Page 1
2481
INSTRUCTION MANUAL
-3/01-980/30
This instruction manual applies to machines
from the serial number 2 809 573 and
software version 0307/010 onwards.
296-12-19 272/002
Instruction Manual engl. 05.16
Page 2
This instruction manual applies for all models and subclasses listed in chapter 3
Technical Data.
The adjustment manual for the machine can be downloaded at no charge
under www.pfaff-industrial.de/de/service-support/downloads/technical.
As an alternative to the Internet download, the adjustment manual can also be
ordered as a hard copy under order no. 296-12-19 273/001.
Reprinting, reproduction and/or translation of PFAFF instruction manuals (including parts
thereof) is only permitted with our prior agreement and citation of the source.
PFAFF Industriesysteme
und Maschinen GmbH
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
Page 3
Table of Contents
Contents ..................................................................................Page
1 Safety .................................................................................................................................... 6
1.01 Directives ............................................................................................................................... 6
1.02 General safety instructions .................................................................................................... 6
1.03 Safety symbols ...................................................................................................................... 7
1.04 Special points of attention for the owner-operator ................................................................ 7
1.05 Operating personnel and technical staff ................................................................................ 8
1.05.01 Operating personnel .............................................................................................................. 8
1.05.02 Technical staff ........................................................................................................................ 8
1.06 Danger warnings .................................................................................................................... 9
2 Proper Use .......................................................................................................................... 10
3 Technical Data
s
................................................................................................................ 11
3.01 PFAFF 2481-980/30 .............................................................................................................. 11
4 Disposal of the Machine .................................................................................................... 12
5 Transport, Packaging and Storage ................................................................................... 13
5.01 Transport to the customer's premises ................................................................................ 13
5.02 Transport within the customer's premises .......................................................................... 13
5.03 Disposal of the packaging materials .................................................................................... 13
5.04 Storage ................................................................................................................................ 13
6 Work Symbols .................................................................................................................... 14
7 Operating Controls ............................................................................................................ 15
7.01 Main switch ......................................................................................................................... 15
7.02 Keys on the machine head .................................................................................................. 15
7.03 Pedal .................................................................................................................................... 16
7.04 Hand lever to raise the sewing foot ..................................................................................... 16
7.05 Knee switch ......................................................................................................................... 17
7.06 Control panel ........................................................................................................................ 17
8 Set-up and Initial Commissioning .................................................................................... 19
8.01 Set-up .................................................................................................................................. 19
8.01.01 Setting the table height ....................................................................................................... 19
8.01.02 Inserting the sewing machine into the stand ...................................................................... 20
8.02 Connecting the plug-in connections and ground cable ........................................................ 22
8.03 Assembling the reel stand ................................................................................................... 23
8.04 Initial start-up ....................................................................................................................... 24
8.05 Switching the machine on / off ............................................................................................ 24
8.06 Checking the start inhibitor function .................................................................................... 24
Page 4
Table of Contents
Contents ..................................................................................Page
9 Set-up .................................................................................................................................. 25
9.01 Inserting the needle ............................................................................................................ 25
9.02 Winding the bobbin thread, adjusting the thread tension .................................................... 26
9.03 Removing / inserting the bobbin case ................................................................................. 27
9.04 Inserting the bobbin case / adjusting the bobbin thread tension ......................................... 27
9.05 Threading the needle thread / adjusting the needle thread tension .................................. 28
9.06 Entering the stitch length .................................................................................................... 29
9.07 Entering the edge guide position ......................................................................................... 30
9.08 Entering the start and end backtacks .................................................................................. 31
9.09 Entering the number of compensation stitches .................................................................. 32
9.10 Setting the number of remaining stitches for the bobbin thread monitor ........................... 33
9.11 Selecting the seam program ................................................................................................ 35
9.12 Setting the control panel ...................................................................................................... 36
9.13 Inserting and removing the SD memory card ...................................................................... 38
10 Sewing ................................................................................................................................ 39
10.01 Manual sewing .................................................................................................................... 39
10.02 Programmed sewing ........................................................................................................... 41
10.03 Error messages .................................................................................................................... 42
11 Input .................................................................................................................................... 43
11.01 Input mode .......................................................................................................................... 43
11.02 Entering seam programs ..................................................................................................... 44
11.03 Example for seam program input ........................................................................................ 50
11.04 Parameter settings .............................................................................................................. 54
11.04.01 Overview of parameter functions ........................................................................................ 54
11.04.02 Example of a parameter entry ............................................................................................. 55
11.04.03 List of parameters ................................................................................................................ 56
11.05 Error messages and description .......................................................................................... 62
11.06 Sewing motor errors ............................................................................................................ 63
Page 5
Table of Contents
Contents ..................................................................................Page
12 Maintenance and Care ....................................................................................................... 64
12.01 Maintenance intervals .......................................................................................................... 64
12.02 Cleaning the machine .......................................................................................................... 64
12.03 Topping up the oil tank ........................................................................................................ 65
12.04 Cleaning the blower air filter ................................................................................................ 65
13 Table Top ............................................................................................................................ 66
13.01 Table top cutout ................................................................................................................... 66
13.02 Table top assembly .............................................................................................................. 67
14 Wearing Parts ..................................................................................................................... 68
Page 6
Safety
1 Safety
1.01 Directives
1.02 General safety instructions
The machine was built in compliance with the European regulations specified in the declara-
tion of conformity and declaration of incorporation.
As a supplement to this instruction manual, please also observe the generally applicable,
legal and other regulations and legislation – also in the country of use – and the valid
environmental protection regulations! Always comply with the locally applicable regulations
of the professional associations and other supervisory authorities!
O The machine may only be operated after you have become acquainted with the associ-
ated instruction manual and only by operating personnel who have received appropriate
training!
O Always read the safety instructions and the instruction manual of the motor manufactur-
er before starting up the machine!
O Always follow the hazard and safety instructions attached to the machine!
O The machine may only be operated for its intended purpose and only with the associated
safety covers, while adhering to all the relevant safety requirements.
O The machine must always be disconnected from the power supply by pressing the main
switch or pulling out the mains plug when sewing tools are replaced (such as the needle,
sewing foot, needle plate and bobbin) and when threading, leaving the workstation, or
performing maintenance!
O The daily maintenance work may only be carried out by suitably qualified personnel!
O Repairs and special maintenance work may only be carried out by technical staff or peo-
ple with appropriate training!
O Work on electrical equipment may only be carried out by qualified technical staff!
O Work on parts and equipment under voltage is not permitted!
O Exceptions are regulated by the EN 50110 standards.
O Modifications and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
O Only those replacement parts approved by us for usage may be used for repairs! We
warn you expressly that spare parts and accessories that are not supplied by us are also
not tested and approved by us.
Fitting or using these products may therefore have negative effects on features which
depend on the machine design. We are not liable for any damage caused by the use of
non-Pfaff parts.
6
Page 7
Safety
1.03 Safety symbols
Hazard point!
Special points of attention.
Risk of injury to operating personnel or technical staff!
Electric voltage!
Danger to operating personnel or technical staff
Caution!
Do not operate without finger guard and safety covers!
Turn off the main switch before threading, changing the
bobbin or needle, cleaning, etc.!
1.04 Special points of attention for the owner-operator
O This instruction manual is a part of the machine and must be made available to the
operating personnel at all times. The instruction manual must have been read before the
initial start-up.
O The operating personnel and technical staff must be instructed about the machine’s
safety covers and about safe working methods.
O The owner-operator may only operate the machine in a flawless condition.
O The owner-operator must ensure that no safety covers are removed or disabled.
O The owner-operator must ensure that only authorised persons work on the machine.
Additional information can be requested from the responsible sales centre.
7
Page 8
Safety
1.05 Operating personnel and technical staff
1
.05.01 Operating personnel
Operating personnel are persons responsible for equipping, operating and cleaning the ma-
chine and for fault clearance in the sewing area.
The operating personnel are obligated to comply with the following points:
O The safety instructions provided in the instruction manual must be followed for all work!
O Any work method jeopardising machine safety must be refrained from!
O Tight-fitting clothing must be worn. The wearing of jewellery such as chains and rings is
prohibited!
O Care must be taken to ensure that no unauthorised persons are located in the machine’s
hazard zone!
O Any changes occurring on the machine which impair its safety must be reported to the
owner-operator immediately!
1.05.02 Technical staff
Technical staff are persons with technical training in electricity/electronics and mechanics.
They are responsible for lubricating, servicing, repairing and adjusting the machine.
The technical staff are obligated to comply with the following points:
O The safety instructions provided in the instruction manual must be followed for all work!
O Turn off the main switch and secure it against reactivation before starting any adjustment
and repair work!
O Never work on live parts and equipment!
Exceptions are regulated by the EN 50110 standards.
O Reattach the safety covers following repair and maintenance work!
8
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Safety
1.06 Danger warnings
A work area of 1 m must be kept free in front of and behind the machine to ensure unobstructed access at all times.
Do not reach into the needle range during the sewing operation!
Risk of injury from the needle!
Do not allow any objects to be placed on the table during the adjustment work!
The objects could become jammed or be slung away!
Risk of injury from parts flying around!
1
Fig. 1 - 01
2
4
3
Do not operate the machine without the take-up lever guard 1!
Risk of injury due to the motion of the take-up lever!
Do not operate the machine without the finger guard 2!
Risk of injury from the needle!
Do not operate machines with an integrated motor without the start inhibitor 3!
Risk of injury due to accidental machine start-up!
Do not operate the machine without the support 4! Risk of damage due to the
top-heavy sewing head!
Machine can tip over backwards when moving it!
9
Page 10
Proper Use
2 Proper Use
The PFAFF 2481-980/30 is an ultra high-speed, single-needle seamer with a needle and drop
feed as well as a seam-program controlled edge guide and edge sensor.
The machines are used for sewing lockstitch seams in the clothing industry.
Any usage not approved by the manufacturer is deemed misuse!
The manufacturer shall assume no liability for damage caused by misuse!
Proper use also includes compliance with the operating, maintenance,
adjustment and repair measures specified by the manufacturer!
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Technical Data
3 Technical Data s
3
.01 PFAFF 2481-980/30
Stitch type: ......................................................................................................... 301 (lockstitch)
Needle system: ...............................................................................................................134 KK
Model BN3.5: ............................................................... for the machining of medium materials
Needle size in 1/100 mm .............................................................................................. 90 - 110
Thread thickness max.: ........................................................................................................ 120
Stitch length max: ..........................................................................................................3.5 mm
Needle bar stroke: ..........................................................................................................30 mm
Speed max.: ............................................................................................... 4500 stitches/min l
Clearance beneath the sewing foot: ............................................................................4 - 6 mm
Passage width: .............................................................................................................300 mm
Clearance height: ..........................................................................................................125 mm
Bed plate dimensions: ............................................................................................... 516 x 177
Sewing head dimensions:
Length: ............................................................................................................. approx. 580 mm
Width: ..............................................................................................................approx. 180 mm
Height (above table): ........................................................................................ approx. 300 mm
Ambient temperature
85% rel. humidity (condensation not permitted) ......................................................... 5 - 40 °C
Connection data:
Operating voltage: ................................................................................ 230 V ± 10%, 50/60 Hz
Max. input power: ...........................................................................................................400 VA
Fuse protection: ...................................................................................................1 x 16 A, inert
Leakage current: .......................................................................................................... < 5 mA
u
Noise data:
Emissions sound pressure level in the workplace at n = 2700 min-1: .............. LpA = 80 dB(A) n
(Noise measurement in accordance with DIN 45 635-48-A-1,ISO 11204, ISO 3744,
ISO 4871)
Net weight of sewing head: ................................................................................ approx. 52 kg
Gross weight of sewing head: ............................................................................. approx. 62 kg
s
Subject to alterations
l
Depending on the material, workstep and stitch length
u
Due to the use of network filters there is a nominal leakage current of < 5 mA.
n
KpA = 2,5 dB
11
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Disposal of the Machine
4 Disposal of the Machine
O It is up to the customer to dispose of the machine properly.
O The materials used for the machine include steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
O The machine must be disposed of in accordance with the locally valid environmental pro-
tection regulations, with a specialised company being contracted if necessary.
Please ensure that parts coated with lubricants are disposed of separately in
accordance with the locally valid environmental protection regulations!
12
Page 13
Transport, Packaging and Storage
5 Transport, Packaging and Storage
5.01 Transport to the customer's premises
All machines are completely packed for delivery.
5.02 Transport within the customer's premises
The manufacturer assumes no liability for transport within the customer's premises or to
the individual usage sites. Please ensure that the machines are only transported in a vertical
position.
5.03 Disposal of the packaging materials
The packaging materials of these machines consists of paper, cardboard and VCI fleece. It is
up to the customer to dispose of the packaging properly.
5.04 Storage
The machine can be stored for up to 6 months when not in use. It must then be protected
from dirt and moisture. For longer storage periods, the machine's single components,
especially its sliding surfaces, must be protected against corrosion, e.g. by an oil film.
13
Page 14
Work Symbols
6 Work Symbols
Activities to be performed or important information in this instruction manual are
emphasised by symbols. The symbols used have the following meaning:
Note, information
Cleaning, care
Lubrication
Maintenance, repairs, adjustment, service work
(only to be carried out by technical staff)
14
Page 15
Operating Controls
7 Operating Controls
7.01 Main switch
Before switching on the
machine, raise the take-up lever
as far as possible.
O Turning the main switch 1 switches the
machine on and off.
1
Fig. 7 - 01
7.02 Keys on the machine head
O The following functions are carried out
by operating the respective keys.
Key 1: Reverse sewing
Key 2: Raise the needle without thread
2
3
trimming
Key 3: Carry out a single stitch
1
Fig. 7 - 02
15
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Operating Controls
7.03 Pedal
O With the main switch turned on
0 = Neutral position
-1
Fig. 7 - 03
-2
0
+1
+1 = Sewing
-1 = Raise sewing foot
-2 = Trim thread/reset bobbin
thread monitor or bobbin rest
thread count function
7.04 Hand lever to raise the sewing foot
1
Fig. 7 - 04
O Turning the hand lever 1 raises the
sewing foot.
16
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Operating Controls
7.05 Knee switch
O When the knee switch 1 is operated,
one stitch is sewn with a reduced stitch
length (standard).
The value for the reduced stitch
length is set with parameter
"835", see chapter 11.04
Parameter settings.
O If the edge guide connector is inserted
into the bushing X47, the edge guide can
1
be moved back using the knee switch.
Fig. 7 - 05
7.06 Control panel
1
2
2 GB
max.
Fig. 7 - 06
The current operating statuses are indicated on the control panel 1. The machine
is operated with constant dialogue between the control unit and the operator; different
pictograms and / or texts are displayed for this purpose according to the operating status of
the machine. Pictograms or texts with a border represent
17
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Operating Controls
functions that can be called up by pressing on the respective point on the monitor. Pressing
the respective function causes its immediate actuation or activation/deactivation or another
menu will appear, e.g. for entering a value. Activated functions are indicated by pictograms
shown inversely. Apart from the bobbin change function, the pictograms and texts without
border are only for display purposes and cannot be called up by pressing them.
SD card 2 in the control panel can be used to import seam programs.
Presentation of functions
Normal pictogram = Function deactivated (inactive)
Inverse pictogram = Function activated (active)
18
Page 19
Set-up and Initial Commissioning
8 Set-up and Initial Commissioning
The machine may only be set up and started up by qualified personnel! All of
the relevant safety regulations must always be complied with in this process!
If the machine was delivered without a table, then the stand and the table top
provided must safely support the weight of the machine and its motor.
Adequate stability of the stand must be guaranteed, even during the sewing
operations.
8.01 Set-up
Suitable electrical supply connections must be provided at the erection site, see chapter 3
Technical Data. The erection site must also have a firm and level subsurface and adequate
lighting.
The table top is lowered for packaging purposes.
The adjustment of the table height is described below.
8.01.01 Setting the table height
1
2
Fig. 8 - 01
O Loosen the screws 1 and 2.
O Move the table top to the desired working height by pulling it out and pushing it in and
align the table top horizontally.
Adjust the stand on both sides evenly to prevent it tilting.
O The stand must have all four feet firmly on the ground to make sure it is positioned
securely.
1
O Firmly tighten the screws 1.
O Adjust and tighten the desired pedal position on the screws 2.
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Set-up and Initial Commissioning
8.01.02 Inserting the sewing machine into the stand
2
1
1
Fig. 8 - 02
O The hinge 1 is screwed to the sewing head base plate.
O Insert the sewing machine into the table top.
O Insert the sewing head support 2 into the table top hole.
Do not operate the machine without the support 2! Risk of damage due to the
top-heavy sewing head!
Machine can tip over backwards when moving it!
20
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8.01.03 Assembling the start inhibitor
2
1
Set-up and Initial Commissioning
Fig. 8 - 03
O Insert the machine into the table top, see chapter 8.01.02 Inserting the sewing
machine into the stand
O After loosening the screws 2, adjust the switch 1 in such a way that the switch 1 is
actuated when the sewing head is mounted.
O Tighten the screws 2 in this position.
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Set-up and Initial Commissioning
8.02 Connecting the plug-in connections and ground cable
ACHTUNG
ATTENTION
Vertauschungsgefahr
Danger of exchange
SSI
X1/B
X11/B
Sollwertgeber
Ausgänge
Eingänge
X13
X5
RS 232/1
X1/A
CAN-BUS
X11/A
X15
Fadenwächter
Motor
X8
0
1
3
E
5
4
2
SM2
X4/A
B
X3
D
D
C
SM1
X4/B
Fig. 8 - 04
O Insert all plugs on the control box 2 in accordance with their designation.
O Insert the "motor" into the bushing X 3 and the bushing X 8.
Caution
Inserting the plug incorrectly can damage the control unit!
O Attach the following ground cables in order to discharge static electricity.
O Securely attach the ground cable from the sewing head 1 to ground point A.
O Securely attach the ground cable from the control point B to ground point B.
O Securely attach the ground cable from the main switch 3 to ground point C.
O Securely attach the ground cable from the stand 4 to ground point D.
O Securely attach the ground cable 5 from the motor to ground point E.
B
A
22
Page 23
8.03 Assembling the reel stand
Set-up and Initial Commissioning
O Assemble the reel stand as shown in the
adjacent illustration.
O Then insert the stand into the
O hole in the table top and secure it with
the enclosed nuts.
Fig. 8 - 05
23
Page 24
Set-up and Initial Commissioning
8.04 Initial start-up
O Remove the plug 1 of the oil reservoir 2
before the initial commissioning.
Danger of machine damage!
The plug 1 serves solely for
transit support and may not be
used during the sewing operations.
1
2
Fig. 8 - 06
Never operate the machine if there are any differences.
The machine must only be connected to a grounded socket!
8.05 Switching the machine on / off
O Switch the machine on (see chapter 7.01 Main switch).
O Inspect the machine, particularly the
electric cables, for any damage.
O Clean the machine thoroughly, see also
chapter 12 Maintenance and Care.
O Arrange for technical staff to check
whether the machine's motor may be
operated at the existing mains voltage
and whether it is connected properly.
24
8.06 Checking the start inhibitor function
O Switch on the machine at the main switch and move the sewing head.
The error message "ERROR: 9" must appear in the control panel.
O If the message does not appear, check the start inhibitor setting as explained in chapter
8.01.03 Assembling the start inhibitor.
O Right the sewing head and acknowledge the error message.
The machine is ready for operation again.
Page 25
Set-up
9 Set-up
Observe and comply with all regulations and instructions in this instruction
manual. Pay particular attention to all safety regulations!
All set-up work may only be carried out by appropriately instructed personnel.
Disconnect the machine from the electricity mains for all set-up work by operat-
ing the main switch or by removing the mains plug!
9.01 Inserting the needle
Switch off the machine!
Risk of injury due to accidental
machine start-up!
Fig. 9 - 01
1
Only use needles of the system
intended for the machine, see
chapter 3 Technical Data!
2
O Bring the needle bar to the top position.
O Loosen the screw 1 and insert the
needle 2 until you feel it stop. The long
groove must point to the left.
O Tighten the screw 1
25
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Set-up
9.02 Winding the bobbin thread, adjusting the thread tension
4
6
7
5
1
3
9
8
2
1
Fig. 9 -02
O Fit the empty bobbin 1 onto the bobbin winder spindle 2 with the rest thread chamber on
the outside.
O Thread in the thread as shown in Fig. 9 - 02 and wind it round the bobbin 1 a few times in
an anti-clockwise direction.
O Switch on the bobbin winder by pressing the bobbin winder spindle 2 and the lever 3
simultaneously.
The bobbin fills up during sewing.
If the machine is only run for bobbin winding (without sewing), a bobbin case
must be fitted in the hook!
Otherwise a jammed thread may damage the hook!
O The tension of the thread on the bobbin 1 can be adjusted with the knurled thumb screw
4.
O The bobbin winder stops automatically when the bobbin 1 is sufficiently full.
O Remove the filled bobbin 1 and cut the thread with the blade 5.
26
O The fill amount of the bobbin 1 can be adjusted with the pin 8 (loosen the screw 9 and
tighten it again).
If the thread is wound unevenly:
O Loosen the nut 6.
O Turn the thread guide 7 accordingly.
O Tighten the nut 6.
Page 27
Set-up
9.03 Removing / inserting the bobbin case
Switch off the machine!
Risk of injury due to accidental
machine start-up!
1
2
Fig. 9 -03
Removing the bobbin case:
O Tilt machine backwards.
O Raise the lever 1 and remove the bobbin
case 2.
Inserting the bobbin case:
O Press the bobbin case 2 until you feel it
snap into the bobbin case base.
Return the machine to its up-
right position using both hands!
Danger of injury by crushing
between the machine and the
table top
9.04 Inserting the bobbin case / adjusting the bobbin thread tension
2
1
5 cm
3
Fig. 9 -04
O Insert the bobbin 1 into the bobbin case 2 as shown in Fig. 9 - 04.
O Pass the thread through the slot under the spring as shown in Fig. 9 - 05.
When the thread is drawn off, the bobbin must turn in the direction shown by the
arrows.
O Adjust the thread tension by turning the screw 3.
Fig. 9 -05
27
Page 28
Set-up
9.05 Threading the needle thread / adjusting the needle thread tension
1
+
-
Fig. 9 - 06
Switch off the machine!
Risk of injury due to accidental machine start-up!
O Thread the needle thread as shown in Fig. 9 - 06. Please ensure that the needle is
threaded from the left.
28
O Adjust the needle thread tension by turning the adjusting wheel 1.
Page 29
Set-up
9.06 Entering the stitch length
The stitch length can be entered or altered directly in manual sewing mode.
O Switch the machine on.
O Call up the stitch length input menu.
O Enter the stitch length with the number keys.
O or
O Alter the stitch length step by step.
O Conclude the input and take over the altered value.
The stitch length value is displayed in mm.
29
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Set-up
9.07 Entering the edge guide position
The edge guide position can be entered or altered directly in the manual sewing mode.
O Switch the machine on.
O Call up the edge guide position input menu.
O Enter the edge guide position with the number keys.
O or
O Alter the edge guide position step by step.
O Conclude the input and take over the altered value.
The edge guide position value is displayed in mm.
30
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Set-up
9.08 Entering the start and end backtacks
The start and end backtacks can be entered or altered directly in the manual sewing mode.
O Switch the machine on.
O Switch on start backtack and/or end backtack (the corresponding symbol is shown as an
inverse symbol).
O Select the desired value for the number of forward stitches (A) of the start backtack.
O Select the desired value for the number of reverse stitches (B) of the start backtack.
O Select the desired value for the number of reverse stitches (C) of the end backtack.
O Select the desired value for the number of forward stitches (D) of the end backtack.
31
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Set-up
9.09 Entering the number of compensation stitches
In the manual sewing mode it is possible to enter the number of compensation stitches,
which will be sewn after the recognition of the material edge till the machine stops.
O Switch the machine on.
O Switch on the edge sensor and call up the compensation stitches input menu.
O Enter the number of compensation stitches with the number keys.
O or
O Enter the number of compensation stitches step by step.
O Conclude the input and take over the altered value.
32
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Set-up
9.10 Setting the number of remaining stitches for the bobbin thread monitor
There is still an amount of remaining thread on the bobbin when the bobbin thread monitor
signals that the bobbin thread has been used up.
O Switch the machine on.
O Call up "Entry" mode.
A 100
O Call up parameter '660'.
A 660
O Switch on the bobbin thread monitor (value "1").
100
1
Explanation of the values for parameter "660" (bobbin thread monitor)
0 = off
1 = remaining thread counter on
2 = bobbin thread reverse counter on
33
Page 34
Set-up
O Call up parameter '760'.
A 760
O Set the number of remaining stitches, which can still be sewn after the signal from the
bobbin thread monitor (depends on the thread size).
O End input entry.
The number of remaining stitches can be altered in 200-steps.
1200
34
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Set-up
9.11 Selecting the seam program
With the seam program selection function it is possible to select either manual or
programmed sewing. The programmed sewing function is called up by selecting a seam
program number from 0 - 65.
O Switch the machine on.
O Call up the seam program selection menu.
0 - 65
O Enter the seam program number with the number keys.
O or
O Scroll through the seam program numbers.
O Conclude the input and change to the programmed sewing mode with the selected
seam program number.
O or
O Take over the selected program number and change into the seam programming
function, see chapter 11.02 Entering the seam program.
O or
O Select the manual sewing mode. The program number is not taken over.
35
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Set-up
9.12 Setting the control panel
O Switch the machine on.
O Call up "Entry" mode.
A 100
O Select user level "C", see chapter 14.11.02 Selecting the user level in the adjustment
manual.
O Call up the service menu.
100
36
O Call up the control panel functions.
Page 37
Set-up
O Change the display contrast.
O Switch the key tone off or on.
O End input entry.
Never reduce the display contrast to such an extent that the display can no
longer be read!
37
Page 38
Set-up
9.13 Inserting and removing the SD memory card
Insert the SD card
O Slide the cover 1 upwards to open it.
1
2
2 GB
max.
3
O Insert the SD card 2 into the card slot with
the label facing forwards.
O Slide the cover 1 upwards to close it.
Only use FAT 16 format
memory cards.
Remove the memory card
O Slide the cover 1 upwards to open it.
O Press gently on the corner of the SD card 2 -
the SD card will be ejected.
O Slide the cover 1 upwards to close it.
Fig. 9 - 07
Adjusting the slide 3 makes it possible to activate ("LOOK" position) or deactivate
the write protection function on the SD card. The write protection function must
be deactivated to store, edit or delete data on the SD card.
O The SD card must be kept for future boot processes.
O The SD card is not a default configuration.
38
.
Page 39
Sewing
10 Sewing
In the sewing mode a difference must be made between manual sewing and programmed
sewing. In the manual sewing mode, in addition to the functions such as edge guide, stitch
length, seam securing, needle functions, presser foot functions and seam end conditions,
the parameter for securing seams are also displayed and can be altered directly. The current
seam lock parameters also apply in programmed sewing. The change from programmed to
manual sewing and vice versa is effected with the program number selection function.
10.01 Manual sewing
In the manual sewing mode all the parameters necessary for the sewing operation can be
changed directly. The manual sewing mode is selected with the program number selection
function, see chapter 9.11 Selecting the seam program. The selection of the manual sew-
ing mode is shown by the symbol of a hand on the display instead of the program number.
O Switch the machine on.
O Select the manual sewing mode, see chapter 9.11 Selecting the seam program.
Description of the functions
Seam program selection
Opens the menu for entering the seam program number or for selecting the manual sewing
mode, see chapter 9.11 Selecting the seam program.
Edge guide position
Opens the menu for entering the edge guide position, see chapter 9.07 Entering the edge
guide position.
Stitch length
Opens the menu for entering the stitch length, see chapter 9.06 Entering the stitch length.
Number of stitches for the start and end backtacks
With the use of this input area the number of stitches for the start and end backtacks are
entered, see chapter 9.08 Entering the start and end backtacks.
39
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Sewing
Start backtack
Switches the start backtack function on or off.
End backtack
Switches the end backtack function on or off.
Needle position raised
When this function is activated, the needle is positioned at top dead centre after sewing
stops.
Sewing foot raised
When this function is activated, the sewing foot is raised after sewing stops.
Seam end with pedal
When this function is activated, the seam end is initialised manually with the pedal.
Seam end with sensor / compensation stitches
Opens the menu for entering the compensation stitches, see chapter 9.09 Entering the
number of compensation stitches.
When this function is switched on, the seam end is initialised automatically with the edge
sensor.
Sewing foot raised after thread trimming
When this function is activated, the sewing foot is raised after thread trimming.
Thread trimming
When the function is activated, thread trimming with the pedal function is possible.
Backtack suppression
When operated, the next bartack is suppressed.
Input mode
Calls up the input mode.
In addition, when the bobbin thread monitoring function is activated, the
number of remaining stitches is shown, and when the speed display function
is activated the current speed is shown, see chapter 11.04.03 List of
parameters.
O Sewing is carried out using the pedal functions, see chapter 7.03 Pedal.
40
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Sewing
10.02 Programmed sewing
In the programmed sewing mode the seam parameters are set in a seam program. The
program number selection function is used to call up a seam program. The selected program
number, a sketch of the seam with the number of programmed seam zones, the current
seam zone and the parameters for the current seam zone are displayed. The parameters for
the current seam zone cannot be changed directly.
O Switch the machine on.
O Select the seam program, see chapter 9.11 Selecting the seam program.
3
Explanation of the functions and displays
Seam program selection
Opens the menu for entering the seam program number or for selecting the manual sewing
mode, see chapter 9.11 Selecting the seam program.
Edge guide position
Displays the current edge guide position.
Stitch length
Displays the current stitch length
Number of seam zones
3
Displays the total number of seam zones in the seam program.
Select seam zones
This function is used to select the seam zones of the current seam program.
Current seam zone
Display and selection of the current seam zone using the number keys.
Backtack suppression
When operated, the next bartack is suppressed.
Enter the seam program
Opens the menu for entering and altering the seam programs, see chapter 11.02 Entering
the seam program.
41
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Sewing
10.03 Error messages
Input mode
Calls up the input mode.
Depending on the seam program, further symbols showing corresponding
values or selected functions may appear on the display.
In addition, when the bobbin thread monitoring function is activated, the
number of remaining stitches is shown, and when the speed display function
is activated the current speed is shown, see chapter 11.04.03 List of
parameters.
O Sewing is carried out using the pedal functions, see chapter 7.03 Pedal.
If an error occurs, the text "ERROR" appears on the display, together with an error code. An
error message is generated by incorrect settings, faulty elements or seam programs, as well
as overloading.
For an explanation of the error codes, see chapter 11.05 Error codes and description.
42
O Correct the fault.
O Acknowledge the elimination of the error.
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Input
11 Input
This chapter describes the input mode functions and how to enter seam programs.
11.01 Input mode
When the machine is in its initial state, it is possible to enter the parameters and the cor-
responding values directly in the control unit. The functions information, adjustment of the
transmitted light sensors and service can be called up.
O Switch the machine on.
O Call up "Entry" mode.
A 100
Description of the functions
Sewing mode
Quit the input mode and call up the sewing mode.
Parameter selection
Select the hundred and unit figures of the desired parameters, see chapter11.04.02
Example of a parameter input.
Altering the parameter value
Change the value of the selected parameter, see chapter11.04.02 Example of a parameter
input.
Software information
Calls up information about the current machine software.
100
Adjusting the transmitted light sensors
Opens the menu for adjusting the transmitted light sensors, see chapter 14.08 Adjusting
the transmitted light sensors in the adjustment manual.
Service
Opens the service menu, see chapter 14.13 Service menu in the adjustment manual.
43
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Input
11.02 Entering seam programs
Seam programs are created by establishing seam zones which are allocated certain
functions and values. It is possible to store up to 65 seam programs each with 15 seam
zones. The maximum number of seam zones in each seam program and the maximum
number of seam programs can be limited by setting appropriate parameters, see chapter
11.04 Parameter settings.
O Switch the machine on.
O Select the program number, see chapter 9.11 Selecting the seam program.
O Call up seam program input.
3
Description of the functions
Seam program selection
Opens the menu for entering the seam program number or for selecting the manual sewing
mode, see chapter 9.11 Selecting the seam program.
Edge guide position
Opens the menu for entering the edge guide position, see chapter 9.07 Entering the edge
guide position.
Stitch length
Opens the menu for entering the stitch length, see chapter 9.06 Entering the stitch length.
Selecting the seam type
Shows the current seam program with the corresponding seam zones and opens the menu
3
for selecting the seam type, see chapter 11.02.01 Selecting the seam types.
44
Start backtack
Switches the start backtack function on or off.
End backtack
Switches the end backtack function on or off.
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Input
Needle position raised
When this function is activated, the needle is positioned at top dead centre after sewing
stops.
Sewing foot raised
When this function is activated, the sewing foot is raised after sewing stops.
Sewing foot raised after thread trimming
When this function is activated, the sewing foot is raised after thread trimming.
Thread trimming
When the function is activated, thread trimming with the pedal function is possible.
Speed
Opens the speed input menu.
When this function is activated, it is possible to sew the seam zone with the set speed,
irrespective of the pedal setting.
Seam end with pedal
When this function is activated, the seam end is initialised manually with the pedal.
Reverse sewing direction
When this function is activated, the corresponding seam zone is sewn in reverse.
Sewing stop
When this function is activated, sewing stops automatically at the end of the seam zone.
Seam zone end with sensor
Opens the menu for entering the seam depth and the correction value for corner stitches,
see chapter 11.02.02 Entering the seam depth.
When this function is switched on, the sensor recognises the seam end automatically.
Seam zone end with stitch counting
Opens the menu for entering the number of stitches for the current seam zone.
When this function is activated, the seam zone end is initialised by the stitch counting
function.
Select seam zones
This function is used to select the seam zones of the current seam program.
Current seam zone
Display and selection of the current seam zone using the number keys.
Sewing mode
Quit the seam program input mode and call up the sewing mode.
45
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Input
11.02.01 Selecting the seam types
For better information during programming and sewing, it is possible to show a diagram of
different seam types. To do so, the seam types must be allocated to the seam programs.
With the exception of the free seam, for each seam type the number of seam zones and the
starting point is set. The functions and values in the individual seam zones can be altered.
The seam types are divided into groups for flaps, cuffs, collars and shoulder flaps. In addi-
tion, one free description space is available, if it is not possible to select a pre-assigned work
step from one of the groups. The group currently activated is shown by an inverse symbol.
O Switch the machine on.
O Select the program number, see chapter 9.11 Selecting the seam program.
O Call up seam program input.
12
3
O Call up the seam type selection menu.
3
46
O Select the desired seam group.
Page 47
Input
O Select the desired seam type.
When a seam type has been selected, the machine switches to the seam program input
function.
O Overview of the seam groups with their corresponding seam types:
Free seam Flap
Cuffs Collars
Shoulder flaps
47
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Input
11.02.02 Entering the seam depth
As the edge sensors are arranged for sewing at right angles, if other angles to the edge
have to be sewn, a correction value must be entered.
O Switch the machine on.
O Select the program number, see chapter 9.11 Selecting the seam program.
O Call up seam program input
12
3
2.0
0.0
0
O Call up the seam depth input menu.
O Enter the desired seam depth.
O Call up the correction value input menu
48
0.0
Page 49
Input
0.0
O Using the number keys call up the correction value input menu and enter the correction
value
O or
O Place the workpiece on the angle outline on the display and adjust the angle.
The correction value is calculated automatically from the adjusted angle.
O Conclude the input and take over the correction value.
49
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Input
3 mm
11.03 Example for seam program input
This is a description of how to enter a seam program, using a seam with corner stitches as
an example.
O Switch the machine on.
Program number 16
Programmnummer: 16
Stitch length = 2.2 mm
Stichlänge = 2,2 mm
45°
3 mm
16
O Call up the seam program number input menu and select program number "16", see
chapter 9.11 Selecting the seam program.
O Call up seam program input.
3
2.0
0.0
0
O Call up the menu for selecting the seam types, see chapter 11.02.01 Selecting the
seam types.
3
O Select the desired seam group.
O Select the desired seam type.
50
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Input
3.0
3.0
3
0
0
1
O Seam zone 0
All values entered in this seam zone are valid for all other seam zones in the
seam program, unless they are altered in the individual seam zones.
O Call up the stitch length input menu and enter the stitch length "2.2", see chapter 9.06
Entering the stitch length.
O Call up the menu for entering the edge guide position and enter the edge guide position
"3.0", see chapter 9.07 Entering the edge guide position.
O Call up the seam depth input menu and enter the seam depth "3.0".
O Select the seam zone one.
2.0
0.0
O Call up the correction value input menu.
1.9
135
135
1.9
3.0
3.0
O Place the workpiece on the angle outline on the display and adjust the angle.
The correction value is calculated automatically from the adjusted angle.
O Conclude the input and take over the correction value.
O Switch on the automatic sewing stop at the end of the seam zone function.
51
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Input
2
3
O Select the seam zone two.
O Call up the correction value input menu.
O Place the workpiece on the angle outline on the display and adjust the angle.
The correction value is calculated automatically from the adjusted angle.
O Conclude the input and take over the correction value.
O Switch on the automatic sewing stop at the end of the seam zone function.
O Select the seam zone three.
O Call up the correction value input menu.
O Place the workpiece on the angle outline on the display and adjust the angle.
The correction value is calculated automatically from the adjusted angle.
O Conclude the input and take over the correction value.
O Switch on the automatic sewing stop at the end of the seam zone function.
4
O Select the seam zone four.
O Call up the correction value input menu.
O Place the workpiece on the angle outline on the display and adjust the angle.
The correction value is calculated automatically from the adjusted angle.
52
O Conclude the input and take over the correction value.
O Switch on the automatic sewing stop at the end of the seam zone function.
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Input
5
6
0.0
O Select the seam zone five.
O Switch on the thread trimming function.
O Select the seam zone six.
O Call up the stitch length input menu and enter the stitch length "0", see chapter 9.06 En-
tering the stitch length.
The fifth seam zone is then recognised as the last seam zone.
O Conclude the seam program input by taking over the inputs and change to the
programmed sewing mode.
53
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Input
11.04 Parameter settings
11
.04.01 Overview of parameter functions
After switching on the machine, the input mode in which the individual parameters can be
called up directly is called up by pressing the corresponding function. All parameter groups
or also individual ones can be protected by a code against unauthorised access.
Select parameter
100 User level
200 Mechanic level
300 Sewing motor positions
400 Times
500 Counter and revolution speed
700 Sewing motor
800 Access rights
54
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Input
11.04.02 Example of a parameter entry
O Switch the machine on.
O Call up "Entry" mode.
A 100
O e.g. Select parameter "660" (bobbin thread monitor)
A 660
100
1
O Switch on the bobbin thread monitor (value "1").
O Conclude the parameter input.
55
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Input
11.04.03 List of parameters
Group
0 10 Bobbin thread monitor current level C 8 - 16 12
11 Bobbin thread monitor stitch counter C 0 - 255 32
(Start value)
1 100 Control panel contrast [%] A 90 - 110 100
101 Control panel key response signal A 0 - 1 1
0=tone off / 1=tone on
102 Start backtack stitches forwards C 0 - 9 3
103 Start backtack stitches in reverse C 0 - 9 3
105 Start backtack speed B 100 - 1500 900
106 Start backtack speed: C OFF - ON OFF
ON = pedal-controlled
OFF = set with param. "105"
107 Pedal-controlled start backtack speed: C OFF - ON OFF
ON = limited with parameter "105"
OFF = limited with parameter "607"
Parameter
Description
User
level
Setting
range
Set
value
108 End backtack stitches in reverse C 0 - 9 3
109 End backtack stitches forwards C 0 - 9 3
110 End backtack speed B 100 - 1500 1000
111 No. of stitches from bright light barrier A 1 - 255 6
to seam end in manual sewing
113 Start with light barrier B OFF - ON ON
ON = only when light barrier is dark
OFF = also when light barrier is bright
114 After light barrier or stitch counting: C OFF - ON OFF
ON = stop
OFF = autom. end backtacks and
seam end
116 Soft starting stitches (soft start) A 0 - 10 1
117 Speed for soft starting stitches B 180 - 1200 400
148 Start backtacks A OFF - ON ON
ON = double / OFF = single
149 End backtacks A OFF - ON ON
ON = double / OFF = single
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Input
Group
1 199 Speed for B 300 - 1500 1200
2 206 Seam interrupt with pedal -2 C OFF - ON OFF
220 Speed level 12 (poti-reserve) [min-1] A 300 - 5000 4500
221 Speed limit B 300 - 5000 4500
for seam programs [min-1]
222 Speed constant B 300 - 5000 3000
for seam programs [min-1]
298 Number of reduced stitches A 1 - 3 1
299 Edge guide position in A 10 - 185 185
"manual sewing" [1/10 mm]
3 323 Min. edge guide position [1/10 mm] B 10 - 50 10
325 Max. edge guide position [1/10 mm] B 165 - 185 185
347 Bobbin changer 0= OFF / 1= ON B OFF - ON 0
348 Bobbin changer (pick-up time in 10 ms) B 0 - 100 20
349 Bobbin changer (hold bobbin, B 0 - 100 10
activate in 10 ms)
350 Bobbin changer (hold bobbin, B 0 - 100 10
deactivate in 10 ms)
4 419 Bartacks: C OFF - ON ON
ON = inverted
OFF = suppressed
478 Corner stitch C OFF - ON ON
ON = accurate
OFF = quick (faster cycle time at
the expense of accuracy)
492 Number of seam programs B 1 - 99 99
493 Number of speed prog. per seam prog. B 1 - 15 25
494 Max. number of sequences B 1 - 15 3
495 Max. number of program entries in the
sequence B 3 - 15 5
5 554 Presser foot after seam section C OFF - ON ON
with pedal forwards:
ON = raised / OFF = lowered
584 Interlock mechanism: C OFF - ON OFF
ON = fourfold / OFF = normal
6 601 Cutting: B OFF - ON ON
ON = on / OFF = off
602 ON = Cutting with pedal -1 C OFF - ON OFF
OFF = Cutting with pedal -2
603 ON = Pedal stops after cutting C OFF - ON ON
OFF = immediate start after seam end
Parameter
Description
light barrier compensation stitches [min-1]
User level
Setting
range
Set
value
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Input
Group
6 604 Cutting: C OFF - ON ON
ON = forwards after semi end backtack
OFF = in reverse too
605 Speed display: B OFF - ON OFF
ON = on / OFF = off
606 Speed level 1 (min.) [min-1] B 30 - 550 180
607 Speed level 12 (max.) [min-1] B 300 - 5000 4500
609 Cutting speed [min-1] B 60 - 500 180
618 Reverse turning angle B OFF - ON OFF
ON = on / OFF = off
624 Start inhibitor: ON = on / OFF = off C OFF - ON ON
642 Presser foot time from switch-on C 10 - 50 50
to tension reduction (timing)
651 Automatic lowering of presser foot: C OFF - ON ON
ON = on / OFF = off
Parameter
Description
User
level
Setting
range
Set
value
660 Bobbin thread monitor: A 0 - 2 1
0 = off, 1 = on
2 = bobbin thread reverse counter on
668 Thread wiper = 1, B 0 - 2 2
Thread clamp = 2, 0 = off
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 B 40 - 80 70
(start thread tension release)
710 Needle position B 80 - 127 106
(needle raised without cutting)
715 Operating time of thread wiper [ms] B 0 - 2550 120
58
718 Moment of B 0 - 100 0
standstill brake (rest brake)
Page 59
Input
Group
7 719 Sewing 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: C 1 - 50 50
1 = flat / 50 = steep
723 Brake ramp: C 4 - 50 50
1 = flat / 50 = steep
729 Start delay after B 0 - 2550 120
lowering the presser foot [ms]
730 Lift delay B 0 - 2550 0
for presser foot after seam end [ms]
731 Stitch count delay for end backtacks C 0 - 2550 70
732 Holdoff time for cutting C 0 - 2550 30
after simple end backtack [ms]
Parameter
Description
User
level
Setting
range
Set
value
733 Holdoff time from C 0 - 200 30
switch-on feed reverse
to speed start [ms]
739 Holdoff time for speed C 0 - 2550 200
after start backtack or
stitch condensation [ms]
740 Stitch count delay for end backt. [ms] C 0 - 2550 60
760 Stitch count to bobbin thread monitor A 0 - 50000 1000
(machine stop in needle lowered pos.)
761 Extension B 0 - 2550 0
Thread tension release/
thread puller [ms]
791 Stitch count delay C 0 - 2550 30
for start backtacks [ms]
797 Hardware test: ON = on / OFF = off B OFF - ON OFF
798 User level: A 0 - 255 0
0 = User level A
1 = Mechanic level B
11 = Service level C
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Input
Group
7 799 Machine class: C 1 - 4 1
1 = 2481
(2 to 4 = other machine classes)
8 800 Rotating direction of motor C OFF - ON ON
801 Reverse turning angle C 5 - 106 16
(618 = ON)
831 Start delay for B 0 - 10 5
stepping motor 2 [increments]
832 Needle position (feed start) B 0 - 127 15
833 Needle position (feed end) B 0 - 127 67
834 Feed regulator balance B -5 - 5 0
[1 semi-step = 5/100mm]
835 Reduced single stitch [%] A 0 - 100 50
843 Distance sensor 1 to sensor 2 B 75 - 85 80
[1/10mm]
Parameter
Description
User
level
Setting
range
Set
value
844 Distance sensor 1 to needle [2/10mm] B 80 - 300 200
845 Speed-controlled B 0 - 3 1
stitch length adjustment
[% per 1000 min-1]
846 Feed regulator characteristic line adj. A 80 - 110
for forward stitch length [%]
847 Feed regulator characteristic line adj. A 80 - 110
for reverse stitch length [%]
849 Maximum stitch length [1/10 mm] A 0 - 60 25
862 Current for stepping motor axis 1 C 16 - 63 32
863 Current for current reduction of C 8 - 63 32
stepping motor axis 1
864 Stepping motor axis 1
Standstill duration of edge
guide (pause between 2 movements B 0 - 2500 20
in ms)
60
= factory set
Page 61
Input
Group
8 880 Starting current main drive C 1 - 10 8
881 Filter parameter for position controller C 0 - 12 5
884 Proportional amplification C 1 - 50 25
of speed control (general)
885 Integral amplification C 0 - 50 35
of speed control
886 Proportional amplification C 1 - 50 30
of position controller
887 Differential amplification C 1 - 50 30
of position controller
889 Time for position control (0 = always) C 0 - 2550 200
890 Proportional amplification of C 1 - 50 25
higher ranking speed controller
for standstill brake (rest brake)
891 Proportional amplification of C 1 - 50 20
lower ranking speed controller
for standstill brake (rest brake)
Parameter
Description
User
level
Setting
range
Set
value
9 901 Cutting release speed C 180 - 500 400
956 Current for stepping motor axis 2 B 30 - 63 56
957 Current for current reduction B 15 - 48 39
of stepping motor axis 2
958 Current red. time stepping motor axis 2 B 0 - 2500 2000
978 Current red. time stepping motor 2 C 0 - 99 0
979 Current red. time stepping motor 1 C 0 - 99 0
985 Position for thread clamp on B 0 - 127 34
986 Position for thread clamp off B 0 - 127 103
61
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Input
11.05 Error messages and description
Error Description
ERROR: 1 Pedal not at neutral position
ERROR: 3 SM 1 Edge guide (for reference)
ERROR: 4 SM 2 Feed regulator (for reference)
ERROR: 5 Control panel
ERROR: 6 OTE
ERROR: 7 Can node missing (if bobbin changer can node is missing)
ERROR: 8 Zig-zag sensor
ERROR: 9 Starting lock-out at standstill
ERROR: 10 Wrong machine class
ERROR: 20 Incorrect software version on BDF - P1
ERROR: 27 SD card
ERROR: 40 Transmitted light sensors
ERROR: 45 Bobbin thread monitor
ERROR: 46 Bobbin changer if timeout
ERROR: 47 Bobbin changer empty (if magazine is empty)
ERROR: 48 Bobbin changer error with can node suberror
ERROR: 60
ERROR: 61 Power supply 24 V too high
ERROR: 62 Short circuit 24 V
ERROR: 63 Overload switch power supply
ERROR: 92 Start inhibitor when motor running
ERROR: 97 SM 1
ERROR: 98 SM 2
ERROR: 100 Non-maskable interrupt
ERROR: 151 System
ERROR: 155 Sewing motor
ERROR: 156 Timeout communication
ERROR: 157 Stepping motor ramps
ERROR: 158 Stepping motor frequency
Power supply 24 V too low
62
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Input
11.06 Sewing motor errors
Error Description
ERROR: 34 Brake path too short
ERROR: 35 Communication
ERROR: 64 Mains monitor
ERROR: 65 Excess current directly after mains on
ERROR: 66 Short circuit
ERROR: 67 Mains off
ERROR: 68 Excess current during operation
ERROR: 69 No increments
ERROR: 70 Motor blocked
ERROR: 71 No incremental encoder connector
ERROR: 73 Faulty motor operation
ERROR: 75 Control locked
ERROR: 170 Transmission invalid
ERROR: 171 Zero mark invalid
ERROR: 173 Motor blocked in 1st stitch
ERROR: 175 Internal starting error
ERROR: 222 Dead man monitoring
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Maintenance and Care
12 Maintenance and Care
12.01 Maintenance intervals
Cleaning ........................................................daily, several times if in continuous operation
Clean the hook area ......................................daily, several times if in continuous operation
Check oil level ...................................................................................... daily, before start-up
Lubricate the bevel gears ..................................................................................once as year
Clean the blower air filter ................................................................................... as required
These maintenance intervals are based on an average running time of a single
shift production shop. Shorter maintenance intervals are recommended for in-
creased running times.
12.02 Cleaning the machine
The required cleaning cycle for the machine depends on the following factors:
O Single or multi-shift operation
O Dust formation caused by the workpieces
Optimal cleaning instructions can therefore only be determined on a case-by-case basis.
Disconnect the machine from the electricity mains for all cleaning work by shut-
ting off the main switch or removing the mains plug! Risk of injury due to acci-
dental machine start-up!
The following tasks are recommended
during single shift operation to avoid
operational errors:
O Tilt machine backwards.
O Clean the hooks and hook area daily or
more often during continuous operation.
Return the machine to its
upright position using both
hands!
64
Danger of injury by crushing
between the edge of the
machine and the table top.
Fig. 12 - 01
Page 65
Maintenance and Care
12.03 Topping up the oil tank
The oil reservoir must always
have oil in it.
O Whenever it is necessary to refill the res-
ervoir, tilt back the machine and let it rest
on the sewing head support.
O Fill the oil through the hole 1 into the res-
1
ervoir 2 up to the level of the front edge
(see arrow).
Return the machine to its
upright position using both
hands!
Fig. 12 - 02
Only use oil with a centre viscosity of 22.0 mm
0.865 g/cm3 at 15 °C.
We recommend PFAFF sewing machine oil part no. 280-1-120 144.
12.04 Cleaning the blower air filter
2
O Remove the cover 1.
O Remove the filter element and blow it
out with compressed air.
O Insert the cleaned filter element and re-
place the cover 1.
Danger of injury by crushing
between the machine and the
table top.
2
/s at 40 °C and a density of
1
Fig. 12 - 03
65
Page 66
Table top assembly
13 Table Top
13.01 Table top cutout
66
Page 67
Table top cutout
13.02 Table top assembly
200
906-3550-005/895
R2 umlaufend
c
c 2
R2 umlaufend
28
28
17
Ø
Lage EMT-Gestell
-0,5
100
35
175
1060
70
14 H11
Ø
150
-0,5
Ausschnitt-Bemaßung
siehe Zeichnung 906-4001-168
-0,5
-0,5
5(6x)
2,5
Ø
18635
40
600
120 102,5 102,5
67
Page 68
Wearing Parts
14 Wearing Parts
91-100 296-25 (2x)
91-701 179-15 (2x)
This list shows the most important wearing parts.
A detailed parts list for the complete machine can be downloaded at www.
pfaff-industrial.de/de/service-support/downloads/technical. As an alternative
to the Internet download, the parts list can also be requested as a hard copy
under order no. 296-12-19 272.
11-330 085-15
11-108 174-25
95-774 361-05
99-137 190-05 (3x)
99-137 186-05
91-262 377-91
99-137 192-05
System 134 KK
91-262 250-91
91-262 376-91
99-137 187-15 (2x)
99-137 188-15
99-137 415-05 (4x)
68
99-137 194-05
99-137 191-05
99-137 193-05
Page 69
Wearing Parts
11-108 087-15
91-264 235-15
91-264 338-91
99-137 151-45
91-264 240-05
11-108 084-15 (2x)
11-108 222-15
91-171 049-05
91-171 042-05
95-774 464-25
91-700 996-15
69
Page 70
PFAFF Industriesysteme
und Maschinen GmbH
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
Tel.: +49 - 6301 3205 - 0
Fax: +49 - 6301 3205 - 1386
E-mail: info@pfaff-industrial.com
Gedruckt in der BRD / Printed in Germany / Imprimé en la R.F.A. / Impreso en la R.F.A
© PFAFF is the exclusive trademark of VSM Group AB I PFAFF Industriesysteme und Maschinen GmbH is an authorized licensee of the PFAFF trademark.
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