Pfaff 2438 plusline Instruction Manual
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Pfaff 2438 plusline Instruction Manual

Pfaff 2438 plusline Instruction Manual

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Industrial
2438
INSTRUCTION MANUAL
This instruction manual applies to machines from the
following serial numbers 2 657 257 and software
version 0307/001 onwards:
296-12-18 708/002
Betriebsanleitung engl. 06.09

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  • Page 1 ® Industrial 2438 INSTRUCTION MANUAL This instruction manual applies to machines from the following serial numbers 2 657 257 and software version 0307/001 onwards: 296-12-18 708/002 Betriebsanleitung engl. 06.09...
  • Page 2 This Instruction Manual is valid for all models and subclasses listed in the chapter "Specifications ". The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or in part, is only permitted with our previous authorization and with written reference to the source.

  • Page 3: Table Of Contents

    Contents Contents ................. Chapter – Page Safety ..........................1 - 1 Regulations ........................1 - 1 General notes on safety ....................1 - 1 Safety symbols ......................1 - 2 Important notes for the user ..................1 - 2 Notes for operating and technical staff ................1 - 3 .05.01 Operating staff .......................

  • Page 4: Contents

    Contents Contents ................. Chapter – Page Removing/inserting the bobbin case ................9 - 3 Threading the bobbin case / Adjusting the bobbin thread tension ........9 - 3 Threading the needle thread / Adjusting the needle thread tension ......... 9 - 4 Setting the zigzag stitch and the stitch position .............
  • Page 5 Contents Contents ................. Chapter – Page .05.16 Hook bearing bracket ....................13 - 18 .05.17 Hook lubrication ......................13 - 19 .05.18 Pre-adjusting the needle height ..................13 - 20 .05.19 Needle rise, hook-to-needle clearance and bobbin case positioning-finger ....13 - 21 .05.20 Final adjustment of the needle height ................13 - 22 .05.21 Bobbin case opener position ..................13 - 23...

  • Page 6: 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 7: 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 8: Notes For Operating And Technical Staff

    Safety Notes for operating and technical staff Operating staff .05.01 Operating staff are the persons responsible for setting up, operating and cleaning the machine and for eliminating any malfunctioning in the sewing area. The operating staff is obliged to observe the following points: The notes on safety in this instruction manual must always be observed! Any working methods, which adversely affect the safety of the machine, must be avoided.!

  • Page 9: Danger Warnings

    Safety Danger warnings A working area of 1 m must be kept free both in front of and behind the machine, so that easy access is possible at all times. Never put your hands in the needle area during sewing! Danger of injury by the needle! Fig.

  • Page 10: Proper Use

    Proper use Proper use The PFAFF 2438 is a high-speed zigzag machine with bottom feed and automatic material edge detector. The machine is used for sewing labels on linings in industry. Any use of these machines which is not approved by the manufacturer shall be...

  • Page 11: Specifications

    Specifications Specifications Stitch type: ....................301 (lockstitch) Max. sewing speed: ..................4500 spm Max. stitch length ....................2.5 mm Needle system: ......................438 KK Needle size in 1/100 mm: ....................80 Effective balance wheel diameter: ................65 mm Presser foot clearance: ..................7 - 9 mm Clearance width: ....................

  • Page 12: 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 materials. The electrical equipment comprises plastic materials and copper. The machine is to be disposed of according to the locally valid pollution control regulations;...

  • Page 13: 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 14: 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 15: Controls

    Controls Controls Main switch The machine is switched on or off by turning the main switch 1. Fig. 7 - 01 Keys on the machine head By operating the respective key, the following functions are carried out: Key 1: Reverse sewing Key 2: Raise needle, without thread trimming...

  • Page 16: Pedal

    Controls Pedal Neutral position Sewing Raise presser foot Trim thread/reset bobbin thread control or remaining bobbin thread count function Fig. 7 - 03 Lever for raising presser foot The presser foot is raised by turning lever 1. Fig. 7 - 04 7 - 2...

  • Page 17: Adjustment Lever For Zigzag Stitch And Needle Position

    Controls Adjustment lever for zigzag stitch and needle position The zigzag stitch adjustment lever 1 is used for adjusting the width of the zigzag stitch. To change the position of the adjustment lever, the locking lever 2 must be pressed against the adjustment lever 1.

  • Page 18: Control Panel

    The control panels switches on all LCD-segments and the horn automatically for a short time during the power-on phase, after which the lettering PFAFF appears on the display, until the higher ranking control unit sends commands to the control panel.
  • Page 19 Controls Start backtacks If this key is pressed, the backtacks at the beginning of the seam (start backtacks) are switched on or off. The number of forward stitches (A) or reverse stitches (B) for the start backtacks can be changed by pressing the +/- key underneath. To convert from double backtack to single backtack set the number of stitches for the corresponding seam section at zero.
  • Page 20 Controls Programmed stop If this key is pressed the corresponding function is switched on or off. When the function is switched on, the machine stops automatically at the end of a seam section. Sensor If this key is pressed the corresponding function is switched on or off. When the function is switched on, the move to the next seam section is carried out by sensor.

  • Page 21: 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, it must be ensured that the frame and the table top which you intend to use can hold the weight of the machine and the motor, even while sewing.

  • Page 22: Fitting The Machine Cover

    Mounting and commissioning the machine Fitting the machine cover .01.02 Slide the slots of the left and right belt guard sections behind the heads of screws 1 and 2. Screw screw 3 with distance sleeve 4 into tapped hole 5. Making sure that the bracket 6 is behind slot 7 and in front of distance sleeve 4, adjust the belt guard.

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

    Mounting and commissioning the machine Connecting the plug-in connections and earth cables .01.04 Fig. 8 - 04 Connect plugs 1-6 as labelled in the control box. Screw the earth cable from the sewing head to earth point A. Screw the earth cable 7 from the motor to earth point B. Connect earth point C and earth point A with an earth cable.

  • Page 24: Commissioning

    Mounting and commissioning the machine Commissioning Examine the machine, in particular the electric cables and pneumatic connection tubes for any damage. Clean the machine thoroughly and then oil it. Have qualified personnel check whether the machine can be operated with the available voltage and whether it is connected properly in the terminal box.

  • Page 25: Mounting/Checking The Start Inhibitor

    Mounting and commissioning the machine Mounting/checking the start inhibitor 81-093 Fig. 8 - 07 81-092 Mounting the start inhibitor For machines delivered without a table, the plate 1 from the accessories should be mounted under the table top, so that the switch lug 2 is resting on plate 1 when the sewing head is in an upright position.

  • Page 26: Setting Up

    Setting up Setting up All instructions and regulations in this instruction manual must be observed. Special attention must be given to all safety regulations! All setting-up work must only be done by personnel with the necessary training. For all setting-up work the machine must be isolated from its power supply by turning off the on/off switch or removing the machine plug from the electric power socket! Inserting the needle...

  • Page 27: Winding The Bobbin Thread / Adjusting The Primary Thread Tension

    Setting up Winding the bobbin thread / adjusting the primary thread tension Fig. 9 - 02 ● Place empty bobbin 1 onto bobbin winder spindle 2 with the remaining thread chamber towards the outside. ● Insert the thread as shown in the above illustration and wind it around the bobbin 1 a few times in a clockwise direction.

  • Page 28: Removing/Inserting The Bobbin Case

    Setting up Removing/inserting the bobbin case Turn the machine off! 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: Threading The Needle Thread / Adjusting The Needle Thread Tension

    Setting up Threading the needle thread / Adjusting the needle thread tension Fig. 9 - 06 Switch off the machine! Danger of injury if the machine is started accidentally! Thread the needle thread as show in the above illustration. Adjust the needle thread tension by turning milled screw 1. 9 - 4...

  • Page 30: Setting The Zigzag Stitch And The Stitch Position

    Setting up Setting the zigzag stitch and the stitch position Set the zigzag stitch width by turning the zigzag lever 1. To vary the adjustment press catch 2 against zigzag lever 1. The setting can be read from scale 3. Set the stitch position by turning stitch position lever 4.

  • Page 31: Entering The Start And End Backtacks

    Setting up Entering the start and end backtacks Switch on the machine. Switch on the corresponding function by pressing the start backtack and/or end backtack keys. (Arrow appears under the corresponding function key.) Change to the input menu for start and end backtacks by pressing the scroll key. By pressing the corresponding +/- key select the desired value for the number of forward stitches (A) of the start backtack.

  • Page 32: Entering The Maximum Speed

    Setting up Entering the maximum speed Switch on the machine. Press the TE/Speed key to call up the input menu for the maximum speed. The status texts "Speed" and "TE" appear on the display. SPEED SPEED 4500 SPEED Set the maximum speed by pressing the corresponding +/- key. Setting the remaining stitches for the bobbin thread control When the bobbin thread monitor signals that the bobbin thread has been used up, there is still a little thread on the bobbin.

  • Page 33: Sewing

    Sewing Sewing In the sewing mode all relevant settings for the sewing operation are displayed. Functions can be switched on or off by pressing a key. Values for the most important parameters can be changed directly. In this mode a difference is made between manual sewing and programmed sewing. To change from manual to programmed sewing, press the PM key.

  • Page 34: Programmed Sewing

    Sewing Programmed sewing In programmed sewing various seam programs can be called up by selecting the corresponding program number. A number of seam sections with corresponding functions can be allocated to each seam program. The number of possible seam programs and seam sections is set with the parameters "492"...

  • Page 35: Error Messages

    Sewing Error messages If a fault occurs, the text "ERROR" appears on the display, together with an error code and short instructions. An error message is caused by incorrect settings, faulty elements or seam programs as well as by overload conditions. For an explanation of the error codes see Chapter 13.13 Explanation of the error messages.

  • Page 36: Input

    Input Input In this chapter the input of seam programs is described. Seam program input Switch on the machine. Press the PM key to call up programmed sewing. The text "PM" must appear on the display. After selecting programmed sewing, seam programs can be entered. The input is carried out by switching functions on or off or by entering values for the seam section of a seam pro- gram.
  • Page 37 Input Overview of the input steps Step /0.0 /0.0 /0.0 /0.0 /0.0 Entering programmed sewing Switch on the machine. Press the PM key. The text "PM" must appear on the display. Selecting the program number Select program number "7" with the corresponding +/- key. 11 - 2...
  • Page 38 Input Selecting the stitch length Set the value for the stitch length at "1.6" with the corresponding +/- key. Press the scroll key to enter the seam depth. Set the value for the seam depth at "0" with the corresponding +/- key. Press the scroll key to select the first seam section.
  • Page 39 Input Selecting seam section 1 Select seam section "1" with the corresponding +/- key. Selecting the functions for seam section 1 - The machine should stop at the end of the seam section. - The end of the seam section should be recognised by sensor. - The presser foot should rise after thread trimming.
  • Page 40 Input Press the programmed stop key, to stop the machine automatically at the end of the seam section. Press the sensor key for recognition of the end of the seam section by sensor. Press foot position after trimming to raise the presser foot after thread trimming. Selecting seam section 3 Select seam section "3"...
  • Page 41 Input Selecting seam section 4 Select seam section "4" with the corresponding +/- key. Selecting the functions for seam section 4 - The machine should stop at the end of the seam section. - The end of the seam section should be recognised by sensor. - The presser foot should rise after thread trimming.
  • Page 42 Input Selecting the functions for seam section 5 - The machine should stop at the end of the seam section. - The thread should be trimmed at the end of the seam section. - The presser foot should rise after thread trimming. - The end of the seam section should be recognised by stitch counting (5 stitches).
  • Page 43 Input Finishing the seam program Select seam section "6" with the corresponding +/- key. Set the stitch length value at "0.0" with the corresponding +/- key. By setting the stitch length in seam section 6 at zero, seam section 5 is recognised as the last seam section in the seam program and the seam program input is finished.

  • Page 44: Program Recording Forms

    Input Program recording forms Step Step 11 - 9...
  • Page 45 Input Step Step 11 - 10...

  • Page 46: Care And Maintenance

    Care and maintenance Care and maintenance Cleaning ............daily, several times by continuous operation Checking the oil level (hook oil tank) ............. once a year Checking the oil tank(zigzag eccentric lubrication) ......daily, before operation Checking/adjusting the air pressure ........daily, before each operation Cleaning the air filter/lubricator ..........

  • Page 47: Lubricating The Hook

    (see arrow in Fig. 12-03). Return the machine to its upright position with both hands. Danger of crushing between machine head and table top! We recommend PFAFF sewing machine oil. Part no. 280-1-120 105. 12 - 2...

  • Page 48: Oiling The Zigzag Drive

    Fill in oil up to the top marking 2. Clean the surface of cover 5, the case and the seal. Replace cover 5 and tighten screws 4. We recommend PFAFF sewing machine oil, part no. 280-1-120 144. 12 - 3...

  • Page 49: Cleaning The Air Filter Of The Air-Filter / Lubricator

    Care and maintenance Cleaning the air filter of the air-filter / lubricator Switch the machine off! Disconnect the air hose at the air-filter / lubricator. To drain water bowl 1: Water bowl 1 drains itself automatically when the compressed-air hose is disconnected from the air-filter / lubricator.

  • Page 50: Adjustment

    Adjustment Adjustment On the PFAFF 2438 no clamp may be fastened to the needle bar, as this would damage the special coating of the needle bar. Notes on adjustment All following adjustments are based on a fully assembled machine and may only be carried out by expert staff trained for this purpose.

  • Page 51: Check And Adjustment Aid

    Adjustment Check and adjustment aid By blocking with holes 1 - 5 the required needle bar positions can be fixed exactly. Fig. 13 - 01 Turn the balance wheel until the needle bar has approximately reached the required position. Place the 5 mm blocking pin in the appropriate hole and put pressure on it. Turn the balance wheel forwards and backwards a little until the blocking pin moves into the slot in the crank behind the bearing plate, thus blocking the machine.

  • Page 52: Adjusting The Basic Machine

    Adjustment Adjusting the basic machine Balancing weight .05.01 Requirement With the needle bar at bdc the largest eccentricity of the balancing weight 1 must be pointing upwards. Fig. 13 - 02 Bring the needle bar to b.d.c. Adjust the balance weight 1 (screw 2) in accordance with the requirement. 13 - 3...

  • Page 53: Centering The Needle In The Needle Hole (In Sewing Direction)

    Adjustment Centering the needle in the needle hole (in sewing direction) .05.02 Requirement With the zigzag setting at "0" and the needle position set at "middle" the needle must enter the center of the needle hole as viewed in the direction of sewing. 81-026 Fig.

  • Page 54: Parallel Guiding Of The Needle Bar

    Adjustment Parallel guiding of the needle bar .05.03 Requirement Guide bar 5 must be parallel to the needle bar. Fig. 13 - 04 Bring the needle bar to tdc (hole 2). Loosen screws 1,2 and nut 3. The largest eccentricity of pin 4 must be facing downwards. Bring the groove on guide bar 5 into a position in which it rests against eccentric pin 4, turn eccentric pin 4 in accordance with the requirement and tighten nut 3.

  • Page 55: Locking Lever

    Adjustment Locking lever .05.04 Requirement The zigzag stitch adjustment lever 3 must be able to be locked in any position. Fig. 13 - 05 Loosen screw 2. Press locking lever 1 against the zigzag stitch adjustment lever 3. Turn pivot pin 4 as far as possible to the left. Release locking lever 1.

  • Page 56: Zero Stitch And Zigzag Stitch Scale

    Adjustment Zero stitch and zigzag stitch scale .05.05 Requirement With the zigzag stitch set at "0": 1. the needle bar must not move laterally when the balancewheel is turned and 2. the marking "0" on scale 1 must be at marking 2. Fig.

  • Page 57: Centering The Needle In The Needle Hole (Crosswise To Sewing Direction)

    Adjustment Centering the needle in the needle hole (crosswise to sewing direction) .05.06 Requirement With the zigzag stitch set at "0" and the needle position setting at "middle" the needle must enter the center of the needle hole as seen across the direction of sewing. 81-023 Fig.

  • Page 58: Zigzag Stitch Width

    Adjustment Zigzag stitch width .05.07 Requirement At the largest zigzag stitch setting, marking 1 must be at the largest zigzag value on scale 2. Fig. 13 - 08 Turn the zigzag stitch adjustment lever 3 in accordance with the requirement. Move screw 4 upwards until it touches and then tighten it.

  • Page 59: Zigzag Stitch Motion

    Adjustment Zigzag stitch motion .05.08 Requirement When the needle bar is at tdc coming from the right bdc (hole 2), the needle bar must not move laterally when the zigzag stitch adjustment lever is moved back and forth. 5 mm Fig.

  • Page 60: Needle Penetration Symmetry

    Adjustment Needle penetration symmetry .05.09 Requirement 1. With the zigzag stitch setting at "0" the needle must enter the middle of the needle hole. 2. At the largest setting of the zigzag stitch the right and left needle-penetrations must be the same distance from the middle penetration.

  • Page 61: Needle Position Adjustment Lever

    Adjustment Needle position adjustment lever .05.10 Requirement The left and right throws of the needle must be the same size at the largest zigzag stitch setting and at the left or right needle position. Fig. 13 - 11 Loosen screws 1 and 2. Set the needle position adjustment lever 3 to "middle"...

  • Page 62: Zero Position Of The Bottom Feed Dog (With Closed Gear Box)

    Adjustment Zero position of the bottom feed dog (with closed gear box) .05.11 Requirement 1. When the stitch length is set at "0", the shaft crank 3 should not carry out a feeding motion when the balance wheel is turned. 2.

  • Page 63: Zeroing The Bottom Feed (With Open Gearbox)

    Adjustment Zeroing the bottom feed (with open gearbox) .05.12 Requirement With the stitch length set at "0" the bottom feed dog must not carry out any feeding motion when the balance wheel is turned. Fig. 13 - 13 Switch on the machine. Set parameter "834"...

  • Page 64: Feeding Motion Of The Bottom Feed Dog

    Adjustment Feeding motion of the bottom feed dog .05.13 Requirement With the maximum stitch length set and the needle bar position 1.0 past tdc (hole 4), the bottom feed dog must not move when the reverse feed lever is pressed. Fig.

  • Page 65: Lifting Motion Of The Bottom Feed Dog

    Adjustment Lifting motion of the bottom feed dog .05.14 Requirement With the stitch length set at "0" and the needle bar position at 0.25 mm past tdc (hole 3) the bottom feed dog must be at its upper point of reversal. Fig.

  • Page 66: Drive Belt In The Gearbox Housing

    Adjustment Drive belt in the gearbox housing .05.15 Requirement Drive belt 4 must be tightened so that the machine runs freely and the belt sprockets do not have any noticeable play. Fig. 13 - 16 Adjust eccentric bearing bush 1 (screw 2) in accordance with the requirement and so that drive belt 4 is in the centre of bobbin opener drive wheel 3.

  • Page 67: Hook Bearing Bracket

    Adjustment Hook bearing bracket .05.16 Requirement The hook shaft must be touching the hook bearing bracket adjustment gauge 1 at the top and the side. 438 - 439 Fig. 13 - 17 Loosen screw 3. Swing the bobbin case opener to the right and remove the hook. Loosen screw 2 and loosen the draw key underneath it by lightly tapping the head of the screw.

  • Page 68: Hook Lubrication

    Adjustment Hook lubrication .05.17 Requirement When the machine is running at full speed, after about 10 seconds a fine oil streak should be visible on a strip of paper held over the needle plate cutout. Fig. 13 - 18 Adjust screw 1 in accordance with the requirement. 13 - 19...

  • Page 69: Pre-Adjusting The Needle Height

    Adjustment Pre-adjusting the needle height .05.18 Requirement With the needle bar at tdc (hole 2) the distance between the point of the needle and the needle plate must be 19 mm. 19 mm Fig. 13 - 19 Without turning it, adjust the needle bar (screws 1) in accordance with the requirement. 13 - 20...

  • Page 70: Needle Rise, Hook-To-Needle Clearance And Bobbin Case Positioning-Finger

    Adjustment Needle rise, hook-to-needle clearance and bobbin case positioning-finger .05.19 Requirement 1. With the needle position set at "middle", the zigzag stitch setting at "0" and the needle bar position 2.0 past bdc (hole 1) the hook point must be in the middle of the needle and the distance between the needle and the hook point must be 0.05 - 0.1 mm.

  • Page 71: Final Adjustment Of The Needle Height

    Adjustment Final adjustment of the needle height .05.20 Requirement With the zigzag stitch set at "0", the needle position set at "left" and the hook point in the middle of the needle, the top edge of the needle eye must be 0.5 mm underneath the hook point.

  • Page 72: Bobbin Case Opener Position

    Adjustment Bobbin case opener position .05.21 Requirement 1. There must be a clearance of 0.5 mm between the top edge of the bobbin case opener and the inner edge of the bottom section of the bobbin case. 2. Between the bobbin case opener finger and the bottom section of the bobbin case opener there must be a clearance of 0.8 mm.

  • Page 73: Bobbin Case Opener Motion

    Adjustment Bobbin case opener motion .05.22 Requirement With the needle bar 2.0 past bdc (hole 1) the bobbin case opener 3 must be at its right point of reversal. Fig. 13 - 23 Adjust bobbin opener eccentric 1 (screws 2) in accordance with the requirement. 13 - 24...

  • Page 74: Bottom Feed Dog Height

    Adjustment Bottom feed dog height .05.23 Requirement With the stitch length set at "0" and the needle bar position at 0.25 past tdc (hole 3) the bottom feed dog must be in the middle of the needle plate cutout and be touching the feed dog height-adjustment gauge along its entire length.

  • Page 75: Presser Foot To Needle Plate Clearance

    Adjustment Presser foot to needle plate clearance .05.24 Requirement When the hand lever is raised, the needle should penetrate exactly in the "needle hole centre" of the presser foot and the presser foot to needle plate clearance should be 7 mm. 81-038 Fig.

  • Page 76: Presser Foot Pressure

    Adjustment Presser foot pressure .05.25 Requirement Even at top sewing speed the material should be fed without problems. There should be no pressure marks on the material. Fig. 13 - 26 Turn screw 1 in accordance with the requirement. The presser foot pressure (screw 1) can be increased (+) or reduced (-) as required.

  • Page 77: Thread Diverter Pin

    Adjustment Thread diverter pin .05.26 Requirement With the needle bar at bdc the top edge of the thread guide hole must be at the same height as the bottom edge of the thread diverter. Fig. 13 - 27 Adjust thread guide bar 1 (screw 2) according to the requirement, taking care that it is parallel to the bed-plate.

  • Page 78: Limiting The Knee Lever Stroke

    Adjustment Limiting the knee lever stroke .05.27 Requirement When the knee lever is pressed the hand lever must drop automatically and the presser foot must be just over 7 mm above the needle plate. 81-038 Fig. 13 - 28 Place the feed dog gauge under the presser foot with its recess facing downwards. Lower the presser foot onto the gauge.

  • Page 79: Knee Lever Play

    Adjustment Knee lever play .05.28 Requirement When lightly pressing the knee lever there should be a noticeable play between nut 1 and fork 3. Fig. 13 - 29 Adjust nut 1 (nut 2) in accordance with the requirement and lock it with nut 2. The knee lever is not a part of the delivery.

  • Page 80: Setting The Zero Point Of The Feed Regulator

    Adjustment Setting the zero point of the feed regulator .05.29 Requirement When the feed regulator is set at "0", at maximum speed (4500 spm) the needle should always penetrate at the same point. Unthread the machine. Switch the machine on. Place the workpiece under the presser foot.

  • Page 81: Stitch Length Adjustment Forwards And In Reverse

    Adjustment Stitch length adjustment forwards and in reverse .05.30 Requirement At a maximum speed of 400 spm, the stitch length selected on the control panel should not differ from the actual stitch length when sewing forwards or in reverse. Thread the machine. Switch the machine on.
  • Page 82 Adjustment Select the calculated value for parameter 846. Switch off the machine. The adjustment of the reverse stitch length is carried out as described in the above work steps with the reverse feed key pressed. More information about selecting and changing parameters and explanations (functions) of the individual parameters is contained in Chapter 13.12 Parameter settings.
  • Page 83 Adjustment Bobbin winder .05.31 Requirement 1. When the bobbin winder is switched on, the bobbin winder spindle should be driven reliably, whereby the friction wheel 5 should not touch drive wheel 1 when the bobbin winder is switched off. 2. The bobbin winder should switch off automatically, when the thread is approx. 1 mm from the edge of the bobbin winder.

  • Page 84: Adjusting The Thread Trimmer

    Adjustment Adjusting the thread trimmer Axial position of the control cam .06.01 Requirement 1. Roller 5 should be at a distance of 0.3 mm from the control cam 1. 2. Adjustment ring 3 should be touching the control cam 1. 0,3 mm 81-048 Fig.

  • Page 85: Preliminary Adjustment Of The Control Cam

    Adjustment Preliminary adjustment of the control cam .06.02 Requirement 1. In the needle rise position (hole 1) the roller lever 4 should lock into the corresponding groove of the control cam. 2. The control cam 1 should be touching adjustment ring 3. 81-049 Fig.

  • Page 86: Position Of The Thread Catcher And Cutting Test

    Adjustment Position of the thread catcher and cutting test .06.03 Requirement When the thread trimmer is in its neutral position, the edge of thread catcher 6 should be flush with the edge of the mounting plate 4. 81-100 4-50 Fig. 13 - 33 Turn linkage rod 1 (nuts 2, left and right thread) in accordance with the requirement.

  • Page 87: Readjustment Of The Control Cam

    Adjustment Readjustment of the control cam .06.04 Requirement 1. When the end of the hook guard 3 is level with of the right edge of the bobbin case position finger 4, the thread catcher 5 should begin moving forwards. 2. The control cam 1 should be touching adjustment ring 6. 14-50 81-098 Fig.

  • Page 88: Needle Thread Tension Release

    Adjustment Needle thread tension release .06.05 Requirement 1. When solenoids 3 are activated, the tensions disks 4 should be at least 0.5 mm apart. 2. When the thread trimmer is in its neutral position and the sewing foot is positioned on the needle plate, the tension should be fully effective.

  • Page 89: Adjusting The Thread Wiper -909/04

    Adjustment Adjusting the thread wiper –909/04 Thread wiper motion .07.01 Requirement 1. The thread wiper 3 should not touch anything during its motion. 2. With the take-up lever at t.d.c., when the engaging solenoid 4 is activated, the thread wiper 3 should have approx. 1 mm clearance under the needle point. Fig.

  • Page 90: Position Of The Thread Wiper

    Adjustment Position of the thread wiper .07.02 Requirement Seen in the direction of sewing 1. The tip of the thread wiper 5 should be approx. 1 – 1.5 mm to the right of the needle. 2. At its front point of reversal, thread wiper 5 should be approx. 2 mm in front of the needle.

  • Page 91: Adjusting The Zigzag Sensor

    Adjustment Adjusting the zigzag sensor Requirement At the right point of penetration of the needle (needle position 1), solenoid 3 should be positioned exactly on switch surface 4, when the main drive of the machine is at position "15". Fig. 13 - 38 Switch on the machine.

  • Page 92: Aligning The Light Transmitter

    Adjustment Aligning the light transmitter Requirement When the work is positioned, the transmitters PS2 and PS1 should display the same value (same receiving power). SERVICE Fig. 13 - 39 Switch on the machine. Select the "PS" function from the service menu, see Chapter 13.14 Service functions. Adjust light transmitter 1 (screw 2) in accordance with the requirement.

  • Page 93: Adjustment Of The Transmitted Light Sensors

    Adjustment Adjustment of the transmitted light sensors Requirement The difference between a material ply and a material ply with label should be recognised. Switch on the machine. Press the F3 key to select the menu for adjusting the transmitted light sensors. To start the adjustment for the material ply, press "+"...

  • Page 94: Function Control Of The Bobbin Thread Monitor

    Adjustment Function control of the bobbin thread monitor Requirement When the thread is pulled, the value under "Rx" must change from "1" to "0" (perfect transmission of the incoming signal of the bobbin thread monitor). SERVICE Fig. 13 - 40 Place the bobbin in the bobbin case and the bobbin case in the hook.

  • Page 95: Parameter Settings

    Adjustment Parameter settings Example of a parameter input .12.01 Switch on the machine. Press the TE/Speed key twice to enter the parameter input function. The status text "TE" appears on the display and the pedal functions are blocked, to avoid the machine starting accidentally.

  • Page 96: List Of Parameters

    Adjustment List of parameters .11.03 Bobbin thread monitor-current level 8 - 16 Bobbin thread monitor-stitch counter (starting 0 - 255 value) Control panel contrast [%] 80 - 110 Control panel key response signal 0 - 3 0=tone off 2=tone on Start backtacks forwards 0 - 9 Start backtacks in reverse...
  • Page 97 Adjustment Speed for light barrier 300 - 1500 1500 compensating stitches [min-1] Seam interruption with Pedal -2 ON - OFF Speed level 12 (Poti-reserve) [min-1] 300 - 4800 4800 Speed limitation for seam programs [min-1] 300 - 4800 4800 Speed constant for seam programs [min-1] 300 - 4800 3000 Number of reduced stitches...
  • Page 98 Adjustment Speed level 1 (min.) [min-1] 30 - 550 Speed level 12 (max.) [min-1] 300 - 4800 4800 Cutting speed [min-1] 60 - 500 Reversing angle ON - OFF Start inhibitor: ON - OFF Presser foot – time from switch-on to tension 10 - 50 reduction (tacting) Automatic lowering of presser foot...
  • Page 99 Adjustment Start delay after lowering presser foot [ms] 0 - 2550 Lift delay for presser foot after seam end [ms] 0 - 2550 Stitch count delay for end backtack 0 - 2550 Delay time for cutting after single end backtack 0 - 2550 [ms] Delay time from switch on feed conversion...
  • Page 100 Adjustment Reduced single stitch [%] 0 - 100 Distance sensor 1 to sensor 2 [1/10mm] 75 - 85 Distance sensor 1 to needle [2/10mm] 80 - 300 Speed-controlled stitch length adjustment 0 - 3 [% pro 1000 min-1] ▲ Feed regulator characteristic line adjustment 70 - 100 for forward stitch length [%] ▲...
  • Page 101 Adjustment Current for current reduction of stepping 15 - 48 motor axis 2 Current reduction time stepping motor axis 2 0 - 2500 2000 Delay power off stepping motor 2 0 - 99 Delay power off stepping motor 1 0 - 99 Position for thread clamp on 0 - 127 Position for thread clamp off...

  • Page 102: Explanation Of The Error Messages

    Adjustment Explanation of the error messages Message Description E001 Pedal not in neutral position E003 SM 1 (for reference) E004 SM 2 (for reference) E009 Start inhibitor at standstill E010 Incorrect machine class E040 Transmitted light sensors E045 Bobbin thread monitoring E062 Short circuit 24V E063...
  • Page 103 Adjustment Message Description E158 Stepping motor frequency E170 Incorrect main drive transmission E171 Logical zero mark invalid E172 Communication error main drive E175 Main drive start E200 Brake path too short E201 Main drive position E222 Time-out monitoring 13 - 54...

  • Page 104: Service Functions

    Adjustment Service functions The service functions help with finding errors and commissioning. After selecting the input mode with the TE/Speed key, with the corresponding authorisation (access level B or C), the menu for selecting service functions can be called up by pressing the F1 key. After the service functions have been called up, the status text "Service"...
  • Page 105 Adjustment Explanation Move stepping motor SM2 (feed regulator) By selecting the type "POS" and entering the desired value with the corresponding +/- keys, the feed regulator positions in the position entered. By selecting the type "REF" and confirming the selection with the corresponding +/- keys, the feed regulator is moved to the reference position.
  • Page 106 Adjustment Plug assignment Pin-No. Comment Function Plug marking Signal marking X11A.2 CAN- CAN_HIGH CAN_TxD X11A.3 X11A.7 CAN+ CAN_LOW CAN_RxD Set value transmitters Pin-No. Comment Function Plug marking Signal marking X11B.4 pedal X11B.5 pedal X11B.6 pedal X11B.7 pedal 2 set value SW2 (analog) X11B.8 pedal 1...
  • Page 107 Adjustment Pin-No. Comment Function Plug marking Signal marking X1B.1 X1B.2 SSI-Out ( TxD) SSOut X1B.3 SSI-Clock SSClk X1B.4 +24V X1B.5 X1B.6 SSI-strobe (Mode) SSStr X1B.7 SSI-In (RxD) SSIn X1B.8 (light barrier 1) (LS1) X1B.9 Incremental transmitter Pin-No. Comment Function Plug marking Signal marking X3.1 incr.transm.
  • Page 108 Adjustment Outputs Pin-No. Comment Function Plug marking Signal marking X13.01 FSL-solenoid(Y8) O1.1 X13.02 FSL-solenoid(Y8+) O1.2 X13.03 PFH-solenoid(Y4) O2.1 X13.04 PFH-solenoid(Y4+) O2.2 X13.05 WI-solenoid(Y3) X13.06 SN-solenoid(Y2) X13.07 X13.08 RAFI-LED(H1) X13.09 X13.10 X13.11 X13.12 (from DX) current source DLS A10/PortA10 X13.13 X13.14 +24V +24V X13.15...

  • Page 109: 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 110: Wearing Parts

    Wearing parts Wearing parts This is a list of the most important wearing parts. You can order a detailed spare parts list for the complete machine under part no. 296-12-18 708. 91-100 296-25 (3x) 11-108 174-15 (2x) 91-701 179-15 11-108 174-25 System 134 95-774 441-91 95-774 375-05...
  • Page 111 Wearing parts 99-137 151-45 91-171 049-05 91-171 042-05 14 - 2...

  • Page 112: Circuit Diagrams

    Circuit diagrams Circuit diagrams Reference list for circuit diagrams Controller Quick P322MS Control panel BDF S2 Incremental transmitter (included in M1) Keyboard Zigzag sensor Light transmitter Light receiver Bobbin thread monitor Set value transmitter Single stitch (included in A4) VR by hand (backtack) (included in A4) Needle position (included in A4) Knee switch (single stitch) Start inhibitor...
  • Page 113 Circuit diagram - View Version 23.01.03 15 - 2...
  • Page 114 91-191 445-95 Circuit diagram Part 1 Version 29.01.02 15 - 3...
  • Page 115 Circuit diagram 91-191 445-95 Version 29.01.02 Part 2 15 - 4...
  • Page 116 91-191 445-95 Circuit diagram Part 3 Version 29.01.02 15 - 5...
  • Page 117 Circuit diagram 91-191 445-95 Version 29.01.02 Part 4 15 - 6...
  • Page 118 PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Telefon: +49 - 6301 3205 - 0 Telefax: +49 - 6301 3205 - 1386 E-mail: info@pfaff-industrial.com Gedruckt in der BRD / Printed in Germany / Imprimé en la R.F.A. / Impreso en la R.F.A...

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