Pfaff 2438 plusline Instruction Manual

INSTRUCTION MANUAL

296-12-18 708/002
Betriebsanleitung engl. 06.09

This instruction manual applies to machines from the

following serial numbers 2 657 257 and software

version 0307/001 onwards:

2438

Industrial

®

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.

PFAFF Industriesysteme
und Maschinen AG

Hans-Geiger-Str. 12 - IG Nord

D-67661 Kaiserslautern

Contents

Contents .................................................................................Chapter – Page

1 Safety ............................................................................................................................ 1 - 1

1.01 Regulations ................................................................................................................... 1 - 1

1.02 General notes on safety ................................................................................................. 1 - 1

1.03 Safety symbols ............................................................................................................. 1 -2

1.04 Important notes for the user .......................................................................................... 1 - 2

1.05 Notes for operating and technical staff........................................................................... 1 - 3

1.05.01 Operating staff ............................................................................................................... 1 - 3

1.05.02 Technical staff ............................................................................................................... 1 -3

1.06 Danger warnings ........................................................................................................... 1 - 4

2 Proper use .................................................................................................................... 2 -1

3 Specifications .............................................................................................................. 3 - 1

4 Disposal of Machine .................................................................................................... 4 - 1

5 Transportation, packing and storage ......................................................................... 5 - 1

5.01 Transportation to customer’s premises ......................................................................... 5 - 1

5.02 Transportation inside the customer’s premises ............................................................. 5 - 1

5.03 Disposal of packing materials........................................................................................ 5 - 1

5.04 Storage .......................................................................................................................... 5 - 1

6 Explanation of symbols ............................................................................................... 6 - 1

7 Controls........................................................................................................................7- 1

7.01 Main switch ..................................................................................................................7- 1

7.02 Keys on the machine head ............................................................................................ 7 - 1

7.03 Pedal ............................................................................................................................. 7 - 2

7.04 Lever for raising presser foot ......................................................................................... 7 - 2

7.05 Adjustment lever for zigzag stitch and needle position ................................................... 7 - 3

7.06 Bobbin thread control ..................................................................................................... 7 - 3

7.07 Control panel ................................................................................................................. 7 - 4

7.07.01 Screen displays ............................................................................................................. 7 - 4

7.07.02 Function keys ................................................................................................................ 7 - 4

8 Mounting and commissioning the machine ............................................................. 8- 1

8.01 Mounting ....................................................................................................................... 8- 1

8.01.01 Adjus ting the t able-top height ........................................................................................ 8 - 1

8.01.02 Fitting the machine cover .............................................................................................. 8 - 2

8.01.03 Fitting the reel stand ...................................................................................................... 8 - 2

8.01.04 Connecting the plug-in connections and earth cables ..................................................... 8 - 3

8.02 Commissioning ............................................................................................................. 8 - 4

8.03 Switching the machine on/off ........................................................................................ 8 - 4

8.04 Mounting/checking the start inhibitor ............................................................................. 8 - 5

9 Setting up ..................................................................................................................... 9- 1

9.01 Inserting the needle ....................................................................................................... 9 -1

9.02 Winding the bobbin thread / adjusting the primary thread tension .................................. 9 - 2

Contents

Contents .................................................................................Chapter – Page

9.03 Removing/inserting the bobbin case .............................................................................. 9 - 3

9.04 Threading the bobbin case / Adjusting the bobbin thread tension ................................... 9 - 3

9.05 Threading the needle thread / Adjusting the needle thread tension ................................. 9 - 4

9.06 Setting the zigzag stitch and the stitch position ............................................................. 9 - 5

9.07 Entering the stitch length ............................................................................................... 9 - 5

9.08 Entering the start and end backtacks............................................................................. 9 - 6

9.09 Entering the maximum speed........................................................................................ 9 - 7

9.10 Setting the remaining stitches for the bobbin thread control ........................................... 9 - 7

10 Sewing ........................................................................................................................10- 1

10.01 Manual sewing ............................................................................................................. 10 -1

10.02 Programmed sewing ....................................................................................................10 - 2

10.03 Error messages ............................................................................................................10 -3

11 Input ............................................................................................................................ 11 - 1

11.01 Seam program input .....................................................................................................11 - 1

11.02 Example of a seam program input ................................................................................ 11 - 1

11.03 Program recording forms ..............................................................................................11 - 9

12 Care and maintenance ................................................................................................ 12 - 1

12.01 Cleaning .......................................................................................................................12 - 1

12.02 Lubricating the hook .....................................................................................................12 - 2

12.03 Oiling the zigzag drive ................................................................................................... 12 -3

12.04 Cleaning the air filter of the air-filter / lubricator .............................................................12 - 4

12.05 Checking/adjusting the air pressure ..............................................................................12 - 4

13 Adjustment .................................................................................................................. 13 - 1

13.01 Notes on adjustment .................................................................................................... 13 - 1

13.02 Tools, gauges and other accessories for adjusting .......................................................13 - 1

13.03 Abbreviations ................................................................................................................ 13 - 1

13.04 Check and adjustment aid ............................................................................................ 13 - 2

13.05 Adjusting the basic machine ........................................................................................13 - 3

13.05.01 Balancing weight ..........................................................................................................13 - 3

13.05.02 Centering the needle in the needle hole (in sewing direction) ....................................... 13 - 4

13.05.03 Parallel guiding of the needle bar ..................................................................................13 - 5

13.05.04 Locking lever ................................................................................................................13 -6

13.05.05 Zero stitch and zigzag stitch scale ...............................................................................13 - 7

13.05.06 Centering the needle in the needle hole (crosswise to sewing direction) ..................... 13 - 8

13.05.07 Zigzag stitch width .......................................................................................................13 - 9

13.05.08 Zigzag stitch motion .....................................................................................................13 - 10

13.05.09 Needle penetration symmetry ...................................................................................... 13 - 11

13.05.10 Needle position adjustment lever ................................................................................. 13 - 12

13.05.11 Zero position of the bottom feed dog (with closed gear box) .........................................13 - 13

13.05.12 Zeroing the bottom feed (with open gearbox) ...............................................................13 - 14

13.05.13 Feeding motion of the bottom feed dog ........................................................................ 13 - 15

13.05.14 Lifting motion of the bottom feed dog ...........................................................................13 - 16

13.05.15 Drive belt in the gearbox housing ................................................................................. 13 - 17

Contents

Contents .................................................................................Chapter – Page

13.05.16 Hook bearing bracket ...................................................................................................13 - 18

13.05.17 Hook lubrication ............................................................................................................13 - 19

13.05.18 Pre-adjusting the needle height .................................................................................... 13 - 20

13.05.19 Needle rise, hook-to-needle clearance and bobbin case positioning-finger ...................13 - 21

13.05.20 Final adjustment of the needle height ...........................................................................13 - 22

13.05.21 Bobbin case opener position ........................................................................................ 13 - 23

13.05.22 Bobbin case opener motion ..........................................................................................13 - 24

13.05.23 Bottom feed dog height ................................................................................................13 - 25

13.05.24 Presser foot to needle plate clearance .......................................................................... 13 - 26

13.05.25 Presser foot pressure ...................................................................................................13 - 27

13.05.26 Thread diverter pin ........................................................................................................13 - 28

13.05.27 Limiting the knee lever stroke ...................................................................................... 13 - 29

13.05.28 Knee lever play .............................................................................................................13 - 30

13.05.29 Setting the zero point of the feed regulator .................................................................... 13 - 31

13.05.30 Stitch length adjustment forwards and in reverse ......................................................... 13 - 32

13.05.31 Spuler ........................................................................................................................... 13 - 34

13.06 Adjusting the thread trimmer ........................................................................................ 13 - 35

13.06.01 Axial position of the control cam .................................................................................. 13 - 35

13.06.02 Preliminary adjustment of the control cam ...................................................................13 - 36

13.06.03 Position of the thread catcher and cutting test .............................................................. 13 - 37

13.06.04 Readjustment of the control cam ..................................................................................13 - 38

13.06.05 Needle thread tension release .......................................................................................13 - 39

13.07 Adjusting the thread wiper –909/04 ...............................................................................13 - 40

13.07.01 Thread wiper motion ..................................................................................................... 13 - 40

13.07.02 Position of the thread wiper ..........................................................................................13 - 41

13.08 Adjusting the zigzag sensor ..........................................................................................13 - 42

13.09 Aligning the light transmitter .........................................................................................13 - 43

13.10 Adjustment of the transmitted light sensors ................................................................. 13 - 44

13.11 Function control of the bobbin thread monitor ............................................................... 13 - 45

13.12 Parameter settings ....................................................................................................... 13 - 46

13.12.01 Example of a parameter input ....................................................................................... 13 - 46

13.12.02 List of parameters ........................................................................................................ 13 - 47

13.13 Explanation of the error messages ...............................................................................13 - 54

13.14 Service functions ..........................................................................................................13-55

13.15 Internet update of the machine software ...................................................................... 13 - 60

14 Wearing parts .............................................................................................................14 - 1

15 Circuit diagrams ......................................................................................................... 15 - 1

Safety

1 - 1

1 Safety

1.01 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!

1.02 General notes on safety

● The machine must only be operated by adequately trained operators and only when the

instruction manual has been fully read and understood!

● All notices on safety and the instruction manual of the motor manufacturer are to be read

before the machine is put into operation!

● All notes on the machine concerning danger and safety must be observed!

● The machine must be used for the purpose for which it is intended and must not be

operated without its safety devices; all regulations relevant to safety must be adhered to.

● When part sets are changed (e.g. needle, presser foot, needle plate, feed dog or bob-bin),

during threading, when the workplace is left unattended and during maintenance work, the

machine must be isolated from the power supply by turning off the on/off switch or

removing the plug from the mains!

● Daily maintenance work must only be carried out by appropriately trained persons!

● Repairs and special maintenance work must only be carried out by qualified technical staff

or persons with appropriate training!

● During maintenance or repairs on the pneumatic system the machine must be isolated

from the compressed air supply! The only exception to this is when adjustments or

function checks are carried out by appropriately trained technical staff!

● Work on the electrical equipment must only be carried out by technical staff who are

qualified to do so!

● Work on parts or equipment connected to the power supply is not permitted! The only

exceptions to this are specified in regulations EN 50110.

● Conversion or modification of the machine must only be carried out under observation of

all relevant safety regulations!

Safety

1 - 2

● Only spare parts which have been approved by us are to be used for repairs! We draw

special attention to the fact that spare parts and accessories not supplied by us have not
been subjected to testing nor approval by us. Fitting and/or use of any such parts may
cause negative changes to the design characteristics of the machine. We shall not accept
any liability for damage caused by the use of non-original parts.

1.03 Safety symbols

Danger!

Special points to observe.

Danger of injury to operating or technical staff!

Electric voltage!

Danger to operating or technical staff!

Caution

Do not operate without finger guard and safety devices.

Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.

I

1.04 Important notes for the user

● This instruction manual belongs to the equipment of the machine and must be available to

the operating staff at all times.

This instruction manual must be read before the machine is operated for the first time.

● Both operating and technical staff must be instructed on the safety devices of the mach-

ine and on safe working methods.

● It is the duty of the user to operate the machine in perfect running order only.

● 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.

Safety

1 - 3

1.05 Notes for operating and technical staff

1.05.01 Operating staff

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.!

● Loose-fitting clothing should be avoided. No jewellery, such as chains and rings, should be

worn!

● Ensure that only authorised persons enter the danger area of the machine!

● Any changes occurring on the machine, which may affect its safety, must be reported to

the user immediately.

1.05.02 Technical staff

Technical staff are persons who have been trained in electrical engineering/electronics and

mechanical engineering. They are responsible for lubricating, servicing, repairing and adjusting

the machine.

The technical staff is obliged to observe the following points:

● The notes on safety in this instruction manual must always be observed!

● Before carrying out any adjustment or repair work the main switch must be switched off

and measures taken to prevent it from being switched on again!

● Never work on parts or equipment still connected to the power supply! Exceptions are only

permissible in accordance with the regulations EN 50110.

● All safety covers must be replaced after the completion of maintenance or repair work!

Safety

1 - 4

81

-

001

1.06 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. 1 - 01

Do not operate the machine without the take-up lever guard 1!

Danger of injury through the movement of the take-up lever.

Do not operate the machine without finger guard 2!

Danger of injury from the movement of the needle!

Do not operate the machine without machine covers 3 and 4!

Danger of injury from moving belts!

Do not operate the machine without start inhibitor 5!

Danger of injury if the machine is started accidentally!

81-002

1

2

3

4

5

Proper use

2 - 1

2 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

considered as improper use! The manufacturer shall not be liable for any dam-

age arising out of improper use! Proper use shall also be considered to include

compliance with the operation, adjustment, service and repair measures speci-

fied by the manufacturer!

Specifications

3 - 1

3 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: .................................................................................................... 260 mm

Clearance height: .................................................................................................... 130 mm

Sewing head dimensions:

Length: ............................................................................................................. ca. 535 mm

Width: ............................................................................................................... ca. 265 mm

Height (above table): ......................................................................................... ca. 330 mm

Bed plate dimensions: ...................................................................................476 x 177 mm

Connection data:

Operating voltage: ........................................................................... 230 V ± 10%, 50/60 Hz

Max. power consumption: ....................................................................................... 1.2 kVA

Fuse protection: ............................................................................................. 1 x 16 A, inert

Noise data:

Noise emission level at workplace with a sewing speed of 2800 spm: ...... L

pA

< 80 dB(A)

■

(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)

Net weight of sewing head: ................................................................................... ca. 48 kg

Gross weight of sewing head: ............................................................................... ca. 56 kg

▲

Subject to alterations

◆

Depending on the material, operation and stitch length

■

KpA = 2.5 dB

Disposal of machine

4 - 1

4 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; if necessary, a specialist ist to be commissioned.

Care must be taken that parts soiled with lubricants are disposed of separately

according to the locally valid pollution control regulations!

Transportation, packing and storage

5 - 1

5 Transportation, packing and storage

5.01 Transportation to customer’s premises

All machines are delivered completely packed.

5.02 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.

5.03 Disposal of packing materials

The packing materials of these machines consist of paper, cardboard and VCE-fibre.

Proper disposal of the packing material is the responsibility of the customer.

5.04 Storage

If the machine is not in use, it can be stored as it is for a period of up to six months, but it

should be protected against dust and moisture.

If the machine is stored for longer periods, the individual parts, especially the surfaces of

moving parts, must be protected against corrosion, e.g. by a film of oil.

Explanation of symbols

6 - 1

6 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)

Controls

7 - 1

77

-

005

81-003

7.02 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

Key 3: Sew single stitch

Fig. 7 - 02

Fig. 7 - 01

7 Controls

7.01 Main switch

● The machine is switched on or off by

turning the main switch 1.

1

3

2

1

Controls

7 - 2

81-004

7.03 Pedal

0 = Neutral position

1 = Sewing

2 = Raise presser foot

3 = Trim thread/reset bobbin thread

control or remaining bobbin

thread count function

Fig. 7 - 03

0

1

2

3

7

.04 Lever for raising presser foot

● The presser foot is raised by turning

lever 1.

Fig. 7 - 04

1

Controls

7 - 3

81

-

105

Fig. 7 - 05

4

M

L

R

2

1

3

7

.05 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.

The current zigzag-stitch width
can be seen on scale 3.

● By turning the needle-position adjustment

lever 4 the required needle position can be

set.

L = needle-position left
M = needle-position center
R = needle-position right

7.06 Bobbin thread control

● When the remaining thread quantity is

reached LED 1 flashes.

After thread trimming a bobbin

symbol appears on the display

with the number of remaining

stitches. To enter the number of
remaining stitches, see Chapter

9.10 Setting the remaining
stitches for the bobbin thread
control.

Fig. 7 - 06

1

Controls

7 - 4

2.0

SPEED

7.07 Control panel

The control panel is used to create and alter seam programs, enter parameter values and read

error messages and service settings.

The control panel consists of display 1 and the function keys described below. The display 1

consists of a two-line alpha-numerical LCD display with 16 symbols per line. The special
symbols 2, 3, and texts 4 show the respective status of the function keys and the operating

status of the machine.

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.

7.07.01 Screen displays

● Activated functions are displayed with a triangular marking 2 below or next to the

respective function key.

● In the sewing mode all relevant sewing data is displayed and these can be changed

directly, depending on the status of the machine, see also Chapter 10 Sewing.

● During the parameter input the selected parameter number with the corresponding value is

displayed, see Chapter 13.12 Parameter settings.

● During the seam program input the inputs are carried out in relevant input menus, see

Chapter 11.01 Seam program input.

7.07.02 Function keys

The function keys described below are used basically to switch machine functions on and off.

If a corresponding value has to be set for the activated function, this is carried out with the
corresponding +/- key. For example, by pressing and holding the +/- key 5, the numerical
value 6 shown above the key is changed slowly to begin with. If the +/- key 5 is held down
longer, the numerical value 6 is changed more quickly.

5

1

24

3

6

Controls

7 - 5

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.

End backtacks

● If this key is pressed, the backtacks at the end of the seam (end backtacks) are switched

on or off. The number of reverse stitches (C) or forward stitches (D) 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.

Needle position

● If this key is pressed the "needle raised after sewing stop" function is switched on or off.

When the function is switched on, the needle positions at t.d.c. after sewing stops.

Foot position after stop

● If this key is pressed the "foot raised after sewing stop" function is switched on or off.

When the function is switched on, the presser foot is raised after sewing stops.

Foot position after trimming

● If this key is pressed the "foot raised after thread trimming" function is switched on or off.

When the function is switched on, the presser foot is raised after thread trimming.

Thread trimmer

● If this key is pressed the thread trimming function is switched on or off.

Speed

● If this key is pressed the corresponding function is switched on or off. When the function

is switched on, the current seam section is sewn at the speed entered irrespective of the

pedal position.

Reverse sewing

● If this key is pressed the corresponding function is switched on or off. When the function

is switched during programmed sewing, the corresponding seam section is sewn in

reverse.

Manual seam end

● 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 not carried out by stitch counting or

sensor, but manually with the use of the pedal (position "-2").

Controls

7 - 6

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.

Stitch counting

● If this key is pressed the corresponding function is switched on or off. When the function

is switched on, the machine moves to the next seam section after sewing the number of

stitches entered.

TE/Speed

● If this key is pressed once while the machine is in the sewing mode, the input menu for

the maximum speed is selected. If no input is made within 5 seconds, the sewing mode

is selected again.

● If this key is pressed twice (within 5 seconds) while the machine is in the sewing mode,

the machine switches to parameter input.

● If this key is pressed once while the machine is in the parameter input mode, the altered

values are stored and the sewing mode is selected.

Scrolling

● If this key is pressed the machine scrolls among the displays (parameters), if more than 4

parameters are directly accessible in the sewing mode.

PM

● If this key is pressed the programmed sewing function is switched on or off. When the

function is switched on, the letters "PM" appear on the display of the control panel. The

parameters related to the program are shown in the alpha-numerical part of the display.

F1

● If this key is pressed the service menu is selected, see Chapter 13.14 Service functions.

F2

No function

F3

● If this key is pressed the adjustment of the light barrier is started, see Chapter 13.10

Adjustment of the transmitted light sensors.

F4

● If this key is pressed, the next bartack is not sewn.

Mounting and commissioning the machine

8 - 1

81-006

8 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.

8.01 Mounting

The necessary electricity supply must be available at the machine’s location.

There must be a stable and horizontal surface and adequate lighting at the machine’s

location.

Due to reasons of packaging, the table top is lowered for transport. The

following is a description of how to adjust the height of the table top.

8.01.01 Adjusting the table-top height

● Loosen screws 1 and 2 and set the desired table-top height.

● Tighten screws 1 well.

● Adjust the position of the pedal so that you can operate it comfortably and tighten

screw 2.

Fig. 8 - 01

1

1

2

2

Mounting and commissioning the machine

8 - 2

81

-

007

8.01.02 Fitting the machine cover

● 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.

● Tighten screws 1 and 2 (accessible

through holes 8 and 9) and screw 3.

Fig. 8 - 02

9

8

7

6

5

1

2

4

3

8.01.03 Fitting the reel stand

● Fit the reel stand as shown in Fig. 8 - 03.

● Afterwards insert the stand in the hole in

the table top and secure it with nuts pro-

vided.

Fig. 8 - 03

Mounting and commissioning the machine

8 - 3

8.01.04 Connecting the plug-in connections and earth cables

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.

● Fasten the earth cable of the main switch 8 to earth point A.

1

2

5

6

3

C

4

A

B

7

8

Mounting and commissioning the machine

8 - 4

8.02 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. If there are any
irregularities do not operate the machine under any circumstances.

● When the machine is running, the balance wheel must turn towards the operator. If this is

not the case, have the motor adjusted by qualified personnel (Parameter "800").

● Connect the machine to the compressed air system. The pressure gauge should show a

pressure of 6 bar. If necessary, adjust the value, see Chapter 12.05 Checking/adjusting

the air pressure.

Fig. 8 - 05

1

2

Fig. 8 - 06

3

4

5

4

● Before commissioning the machine remove plug 1 from its hole and fill in oil up to

marking 2, see Chapter 12.02 Oiling the hook.

Plug 1 serves as a safety device for transportation and should not be used during

sewing operations.

● Before commissioning the machine remove screw 3 and fill in oil up to the marking

(inspection glass on the front side of the machine), see Chapter 12.03 Oiling the zigzag

drive.

8.03 Switching the machine on/off

● Switch the machine on, see Chapter 7.01 Main switch.

● Carry out a test run.

Mounting and commissioning the machine

8 - 5

-

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.

● After loosing the screws 4, adjust switch 3 so that the switch is off when the sewing head

is tilted over and activated by switch lug 2 when the sewing head is upright.

Checking the start inhibitor

8.04 Mounting/checking the start inhibitor

Fig. 8 - 07

● Switch the machine on at the main switch and tilt it over.

The error message "E009" must appear on the control panel.

● If the message does not appear, check the setting of switch 3.

● Set the sewing head upright and acknowledge the error message by pressing the TE/

Speed key. The machine is ready for operation again.

E009

PRESS TE-SPEED

ERROR

2

3

4

81-093

1

Setting up

9 - 1

9 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!

9.01 Inserting the needle

Switch off the machine!

Danger of injury if the machine

is started accidentally!

Only use needles of system 438 KK.

● Bring the needle bar into its highest

position.

● Loosen screw 1.

● Insert the needle 2 as far as possible.

● The long needle groove must be facing

forwards.

● Tighten screw 1.

Fig. 9 - 01

1

2

Setting up

9 - 2

● 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.

● Switch on the bobbin winder by pressing the bobbin winder spindle 2 and lever 3 at the
same time.

The bobbin is filled during sewing.

If the machine is only operated for winding (without sewing), a bobbin case
must be inserted in the hook!
Otherwise the hook can be damaged by the thread jamming!

● The thread tension on bobbin 1 can be set with milled screw 4.

● The bobbin winder stops automatically, when bobbin 1 has been filled sufficiently.

If the thread is wound unevenly:

● Loosen nut 5.

● Turn thread guide 6 accordingly.

● Tighten nut 5.

9.02 Winding the bobbin thread / adjusting the primary thread tension

Fig. 9 - 02

4

3

2

1

6

5

1

Setting up

9 - 3

Fig. 9 - 03

1

2

9.03 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.

-

9.04 Threading the bobbin case / Adjusting the bobbin thread tension

Fig. 9 - 04

2

1

● Insert bobbin 1 into bobbin case 2 as shown in the above illustration.

● Pass the thread through the slot under the spring as shown in the adjacent illustration.

● Adjust the thread tension by turning screw 3.

When the thread is pulled, the bobbin must rotate in the direction of the arrow.

Fig. 9 - 05

5 cm

3

+

-

Setting up

9 - 4

81-012

9.05 Threading the needle thread / Adjusting the needle thread tension

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.

Fig. 9 - 06

1

+

-

6 cm

Setting up

9 - 5

9.06 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.

L = stitch position on left
M = stitch position in the middle
R = stitch position on the right

M

L

R

4

3

2

1

Fig. 9 - 07

9.07 Entering the stitch length

● Switch on the machine.

After the machine has been switched on, the current stitch length is displayed.

● Adjust the stitch length by pressing the corresponding +/- key.

2.0

Setting up

9 - 6

9.08 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.

A B C D
3333

PM

A

B

C

D

● By pressing the corresponding +/- key select the desired value for the number of forward

stitches (A) of the start backtack.

● By pressing the corresponding +/- key select the desired value for the number of reverse

stitches (B) of the start backtack.

● By pressing the corresponding +/- key select the desired value for the number of reverse

stitches (C) of the end backtack.

● By pressing the corresponding +/- key select the desired value for the number of forward

stitches (D) of the end backtack.

● Call up the stitch length input menu again by pressing the scroll key.

2.0

Setting up

9 - 7

9.09 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.

● Set the maximum speed by pressing the corresponding +/- key.

No SPEED
220 4500

SPEED TE

SPEED

9.10 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.

● Switch on the machine.

● Press the TE/Speed key twice to enter the parameter input function.

2 x

● Select the parameter "760" by pressing the corresponding +/- key.

● By pressing the corresponding +/- key set the number of remaining stitches which can still

be sewn after the detection of the bobbin thread monitor (depends on the thread size).

● By pressing the TE/Speed key the value is taken over and the machine changes to the

sewing mode.

The bobbin thread rest counter can only be used when parameter "660" is set at

"1" or "2".

No

VAL

No VAL
760 400

TE

Sewing

10 - 1

10 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. In programmed sewing the

text "PM" appears on the display. The program numbers 1 – 15 can each be used for one

seam program with up to 15 seam sections.

10.01 Manual sewing

After the machine has been switched on (Chapter 7.01 Main switch) and the manual sewing
mode has been selected with the PM key, the display appears for entering the stitch length,
also see Chapter 9.07 Entering the stitch length.

If the backtack function is switched on, the display appears for entering the backtack values,
also see Chapter 9.08 Entering the start and end backtacks.
It is possible to switch from one display to the other by pressing the scroll key.

ABCD
3333

2.0

Further functions in manual sewing, also see Chapter 7.06.02 Function keys:

Start backtacks on/off Presser foot raised at end of seam on/off

End backtacks on/off Thread trimming on/off

Needle position raised on/off Reverse sewing on/off

Presser foot raised on/off Sensor on/off

Sewing is carried out with the pedal functions, see Chapter 7.03 Pedal.

Sewing

10 - 2

10.02 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" or "493", see Chapter 13.12 Parameter settings.

In addition to just sewing, that is to say working through seam programs, in programmed
sewing seam programs can be entered and altered, also see Chapter 11.01 Entering seam

programs.

After the machine has been switched on (Chapter 7.01 Main switch) and the programmed
sewing mode has been selected with the PM key, the display appears for selecting the pro-

gram number, seam section and stitch length.

If other functions, such as sensor or stitch count have been activated, it is possible to switch
to other displays for entering corresponding values by pressing the scroll key.

The number of backtack stitches is set in manual sewing, see Chapter 9.08
Entering the start and end backtacks. The values entered apply to all seam

programs.

Functions in programmed sewing, also see Chapter 7.07.02 Function keys:

Start backtacks on/off Fixed speed on/off

End backtacks on/off Reverse sewing direction on/off

Needle position raised on/off Manual seam end on/off

Presser foot raised on/off Programmed stop on/off

Presser foot raised after Sensor on/off

thread trimming on/off

Stitch count on/off

Thread trimming on/off

Sewing is carried out with the pedal functions, see Chapter 7.03 Pedal.

If several seam sections belong to one seam program, the separate seam

sections are sewn automatically one after the other.

15 1 2.0

PM

Sewing

10 - 3

10.03 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.

● Correct the error.

● Acknowledge error correction by pressing the TE/Speed key.

ERROR

E009

PRESS TE-SPEED

Input

11 - 1

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. All functions available in programmed sewing can be used for the seam program input,
see Chapter 10.02 Programmed sewing.

The seam program input is described in the following example.

11 Input

In this chapter the input of seam programs is described.

11.01 Seam program input

● Switch on the machine.

● Press the PM key to call up programmed sewing.

The text "PM" must appear on the display.

15 0 2.0

PM

11.02 Example of a seam program input

A seam program consists of the program number and at least one seam section with

allocated functions.

Below is an example of a seam program input for a label.

1st seam

section

3rd seam

section

5th seam

section

Program number: 7

Stitch length: 1.6 mm

2

nd

seam section

4

th

seam section

Input

11 - 2

Entering programmed sewing

● Switch on the machine.

● Press the PM key.

The text "PM" must appear on the display.

15 0 2.0

PM

Selecting the program number

● Select program number "7" with the corresponding +/- key.

7 0 2.0

PM

1 7 0 1.6 - - - - ● -- --●●/0.0 -
2 7 1 1.6 - - - - ● -- --●●/0.0 -
3 7 2 1.6 - - - - ● -- --●●/0.0 -
4 7 3 1.6 - - - - ● -- --●●/0.0 -
5 7 4 1.6 - - -- ● -- --●●/0.0 -
6 7 5 1.6 - - - - ●●-----●/5

7 760.0------------

E

Step

A/B

C/D

Overview of the input steps

Input

11 - 3

Selecting the stitch length

● Set the value for the stitch length at "1.6" with the corresponding +/- key.

7 0 1.6

PM

● Press the scroll key to enter the seam depth.

0.0

PM

● Set the value for the seam depth at "0" with the corresponding +/- key.

0.0

PM

● Press the scroll key to select the first seam section.

7 0 1.6

PM

The values entered in the seam section "0" apply for all seam sections, if these

are not altered within the individual seam sections.

Input

11 - 4

Selecting seam section 2

● Select seam section "2" with the corresponding +/- key.

7 2 1.6

PM

Selecting the functions for seam section 2

- 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.

- The seam depth should be "0" (input made in seam section "0").

Selecting seam section 1

● Select seam section "1" with the corresponding +/- key.

7 1 1.6

PM

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.

- The seam depth should be "0" (input made in seam section "0").

● 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.

7 1 1.6

PM

Input

11 - 5

Selecting the functions for seam section 3

- The machine should stop at the end of the seam section.

- The end of the seam section should be recognised by sensor.

- The seam depth should be "0" (input made in seam section "0").

● 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.

7 3 1.6

PM

7 2 1.6

PM

Selecting seam section 3

● Select seam section "3" with the corresponding +/- key.

7 3 1.6

PM

● 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.

Input

11 - 6

Selecting seam section 4

● Select seam section "4" with the corresponding +/- key.

7 4 1.6

PM

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.

- The seam depth should be "0" (input made in seam section "0").

● 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.

7 4 1.6

PM

Selecting seam section 5

● Select seam section "5" with the corresponding +/- key.

7 5 1.6

PM

Input

11 - 7

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).

● Press the programmed stop key, to stop the machine automatically at the end of the

seam section.

● Press the thread trimming key for automatic trimming of the thread a the end of the

seam section.

● Press foot position after trimming to raise the presser foot after thread trimming.

● Press the stitch count key to enable the recognition of the end of the seam section by the

number of stitches.

● Press the scroll key to enter the number of stitches.

7 5 1.6

PM

5

PM

● Enter the number of stitches for stitch counting with the corresponding +/- key.

● Press the scroll key to finish the seam program.

7 5 1.6

PM

Input

11 - 8

7 1 1.6

PM

● Using the pedal functions sew a test seam.

● 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.

Sewing a test seam

● Select seam section "1" with the corresponding +/- key.

Finishing the seam program

● Select seam section "6" with the corresponding +/- key.

7 6 0.0

PM

Input

11 - 9

11.03 Program recording forms

1
2
3
4
5
6
7

8

9

10

11

12

13

14

15

E

Step

A/B

C/D

1
2
3
4
5
6
7

8

9

10

11

12

13

14

15

E

Step

A/B

C/D

Input

11 - 10

1
2
3
4
5
6
7

8

9

10

11

12

13

14

15

E

Step

A/B

C/D

1
2
3
4
5
6
7

8

9

10

11

12

13

14

15

E

Step

A/B

C/D

Care and maintenance

12 - 1

12 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............................................ Cleaning the air filter/lubricator

▲

This maintenance interval if for an average machine running time in a single

shift operation. If the machine running times are longer, shorter maintenance

intervals are recommended.

12.01 Cleaning

Switch off the machine!

Danger of injury if the machine is started accidentally!

● Tilt back the machine head.

● Clean the hook and the hook

compartment daily, more often if in

continuous operation.

Use both hands to set the

machine upright!

Danger of crushing between

sewing head and table top!

Fig. 12 - 01

Care and maintenance

12 - 2

12.02 Lubricating the hook

Fig. 12 - 02 Fig. 12 - 03

3

2

1

Turn the machine off!

Danger of injury if the machine is started accidentally!

Only use oil with a mean viscosity of 10.0 mm

2

/s at 40°C and a density of 0.847

g/cm3 at 15°C.

● Lay the machine head on its back.

● Fill the oil reservoir 1 up to the upper marking 3 through hole 2.

● Before operating the machine for the first time or after longer stationary periods,

add a few additional drops of oil into the hook race (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.

Care and maintenance

12 - 3

81

-

014

-013

Fig. 12 - 04 Fig. 12 - 05

2

3

1

4

5

4

Switch off the machine!

Danger of injury if the machine is started accidentally!

Only use oil with a mean viscosity of 22.00 m

2

/s at 40° C and a density of 0.865

g/cm3 at 15° C.

● Check the oil level before each operation.

● If necessary, remove screw 1 and fill in oil up to top marking 2.

● Tighten screw 1.

Never allow the oil level to sink below the minimum mark 3!

Danger of damage to the machine!

To fill in larger quantities of oil, e.g. when filling for the first time before
commissioning, it is better to remove cover 5.

● Loosen screws 4 and remove cover 5.

● Take care that no dirt gets into the case.

● 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.

12.03 Oiling the zigzag drive

Care and maintenance

12 - 4

12.04 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.

Cleaning filter 2:

● Unscrew water bowl 1.

● Take out filter 2.

● Clean filter 2 with compressed air or

isopropyl alkohol ( part No. 95-665 735-91 ).

● Screw in filter 2 and screw on water bowl 1.

Fig. 12 - 06

10

12

0

6

4

2

8

16

14

100

50

150

0

200

230

1

2

12.05 Checking/adjusting the air pressure

● Before operating the machine, always

check the air pressure on gauge 1.

● 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.

Fig. 12 - 07

10

12

0

6

4

2

8

16

14

100

50

150

0

200

230

2

1

Adjustment

13 - 1

13 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.

13.01 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.

Machine covers, which have to be removed and replaced to carry out checks and

adjustments, are not mentioned in the text.

The order of the following chapters corresponds to the most logical work sequence for

machines which have to be completely adjusted. If only specific individual work steps are

carried out, both the preceding and following chapters must be observed.

Screws, nuts indicated in brackets ( ) are fastenings for machine parts, which must be

loosened before adjustment and tightened again afterwards.

The machine must be switched off for all adjustment work!

Danger of injury if the machine is started accidentally!

13.02 Tools, gauges and other accessories for adjusting

● 1 set of screwdrivers with blade widths from 2 to 10 mm

● 1 set of wrenches with jaw widths from 7 to 14 mm

● 1 set of Allan keys from 1.5 to 6 mm

● 1 metal rule, (Part No. 08-880 218-00)

● Locking pin (5 mm diameter), part no. 13-030 341-05

● Feed dog adjustment gauge, part no. 91-119 995-05

● Hook bearing adjustment gauge, part no. 91-119 996-05

● Needles, threads and test material

13.03 Abbreviations

TDC = top dead center

BDC = bottom dead center

Adjustment

13 - 2

81

-

015

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.

Hole 1 = 2.0 mm after the bottom dead center of the needle bar (2.0 past tdc)
Hole 2 = Top dead center of the needle bar (tdc)
Hole 3 = 0.25 mm after the top dead center of the needle bar (0.25 past bdc)
Hole 4 = 1.0 mm after the top dead center of the needle bar (1.0 mm past tdc)
Hole 5 = 4 mm after the bottom dead center of the needle bar (4.0 past bdc)

13.04 Check and adjustment aid

By blocking with holes 1 - 5 the required needle bar positions can be fixed

exactly.

81-016

4

2

5

1

3

Adjustment

13 - 3

81

-

060

2

1

Fig. 13 - 02

● Bring the needle bar to b.d.c.

● Adjust the balance weight 1 (screw 2) in accordance with the requirement.

13.05 Adjusting the basic machine

13.05.01 Balancing weight

Requirement

With the needle bar at bdc the largest eccentricity of the balancing weight 1 must be

pointing upwards.

Adjustment

13 - 4

81-061

Fig. 13 - 03

● Bring the needle bar to b.d.c.

● Adjust the eccentric pin 1 (nut 2 and screw 3) in accordance with the requirement.

3

2

1

13.05.02 Centering the needle in the needle hole (in sewing direction)

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

Adjustment

13 - 5

Fig. 13 - 04

6

5

4

3

1

● 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.

● Push guide bar 5 downwards and then upwards as far as possible. Bushing 6 must not

move laterally during this movement (readjust eccentric pin 4 if necessary).

● Move guide bar 5 until it rests against eccentric pin 4 and tighten screws 1 and 2.

13.05.03 Parallel guiding of the needle bar

Requirement
Guide bar 5 must be parallel to the needle bar.

81-018

81-019

4

2

5

1

3

2

Adjustment

13 - 6

13.05.04 Locking lever

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.

● Locking lever 1 must be parallel to the zigzag stitch adjustment lever 3.

● Tighten screw 2.

0

1

2

6

5

3

4

1

3

4

2

Adjustment

13 - 7

Fig. 13 - 06

● Set the needle position adjustment lever 4 to "middle" and loosen screws 5 and 6.

● Run the machine slowly and turn the zigzag stitch adjustment lever 3 to the right until the

needle bar no longer moves laterally.

● Turn the machine off. Move screw 5 to the right until it touches and then tighten it.

● Loosen screws 7 and move scale 1 in accordance with requirement 2.

● Tighten screws 7.

Screw 6 remains loose for the following adjustment.

13.05.05 Zero stitch and zigzag stitch scale

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.

81

-

022

2

1

7

7

6

5

3

4

Adjustment

13 - 8

81-062

13.05.06 Centering the needle in the needle hole (crosswise to sewing direction)

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.

1

Fig. 13 - 07

● Adjust the eccentric pin 1 (nut 2) in accordance with the requirement.

2

81-023

Adjustment

13 - 9

13.05.07 Zigzag stitch width

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.

If the machine is equipped with a needle plate with a smaller hole than is

marked on the scale, the zigzag limit must be set according to the needle hole

width on the needle plate.

1

2

4

3

Adjustment

13 - 10

81

-

025

Fig. 13 - 09

1

● Adjust zigzag stitch eccentric 1 (screws 2) in accordance with the requirement, taking

care that the zigzag eccentric 1 is at a distance of approx. 5 mm from the inside right wall

of the case.

13.05.08 Zigzag stitch motion

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

81-019

4

2

5

1

3

2

Adjustment

13 - 11

● Move the needle position lever 1 to "middle" and the zigzag stitch adjustment lever 2

to "0".

● Place a piece of paper underneath the presser foot and perforate it with the needle.

● Raise the needle a little and set the zigzag stitch adjustment lever 2 to the largest setting.

● Perforate the paper to the right and left by turning the balancewheel back and forth.

● Without turning it, move zigzag stitch eccentric 3 (screw 4) in accordance with the

requirement.

13.05.09 Needle penetration symmetry

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.

Fig. 13 - 10

81

-

026

3

81-027

1

2

81-028

4

Adjustment

13 - 12

81

-

029

Fig. 13 - 11

3

1

2

4

● Loosen screws 1 and 2.

● Set the needle position adjustment lever 3 to "middle" and the zigzag stitch adjustment

lever 4 at the largest zigzag stitch.

● Place a piece of paper underneath the presser foot and perforate it to the left and right

with the needle.

● Set the zigzag stitch adjustment lever 4 at "0" and move the needle position adjustment lever

3 to the right/left until the needle is exactly over the perforations made in the last step.

● For the left needle-position bring screw 1 to a position where it touches and tighten it and

for the right needle-position do the same with screw 2.

13.05.10 Needle position adjustment lever

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.

Adjustment

13 - 13

81-074

Fig. 13 - 12

● Switch on the machine.

● Set parameter "834" at "0".

● Switch off the start inhibitor by setting parameter "624" at "II".

● Adjust toothed segment 1 (screws 2) in accordance with the requirements.

● Switch on the start inhibitor again.

● Switch off the machine.

13.05.11 Zero position of the bottom feed dog (with closed gear box)

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. Toothed segment 1 should be centred to the stepping motor axis.

3. Toothed segment 1 and toothed wheel should function smoothly and without backlash.

81-030

3

1

2

Adjustment

13 - 14

13.05.12 Zeroing the bottom feed (with open gearbox)

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.

2

1

3

● Switch on the machine.

● Set parameter "834" at "0".

● While continuously turning the balance wheel, adjust reversing crank 1 (screw 2) in

accordance with the requirement.

● Switch off the machine.

Fig. 13 - 13

Adjustment

13 - 15

81-063

13.05.13 Feeding motion of the bottom feed dog

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.

● While continuously operating the reverse feed control, adjust feeding eccentric 1

(screws 2) in accordance with the requirement (the counter-sinking in feeding eccentric 1

must be visible).

An axial displacement of feeding eccentric 1 is not allowed.

1

2

Fig. 13 - 14

Adjustment

13 - 16

81-064

13.05.14 Lifting motion of the bottom feed dog

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.

2

1

Fig. 13 - 15

● Adjust feed lifting eccentric 1 (screw 2) in accordance with the requirement.

An axial displacement of feed lifting eccentric 1 is not allowed.

Adjustment

13 - 17

3

1

2

4

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.

13.05.15 Drive belt in the gearbox housing

Requirement

Drive belt 4 must be tightened so that the machine runs freely and the belt sprockets

do not have any noticeable play.

Adjustment

13 - 18

81-076

418 - 419

438 - 439

81-075

● 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.

● Screw on the hook bearing bracket adjustment gauge.

● It must be possible to read the numbers "438-439" from the front.

● Move or turn hook bearing bracket 4 in accordance with the requirement.

● Tighten screw 2.

● Adjust the bobbin case opener in accordance with subsection 13.05.21 Bobbin case

opener position.

Fig. 13 - 17

13.05.16 Hook bearing bracket

Requirement

The hook shaft must be touching the hook bearing bracket adjustment gauge 1 at the top

and the side.

1

3

1

2

4

Adjustment

13 - 19

13

.05.17 Hook lubrication

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.

● Adjust screw 1 in accordance with the requirement.

Fig. 13 - 18

1

Adjustment

13 - 20

13

.05.18 Pre-adjusting the needle height

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.

81

-

034

Fig. 13 - 19

1

● Without turning it, adjust the needle bar (screws 1) in accordance with the requirement.

81-019

4

2

5

1

3

81-079

19 mm

Adjustment

13 - 21

81-066

81-065

81-067

Fig. 13 - 20

0,5 mm

0,05 - 0,1 mm

● Adjust the hook (screw 1) in accordance with requirement 1.

● Fit the bobbin case position stop in accordance with requirement 2.

13.05.19 Needle rise, hook-to-needle clearance and bobbin case positioning-finger

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.

2. The bobbin case positioning-finger must be fitted so that there is a clearance of 0.5 mm

between the bottom section of the bobbin case and the front edge of the bobbin case

positioning-finger (see arrow).

1

Adjustment

13 - 22

13.05.20 Final adjustment of the needle height

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.

Fig. 13 - 21

● Without turning it, adjust the needle bar (screws 1) in accordance with the requirement.

1

81-081

0,5 mm

Adjustment

13 - 23

81-071

1

2

3

4

5

Fig. 13 - 22

● Loosen screw 2.

● Place bobbin opener 1 on the right side of the bobbin case base, press it against clamp

crank 3 located underneath this and slightly tighten screw 2.

● Adjust eccentric bearing bush 4 (screw 5) in accordance with requirements 1 and 2.

● Adjust bobbin opener 1 in accordance with requirement 3 and tighten screw 2, taking care

to see that bobbin opener 1 is touching clamp crank 3.

13.05.21 Bobbin case opener position

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.

3. At the left point of reversal of the bobbin case opener the bobbin case positioning-finger

must be approx. 0.3 mm from the right side of the groove in the bottom section of the

bobbin case.

81-068

81-069

81-070

0,5 mm

0,8 mm

0,3 mm

Adjustment

13 - 24

13.05.22 Bobbin case opener motion

Requirement

With the needle bar 2.0 past bdc (hole 1) the bobbin case opener 3 must be at its right

point of reversal.

3

1

2

Fig. 13 - 23

● Adjust bobbin opener eccentric 1 (screws 2) in accordance with the requirement.

81-073

Adjustment

13 - 25

81-074

13.05.23 Bottom feed dog height

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.

2

1

3

4

Fig. 13 - 24

● Position the feed dog adjustment gauge underneath the presser foot with the cutout facing

downwards.

● Lower the presser foot onto it.

● Press the feed dog carrier up and position the feed dog in the middle of the needle plate

cutout.

● Adjust lifting crank 1 (screws 2) and clamp bushing 3 (screws 4) in accordance with the

requirement.

81-102

1,1 mm

Adjustment

13 - 26

81-039

1

+

-

13.05.24 Presser foot to needle plate clearance

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.

Fig. 13 - 25

● Set the zigzag stitch adjustment lever at "0" and the stitch position adjustment lever at

"centre".

● Let the presser foot drop onto the needle plate and reduce the pressure on the presser bar

by turning screws 1.

● Place the feed dog adjustment gauge under the presser foot with the recess at the bottom.

● Loosen screw 2 and raise hand lever 3.

● Allow the needle to penetrate the needle hole and align the presser foot in accordance with

the requirement.

● Press the presser bar lifting piece down and tighten screw 2.

81-036

81-038

2

3

7 mm

Adjustment

13 - 27

81-039

13.05.25 Presser foot pressure

Requirement

Even at top sewing speed the material should be fed without problems. There should be no

pressure marks on the material.

● Turn screw 1 in accordance with the requirement.

The presser foot pressure (screw 1) can be increased (+) or reduced (-) as

required.

Fig. 13 - 26

1

+

-

Adjustment

13 - 28

13.05.26 Thread diverter pin

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.

81

-

040

Fig. 13 - 27

2

1

● Adjust thread guide bar 1 (screw 2) according to the requirement, taking care that it is

parallel to the bed-plate.

Adjustment

13 - 29

13.05.27 Limiting the knee lever stroke

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.

1

2

Fig. 13 - 28

● Place the feed dog gauge under the presser foot with its recess facing downwards.

● Lower the presser foot onto the gauge.

● Loosen nut 1 and turn screw 2 out a few turns.

● Move the knee lever to the right until a noticeable resistance is felt, making sure that the

presser foot is not lifted off the gauge, and hold it at this position.

● Turn screw 2 in as far as it will go, then back out by one turn, and lock it in place with

nut 1.

The knee lever is not a part of the delivery.

81-038

7 mm

Adjustment

13 - 30

81-042

13.05.28 Knee lever play

Requirement

When lightly pressing the knee lever there should be a noticeable play between nut 1 and
fork 3.

1

2

3

● 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.

Fig. 13 - 29

Adjustment

13 - 31

13.05.29 Setting the zero point of the feed regulator

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.

● Let the machine sew at maximum speed and check the requirement.

(The workpiece should not move).

● Change the value for parameter 834 within the permissible values in accordance with the

requirement.

The permissible values for parameter 834 are "-1", "0" or "1".

If the zero point of the feed regulator cannot be set by selecting one of the

permissible values, the mechanical setting must be checked or corrected, see

Chapter 13.05.11 Zero position of the bottom feed dog.

The zero point of the feed regulator is always recognisable in a range of 3 values.

When making the adjustment, the average value must be selected.

● Switch off the machine.

More information about selecting and changing parameters and explanations
(functions) of the individual parameters is contained in Chapter 13.12 Parameter

settings.

Adjustment

13 - 32

13.05.30 Stitch length adjustment forwards and in reverse

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.

● Selected the stitch length being used on the control panel.

● With parameter 607 limit the maximum speed to 400 spm.

● Set parameter 846 at 100.

● Place the workpiece under the presser foot.

● Sew a seam with at least 20 stitches.

● Measure the length of the seam over 20 stitches and calculate the actual stitch length.

● If the difference, measured over 20 stitches, is larger than +/- 0.5 mm, the value for

parameter 846 must be corrected.

● Take the value for parameter 846 from the table or calculate it with the aid of the formula:

Set stitch length

Actual stitch length

x 100

Stitch length 2.2 mm Stitch length 2.0 mm Stitch length 1.6 mm Stitch length 1.4 mm

56,0 78 52,0 77
55,5 79 51,5 78
55,0 80 51,0 78

54,5 81 50,5 79

54,0 81 50,0 80 42,0 76
53,5 82 49,5 81 41,5 77
53,0 83 49,0 82 41,0 78
52,5 84 48,5 82 40,5 79
52,0 85 48,0 83 40,0 80 36,0 77
51,5 85 47,5 84 39,5 81 35,5 79
51,0 86 47,0 85 39,0 82 35,0 80
50,5 87 46,5 86 38,5 83 34,5 81
50,0 88 46,0 87 38,0 84 34,0 82
49,5 89 45,5 88 37,5 85 33,5 84
49,0 90 45,0 89 37,0 86 33,0 85
48,5 91 44,5 90 36,5 88 32,5 86
48,0 92 44,0 91 36,0 89 32,0 87
47,5 93 43,5 92 35,5 90 31,5 89
47,0 94 43,0 93 35,0 91 31,0 90
46,5 95 42,5 94 34,5 93 30,5 92
46,0 96 42,0 95 34,0 94 30,0 93
45,5 97 41,5 96 33,5 96 29,5 95
45,0 98 41,0 98 33,0 97 29,0 97
44,5 99 40,5 99 32,5 98 28,5 98
44,0 100 40,0 100 32,0 100 28,0 100

Length over

20 stitches

Value for

parameter

846 / 847

Length over

20 stitches

Value for

parameter

846 / 847

Length over

20 stitches

Value for

parameter

846 / 847

Length over

20 stitches

Value for

parameter

846 / 847

Adjustment

13 - 33

● 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.

Adjustment

13 - 34

81-

08

81-043

3

4

1 mm

2

1

5

Fig. 13 - 30

● Adjust drive wheel 1 (screw 2) in accordance with requirement 1.

● Place a bobbin on the bobbin winder, thread the bobbin and switch on the bobbin winder.

● Adjust pin 3 (screw 4) in accordance with requirement 2 and turn it in accordance with

requirement 3.

13.05.31 Bobbin winder

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.

3. The eccentric pin 3 should be positioned in the centre of the large bobbin chamber.

81-043a

3

Adjustment

13 - 35

81-042

13.06 Adjusting the thread trimmer

13.06.01 Axial position of the control cam

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.

Fig. 13 - 31

● Shift control cam 1 (screw 2) and adjustment ring 3 (screw 4) in accordance with the

requirements.

81-048

5

1

2

3

4

0,3 mm

Adjustment

13 - 36

81-042

13.06.02 Preliminary adjustment of the control cam

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.

Fig. 13 - 32

● Turn control cam 1 (screws 2) in accordance with requirement 1 and shift it in accordance

with requirement 2.

81-049

4

1

2

3

Adjustment

13 - 37

13.06.03 Position of the thread catcher and cutting test

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.

-50

3

3

1

2

4

6

Fig. 13 - 33

● Turn linkage rod 1 (nuts 2, left and right thread) in accordance with the requirement.

● During the cutting test, remove linkage rod 1, loosen screws 3 and remove mounting

plate 4.

● Carry out the cutting test with double thread.

● By turning screw 5 adjust the cutting pressure.

● Fit mounting plate 4 so that its edge is flush with the edge of the bed-plate.

● Tighten screws 3 and replace linkage rod 1.

81-100

5

Adjustment

13 - 38

13.06.04 Readjustment of the control cam

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.

● Bring the needle bar to b.d.c.

● Turn control cam 1 (screws 2) in accordance with requirement 1 and shift it in accordance

with requirement 2.

Fig. 13 - 34

14-50

5

81-098

1

2

6

81-044

4

3

Adjustment

13 - 39

81-104

13.06.05 Needle thread tension release

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.

Fig. 13 - 35

● Unscrew the thread wiper.

● Turn nut 1 (nut 2) in accordance with the requirements.

● Screw thread wiper back into place.

81-045

1

2

3

57-05

0,5 mm

4

Adjustment

13 - 40

81-103

13.07 Adjusting the thread wiper –909/04

13.07.01 Thread wiper motion

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.

● Bring the take-up lever to t.d.c.

● Adjust holder 1 (screw 2) in accordance with the requirements.

Fig. 13 - 36

1

2

3

3

1 mm

4

Adjustment

13 - 41

81

-

051

Fig. 13 - 37

1

2

4

3

13.07.02 Position of the thread wiper

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.

● Without twisting it, move holder 1 (screw 2) on the shaft in accordance with

requirement 1.

● Turn rod 3 (nut 4) in accordance with requirement 2.

1 - 1,5 mm

5

2 mm

5

Adjustment

13 - 42

13.08 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".

● Switch on the machine.

● Select parameter '702', see Chapter 13.12 Parameter settings.

● Turn the balance wheel until the needle is at its right point of penetration and parameter

'702' has the value "15".

● Turn the mounting plate 1 (screw 2) in accordance with the requirement.

● Switch off the machine.

Fig. 13 - 38

81-047

1

2

4

3

Adjustment

13 - 43

81-106

13.09 Aligning the light transmitter

Requirement

When the work is positioned, the transmitters PS2 and PS1 should display the same value

(same receiving power).

● 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.

● Switch off the machine.

Fig. 13 - 39

FKT PS2 PS1 Tx

PS 34% 34% Lo

SERVICE

2

1

Adjustment

13 - 44

13.10 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 "+" on the corresponding +/- key.

● Move the material ply to and fro under the sensors for a short time.

● To end the adjustment for the material ply, press "-" on the corresponding +/- key.

● To start the adjustment for the material ply with label, press "+" on the corresponding +/-

key.

● Move the material ply with label to and fro under the sensors for a short time.

● To end the adjustment for the material ply with label, press "-" on the corresponding +/-

key.

● If necessary, increase the transmitting power with the corresponding +/- key.

● Press the TE/Speed key and sew a test seam.

● Switch off the machine.

L -

L -

L =

L =

Tx

Adjustment

13 - 45

13.11 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).

● Place the bobbin in the bobbin case and the bobbin case in the hook.

● Switch on the machine.

● Select the "TM" function from the service menu, see Chapter 13.14 Service functions.

● Pull the bobbin thread while checking the bobbin thread monitor in accordance with the

requirement.

● If necessary, increase the transmitting power.

● Switch off the machine.

Fig. 13 - 40

Tx

8

1-1

0

7

FKT Rx Tx
TM 1 12

SERVICE

Adjustment

13 - 46

13.12 Parameter settings

13.12.01 Example of a parameter input

● 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.

● Select the desired parameter, e.g. "660" bobbin thread control, by pressing the

corresponding plus/minus key.

● With the corresponding plus/minus key, set the desired value for the parameter, e.g. "0"

to switch off the bobbin thread control function.

No

No VAL
660 1

TE

VAL

2 x

● By pressing the TE/Speed key the value is taken over and the machine switches to the

sewing mode.

No VAL
660 0

TE

No VAL
101 II

TE

Adjustment

13 - 47

13

.11.03 List of parameters

Group

Parameter

Description

User level

Setting range

Set value

0

10 Bobbin thread monitor-current level C 8 - 16 12

11 Bobbin thread monitor-stitch counter (starting

value)

C 0 - 255 32

1

100 Control panel contrast [%] A 80 - 110 90

101 Control panel key response signal

0=tone off

2=tone on

A 0 - 3 2

102 Start backtacks forwards C 0 - 9 3

103 Start backtacks in reverse C 0 - 9 3

105 Start backtacks speed B 100 - 1500 900

106 Start backtacks speed

ON = pedal-controlled

OFF = set with param. "105"

C ON - OFF OFF

107 Pedal-controlled speed start backtacks

ON = limited with parameter "105"

OFF = limited with parameter "607"

C ON - OFF OFF

108 End backtacks in reverse C 0 - 9 3

109 End backtacks forwards C 0 - 9 3

110 End backtacks speed B 100 - 1500 1000

111 No. of stitches from bright light barrier to

seam end in manual sewing

A 1 - 255 6

113 Start with light barrier

ON = only when light barrier is dark

OFF = also when light barrier is bright

B ON - OFF ON

114 After light barrier or stitch counting

ON = stop

OFF = autom. end backtacks and seam end

C ON - OFF OFF

116 Soft start stitches (soft start) A 0 - 10 1

117 Speed for soft start stitches B 180 - 1200 600

148 Start backtacks

ON = double / OFF = single

A ON - OFF ON

149 End backtacks

ON = double / OFF = single

A ON - OFF ON

Adjustment

13 - 48

Group

Parameter

Description

User level

Setting range

Set value

1

199 Speed for light barrier

compensating stitches [min-1]

B 300 - 1500 1500

2

206 Seam interruption with Pedal -2 C ON - OFF OFF

220 Speed level 12 (Poti-reserve) [min-1] A 300 - 4800 4800

221 Speed limitation for seam programs [min-1] B 300 - 4800 4800

222 Speed constant for seam programs [min-1] B 300 - 4800 3000

298 Number of reduced stitches A 1 - 3 1

299 Edge guide position in manual sewing [1/10 mm] A 10 - 185 185

3

323 Edge guide position min [1/10 mm] B 10 - 50 10

325 Edge guide position max [1/10 mm] B 165 - 185 185

4

419 Bartacks:

ON = inverted

OFF = suppressed

C ON - OFF ON

478 Corner stitch

ON = accurate

OFF = fast

C ON - OFF ON

492 Number of seam programs B 1 - 99 99

493 Number of seam segments per seam program B 1 - 15 15

5

554 Presser foot after seam segment with pedal

forwards:

ON = raised / OFF = lowered

C ON - OFF ON

584 Backtack stitches

ON = fourfold / OFF = normal

C ON - OFF OFF

6

601 Cutting: C ON - OFF ON

602 ON = Cutting with pedal -1

OFF = Cutting with pedal -2

C ON - OFF OFF

603 ON = Pedal stops after cutting

OFF = immediate start after end of seam

C ON - OFF ON

604 Cutting:

ON = forwards after semi end backtack

OFF = in reverse too

C ON - OFF ON

605 Speed display B ON - OFF OFF

Adjustment

13 - 49

Group

Parameter

Description

User level

Setting range

Set value

6

606 Speed level 1 (min.) [min-1] B 30 - 550 180

607 Speed level 12 (max.) [min-1] B 300 - 4800 4800

609 Cutting speed [min-1] B 60 - 500 180

618 Reversing angle C ON - OFF OFF

624 St

art inhibitor: C

ON - OFF ON

642 Presser foot – time from switch-on to tension

reduction (tacting)

C 10 - 50 50

651 Automatic lowering of presser foot C ON - OFF ON

660 Bobbin thread monitoring

0 = off

1 = on

2 = bobbin thread reverse counter on

A 0 - 2 1

668 Thread wiper = 1,

Thread clamp = 2,

off = 0

B 0 - 2 1

7

700 Logical zero mark [increments] B 0 - 127 0

702 Needle position (needle lowered) B 0 - 30 15

703 Needle position (take-up lever raised) B 100 - 127 113

705 Needle position (end of cutting signal) B 80 - 127 98

706 Needle position (start of cutting signal) B 40 - 80 68

707 Needle position (start thread tension release) B 40 - 80 70

710 Needle position (needle raised without cutting) B 80 - 127 106

715 Operating time thread wiper [ms] B 0 - 2550 120

718 Moment of standstill brake (rest brake) B 0 - 100 0

719 Presser foot-holding current B 0 - 50 40

720 Cutting–holding current B 0 - 50 40

721 Feed converter-holding current C 0 - 50 40

722 Acceleration ramp:

1 = fl at,

50 = steep

C 1 - 50 50

723 Brake ramp:

1 = fl at,

50 = steep

C 4 - 50 50

Adjustment

13 - 50

Group

Parameter

Description

User level

Setting range

Set value

7

729 Start delay after lowering presser foot [ms] B 0 - 2550 120

730 Lift delay for presser foot after seam end [ms] B 0 - 2550 0

731 Stitch count delay for end backtack C 0 - 2550 70

732 Delay time for cutting after single end backtack

[ms]

C 0 - 2550 30

733 Delay time from switch on feed conversion

to speed start [ms]

C 0 - 200 30

739 Delay time for speed after start backtack or

stitch condensation [ms]

C 0 - 2550 200

740 Stitch count delay for end backtack [ms] C 0 - 2550 60

760 Stitch count to bobbin thread monitor

(machine stop in needle lowered position)

A 0 - 50000 1000

761 Extension thread tension release/pull thread

[ms]

B 0 - 2550 0

791 Stitch count delay for start backtack [ms] C 0 - 2550 30

797 Hardware test B ON - OFF OFF

798 User level

0 = user level A

1 = mechanic level C

11 = service level C

A 0 - 11 0

799 Selected machine class

1 = 2481-980

2 = 2483-980

3 = 2438-980

4 = 2481-906

C 1 - 4 3

800 Motor rotating direction when looking at V-

Celt pulley

1= anti-clockwise, 0 = clockwise

C ON - OFF OFF

8

801 Reversing angle (618 = ON) C 5 - 106 16

831 Start delay for stepping motor 2 [increments] B 0 - 10 5

832 Needle position (feed start) B 0 - 127 77

833 Needle position (feed end) B 0 - 127 6

834 Feed regulator-balance

[1 semi-step = 5/100mm]

B -5 - 5 0

Adjustment

13 - 51

Group

Parameter

Description

User level

Setting range

Set value

8

835 Reduced single stitch [%] A 0 - 100 50

843 Distance sensor 1 to sensor 2 [1/10mm] B 75 - 85 80

844 Distance sensor 1 to needle [2/10mm] B 80 - 300 100

845 Speed-controlled stitch length adjustment

[% pro 1000 min-1]

B 0 - 3 1

846 Feed regulator characteristic line adjustment

for forward stitch length [%]

A 70 - 100

▲

847 Feed regulator characteristic line adjustment

for reverse stitch length [%]

A 70 - 100

▲

849 Maximum stitch length [1/10 mm] A 0 - 60 25

862 Current for stepping motor axis 1 A 16 - 63 32

863 Current for current reduction of stepping

motor axis 1

A 8 - 63 32

864 Proportional amplifi cation of the speed control

(general)

B 0 - 2500 500

880 Starting current main drive C 1 - 10 10

881 Filter parameter for position controller C 0 - 12 5

884 Proportional amplifi cation of the speed con-

trol (general)

C 1 - 50 15

885 Integral amplifi cation of the speed control C 1 - 50 35

886 Proportional amplifi cation of the position con-

troller

C 1 - 50 30

887 Differential amplifi cation of the position con-

troller

C 1 - 50 30

889 Time for position control (0 = permanently) C 0 - 2550 200

890 Proportional amplifi cation of higher rank-

ing speed controller for standstill brake (rest

brake)

C 1 - 50 25

891 Proportional amplifi cation of subordinate

speed controller for standstill brake (rest brake)

C 1 - 50 20

9

901 Cutting release-speed C 180 - 500 400

956 Current for stepping motor axis 2 B 30 - 63 56

▲

= By the factory adjusted