When bobbin opener 3 is at its left point of reversal, the top edge of its finger should be 0.5 mm above the bottom edge of the bobbin case cam. Fig. 13 - 21 Loosen screw 2.

  • Page 92: Adjustment Of The Bobbin Opener

    Adjustment Adjustment of the bobbin opener .05.22 Requirement 1. The distance between the finger of the bobbin opener 3 and the edge of the bobbin case base 5 must be 0.8 mm. 2. When the bobbin opener 3 is at its left point of reversal, the bobbin case base 5 should be deflected by approx.

  • Page 93: Bobbin Case Opener

    Adjustment Bobbin case opener .05.23 Requirement When the needle bar is positioned 1.8 mm past b.d.c., the bobbin opener 3 should be at its right point of reversal. Fig. 13 - 23 Loosen screws 2. Adjust bobbin opener eccentric 1 according to the requirement. Tighten screws 2.

  • Page 94: Needle Thread Tension Release

    Adjustment Needle thread tension release .05.24 Requirement When the hand lever 1 is raised, the tension discs should be at least 0.5 mm apart. 0,5 mm Fig. 13 - 24 Adjust tension release clip 2 (screw 3) according to the requirement. Lower the presser foot onto the needle plate.

  • Page 95: Thread Check Spring

    Adjustment Thread check spring .05.25 Requirement The movement of the thread check spring 3 must be finished when the needle point enters the material (spring path approx. 7 mm). Fig. 13 - 25 Adjust thread tension 1 (screws 2) according to the requirement..The path of thread check spring 3 is dependent on the material and thread and must be corrected in accordance with the sewing results.

  • Page 96: Bobbin Winder

    Adjustment Bobbin winder .05.26 Requirement 1. When the bobbin winder is engaged, the winding spindle must be driven reliably. When it is disengaged, friction wheel 3 must not rest on drive wheel 1. 2. The bobbin winder should switch itself off, when the thread is approx. 1 mm from the edge of the bobbin.

  • Page 97: Position Of The Top Feed Dog In Relation To The Sewing Foot

    Adjustment Position of the top feed dog in relation to the sewing foot .05.27 Requirement When the take-up lever is at its t.d.c., the teeth of the top feed dog should not be below the presser foot shoe, when the presser foot is raised. Fig.

  • Page 98: Top Feed Dog And Sewing Foot Pressure

    Adjustment Top feed dog and sewing foot pressure .05.28 Requirement Even at top speed, the material must be fed perfectly. No pressure marks should appear on the material. ca. 12 mm Fig. 13 - 28 Adjust screws 1 and 2 according to the requirement. 13 - 30...

  • Page 99: Stitch Condensation

    Adjustment Stitch condensation .05.29 Requirement When cylinder 3 is actuated, the machine must sew with a shorter stitch length than that indicated on the stitch length adjuster. Fig. 13 - 29 Activate the stitch condensation and sew a test seam. If necessary adjust retaining bracket 1 (screws 2) accordingly.

  • Page 100: Adjusting The Thread Trimmer

    Adjustment Adjusting the thread trimmer Pre-adjusting the control cam .06.01 Requirements At the t.d.c of the needle bar, 1. the beginning of the highest point of the trip of the control cam 6 sould be positioned under the tip of pawl 8 and 2.

  • Page 101: Roller Lever

    Adjustment Roller lever .06.02 Requirements When the needle bar is positioned 1.8 mm after the b.d.c, 1. the roller of the roller lever 4 should engage easily with the control cam 7 and 2. the roller of roller lever 4 should be centred in the cam notch of the control cam 7 Fig.

  • Page 102: Pawl

    Adjustment Pawl .06.03 Requirement With the thread trimmer in resting position, the distance between pawl 2 and the highest point of the control cam should be 0.3 mm. 0,3 mm Fig. 13 - 32 Position the bearing surface of control cam 1 with its highest point below pawl 2 2 2 2 2 by turning the hand wheel.

  • Page 103: Engaging Solenoid

    Adjustment Engaging solenoid .06.04 Requirement When the needle bar is positioned 1.8 mm after the b.d.c and the engaging solenoid is actuated, the distance between the engaging lever 1 and the pawl 2 should be between 0.2 and 0.3 mm. Fig.

  • Page 104: Release Lever

    Adjustment Release lever .06.05 Requirement When the needle bar is positioned 1.8 mm after the b.d.c and the engaging lever 1 1 1 1 1 is actuated, the distance between the roller of the roller lever 2 2 2 2 2 and the bottom of the control cam 3 must be approx.

  • Page 105: Engaging Lever

    Adjustment Engaging lever .06.06 Requirement When the needle bar is at the t.d.c and the thread trimmer is in resting position, the distance between the roller of the roller lever 3 and the outer diameter of the control cam 4 should be between 0.3 and 0.5 mm. 0,3 - 0,5 mm Fig.

  • Page 106: Lateral Adjusting Of The Thread Catcher

    Adjustment Lateral adjusting of the thread catcher .06.07 Requirement 1. The tip of the thread catcher 6 should point exactly to the middle of the needle. 2. The thread catcher 6 should not touch anywhere when in motion. Fig. 13 - 36 Unscrew needle plate and feed dog.

  • Page 107: Front Reversal Point Of The Thread Catcher

    Adjustment Front reversal point of the thread catcher .06.08 Requirement In the front reversal point of the thread catcher 3 the rear edge of thread catcher cutout should be 1 mm in front of the bobbin case position finger 4. Fig.

  • Page 108: Re-Adjusting The Control Cam

    Adjustment Re-adjusting the control cam .06.09 Requirement When the end of the hook plate 1 is positioned 2 mm behind the middle of the lug of the bobbin case position finger, the distance between the tip of the thread catcher 6 and the middle of the lug should also be 2 mm.

  • Page 109: Retaining Spring

    Adjustment Retaining spring .06.10 Requirement When the thread trimmer is in resting position, the distance between the retaining spring 1 and the roller lever 3 3 3 3 3 should be 0.5 mm. 0,5 mm Fig. 13 - 39 Position retaining spring 1 together with the cover disk. Tighten screws 2 sligthly.

  • Page 110: Knife To Needle Clearance

    Adjustment Knife to needle clearance .06.11 Requirement The distance between the front edge of the knife 1 and the needle should be 4 mm. 4 mm Fig. 13 - 40 On needle-feed machines set the stitch length to "O". Position the needle bar at b.d.c Push knife 1 under the safety plate and align in accordance with the requirement.

  • Page 111: Manual Trimming Control

    Adjustment Manual trimming control .06.12 Requirement Both threads have to be cut perfectly in the catcher cutout on both right and left-hand side. Fig.13 - 41 Position the needle bar at b.d.c and activate the engaging lever manually. Turn the hand wheel until thread catcher 1 is its front reversal point. Double a thread and insert it into the cutout of thread catcher 1.

  • Page 112: Tension Release Of Needle Thread

    Adjustment Tension release of needle thread .06.13 Requirements 1. When the thread trimming unit is in resting position, trip 5 should be engaged and at a distance of 0.5 mm from the release cone 1. 2. When trip 5 is positioned at the highest point of the release cone 1, the tension disks should be spaced at a mimimum of 0.5 mm from each other.

  • Page 113: Attaching And Removing The Thread Trimming Unit

    Adjustment Attaching and removing the thread trimming unit .06.14 Fig. 13 - 43 To remove the thread trimming unit, disconnect the plug from the control box. Loosen screw 1 and remove linkage 2 from its slot. Remove connecting rod 3. Unscrew screws 4 and remove the complete thread trimming unit.

  • Page 114: Adjusting The Edge Trimming Device On The Pfaff 3822-2/42

    Adjustment Adjusting the edge trimming device on the PFAFF 3822-2/42 Knife stroke .07.01 Requirement When the needle bar is at its t.d.c. (adjustment hole 5), the knife must be at the top of its stroke. Fig. 13 - 44 Switch on the machine.

  • Page 115: Neutral Position Of The Knife Stroke

    Adjustment Neutral position of the knife stroke .07.02 Requirement When the edge trimming device is switched off, the top knife should not move when the balance wheel is turned. Fig. 13 - 45 Turn crank 1 (screw 2) according to the requirement. 13 - 47...

  • Page 116: Knife Height

    Adjustment Knife height .07.03 Requirement When the knife 1 is in its lowest position, the front edge of the knife blade should be approx. 0.5 mm below the top edge of the needle plate. 49-054 Fig. 13 - 46 Adjust knife 1 (screws 2) according to the requirement. 13 - 48...

  • Page 117: Aligning The Knife

    Adjustment Aligning the knife .07.04 Requirement 1. The needle must be in the centre of the knife-edge. 2. The knife should be resting on the stationary knife with light pressure, without the knife spur striking the stationary knife. 3. The knife should stand slightly slanted to the stationary knife (shear effect). 49-053 49-45a Fig.

  • Page 118: Adjusting The Stop Eccentric

    Adjustment Adjusting the stop eccentric .07.05 Requirement When stop 4 is touching eccentric 2, there should be a distance of approx. 5 mm between the front edge of the case and lever 5. 49-063 Fig. 13 - 48 Pull down lifting rod 1 as far as possible. Adjust eccentric 2 (screw 3) according to the requirement.

  • Page 119: Adjusting The Feathered Trimming Device On The Pfaff 3822-2/44

    Adjustment Adjusting the feathered trimming device on the PFAFF 3822-2/44 Top stroke motion of the knife .08.01 Requirement The downward motion of the knife must begin, when the descending needle eye is level with the needle plate. Fig. 13 - 49 Switch on the machine.

  • Page 120: Cutting Angle Of The Front Knife

    Adjustment Cutting angle of the front knife .08.02 Requirement The knife 5 should 1. Touch the stationary knife without pressure and 2. Be at a 0.1 mm slant to the stationary knife. 0,1 mm Fig. 13 - 50 Adjust knife mounting 1 (screws 2) according to requirement 1. Adjust angle bracket 3 (screw 4) according to requirement 2.

  • Page 121: Cutting Position Of The Front Knife

    Adjustment Cutting position of the front knife .08.03 Requirement The rear edge of knife 3 must be positioned 0.8 mm in front of the needle plate cutout. 0,8 mm Fig. 13 - 51 Adjust knife mounting 1 (screw 2) according to the requirement. 13 - 53...

  • Page 122: Cutting Pressure Of The Front Knife

    Adjustment Cutting pressure of the front knife .08.04 Requirement 1. Only as much cutting pressure as absolutely necessary should be applied. 2. After the cutting pressure has been set, the slant of the knife must not be less than 0.05 mm. 0,05 mm Fig.

  • Page 123: Knife Stroke Zero Point

    Adjustment Knife stroke zero point .08.05 Requirement When the feathered trimming device is switched off, the top knives should not move when the balance wheel is turned. Fig. 13 - 53 Adjust crank 1 (screw 2) according to the requirement. 13 - 55...

  • Page 124: Side Position Of The Back Knife In Relation To The Hook Knife

    Adjustment Side position of the back knife in relation to the hook knife .08.06 Requirement The back edge of the back knife 1 should be even with hook knife 3. 49-056 Fig. 13 - 54 Adjust knife 1 (screws 2) according to the requirement. 13 - 56...

  • Page 125: Cutting Angle Of The Back Knife In Relation To The Hook Knife

    Adjustment Cutting angle of the back knife in relation to the hook knife .08.07 Requirement The hook knife 1 should be at a 0.05 – 0.1 mm slant to the back knife 2. 0,05 - 0,1 mm Fig. 13 - 55 Switch the machine on and let it move into position.

  • Page 126: Cutting Pressure Between The Back Knife And The Hook Knife

    Adjustment Cutting pressure between the back knife and the hook knife .08.08 Requirement 1. Only as much cutting pressure as absolutely necessary should be applied. 2. After the cutting pressure has been set, the slant of the back knife must not be less than 0.05 mm.

  • Page 127: Cutting Depth Of The Back Knife

    Adjustment Cutting depth of the back knife .08.09 Requirement In its lowest position the back knife should move approx. 0.5 mm into the hook knife. 49-052 Fig. 13 - 57 Switch the machine on and let it move into position. Switch on the edge trimming and feathered trimming device (keyboard).

  • Page 128: Cutting Depth Of The Front Knife

    Adjustment Cutting depth of the front knife .08.10 Requirement When the back knife 3 begins cutting, the front knife 1 should already have completed 2/3 of its cut. 49-055 Fig. 13 - 58 Switch on the machine. Switch on the edge trimming device (keyboard). Bring the hook knife into cutting position (knee switch).

  • Page 129: Trimming Margin

    Adjustment Trimming margin .08.11 Requirement The trimming margin should be 3.5 mm. 49-73 Fig. 13 - 59 Adjust knife 1 (screws 2) according to the requirement. Sew a test seam and check the trimming margin, if necessary repeat the adjustment. Pay attention to the cutting pressure of the hook knife! 13 - 61...

  • Page 130: Sensor Control Of The Hook Knife

    Adjustment Sensor control of the hook knife .08.12 Requirement When sewing with the feathered edge trimming device, the sewing and trimming operation must not begin until the hook knife is in cutting position. Fig. 13 - 60 Switch the machine on and let it move into position. Hold the sensor gauge (0.1 mm) between stop plate 1 and pin 2.

  • Page 131: Air-Blast Tube For Separating The Material Plies

    Adjustment Air-blast tube for separating the material plies .08.13 Requirement The material plies should be blown far enough apart to enable the hook knife to move between both material plies without difficulty. Fig. 13 - 61 Align air-blast tube 1 according to the requirement. Adjust air pressure (throttle valve 2) according to the requirement.

  • Page 132: Air-Blast Tube For Cutting Waste

    Adjustment Air-blast tube for cutting waste .08.14 Requirement The cutting waste should be guided into the waste channel as well as possible. Fig. 13 - 62 Align air-blast tube 1 according to the requirement. Adjust air pressure (throttle valve 2) according to the requirement. 13 - 64...

  • Page 133: Parameter Settings

    Adjustment Parameter settings Overview of the parameter functions .09.01 After the machine has been switched on, by pressing the appropriate function the input mode is called up, in which the individual parameters can be called up directly. With a code it is possible to protect all or individual parameter groups against unauthorised access.

  • Page 134: Example Of A Parameter Input

    Adjustment Example of a parameter input .07.02 Switch on the machine. Call up the input mode. e.g. call up parameter "113" (switch beep tone for section change on/off) e.g. switch beep tone on (value "ON"). Conclude the input. 13 - 66...

  • Page 135: List Of Parameters

    OFF - ON Max. speed forwards at each OFF - ON pedal position Machine configuration 3 - 7 6 = 3822-2/42 7 = 3822-2/44 Fullness adjustment value (keyboard) 0 - 9 Switch off edge knife (with pedal position "-2") OFF - ON...
  • Page 136 Adjustment Group Parameter Description Setting range value D-quota position controller 1 – 100 Time for position controller 0 – 100 P-quota position controller for rest brake 1 – 50 D-quota position controller for rest brake 1 – 50 Maximum moment for rest brake 0 –...

  • Page 137: Sewing Motor Errors

    Adjustment Sewing motor errors Error message Description Brake path too short Communication error with limit control Switch on sequence not ready Extint low with Init Short circuit Extint low in operation No increments Motor stalling No incremental plug Disturbed motor running Regulator blocked Invalid transmission Invalid zero point...

  • Page 138: Explanation Of The Error Messages

    Adjustment Explanation of the error messages Message Description E001 System error E002 Sewing motor E002/BB/xxx BB = 20: Time-out 02: Position forwards 03: Position in reverse 05: Position by shortest path 09: Write parameter 10: Speed 0A: Reset stitch counter 0B: Stop after xxx stitches 30: Time-out for increasing speed 31: Time-out for uncertain positioning...

  • Page 139: Table Of Inputs

    Adjustment Table of inputs Knee switch hook knife on Hook knife at front not assigned Start inhibitor not assigned Knee switch not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned Light barrier tape feed (on machines with tape feed) Reference for fullness adjustment Table of outputs Raise sewing foot (O1.1 and O1.2)

  • Page 140: Service Menu

    Adjustment Service menu In the service menu information is displayed about the machine’s inputs and outputs, as well as the values for the pedal and the balance wheel position. In addition the following functions can also be carried out. Switch on the machine. Call up the input mode.

  • Page 141: Carry Out A Cold Start

    Adjustment Carry out a cold start Switch on the machine. Call up the input mode. Call up the service menu. Carry out a cold start. After a cold start all programmed values are set back to their status at the time of delivery.

  • Page 142: Internet Update Of The Machine Software

    Adjustment Internet update of the machine software The machine software can be updated with PFAFF flash programming. For this purpose the PFP boot program and the appropriate control software for the machine type must be installed on a PC. To transfer the data to the machine, the PC and the machine control unit must be connected with an appropriate null modem cable ( part no.

  • Page 143: Wearing Parts

    As an alternative to the internet download the parts lists can also be ordered in book form under part no. 296-12-18 592. 11-108 174-25 PFAFF 3822-2/44 91-150 648-01 91-100 296-25 PFAFF 3822-2/42 (2x) 91-158 660-03/001 11-330 085-15 91-100 296-25 (2x)
  • Page 144 91-165 505-05 11-108 084-15 (2x) 91-108 222-15 99-137 151-45 91-171 049-05 91-171 042-05 95-774 464-25 91-700 996-15 PFAFF 3822-2/44 PFAFF 3822-2/42 11-108 132-15 (2x) 11-225 091-15 (2x) 11-108 084-15 (2x) 11-108 132-15 (2x) 91-189 140-05 91-188 294-05 91-188 303-05 91-169 395-04/002...
  • Page 145 95-196 283-95 Pneumatics-switch diagram Version 27.07.05 15 - 1...

  • Page 146: Circuit Diagrams

    Circuit diagrams Circuit diagrams Reference list for circuit diagrams Controller Quick P 320MS Y6 -917/.. Stitch condensing unit Control panel T1 Y7 -731/.. Edge trimming device Keyboard Y8 Extraction Sewing head identification (OTE) Y9 Feathered trimming (only on the 3822-2/44) Hook knife at front Y10 Separate plies Initiator SM1, reference...
  • Page 147 91-191 494-95 Circuit diagrams Page 1 Version 01.09.05 15 - 3...
  • Page 148 Circuit diagrams 91-191 494-95 Version 01.09.05 Page 2 15 - 4...
  • Page 149 91-191 494-95 Circuit diagrams Page 3 Version 01.09.05 15 - 5...
  • Page 150 Circuit diagrams 91-191 494-95 Version 01.09.05 Page 4 15 - 6...
  • Page 151 Notes...
  • Page 152 PFAFF Industrie Maschinen AG Postfach 3020 D-67653 Kaiserslautern Königstr. 154 D-67655 Kaiserslautern Telefon: (0631) 200-0 Telefax: (0631) 17202 E-Mail: info@pfaff-industrial.com...

This manual is also suitable for:

3822-2/44

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