Page 1 3519 -4/01 INSTRUCTION MANUAL This instruction manual applies to machines from serial number 2 763 205 and software version 0361/013 onwards. 296-12-18 635/002 Betriebsanleitung engl. 03.11...
Page 2 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. PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern...
Page 3: Table Of Contents
Contents Contents ..................Chapter - Page Safety ........................... 7 Directives ..........................7 General notes on safety ......................7 Safety symbols ........................8 Important points for the user ....................8 Operating and specialist personnel ..................9 .05.01 Operating personnel ......................9 .05.02 Specialist personnel .......................
Page 4: Contents
Contents Contents ..................Chapter - Page Preparation ......................... 27 Inserting the needle ......................27 Threading the needle thread / Adjusting the needle thread tension ........28 Winding the bobbin thread / regulating the bobbin winder tension ........29 Changing the bobbin / adjusting the bobbin thread tension ..........30 Changing the dart insert ......................
Page 5 Contents Contents ..................Chapter - Page Tools, gauges and other accessories .................. 66 Abbreviations ........................66 Servicing position of the sewing head ................. 67 Adjusting the sewing head ....................69 .05.01 Adjustment aids ........................69 .05.02 Basic position of the machine drive ................... 70 .05.03 Needle in needle hole centre ....................
Page 6 Contents Contents ..................Chapter - Page Adjusting the workholder bar ..................... 103 .17 .01 Zero point of the workholder bar ..................103 .17 .02 Workholder bar stop ......................104 Adjusting the pneumatic table pressure ................105 Adjusting the pressure control device ................106 Adjusting the stacker ......................
Page 7: Safety
Safety Safety Directives This machine is constructed in accordance with the European regulations contained in the conformity and manufacturer’s declarations. In addition to this Instruction Manual, also observe all generally accepted, statutory and other regulations and legal requirements and all valid environmental protection regulations! The regionally valid regulations of the social insurance society for occupational accidents or other supervisory organizations are to be strictly adhered to! General notes on safety...
Page 8: Safety Symbols
It is the obligation of the user to ensure that none of the safety mechanisms are removed or deactivated. ● It is the obligation of the user to ensure that only authorized persons operate and work on the machine. Further information can be obtained from your PFAFF agent.
Page 9: Operating And Specialist Personnel
Safety Operating and specialist personnel Operating personnel .05.01 Operating personnel are persons responsible for the equipping, operating and cleaning of the machine as well as for taking care of problems arising in the sewing area. The operating personnel is required to observe the following points and must: ●...
Page 10: Danger
Safety Danger A working area of 1 meter is to be kept free both in front of and behind the ma- chine while it is in operation so that it is always easily accessible. During sewing do not place hands in the working area of the machine! Danger of injury from the sewing head needles and loading equipment! Never leave objects on the table while adjusting the machine settings! Objects can become trapped or be slung away! Danger of injury!
Page 11: Proper Use
Proper use Proper use The PFAFF 3519-4/01 is an automatic sewing unit for sewing single- or double-pointed jacket breast darts. Any and all uses of this machine which have not been approved of by the manufacturer are considered to be inappropriate! The manufacturer cannot be...
Page 12: Specifi Cations
Speciﬁ cations ▲ Speciﬁ cations Stitch type: ......................301 (lockstitch) Needle system: ........................134 Needle size in 1/100 mm: ..................... 80 - 100 Stitch length: ......................0,5 - 3,0 mm Max. sewing speed:....................4300 spm Stitch length start tacks: ......Standard stitch length or half standard stitch length Number of stitches for start tacks: ..................
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 materials. The electrical equipment comprises plastic materials and copper. ●...
Page 14: Transportation, Packing And Storage
Transportation, packing and storage Transportation, packing and storage Transportation to customer‘s premises The 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)
Page 16: Controls
Controls Controls On/off switch ● Switch the machine on or off by turning main switch 1. Fig. 7 - 01 Machine control unit button ● After the power supply has been swit- ched on with the main switch, see Chap- ter 7.01.
Page 17: Switch For The Extractor Fan (Optional)
Controls Switch for the extractor fan (optional) The extractor fan integrated in the machine is only required, if there is no vacuum network at the machine’s location. ● Press key 1 to switch on the extractor fan. ● Press key 2 to switch off the extractor fan.
Page 18: Control Panel
Controls Control panel The current operating conditions are dis- played on control panel 1. Operation takes place in a constant dialogue between the control unit and the operator. For this pur- pose, depending on the operating conditi- on of the machine, different symbols and/or texts are displayed.
Page 19: Start Keys
Controls Start keys Fig. 7 - 07 ● By pressing both start keys 1 at the same time, the sewing cycle is started. After the sewing cycle has been completed, the illuminated start keys 1 indica- te that the next sewing cycle can be started. ●...
Page 20: Installation And Commissioning
Installation and commissioning Installation and commissioning This machine may only be installed and commissioned by qualiﬁ ed specialists! All relevant safety regulations are to be adhered to! Installation Suitable connections for the supply of electricity and compressed air must be available at the machine site, see Chapter 3 Speciﬁ...
Page 21: Detaching The Transit Lock On The Loading Table
Installation and commissioning Detaching the transit lock on the loading table .01.02 ● Remove screw ● Loosen screw 2 and remove bracket 3. ● Re-tighten screw Fig. 8 - 02 Detaching the transit lock on the sewing head .01.03 ● Remove screws 1 und 2.
Page 22: Detaching The Transit Lock On The Loading Clamp
Installation and commissioning Detaching the transit lock on the loading clamp .01.04 Fig. 8 - 04 ● Open cover ● Remove screws ● Close 1 cover 1.
Page 23: Fitting The Reel Stand
Installation and commissioning Fitting the reel stand .01.04 ● Fit the reel stand as shown in Fig. 8 - 04. ● Afterwards ﬁ t the stand into the hole on the machine stand and fasten it with the enclosed nuts. Fig.
Page 24: Commissioning
Installation and commissioning Commissioning ● Before commissioning the machine, clean it thoroughly and lubricate it, or ﬁ ll in oil, see Chapter 12 Care and Maintenance! ● Check the machine, in particular the electric cables and the pneumatic connection tubes, for any damage.
Page 25: Switching The Machine On / Off
Installation and commissioning Switching the machine on / off Switching on the machine ● Switch on the main switch, see Chapter 7.01 Main switch. ● Switch on the machine control unit, see Chapter 7.02 Machine control unit button. ● After booting the machine control unit, move the machine to its basic position to conﬁ rm the switch-on operation.
Page 26: Adjusting The Control Panel
Installation and commissioning 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! ●...
Page 27: 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 Only use needles from the sys-...
Page 28: Threading The Needle Thread / Adjusting The Needle Thread Tension
Preparation Threading the needle thread / Adjusting the needle thread tension Fig. 9 - 02 ● Switch on the machine. ● Call up the threading aid. The feed bar moves out of the needle area, the sewing foot is lowered and the sewing start function is locked.
Page 29: Winding The Bobbin Thread / Regulating The Bobbin Winder Tension
Preparation Winding the bobbin thread / regulating the bobbin winder tension Fig. 9 - 03 ● Fit empty bobbin 1 onto bobbin winder spindle 2 with the rest thread chamber on the outside. ● Thread the thread as shown in Fig. 9.03 and wind it around the bobbin 1 a few times in an anti-clockwise direction.
Page 30: Changing The Bobbin / Adjusting The Bobbin Thread Tension
Preparation Changing the bobbin / adjusting the bobbin thread tension Fig. 9 - 04 ● Switch on the machine. ● Call up the threading aid. The feed bar moves out of the needle area, the sewing foot is lowered and the sewing start function is locked.
Page 31: Changing The Dart Insert
Preparation Changing the dart insert Fig. 9 - 05 ● Screw the enclosed pin 1 into the threaded hole in insert 2. ● Pull out insert ● Fit new insert to match the dart depth.. Insert blind insert 3 for double pointed darts.
Page 32: Adjusting The Loading Unit For Ironing Compensation Strips
Preparation Adjusting the loading unit for ironing compensation strips Fig. 9 - 06 ● Loosen screw ● Adjust the loading unit for ironing compensation strips to match the dart length.
Page 33: Selecting A Program Number
Preparation Selecting a program number ● Switch on the machine. ● Call up the menu for entering the program number. ● Select the desired program number. The program numbers are allocated as follows: Program numbers 0 - 199: single-pointed darts Program numbers 200 - 299: double-pointed darts Program numbers 300 - 399:...
Page 34: Selecting / Confi Guring Program Groups
Preparation Selecting / conﬁ guring program groups Selecting a program group .08.01 Instead of selecting a program number, it is also possible to select the corresponding group of seam programs, providing the individual seam program has been allocated to a group, see Chapter 9.08.02 Conﬁ...
Page 35: Confi Guring A Program Group
Preparation Conﬁ guring a program group .08.02 Up to 10 seam programs can be allocated to a program group. The seam programs of a se- lected program group appear as a function on the display during sewing, and can be selec- ted directly.
Page 36: Sewing
Sewing Sewing The machine may only be operated by appropriately instructed personnel! The operating staff must make sure that only authorized persons are in the danger area of the machine! In particular for the production, in addition to the input mode, see Chapter 11 Input, the sew- ing mode is available.
Page 37: Inserting The Workpiece
Sewing Inserting the workpiece Inserting the workpiece with the positioning tube .01.01 Workpieces with a striped or checked pattern can be aligned with the aid of a la- ser beam. Do not look into laser beam either with or without optical equipment! Danger of injury to the retina from the directed light! Single pointed darts 0 - 320 mm...
Page 38 Sewing Double pointed darts Insertion marking 0 - 320 mm Insertion marking 0 - 320 mm Fig. 10 - 02...
Page 39: Insert The Workpiece Using The Loading Table
Sewing Insert the workpiece using the loading table .01.02 Double pointed darts Insertion marking 0 - 320 mm Insertion marking 0 - 320 mm Fig. 10 - 03...
Page 40: Sewing In Automatic Operation
Sewing Sewing in automatic operation When the machine is switched on, the automatic operation function of the sewing mode is always selected automatically. ● Switch on the machine. ● Switch on the suction air of the positioning tube or the loading table, see Chapter 7.06 Pedal.
Page 41: Manual Sewing Mode
Sewing Threading aid This function activates the threading aid, see e.g. Chapter 9.01 Inserting the needle. Stacker up/down This function is used to raise or lower the stacker. Stop (This function only appears during the sewing cycle.) This function is used to stop the sewing cycle. Start (This function only appears if the sewing cycle was stopped.) This function is used to start the sewing cycle.
Page 42 Sewing Program selection Each of these functions is used to select a program from the respective program group, also see Chapter 9.08 Selecting / conﬁ guring program groups. Material thickness This function opens a menu for changing the material thickness. Manual operation This function shows the current operating mode and changes between manual and auto- matic operation.
Page 43: Error Messages
Sewing Error messages If a malfunction occurs, an error code appears on the display. An error message may be caused by incorrect operation, machine defects, as well as by overload conditions. (For a description of the error codes see Chapter 14.02 Description of the error codes). Errors when connecting outputs If an error occurs when connecting an output, the output concerned is shown with the desi- red switching state (0) or (I).
Page 44: Input
Input Input In addition to the functions for entering or altering seam programs, in the input mode there are functions for displaying information, for program management, for machine conﬁ guration and settings (country settings and access codes etc.), as well as for supporting service and adjustment work.
Page 45 Input Info This function opens a menu for displaying the following information: - current software status of the machine - current ﬁ rmware status of the machine - current ﬁ rmware status of the control panel - day piece counter - stitch counter for bobbin thread monitoring - operating hours meter - production hours meter...
Page 46: Creating / Altering Seam Programs
Input Creating / altering seam programs When creating or altering seam programs, a basic distinction is made between 3 different seam types: ● Single-pointed darts L3 = L4; Program numbers 0 – 199 ● Double-pointed darts L3 < 4.5 mm; not to be cut; Program numbers 200 - 299 ●...
Page 47 Input Description of the functions Input mode This function is used to changed to the initial state of the input mode. Conclude input This function is used to conclude the input, and the machines changes to the sewing mode. Single-pointed darts This function is used to call up the input function for single-pointed darts, see Chapter 11.02.01 Creating / altering single-pointed darts.
Page 48: Creating / Altering Single-Pointed Darts
Input Creating / altering single-pointed darts .02.01 ● Switch on the machine. ● Call up the input mode. ● Call up the seam program input function. ● Call up the input function for single-pointed darts. ● Select the program number, see Chapter 9.07 Selecting a program number.
Page 49: Creating / Altering Double-Pointed Darts
Input Creating / altering double-pointed darts .02.02 ● Switch on the machine. ● Call up the input mode. ● Call up the seam program input function. ● Call up the input function for double-pointed darts. ● Select the program number, see Chapter 9.07 Selecting a program number.
Page 50: Creating / Altering Tapered Darts
Input Creating / altering tapered darts .02.03 ● Switch on the machine. ● Call up the input mode. ● Call up the seam program input function. ● Call up the input function for tapered darts. ● Select the program number, see Chapter 9.07 Selecting a program number ●...
Page 51: Entering A Comment
Input Entering a comment .02.04 In the seam programming function, it is possible to add a comment to the seam program, af- ter calling up the appropriate function. The comment is displayed as information about the corresponding seam program with the program selection function and the program manage- ment function.
Page 52: Entering Correction Values
Input Entering correction values .02.05 In the seam programming function, it is possible to enter correction values for the current seam program, after calling up the appropriate function. In the case of single-pointed and ta- pered darts it is also possible to ﬁ x the value for the uncut material fold length. ●...
Page 53: Concluding Seam Programming
Input Concluding seam programming .02.06 After all inputs for the programming have been made, the seam programming can be conclu- ded by pressing the corresponding function. Description of the functions The input is interrupted and the operator returns to the initial status of the programming function.
Page 54: Program Management
Input Program management The program management function is used to manage seam programs as well as conﬁ gura- tion and machine data. Files can be selected from the machine memory or from a SD-Card and be copied or deleted. ● Switch on the machine.
Page 55 Input Description of the functions Input mode This function is used to changed to the initial state of the input mode. Update disk drives This function is used to update (upload )the drives. Conclude input This function is used to conclude the input, and the machines changes to the sewing mode. Data selection With these functions the desired ﬁ...
Page 56: Rights Of Access
Input Rights of access The functions, which can be called up with the control panel, are classiﬁ ed by code numbers and can be protected from unauthorised access. For this purpose, the control unit differenti- ates between 3 user groups (user 1, 2 and 3), all of which can be assigned a corresponding PIN.
Page 57 Input Allocation of the code numbers Standard setting Code Function Symbol number User 1 User 2 User 3 Program number selection Correct program Input Create program Program management Parameter settings Parameter group 100 General settings Parameter group 200 Seam parameters Parameter group 300 Sewing motor positions Parameter group 400...
Page 58 Input Standard setting Code Function Symbol number User 1 User 2 User 3 Service Carry out a cold start Machine conﬁ guration Load software Set contrast control panel Thread trimming cycle Needle position...
Page 59: Care And Maintenance
Care and maintenance Care and maintenance Maintenance intervals Clean the entire machine ..................once a week Clean the needle area ................several times daily Clean the hook area ................several times daily Clean the fan air ﬁ lter ..................as required Clean the air ﬁ...
Page 60: Cleaning The Needle Area And Hook Compartment
Care and maintenance Cleaning the needle area and hook compartment Fig. 12 - 01 ● Switch on the machine. ● Call up the threading aid. The feed bar moves out of the needle area, the sewing foot is lowered and the sewing start function is locked.
Page 61: Cleaning The Fan Air Fi Lter
Care and maintenance Cleaning the fan air ﬁ lter ● Remove cover ● Remove the ﬁ lter unit and blast clean with compressed air. ● Insert the clean ﬁ lter unit and replace cover 1. Fig. 12 - 02 Cleaning the air ﬁ lter of the air-ﬁ lter/lubricator Switch off the machine! Push down the sliding seal on the maintenance unit, see...
Page 62: 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 63: Checking The Oil Level
The oil tank 3 is not used as an oil level indicator, but only for ﬁ lling tank 1. Only use oil with a mean viscosity of 22.0 mm /s at 40°C and a density of 0.865 g/cm at 15°C. We recommend PFAFF sewing machine oil, part no. 280-1-120 144.
Page 64: Lubricating The Cutting Device
Danger of injury if the machine suddenly starts running! ● Before each start up, apply a few drops of silicone oil to the cutting device through hole Only use oil with a density of 0.810 g/cm at 21°C. We recommend PFAFF sewing machine oil, part no. 280-1-120 217.
Page 65: Lubricating The Stacker Drive
Care and maintenance Lubricating the stacker drive Fig. 12 - 07 Switch off the machine! Danger of injury if the machine suddenly starts running! ● Clean bar 1 every 6 months and then grease it. Only use Isoﬂ ex Topas L32 heavy-duty grease, part no. 280-1 120 210.
Page 66: Adjustment
Adjustment Adjustment On the PFAFF 3519-4/01 do not use a screw clamp on the needle bar! The special coating of the needle bar could be damaged. 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 67: Servicing Position Of The Sewing Head
Adjustment Servicing position of the sewing head For maintenance and adjusting work the sewing head can be lifted out of the machine stand. Fig. 13 - 01 Switch off the machine! Danger of injury if the machine suddenly starts running! Bring the sewing head into the servicing position ●...
Page 68 Adjustment Bringing the sewing head into the working position Use both hands to bring the sewing head into an upright position! Danger of hands being crushed between sewing head and machine stand! ● Bring the sewing head into an upright position and slide it up to the limit stop into the machine stand.
Page 69: Adjusting The Sewing Head
Adjustment Adjusting the sewing head Adjustment aids .05.01 With the help of adjustment gauge 1 (part no. 95-752 474-05) the needle bar can be ﬁ xed in the needle rise position (needle bar position 1.8 mm below b.d.c.) Fig. 13 - 02 ●...
Page 70: Basic Position Of The Machine Drive
Adjustment Basic position of the machine drive .05.02 This setting is only necessary if toothed belt 2 was detached Requirement When the needle bar is positioned 1.8 mm past b.d.c., the markings 3 and 4 should be in alignment.. 57-42a Fig.
Page 71: Needle In Needle Hole Centre
Adjustment Needle in needle hole centre .05.03 Requirement The needle should enter exactly in the centre of the needle hole. 50-025 Fig. 13 - 04 ● Position the needle directly above the needle hole. ● Loosen screws 1, 2 and 3. ●...
Page 72: Hook Shaft Bearing And Toothed Belt Tension
Adjustment Hook shaft bearing and toothed belt tension .05.04 Requirement The front edge of the hook shaft 6 must be at a distance of 14.5 mm to the needle center. At the same time, the slot in the hook shaft bearing 1 (see arrow) must be parallel to the bedplate and pointing opposite to the direction of sewing.
Page 73: Hook Lubrication
Adjustment Hook lubrication .05.05 Requirement The centrifugal disk 1 must be positioned 1.5 mm in front of the oil ring 3. When the machine is running at full speed, after approx. 10 seconds a mark should be made by a ﬁ ne stripe of oil on the strip of paper placed over the needle plate cutout. Fig.
Page 74: Needle Rise, Hook-To-Needle Clearance, Needle Height And Bobbin Case Position Fi Nger
Adjustment Needle rise, hook-to-needle clearance, needle height and bobbin case positi- .05.06 on ﬁ nger Requirement With the needle at 1.8 mm after BDC, the hook point 6 must point to the middle of the needle and be at a distance of 0.05 mm - 0.1 mm to the clearance cut of the needle, and the top edge of the needle eye must be 0.8 mm below the hook point.
Page 75: Thread Check Spring And Slack Thread Regulator
Adjustment Thread check spring and slack thread regulator .05.07 Requirement The motion of the thread check spring must be completed when the needle point en- ters the material (spring stroke approx. 7 mm). When the thread loop is at its largest when going around the hook, the thread check spring must have moved by approx.
Page 76: Bobbin Winder
Adjustment Bobbin winder .05.08 Requirement With the bobbin winder on, the drive wheel 1 must engage reliably. With the bobbin winder off, the friction wheel 5 must not be driven by the drive wheel 1. The bobbin winder must turn off automatically when the thread level is approx. 1 mm from the edge of the bobbin.
Page 77: Adjusting The Thread Trimming Device
Adjustment Adjusting the thread trimming device Preliminary adjustment of the control cam .06.01 Requirement When the needle bar is at its t.d.c., the surface 1 of the control cam should be parallel to the bed-plate. Fig. 13 - 10 ● Adjust control cam 1 (screws 2) in accordance with the requirement.
Page 78: Adjusting The Roller Lever
Adjustment Adjusting the roller lever .06.02 Requirement When cylinder 3 is fully extended, the roller of roller lever 4 should be 0.1 mm away from the highest point of control cam 5. Cylinder 3 should be parallel to the front edge of the bed-plate. 50-65a Fig.
Page 79: Lateral Adjustment Of The Thread Catcher
Adjustment Lateral adjustment of the thread catcher .06.03 Requirement The tip of thread catcher 5 should point exactly towards the centre of the needle. The thread catcher 5 should be horizontal and not touch anything when it moves. Fig. 13 - 12 ●...
Page 80: Knife Position
Adjustment Knife position .06.04 Requirement There must be a distance of 4 mm between the cutting edge of the knife and the needle. The right edge of the knife 1 must not extend beyond the right edge of the thread catcher (see arrow).
Page 81: Front Point Of Reversal Of The Thread Catcher
Adjustment Front point of reversal of the thread catcher .06.05 Requirement When the thread catcher 5 is at its front point of reversal, the rear edge of the thread cat- cher cutout must be positioned 1 mm before the bobbin case position ﬁ nger 6. Fig.
Page 82: Manual Trimming Check
Adjustment Manual trimming check .06.06 Requirement Two threads must be cut perfectly both left and right in the cutout of thread catcher 1. Fig. 13 - 15 ● Move thread catcher 1 by hand to its front point of reversal. ●...
Page 83: Readjusting The Control Cam
Adjustment Readjusting the control cam .06.07 Requirement When the end of the thread ﬂ ange 3 is 2 mm behind the centre of the catch of the bob- bin case position ﬁ nger 4, there should also be a 2 mm distance between the tip of thread catcher 6 and the centre of the catch.
Page 84: Adjusting The Loading Table
Adjustment Adjusting the loading table Basic setting of the loading table height .07 .01 Requirement Loading table 3 should be in the centre between the bars 4 and 5 and be parallel to them. Fig. 13 - 17 ● Adjust screws 1 (screws 2) in accordance with the requirement.
Page 85: Positioning The Loading Table
Adjustment Positioning the loading table .07 .02 Requirement Loading table 1 should be parallel to bar 3. Fig. 13 - 18 ● Detach the cover plate from the loading table ● Move loading table 1 in by hand. ● Adjust loading table 1 (screws 2) in accordance with the requirement.
Page 86: Retraction Depth Of The Loading Table
Adjustment Retraction depth of the loading table .07 .03 Requirement With the loading table retracted, there must be a distance of 12 mm between the front edge of the table and the center of the needle hole. With the loading table extended, screws 4 must touch the stops.
Page 87: Adjusting The Sewing Head
Adjustment Adjusting the sewing head Height of the sewing head .08.01 Requirement The top edge of the machine’s bedplate should have a clearance of 0.5 mm to cloth plate 5. Fig. 13 - 20 ● Bring the machine head into the servicing position, see Chapter 13.04 Servicing position of the machine head.
Page 88: Side Adjustment Of The Machine Head
Adjustment Side adjustment of the machine head .08.02 Requirement There should be a clearance of 50 mm between the front edge of the spreader 5 and the centre of the needle hole. The sewing head should be positioned at right angles to the loading table. Fig.
Page 89: Adjusting The Cloth Plate
Adjustment Adjusting the cloth plate Requirement The cloth plate 1 should be parallel to the front edge of the loading table. There should be a clearance of 1 mm between the needle plate insert and the cloth plate 1. 1 mm Fig.
Page 90: Adjusting The Positioning Tube
Adjustment Adjusting the positioning tube Pre-setting the positioning tube .10.01 Requirement When the positioning tube is in its top position, holder 1 should be parallel to holder 3. Fig. 13 - 24 ● Adjust holder 1 (screw 2) in accordance with the requirement.
Page 91: Front End Position Of The Positioning Tube
Adjustment Front end position of the positioning tube .10.02 Requirement When the positioning tube 1 is in its front end position, it should be parallel to and tou- ching the loading table. Fig. 13 - 25 ● Adjust positioning tube 1 (screws 2) in accordance with the requirement.
Page 92: Height And Location Of The Positioning Tube
Adjustment Height and location of the positioning tube .10.03 Requirement When positioning tube 3 is in its front end position its top edge should be at a distance of 18.9 mm from the top side of the loading table and the corresponding holes on the marking should be centred to the needles of the loading table.
Page 93: Height Of The Needles
Adjustment Height of the needles Requirement When the needles are extended, there should be a 4 mm clearance between the needle points and the front edge of the loading table 1. Fig. 13 - 27 ● Detach the cover plate of loading table ●...
Page 94: Adjusting The Spreader
Adjustment Adjusting the spreader Requirement When retracted, spreader 1 should be ﬂ ush with the front edge of the loading table. When being extended, spreader 1 should cover a distance of 3 mm. Fig. 13 - 28 ● Adjust spreader 1 (screws 2) in accordance with requirement 1.
Page 95: Adjusting The Table Extension
Adjustment Adjusting the table extension Requirement When the table extension 1 is in the extended position, its front edge should be ﬂ ush with the front edge of the loading table. Fig. 13 - 29 ● Adjust table extension 1 (screws 2) in accordance with the requirement. If required, the distance between the inserted table extension 1 and the loading table can be altered to match the depth of the notch on screw 3 (nut 4).
Page 96: Adjusting The Loading Clamp
Adjustment Adjusting the loading clamp Height of the loading clamp .14.01 Requirement The claws of the loading clamp must touch the retracted loading table from the top and the bottom at the same time. The claws must be parallel to the loading table. Fig.
Page 97: Position Of The Loading Clamp
Adjustment Position of the loading clamp .14.02 Requirement The inner claws of the loading clamp must touch the retracted loading table approx. to 7 mm behind the front edge. The distance between the front claw edge of the loading clamp and the center of the needle hole must be 50 mm.
Page 98: Adjusting The Brushes
Adjustment Adjusting the brushes Adjusting the long brushes .15.01 Requirement The closed brushes 1 should rest parallel on the loading table and close to such an ex- tent, that the material is smoothed perfectly, whereby the loading table should move into the exact centre between brushes 1.
Page 99: Adjusting The Short Brushes
Adjustment Adjusting the short brushes .15.02 Requirement When the brushes are closed, the top and the bottom brush should just be resting on or touching on the loading table. When the brushes are open, the top and the bottom brush should each have a dis- tance of approx.
Page 100: Adjusting The Knife Unit
Adjustment Adjusting the knife unit Pre-setting the knife unit .16.01 Requirement The rear edge of the engaged catcher should be tilted approx. 2° forwards. (In this case, the centre of screw 6 is more or less ﬂ ush with the outer edge of screw 7 .) Position the catcher on the material fold (in the case of medium material thickness).
Page 101: Height Of The Knife Unit
Adjustment Height of the knife unit .16.02 Requirement The catcher should move into the centre of the spreader. Fig. 13 - 35 ● Loosen screws ● Adjust plate 2 (screws 3) in accordance with the requirement. ● Press against bar 4 in the direction of the arrow and tighten screw 1.
Page 102: Knife Change
Adjustment Knife change .16.03 Requirement When the knife starts to cut less well, it must be changed. Fig. 13 - 36 ● Open the clamping lever on the loading clamp. ● Loosen the capstan screws and push the loading clamp in the direction of the arrow. ●...
Page 103: Adjusting The Workholder Bar
Adjustment Adjusting the workholder bar Zero point of the workholder bar .17 .01 Requirement There should be a distance of 5 mm between the front edge of the workholder bar and the centre of the needle. There should be a distance of approx. 0.5 mm between the rear edge of the workhol- der bar and the front edge of the presser foot.
Page 104: Workholder Bar Stop
Adjustment Workholder bar stop .17 .02 Requirement When lowered, the workholder bar must touch the surface evenly over the entire length. Fig. 13 - 38 ● Adjust screws 1 (nuts 2) on both sides in accordance with the requirement.
Page 105: Adjusting The Pneumatic Table Pressure
Adjustment Adjusting the pneumatic table pressure Requirement When retracting the loading table, the material should not be displaced. Fig. 13 - 39 ● Adjust piston rod 1 (nut 2) in accordance with the requirement.
Page 106: Adjusting The Pressure Control Device
Adjustment Adjusting the pressure control device Requirement The pressure control device should switch off the machine when a pressure of 4.5 bar is reached. Fig. 13 - 40 ● Remove cap ● Adjust screw 2 (nut 3) in accordance with the requirement. ●...
Page 107: Adjusting The Stacker
Adjustment Adjusting the stacker Requirement The stacker support must move reliably to its rearmost ﬁ nal position. The stacker must move evenly and reliably to its highest position when loaded. Fig. 13 - 41 ● Adjust throttle 1 in accordance with requirement 1. ●...
Page 108: Adjusting The Sensor On The Stacker Clamp
Adjustment Adjusting the sensor on the stacker clamp Requirement 1. LED 2 should light up, if there is no material between sensor 3 and reﬂ ector 4. 2. LED 5 should light up, if there is material between sensor 3 and reﬂ ector 4. Fig.
Page 109 Adjustment Extended function control: ● Call up the service menu. ● 1 input 13 (see arrow) must switch from 0 to 1, when material is placed between sensor and reﬂ ector.
Page 110: Boot Key
Adjustment Boot key Danger – electric voltage! Fig. 13 - 43 Boot key 1 in control box 2 is used to boot the machine control unit, see Chapter 13.23.03 Loading / updating the operating program.
Page 111: Service Menu
Adjustment Service menu The status of the digital and analog inputs is displayed in the service menu. The outputs can be set or reset manually. In addition it is also possible to call up functions for carrying out a cold start, for the machine conﬁ guration, for loading the operating program and for setting the control panel.
Page 112 Adjustment Loading the operating program This function is used to load the machine operating program, see Chapter 13.23.03 Loading/ updating the operating program. Control panel settings This function is used to call up a menu for changing the display contrast and for switching the key tone on or off, see Chapter 8.04 Setting the control panel.
Page 113: Cold Start
Adjustment Cold start .23.01 When a cold start is carried out, all newly created or altered programs, as well as all altered parameter settings are deleted! The machine memory is deleted or set back to the status at the time of delivery.
Page 114: Machine Confi Guration
Adjustment Machine conﬁ guration .23.02 With the machine conﬁ guration function, the machine’s control unit receives the necessary information about the installed components. Whenever the machine components are altered, the machine conﬁ guration must be adapted accordingly. ● Switch on the machine and call up the input mode. ●...
Page 115: Loading / Updating The Operating Program
Adjustment Loading / updating the operating program .23.03 To boot a new machine software, a sd-card with the needed ﬁ les has to be plugged in the sd-slot of the control panel. During the loading of the operating program all data in the machine memory is deleted! ●...
Page 116: Sewing Motormenu
Adjustment Sewing motor menu In this menu the sewing motor functions are tested and the t.d.c. needle position is set. ● Switch on the machine. ● Call up the input mode. ● Call up the sewing motor menu. Explanation of the functions Input mode This function is used to change to the initial state of the input mode.
Page 117: Parameter Settings
Adjustment Parameter settings All parameters which can be altered are shown in the list of parameters (Chapter 13.25.02). A description of how to select parameters and alter the values is given below. Selecting and altering parameters. .25.01 ● Switch on the machine and call up the input mode. ●...
Page 118: Parameter List
Adjustment Parameter list .25.02 Bobbin thread monitor 0 - 2 Bobbin thread reverse counter 0 - 999 Needle thread monitor ON - OFF Fade-out stitches needle thread monitor 0 - 99 Reaction time needle / bobbin thread monitor 1 - 9 Cycle without positioning tube ON - OFF Ironing compensation strip...
Page 119 Adjustment Seam end angle [°] 0 - 90 No. of stitches for seam end angle 1 - 9 Stitch length [0.1 mm] 10 - 30 No. of trim stitches 1 - 5 Correction value for starting point of -100 - 800 x-coordinates [0.1 mm] Wiper position right part Wiper position left part...
Page 120: Control Unit
Control unit Control unit Basic setting / Diagnosis / Pin assignment Power unit A30 .01.01 Voltage Fuse Mains ......230 V AC F6 ....(6.3 A T) Processor ....5 V DC F1 ....(2 A T) Control panel ...18 V DC F2 ....(500 mA T) I/O ......24 V DC F3 ....(2.5 A T) Stepping motor ..80 V DC...
Page 121 Control unit X2 (BS3) Signal Signal 1 ....GND 5 V 4 ......5 V 2 ....GND 5 V 5 ......5 V 3 ....GND 5 V 6 ......5 V 7 ....18 V AC 8 ......18 V AC 9 ....
Page 122: Basic Control Unit A20
Control unit Basic control unit A20 .01.02 Supply ﬂ oppy PC 104 Floppy Flat conductor ﬂ oppy Pin assignment X103 (COM1) X101 (COM2) Signal Signal 1 ....Vterm1 2 ....RxD 7 ......RTS 3 ....TxD 8 ......CTS ......
Page 123 Control unit X301 (X-axis / motor 1) X302 (Y-axis / motor 2)) Signal Signal 1 ....Pulse + 9 ......Pulse - 2 ....Direction + 10 ......Direction - 3 ....Gate/Enable + 11 ......Gate/Enable - 4 ....Current control + 12 ......
Page 124: Sewing Drive A22
Control unit Sewing drive A22 .01.03 Before leaving the factory the sewing drive controller is equipped with the ne- cessary operating software. This software may only be replaced by appropriate- ly trained personnel. The LED "Power on" shows that the unit is ready for operation. Diagnosis functions and fuses are not available.
Page 125: Stepping Motor Drive
Control unit Stepping motor drive .01.04 The stepping motor controller has the following initial setting: Motor 1: 6 A, SIN 4 Motor 2: 6 A, SIN 4 Current reduction 30 %, with coupling of motor 1 and motor 2 These settings are loaded. Software number: 79-001 358-91/002 For information about LED status indications see Chapter 14.02.05 Errors - Stepping motor drive.
Page 126: Can Node A10, A11, A12
Control unit X2, X3, X4 (Drive motor 1 to 33) Signal Signal 1 ....Pulse + 9 ......Pulse - 2 ....Direction + 10 ......Direction - 3 ....Gate/Enable + 11 ......Gate/Enable - 4 ....Current control + 12 ......
Page 127 Control unit X300 (Inputs) Signal Signal Signal ..........3 ......IN1 21 ....GND 39 ...... 24 V 4 ......IN2 22 ....GND 40 ...... 24 V 5 ......IN3 23 ....GND 41 ...... 24 V 6 ......IN4 24 ....
Page 128: Description Of The Error Messages
Control unit Description of the error messages General errors .02.01 Display Description ERROR: 3 Error in allocation EMS memory ERROR: 4 C167 not reacting ERROR: 5 Boot ﬁ le (c167boot.bin) cannot be opened ERROR: 6 Error in ﬂ ash-programming ERROR: 7 Error when opening a ﬁ...
Page 129 Control unit Display Description ERROR: 215 Ramp not completed ERROR: 216 Material does not reach clamp ERROR: 217 Needle thread error ERROR: 241 Sewing motor error (#sewing motor error) see Chapter 14.02.04 Sewing motor error ERROR: 242 Remove material ERROR: 281 Remove material, material not in clamp ERROR: 282 Stacker full...
Page 130: Can-Error
Control unit Display Description ERROR: 402 Error when reading text ﬁ le ERROR: 403 Error in allocation of storage space for texts ERROR: 501 Error when opening ﬁ le "pikto.hex" or "vorlagen.hex" ERROR: 502 No ACK from control panel CAN-Error .02.02 Error byte Description...
Page 131: Sewing Motor Error
Control unit Sewing motor error .02.04 Display Description Transmission error Timeout serial interface Check sum error in incoming data Timeout command (48) Timeout-slave expired (command string incomplete) (49) Incorrect command code Framing or parity err or (51) Check sum incorrect (52) Incorrect date request (53)
Page 132: Errors - Stepping Motor Drive
Control unit Errors – Stepping motor drive .02.05 If problems occur with the stepping motor drive during the operation, an error might have occurred in the stepping motor controller. The error message is indicated by LEDs on the stepping motor controller. Meaning H 9 (red) Temperature too high in end phase...
Page 133: List Of Outputs And Inputs
Control unit List of outputs and inputs CAN-Nodes 1 .03.01 Output Term Function Remark OUT1 Thread trimming on Valve OUT2 Vacuum positioning tube on Valve OUT3 Vacuum table on Valve OUT4 Workholder bar down Valve OUT5 Workholder bar up Valve OUT6 Cloth plate forwards Valve...
Page 134: Can-Nodes 2
Control unit CAN-Nodes 2 .03.02 Output Term Function Remark OUT1 Knife on Contactor OUT2 Wiper 2 off Valve OUT3 Wiper 1 off Valve OUT4 bobres Reset for bobbin thread monitor Dig. signal (active low) OUT5 Loading clamp 1 off Valve OUT6 Loading clamp 2 off Valve...
Page 135: Can-Nodes 3
Control unit CAN-Nodes 3 .03.03 Output Term Function Remark Positioning tube cylinder 1 down (vertical) OUT1 Y27U1 Pulse valve OUT2 Y27U2 Positioning tube cylinder 1 up (vertikal) Pulse valve OUT3 Y28U1 Pulse valve Positioning tube cylinder 2 down (vertikal) OUT4 Y28U2 Pulse valve Positioning tube cylinder 2 up (vertikal)
Page 136: Special Outputs
Control unit Special outputs .03.04 Term Function Remark Positioning tube down Positioning tube up Positioning tube centre vertical Loading table back Loading table forwards Loading table special position Positioning tube back Positioning tube forwards Positioning tube centre horizontal Workholder bar down without pressure Workholder bar down with pressure Workholder bar up...
Page 137: Pneumatic System Circuit Diagram
91-744 699-95 Pneumatics-switch diagram Stromlaufpläne Stromlaufpläne Part 1 Version 14.06.06 Pneumatic system circuit diagram The pneumatics plan is illustrated in the basic position (Home-Position). Power (air and elec- tricity) is connected. The components have a ﬁ xed status.
Page 138 Pneumatics-switch diagram 91-744 699-95 Version 14.06.06 Part 2...
Page 139 91-744 699-95 Pneumatics-switch diagram Part 3 Version 14.06.06...
Page 140 Pneumatics-switch diagram 91-744 699-95 Version 14.06.06 Part 4...
Page 141 91-744 699-95 Pneumatics-switch diagram Part 5 Version 14.06.06...
Page 142 Pneumatics-switch diagram 91-744 699-95 Version 14.06.06 Part 6...
Page 143 91-744 699-95 Pneumatics-switch diagram Part 7 Version 14.06.06...
Page 144: Circuit Diagrams
Circuit diagrams Circuit diagrams Reference list for the Circuit diagrams CAN 1 S200 =>1 CAN 2 S200 =>2 CAN 3 S200 =>3 Control unit BS3 Sewing motor control unit Q201 Needle thread monitor evaluation Needle thread monitor optics P1 control panel Laser optics Bobbin thread monitor evaluation Bobbin thread monitor optics...
Page 145 Circuit diagrams B34U1 A12 CAN3 E34U1 Turn-up back B34U2 A12 CAN3 E34U2 Turn-up forwards A12 CAN3 E36 Spreader back A12 CAN3 E38 Table position workholder bar Capacitor for cutting motor M5 A10 CAN1 Workholder bar up A10 CAN1 Cloth plate forwards A10 CAN1 Clamp feed right E10A...
Page 146 Circuit diagrams A30 LED => F1-2 A A30 LED => F3-2.5 A A30 LED => F4-6.3 A A30 LED => F5-0.5 A A30 LED => F2-0.5 A A31 LED power unit pulse +24V / 5A / 125 VA A40 LED axis 1 ready A40 LED axis 2 ready A40 LED axis 3 ready A40 LED axis 1 overcurrent...
Page 147 Circuit diagrams X101 COM 2 interface X103 COM 1 interface X208 CAN – bus X301 X – axis / motor SM 1 (M2) X302 Y – axis / motor SM 2 (M3) X303 B – axis / motor SM 3 (M4) option X400 Main drive sewing motor M1 X401...
Page 148 Circuit diagrams Vacuum motor M6 (option) X111 A10 CAN1 Thread trimmer on X112 A10 CAN1 Vacuum positioning tube on X113 A10 CAN1 Vacuum table on X114 A10 CAN1 Workholder bar down X115 A10 CAN1 Workholder bar up X116 A10 CAN1 Cloth plate forwards X117 A10 CAN1...
Page 149 Circuit diagrams A10 CAN1 Cloth plate forwards A10 CAN1 Top clamp closed A10 CAN1 Swing down bottom clamp A10 CAN1 Clamp clutch on A10 CAN1 Clamp feed to right A10 CAN1 Clamp feed to left A10 CAN1 Stacker table up A10 CAN1 Needle thread tension off A10 CAN1...
Page 150 Circuit diagram 91-191 499-95 Version 10.07 .08 Part 1...
Page 151 91-191 499-95 Circuit diagram Part 2 Version 30.03.06...
Page 152 Circuit diagram 91-191 499-95 Version 30.03.06 Part 3...
Page 153 91-191 499-95 Circuit diagram Part 4 Version 11.02.11...
Page 154 Circuit diagram 91-191 499-95 Version 30.11.05 Part 5...
Page 155 91-191 499-95 Circuit diagram Part 6 Version 10.07 .08...
Page 156 Circuit diagram 91-191 499-95 Version 30.03.08 Part 7...
Page 157 91-191 499-95 Circuit diagram Part 8 Version 01.10.08...
Page 158 Circuit diagram 91-191 499-95 Version 30.03.06 Part 7...
Page 159 91-191 499-95 Circuit diagram Part 8 Version 07 .07 .06...
Page 160 PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Phone: +49 - 6301 3205 - 0 Fax: +49 - 6301 3205 1386 E-mail: info@pfaff-industrial.com Hotlines: Technical service: +49 - 175/2243-101 Application consultance: +49 - 175/2243-102 Spare-parts hotline:...

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