Page 1
3519-5/01
INSTRUCTION MANUAL
This instruction manual applies to machines
from the serial number 2 814 134 and
software version 0361/021 onwards.
296-12-19 384/002
Instruction manual engl. 12.17
Page 2
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 .................................................................................................................................... 7
1.01 Directives ............................................................................................................................... 7
1.02 General safety instructions .................................................................................................... 7
1.03 Safety symbols ...................................................................................................................... 8
1.04 Special points of attention for the owner-operator ................................................................ 8
1.05 Operating personnel and technical staff ................................................................................ 9
1.05.01 Operating personnel .............................................................................................................. 9
1.05.02 Technical staff ........................................................................................................................ 9
1.06 Danger warnings .................................................................................................................. 10
2 Proper Use .......................................................................................................................... 11
3 Technical Data
................................................................................................................. 12
4 Disposal of the Machine .................................................................................................... 13
5 Transportation, Packaging and Storage .......................................................................... 14
5.01 Transport to the customer's premises ................................................................................ 14
5.02 Transport within the customer's premises .......................................................................... 14
5.03 Disposal of the packaging materials .................................................................................... 14
5.04 Storage ................................................................................................................................ 14
6 Work Symbols .................................................................................................................... 15
7 Operating Controls ............................................................................................................ 16
7.01 Main switch ......................................................................................................................... 16
7.02 Push-buttons on the machine control unit ........................................................................... 16
7.03 Switch for the suction air blower (option) ............................................................................ 17
7.04 Emergency stop push-button .............................................................................................. 17
7.05 Control panel ........................................................................................................................ 18
7.06 Pedal .................................................................................................................................... 18
7.07 Start keys ............................................................................................................................. 19
7.08 Key for small parts stacker .................................................................................................. 19
8 Set-up and Initial Start-up ................................................................................................. 20
8.01 Set-up .................................................................................................................................. 20
8.01.01 Aligning the machine ........................................................................................................... 20
8.01.02 Removing the transit support on the infeed table ............................................................... 21
8.01.03 Removing the sewing machine transit support ................................................................... 21
8.01.04 Removing the loading clamp transit support ....................................................................... 22
8.01.05 Assembling the reel stand ................................................................................................... 23
8.01.06 Connecting the pedal ........................................................................................................... 23
8.02 Initial start-up ....................................................................................................................... 24
8.03 Switching the machine on / off ............................................................................................ 25
8.04 Setting the control panel (only for the control panel BDF T1) .............................................. 26
Page 4
Table of Contents
Contents ..................................................................................Page
9 Set-up .................................................................................................................................. 27
9.01 Inserting the needle ............................................................................................................. 27
9.02 Threading the needle thread / adjusting the needle thread tension .................................... 28
9.03 Winding the bobbin thread / adjusting the bobbin thread tension ....................................... 29
9.04 Changing the bobbin / adjusting the bobbin thread tension ................................................ 30
9.05 Changing the insert for darts ............................................................................................... 31
9.06 Adjusting the ironing compensation strip feeder ................................................................. 32
9.07 Selecting a program number ............................................................................................... 33
9.08 Selecting / compiling program groups ................................................................................. 34
9.08.01 Selecting a program group ................................................................................................... 34
9.08.02 Compiling a program group ................................................................................................. 35
10 Sewing ................................................................................................................................ 36
10.01 Inserting the workpiece ....................................................................................................... 37
10.01.01 Inserting the workpiece using the positioning tube ............................................................. 37
10.01.02 Inserting the workpiece using the infeed table ................................................................... 39
10.02 Sewing in automatic mode .................................................................................................. 40
10.03 Sewing in manual mode ...................................................................................................... 41
10.04 Error messages .................................................................................................................... 43
11 Input .................................................................................................................................... 44
11.01 Overview of the functions in input mode ............................................................................ 44
11.02 Creating / altering seam programs ....................................................................................... 46
11.02.01 Creating / altering single-point darts .................................................................................... 48
11.02.02 Creating / altering double-point darts ................................................................................... 49
11.02.03 Creating / altering tapered darts .......................................................................................... 50
11.02.04 Entering a comment ............................................................................................................ 51
11.02.05 Entering correction values ................................................................................................... 52
11.02.06 Concluding seam programming ........................................................................................... 53
11.03 Program management ......................................................................................................... 54
11.04 Rights of access .................................................................................................................. 56
12 Maintenance and Care ....................................................................................................... 59
12.01 Maintenance intervals .......................................................................................................... 59
12.02 Cleaning the entire machine ................................................................................................ 59
12.03 Cleaning the needle area and hook area .............................................................................. 60
12.04 Cleaning the blower air filter ................................................................................................ 61
12.05 Cleaning the maintenance unit air filter ............................................................................... 61
12.06 Checking / setting the air pressure ...................................................................................... 62
12.07 Checking the oil level ........................................................................................................... 63
12.08 Lubricating the trimmer ....................................................................................................... 64
12.09 Lubricating the stacker drive ................................................................................................ 65
13 Adjustment ......................................................................................................................... 66
13.01 Notes on adjustment ........................................................................................................... 66
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Table of Contents
Contents ..................................................................................Page
13.02 Tools, gauges and other accessories .................................................................................. 66
13.03 Abbreviations ....................................................................................................................... 66
13.04 Sewing head service position .............................................................................................. 67
13.05 Adjusting the sewing head .................................................................................................. 69
13.05.01 Adjustment aid ..................................................................................................................... 69
13.05.02 Machine drive home position .............................................................................................. 70
13.05.03 Needle in needle hole centre ............................................................................................... 71
13.05.05 Hook lubrication ................................................................................................................... 73
13.05.06 Needle bar rise, hook-to-needle clearance, needle height and bobbin case position finger 74
13.05.07 Thread check spring and slack thread regulator .................................................................. 75
13.05.08 Bobbin winder ...................................................................................................................... 76
13.06 Adjusting the thread trimmer ............................................................................................... 77
13.06.01 Pre-adjusting the control cam .............................................................................................. 77
13.06.02 Roller lever setting ............................................................................................................... 78
13.06.03 Aligning the thread trimmer laterally .................................................................................... 79
13.06.04 Knife position ....................................................................................................................... 80
13.06.05 Front turning point of the thread catcher ............................................................................. 81
13.06.06 Manual cutting control ......................................................................................................... 82
13.08.07 Control cam (recalibrating) ................................................................................................... 83
13.07 Adjusting the loading plate .................................................................................................. 84
13.07.01 Basic setting of the loading plate height .............................................................................. 84
13.07.02 Loading plate position .......................................................................................................... 85
13.07.03 Insertion depth of the loading plate ..................................................................................... 86
13.08 Aligning the sewing head .................................................................................................... 87
13.08.01 Sewing head height ............................................................................................................. 87
13.08.02 Aligning the sewing head laterally ....................................................................................... 88
13.09 Aligning the surface plate .................................................................................................... 89
13.10 Adjusting the positioning tube ............................................................................................. 90
13.10.01 Presetting the positioning tube ............................................................................................ 90
13.10.02 Front final position of the positioning tube .......................................................................... 91
13.10.03 Height and alignment of the positioning tube ...................................................................... 92
13.11 Height of the needles .......................................................................................................... 93
13.12 Adjusting the spreader ......................................................................................................... 94
13.13 Adjusting the table extension .............................................................................................. 95
13.14 Adjusting the loading clamp ................................................................................................. 96
13.14.01 Loading clamp height ........................................................................................................... 96
13.14.02 Position of the loading clamp ............................................................................................... 97
13.15 Adjusting the brushes .......................................................................................................... 98
13.15.01 Adjusting the long brushes .................................................................................................. 98
13.15.02 Adjusting the short brushes ................................................................................................. 99
13.16 Adjusting the knife unit ...................................................................................................... 100
13.16.01 Presetting the knife unit .................................................................................................... 100
13.16.02 Knife unit height ................................................................................................................. 101
13.16.03 Changing the knife ............................................................................................................. 102
13.17 Aligning the workholder bar ............................................................................................... 103
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Table of Contents
Contents ..................................................................................Page
13.17.01 Zero point of the workholder bar ....................................................................................... 103
13.17.02 Workholder bar stop .......................................................................................................... 104
13.18 Setting the pneumatic table pressure ................................................................................ 105
13.19 Adjusting the pressure controller ....................................................................................... 106
13.20 Adjusting the stacker ......................................................................................................... 107
13.21 Adjusting the small parts stacker ....................................................................................... 108
13.22 Boot key ............................................................................................................................. 109
13.23 Service menu ..................................................................................................................... 110
13.23.01 Cold start ........................................................................................................................... 112
13.23.02 Machine configuration ....................................................................................................... 113
13.23.03 Loading / updating the operating program ......................................................................... 114
13.24 Sewing motor menu .......................................................................................................... 115
13.25 Parameter settings ............................................................................................................ 116
13.25.01 Selecting and changing parameters ................................................................................... 116
13.25.02 List of parameters .............................................................................................................. 117
14 Control .............................................................................................................................. 119
14.01 Home position / diagnostics / pin assignment ................................................................... 119
14.01.01 Power supply A30 .............................................................................................................. 119
14.01.02 Basic control unit A20 ........................................................................................................ 121
14.01.03 Sewing drive A22 ............................................................................................................... 123
14.01.04 Stepping motor drive ......................................................................................................... 124
14.01.05 CAN nodes A10, A11, A12 ................................................................................................ 125
14.02 Explanation of error messages .......................................................................................... 127
14.02.01 General errors .................................................................................................................... 127
14.02.02 CAN errors ......................................................................................................................... 129
14.02.03 Stitch generation ................................................................................................................ 129
14.02.04 Sewing motor errors .......................................................................................................... 130
14.02.05 Stepping motor drive errors ............................................................................................... 131
14.03 List of inputs and outputs .................................................................................................. 132
14.03.01 CAN node 1 ....................................................................................................................... 132
14.03.02 CAN node 2 ....................................................................................................................... 133
14.03.03 CAN node 3 ....................................................................................................................... 134
14.03.04 Special outputs .................................................................................................................. 135
15 Pneumatic Circuit Diagram ............................................................................................. 136
16 Circuit Diagrams ...........................................................................................................143
Reference list for the circuit diagrams ................................................................... 143
Page 7
Safety
1 Safety
1
.01 Directives
The machine was built in compliance with the regulations specified in the EC declaration 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!
1.02 General safety instructions
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!
Always read the safety instructions and the instruction manual of the motor manufacturer
before starting up the machine!
Always follow the hazard and safety instructions attached to the machine that must not
be removed!
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.
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, presser foot, needle plate etc.) when leaving the workstation and performing
maintenance!
The daily maintenance work may only be carried out by suitably qualified personnel!
The machine must be isolated from the power supply and pneumatic supplies before
any maintenance work and repairs are performed! The only permitted exceptions are for
adjustment work and functional tests by appropriately trained technical staff!
Repairs and special maintenance work may only be carried out by technical staff or
people with appropriate training!
Work on electrical equipment may only be carried out by qualified technical staff!
Work on parts and equipment under voltage is not permitted!
Exceptions are regulated by the EN 50110 standards.
Modifications and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
Only the 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 and/or using these products may therefore have neg-
ative effects on features which depend on the machine design. We are not liable for any
damage caused by the use of non-Pfaff parts.
7
Page 8
Safety
1.03 Safety symbols
Hazard point!
Special points of attention
Risk of injury to operating personnel and technical staff!
Danger area due to laser beam!
Attention!
Do not operate without the finger guard and safety cov-
ers!
Turn off the main switch before set-up, maintenance
and cleaning work!
Only one person in the work area!
Only one person may be in the work area of the machine during operation!
Do not lean on!
The feed mechanism can be damaged if you lean on the infeed table!
1.04 Special points of attention for the owner-operator
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.
The operating personnel and technical staff must be instructed about the machine's
safety covers and about safe working methods.
The owner-operator may only operate the machine in a flawless condition.
The owner-operator must ensure that no safety covers are removed or disabled.
The owner-operator must ensure that only authorised persons work on the machine.
Additional information can be requested from the responsible sales centre.
8
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Safety
1.05 Operating personnel and technical staff
1
.05.01 Operating personnel
Operating personnel are persons responsible for setting up, operating and cleaning the
machine, and for error clearance in the work area.
The operating personnel are obligated to comply with the following points:
The safety instructions provided in the instruction manual must be followed for all work!
Any work method jeopardising machine safety must be refrained from!
Tight-fitting clothing must be worn. The wearing of jewellery such as chains and rings is
prohibited!
Care must be taken to ensure that no unauthorised persons are located in the machine's
hazard zone!
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:
The safety instructions provided in the instruction manual must be followed for all work!
Turn off the main switch and secure it against reactivation before starting any adjustment
and repair work!
Never work on live parts and equipment! Exceptions are regulated by the EN 50110
standards.
Reattach the safety covers following repair and maintenance work!
9
Page 10
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 work area of the machine during the sewing operation!
Risk of injury from the needles in the sewing head and feed unit!
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!
Do not look at the laser beam with or without optical aids!
Risk of retinal injuries to the eye from the concentrated light!
2
3
1
4
5
10
Fig. 1 - 01
Only operate the machine with the closed covers 1 and 2!
Risk of injury from moving machine parts!
The emergency stop push-button 3 is used to stop the machine immediately in
emergency situations.
Page 11
2 Proper Use
The PFAFF 3519-5/01 is an automatic sewing machine and is used for sewing single and
double-point breast darts on jackets.
Proper Use
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!
11
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Technical Data
3 Technical Data
Stitch type: ......................................................................................................... 301 (lockstitch)
Needle system: .................................................................................................................... 134
Needle size in 1/100 mm: ............................................................................................. 80 - 100
Stitch length: ..........................................................................................................0.5 - 3.0 mm
Max. stitch count: ......................................................................................... 4300 stitches/min
Start backtack stitch length: ................ Standard stitch length of half of standard stitch length
Start backtack stitch count: ................................................................................................ 1 - 9
Starting / end stitch condensation stitch length: .........................................................1 - 3 mm
Starting / end stitch condensation stitch count: .................................................................. 1- 9
Size of sewing area
Dart depth: .................................................................................................................5 - 12 mm
Dart length: ............................................................................................................ 80 - 395 mm
Max. sewable material thickness: ....................................................................................4 mm
Machine dimensions
Length: .......................................................................................................... approx. 2,800 mm
Width: ............................................................................................................1,200 - 1,800 mm
Height: ...........................................................................................................approx. 1400 mm
Weight
Net weight ......................................................................................................... approx. 628 kg
Gross weight ..................................................................................................... approx. 796 kg
Connection data
Operating voltage: ............................................................................... 230 V ± 10 %, 50/60 Hz
Max. input power: .............................................................................................................3 kVA
Fuse protection: ...................................................................................................1 x 16 A, inert
Leakage current: .......................................................................................................... < 5 mA
Working air pressure .......................................................................................................... 6 bar
Air consumption: ...............................................................................approx. 25 l/working cycle
Ambient temperature
85% rel. humidity (condensation not permitted) ......................................................... 5 - 40 °C
Noise data
Noise emission level at workplace with a sewing speed of 4300 min
-1
: ........LpA < 81.9 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204,
ISO 3744, ISO 4871)
12
Subject to alterations
Due to the use of network filters there is a nominal leakage current of < 5 mA.
KpA = 2.5 dB
Page 13
Disposal of the Machine
4 Disposal of the Machine
It is up to the customer to dispose of the machine properly.
The materials used for the machine include steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
The machine must be disposed of in accordance with the locally valid environmental
protection 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!
13
Page 14
Transportation, Packaging and Storage
5 Transportation, 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 consist 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.
14
Page 15
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)
15
Page 16
Operating Controls
7 Operating Controls
7
.01 Main switch
Turning the main switch 1 switches the
power supply on or off.
1
Fig. 7 - 01
7.02 Push-buttons on the machine control unit
Pressing the push-button 1 after
switching on the power supply via the
main switch, see chapter 7.01 Main
switch, switches the machine control
unit on and the machine is ready for
1
operation.
The push-button 1 lights up
when the machine is ready for
operation.
16
Fig. 7 - 02
Page 17
Operating Controls
7.03 Switch for the suction air blower (option)
The suction blower integrated
into the machine is only
required if there is no vacuum
network at the erection site.
Pressing the push-button 1 switches the
suction air blower on.
Pressing the push-button 2 switched the
suction air blower off.
2
Fig. 7 - 03
1
7.04 Emergency stop push-button
1
Fig. 7 - 04
Pressing the emergency stop push-
button 1 stops the machine immediately
in emergency situations.
The emergency stop pushbutton 1 must only be pressed
in emergency situations!
After releasing the depressed
EMERGENCY STOP pushbutton 1, the machine can be
switched on again via the push-
button on the machine control
unit, see chapter 7.02 Push-
buttons on the machine
control unit.
17
Page 18
Operating Controls
2 GB
max.
7.05 Control panel
The current operating statuses are indicated
on the control panel 1. The machine is
1
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
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.
2
Fig. 7 - 05
Activated functions are indicated by pictograms shown inversely. Pictograms or texts
without a border are only used for display purposes and cannot be called up by pressing
them.
The SD card 2 in the control panel can be used to import seam programs and operating
software.
7.06 Pedal
Pressing the pedal 1 switches the
suction air for the infeed table and the
positioning tube on or off.
1
18
Fig. 7 - 06
Page 19
Operating Controls
7.07 Start keys
1
1
Fig. 7 - 07
The sewing cycle is started by pressing the two start keys 1 at the same time.
After processing the sewing cycle, the lit start keys 1 show that the next
sewing cycle can be started.
When the threading aid function is active, the infeed table is moved forward and the
hook area of the sewing head becomes accessible after pressing both of the start keys 1
at the same time.
7
.08 Key for small parts stacker
1
Pressing the key 1 switches the small
parts stacker on or off.
Fig. 7 - 08
19
Page 20
Set-up and Initial Start-up
8 Set-up and Initial Start-up
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!
8.01 Set-up
Suitable electrical and compressed air 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.
8.01.01 Aligning the machine
1
2
20
Fig. 8 - 01
Loosen the nuts 1 and turn the feet 2 so that the machine is horizontal.
Tighten the nuts 1.
The alignment on the lower frame tubes can be checked with a spirit level.
Page 21
Set-up and Initial Start-up
8.01.02 Removing the transit support on the infeed table
Unscrew the screw 1.
Loosen the screw 2 and remove the
angle bracket 3.
Tighten the screw 2 again.
2
3
1
Fig. 8 - 02
8.01.03 Removing the sewing machine transit support
Unscrew the screws 1 and 2.
Remove the angle bracket 3.
3
1
2
2
Fig. 8 - 03
21
Page 22
Set-up and Initial Start-up
8.01.04 Removing the loading clamp transit support
2
1
2
Fig. 8 - 04
Open the cover 1.
Unscrew the screws 2.
Close the cover 1 again.
22
Page 23
8.01.05 Assembling the reel stand
Set-up and Initial Start-up
Assemble the reel stand as shown in the
adjacent illustration.
Then insert the stand into the hole on
the machine stand and secure it with the
enclosed nuts.
Fig. 8 - 05
8.01.06 Connecting the pedal
Insert the connector 1 into the corre-
2
sponding bushing on the machine stand.
1
Secure the connector with the lever 2.
Secure the supply cable to the
pedal 3 on the machine stand
(e.g. with cable clips) to prevent
a tripping hazard!
3
Fig. 8 - 06
23
Page 24
Set-up and Initial Start-up
8.02 Initial start-up
Before the initial start-up, clean the machine thoroughly and lubricate or fill the oil, see
chapter 12 Maintenance and Care!
Inspect the machine and in particular the electric lines and pneumatic connecting hoses
for possible damage.
Arrange for technical staff to check whether the machine may be operated at the existing
mains voltage and whether it is connected properly.
Do not operate the machine if there are any differences!
The machine must only be connected to a grounded socket!
Connect the machine to the compressed
air system and push the slide closure 1
upwards.
Fig. 8 - 07
It must have a supply pressure of 6 bar.
Set this value if necessary, see chap-
ter 12.06 Monitoring / adjusting the air
pressure.
1
24
Page 25
8.03 Switching the machine on / off
Switch the machine on
Switch on the main switch, see chapter 7.01 Main switch.
Switch on the machine control unit, see chapter 7.02 Push-buttons on the machine
control unit.
Move the machine to home position after booting up the machine control unit to confirm
the switch-on process.
Switch on the suction air blower if necessary, see chapter 7.03 Switch for the suction
air blower.
Set-up and Initial Start-up
Carry out a test run, see chapter 10 Sewing.
Switch the machine off
Switch off the main switch.
Description of further functions on the display
Input menu
This function is used to call up input mode, see chapter 11 Input.
25
Page 26
Set-up and Initial Start-up
8.04 Setting the control panel (only for the control panel BDF T1)
Switch the machine on.
Call up "Input" mode.
Call up the service menu.
Change the display contrast.
Never reduce the display contrast to such an extent that the display can no
longer be read!
Conclude the input.
26
Page 27
Set-up
9 Set-up
Observe and comply with all regulations and information 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
operating the main switch or by removing the mains plug!
9.01 Inserting the needle
Only use needles of the system
intended for the machine, see
chapter 3 Technical Data!
1
2
Fig. 9 - 01
Switch on the machine, see chapter 8.03 Switching the machine on / off.
Call up the threading aid function.
The workholder bar moves out of the needle area, the presser foot is lowered and the
sewing start is disengaged.
Loosen the screw 1 and insert the needle 2 into the needle bar until you feel it stop.
Adjust the needle 2 so that the long needle groove is pointing forwards and tighten the
screw 1.
Move the machine to the last position prior to the threading.
or
Move the machine to home position.
27
Page 28
Set-up
9.02 Threading the needle thread / adjusting the needle thread tension
1
+
-
Fig. 9 - 02
Switch on the machine, see chapter 8.03 Switching the machine on / off.
Call up the threading aid function.
The workholder bar moves out of the needle area, the presser foot is lowered and the
sewing start is disengaged.
Thread the needle thread as shown in Fig. 9 - 02. Please ensure that the needle is
threaded from the left.
Adjust the needle thread tension by turning the adjusting wheel 1.
28
Move the machine to the last position prior to the threading.
or
Move the machine to home position.
Page 29
Set-up
9.03 Winding the bobbin thread / adjusting the bobbin thread tension
4
1
5
9
3
2
8
6
7
Fig. 9 - 03
Switch on the machine, see chapter 8.03 Switching the machine on / off.
Fit the empty bobbin 1 onto the bobbin winder spindle 2 with the rest thread chamber on
the outside.
Thread in the thread as shown in Fig. 9-03 and wind it round the bobbin 1 a few times in
an anti-clockwise direction.
Switch on the bobbin winder by pressing the bobbin winder spindle 2 and the lever 3
simultaneously.
The bobbin 1 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!
The tension of the thread on the bobbin 1 can be adjusted with the knurled thumb screw
4.
The winder will stop automatically when the bobbin 1 is sufficiently full.
Remove the filled bobbin 1 and cut the thread with the knife 5.
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:
Loosen the nut 6.
Turn the thread guide 7 accordingly.
Tighten the nut 6.
See chapter 13.05.08 Bobbin winder to adjust the fill amount.
29
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Set-up
9.04 Changing the bobbin / adjusting the bobbin thread tension
2
1
+
Fig. 9 - 04
Switch on the machine, see chapter 8.03 Switching the machine on / off.
5 cm
3
Call up the threading aid function.
The workholder bar moves out of the needle area, the presser foot is lowered and the
sewing start is disengaged.
Press both start keys at the same time, see chapter 7.07 Start keys.
The infeed table moves forward and the hook area of the sewing head becomes
accessible.
Raise the lever 1 and remove the bobbin case 2 together with the bobbin.
Insert the filled bobbin in the bobbin case 2 so that the bobbin turns in the direction of
the arrow when taking up the thread.
Pass the thread through the slot under the spring as shown in Fig. 9-04.
Adjust the bobbin thread tension by turning the screw 3.
Raise the lever 1 and insert the bobbin case 2 together with the bobbin into the hook.
Release the lever 1 and press the bobbin case into the hook until you feel it snap in.
Move the machine to the last position prior to the threading.
or
Move the machine to home position.
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Set-up
9.05 Changing the insert for darts
1
2
3
Fig. 9 - 05
Screw the pin 1 provided into the threaded hole of the insert 2.
Pull out the insert 2.
Insert a new insert according to the dart depth.
Use the blind insert 3 for double-point darts.
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Set-up
9.06 Adjusting the ironing compensation strip feeder
1
Fig. 9 - 06
Loosen the screw 1.
Adjust the ironing compensation strip feeder according to the dart length.
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Set-up
9.07 Selecting a program number
Switch the machine on.
Call up the menu to input the program number.
Select the desired program number.
...
The program numbers are allocated as follows:
Program numbers 0 - 199: Single-point darts
Program numbers 200 - 299: Double-point darts
Program numbers 300 - 399: Tapered darts
Confirm the selection and leave the selection menu.
Description of further functions
Clear
This function sets the value to "0".
Arrow keys
These functions increase or decrease the value.
Esc
This function cancels the entry without the value entered being taken over.
Group selection
This function opens the menu to select or compile a program group, see chapter 9.08 Selecting / compiling program groups.
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Set-up
9.08 Selecting / compiling program groups
9
.08.01 Selecting a program group
The corresponding group of seam programs can also be se lected instead of a program
number. This assumes that the individual seam program has been assigned to a group, see
chapter 9.08.02 Compiling a program group.
Switch the machine on.
Call up the menu to input the program number.
Call up the menu to input the group number.
...
Select the desired group number.
Confirm the selection and leave the selection menu.
Description of further functions
Clear
This function sets the value to "0".
Arrow keys
These functions increase or decrease the value.
Esc
This function cancels the entry without the value entered being taken over.
Program number selection
This functions opens the menu for selecting a seam program number, see chapter 9.07
Selecting a program number.
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Set-up
9.08.02 Compiling a program group
Up to 10 seam programs can be assigned to a program group. The seam programs in a se-
lected program group appear as a function on the display when sewing and can be selected
directly.
Call up the menu to input the group number and select the desired group number with-
out leaving the selection menu, see chapter 9.08.01 Selecting a program group.
Call up group programming.
Compile a program group from the existing seam programs by entering the program
numbers on the number block.
0 - 399
The cursor in the window shows which seam program is removed from the group or at
which point a new seam program is inserted. The cursor can be moved with the arrow
keys.
Insert (INS) the seam program at the current cursor position or delete (DEL) a marked
seam program from the sequence, as required.
Conclude group programming.
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Sewing
10 Sewing
The machine may only be operated by properly instructed personnel! The oper-
ating personnel must make sure that only authorised persons are in the danger
zone of the machine!
The sewing mode is available for the production in particular in addition to input mode, see
chapter 11 Input. All relevant functions and settings for the production are shown here
on the display depending on the program selection and the machine status. The machine
normally works in automatic mode but it can be switched to manual mode to set up and test
processes.
The following conditions must be fulfilled for the production:
O All safety devices must be fitted and all covers must be closed, see chapter 1.06 Hazard
information.
O The machine must be set up and started up properly as explained in chapter 8 Set-up
and initial start-up.
O All set-up work must have been carried out, see chapter 9 Set-up.
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Sewing
10.01 Inserting the workpiece
10
.01.01 Inserting the workpiece using the positioning tube
Workpieces with a striped or checked patter can be aligned with the aid of the
laser beam.
Do not look at the laser beam with or without optical aids!
Risk of retinal injuries to the eye from the concentrated light!
Single-point darts
0 - 320 mm
0 - 320 mm
Fig. 10 - 01
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Sewing
Double-point darts
Insertion mark
0 - 320 mm
Fig. 10 - 02
Insertion mark
0 - 320 mm
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Sewing
10.01.02 Inserting the workpiece using the infeed table
Double-point darts
Insertion mark
0 - 320 mm
Insertion mark
0 - 320 mm
Fig. 10 - 03
39
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Sewing
10.02 Sewing in automatic mode
Automatic sewing mode is always called up first after switching on the machine.
O Switch the machine on.
O Switch on the suction of the positioning tube or infeed table, see chapter 7.06 Pedal.
O Insert the workpiece, see chapter 10.01 Inserting the workpiece.
O Press the start keys to start the sewing process, see chapter 7.07 Start keys.
Description of the functions on the display
Menu to input the program number
This functions opens the menu for inputting the program number, see chapter 9.07
Selecting a program number.
Input menu
This function is used to call up input mode, see chapter 11 Input.
Program selection
These functions are used to select a program from the associated program group, see also
chapter 9.08 Selecting / compiling program groups.
Material thickness
This function opens a menu to change the material thickness.
Automatic mode
This function displays the current operating mode and switches between automatic and
manual mode.
40
Presser foot up/down
This function is used to raise or lower the presser foot.
Right/left part
This function is used to turn the automatic switching between the right and left part on or
off. The part currently being processed is displayed.
Page 41
Sewing
Threading aid function
This function activates the threading aid function, for example, see chapter 9.01 Inserting
the needle.
Stacker up/down
This function is used to move the stacker up or down.
Stop
(The function appears only during the sewing process.)
This function is used to stop the sewing process.
Start
(The function appears only when the sewing process has been stopped.)
This function is used to start the sewing sequence.
Home position
This function is used to move the machine to home position.
10.03 Sewing in manual mode
O Switch on the machine, see chapter 8.03 Switching the machine on / off.
O Call up manual sewing.
O Switch on the suction of the positioning tube or infeed table, see chapter 7.06 Pedal.
O Insert the workpiece, see chapter 10.01 Inserting the workpiece.
Description of the functions on the display
Menu to input the program number
This functions opens the menu for inputting the program number, see chapter 9.07
Selecting a program number.
Input menu
This function is used to call up input mode, see chapter 11 Input.
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Sewing
Program selection
These functions are used to select a program from the associated group, see also chapter
9.08 Selecting / compiling program groups.
Material thickness
This function opens a menu to change the material thickness.
Manual mode
This function displays the current operating mode and switches between manual and
automatic mode.
Presser foot up/down
This function is used to raise or lower the presser foot.
Right/left part
This function is used to turn the automatic switching between the right and left part on or
off. The part currently being processed is displayed.
Threading aid function
This function activates the threading aid, for example, see chapter 9.01 Inserting the
needle.
Stacker up/down
This function is used to move the stacker up or down.
Stop
(The function appears only during the sewing process.)
This function is used to stop the sewing process.
Start
This function is used to start the sewing sequence.
Home position
This function is used to move the machine to home position.
Move through the feed cycle
This function is used to move through the material feed cycle step by step.
42
Move the cycle forwards
This function is used to move forward through the sewing process step by step.
Move the cycle backwards
This function is used to move backwards through the sewing process step by step.
Page 43
Sewing
10.04 Error messages
General
The display will show a error code if a malfunction occurs. An error message is generated by
incorrect handling, malfunctions on the machine or by overload conditions. (For an explanation of the error codes, see chapter 14.02 Explanation of the error messages.)
Error when switching outputs
If an error occurs when switching an output, the relevant output is displayed with the desired switching state (0) or (I).
(0) means that the output should be switched off and (I) means that the output should be
switched on.
The cause of the error is displayed on the next line.
The target state is shown in brackets to achieve an error-free process.
The output S5 should be activated in the following example.
Condition: E4 must be set to (1).
Infeed table forwards
Workholder bar up
O Check E4 and correct the error.
O Acknowledge the elimination of the error.
Target state
Infeed table forwards
Target state
Workholder bar up
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Input
11 Input
Input mode contains the functions for displaying information, program management,
machine adjustment and configuration (incl. the choice of country and access rights), as well
as for supporting service and adjustment work in addition to the functions for inputting or
altering seam programs.
Any start-up of the machine is disabled in input mode to avoid the unintentional start-up of
the machine.
11.01 Overview of the functions in input mode
Switch the machine on.
Call up input mode.
Description of the functions
Conclude input
This function is used to conclude the input and the machine switches to sewing mode.
Seam program input
This function is used to call up the menu for inputting or altering seam programs, see
chapter 11.02 Creating/altering seam programs.
Program management
This function is used to manage the data from the machine memory and SD card, see
chapter 11.03 Program management.
Parameter settings
This function is used to call up the menu for changing parameter settings, see chapter
13.25 Parameter settings.
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Input
Info
This function opens a menu to display the following information:
- Current software status of the machine
- Current firmware status of the machine
- Current firmware status of the control panel
- Daily piece counter
- Bobbin thread monitor stitch counter
- Operating hours counter
- Production hours counter
The daily piece counter and bobbin thread monitor counter can be reset using
the “Clear” function.
Country settings
This functions opens a menu to select the language displayed on the control panel.
Rights of access
This function opens a menu to define the rights of access, see chapter 11.04 Rights of
access.
Stepping motors
This function opens a menu to move the stepping motors.
Sewing motor
This function opens a menu to test and adjust the sewing motor, see chapter 13.24 Sewing
motor menu.
Service menu
This function is used to call up the menu for selecting various service functions, see chapter
13.23 Service menu.
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Input
11.02 Creating / altering seam programs
A distinction is made between three different seam types when creating or altering the
seam programs:
Single-point darts
L3 = L4; program numbers 0 - 199
Double-point darts
L3 < 4.5 mm; is not cut, program numbers 200 - 299
Tapered darts
L3 < L4; program numbers 300 - 399
Dart length L1
Outer fabric edge
Table edge
Uncut material fold
length L5
L1
CORR
Dart depth L3
CORR
L3
Starting stitch
condensation or start
backtack
Fig. 11 - 01
Waist length L2
Waist depth L4
CORR
L4
End stitch condensation
The seam program input is accessed by selecting the desired seam type.
Switch the machine on.
Call up input mode.
Call up seam program input.
Material thickness
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Input
Description of the functions
Input mode
This function is used to change the initial status of input mode.
Conclude input
This function is used to conclude the input and the machine switches to sewing mode.
Single-point darts
This function is used to call up the entry of single-point darts, see chapter 11.02.01
Creating / altering single-point darts .
Double-point darts
This function is used to call up the entry of double-point darts, see chapter 11.02.02
Creating / altering double-point darts.
Tapered darts
This function is used to call up the entry of tapered darts, see chapter 11.02.03 Creating /
altering tapered darts.
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Input
11.02.01 Creating / altering single-point darts
Switch the machine on.
Call up input mode.
Call up seam program input.
Call up the entry for single-point darts.
Select the program number, see chapter 9.07 Selecting a program number.
Enter or alter the values for dart length L1, waist length L2 and dart depth L3.
Enter or change the material thickness.
Description of further functions
Start backtack
This function is used to switch the start backtack on or off.
Starting stitch condensation
This function is used to switch the starting stitch condensation on or off.
Comment
This function opens a menu for entering a comment about the current program, see chapter
11.02.04 Entering a comment.
Correction values
This function opens a menu for entering the correction values and the uncut material fold
length, see chapter 11.02.05 Entering correction values.
48
Conclude programming
This function concludes seam programming, see chapter 11.02.06 Concluding seam
programming.
Page 49
Input
11.02.02 Creating / altering double-point darts
Switch the machine on.
Call up input mode.
Call up seam program input.
Call up the entry for double-point darts.
Select the program number, see chapter 9.07 Selecting a program number.
Enter or alter the values for dart length L1, waist length L2, dart depth L3 and waist
depth L4.
Enter or change the material thickness.
Description of further functions
Start backtack
This function is used to switch the start backtack on or off.
Starting stitch condensation
This function is used to switch the starting stitch condensation on or off.
Comment
This function opens a menu for entering a comment about the current program, see chapter
11.02.04 Entering a comment.
Correction values
This function opens a menu for entering the correction values and the uncut material fold
length, see chapter 11.02.05 Entering correction values.
Conclude programming
This function concludes programming, see chapter 11.02.06 Concluding seam programming.
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Input
11.02.03 Creating / altering tapered darts
Switch the machine on.
Call up input mode.
Call up seam program input.
Call up the entry for tapered darts.
Select the program number, see chapter 9.07 Selecting a program number.
Enter or alter the values for dart length L1, waist length L2, dart depth L3 and waist
depth L4.
Enter or change the material thickness.
Description of further functions
Start backtack
This function is used to switch the start backtack on or off.
Starting stitch condensation
This function is used to switch the starting stitch condensation on or off.
Comment
This function opens a menu for entering a comment about the current program, see chapter
11.02.04 Entering a comment.
Correction values
This function opens a menu for entering the correction values and the uncut material fold
length, see chapter 11.02.05 Entering correction values.
Conclude programming
This function concludes programming, see chapter 11.02.06 Concluding seam
programming.
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Input
11.02.04 Entering a comment
A comment can be added to the seam program after calling up the appropriate function
within seam programming. The comment is displayed as information about the appropriate
seam program in the program selection and program management functions.
Enter the desired text, e.g. "PRG".
Change to number input.
Enter the desired numbers, e.g. "1".
Conclude the comment input.
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Input
11.02.05 Entering correction values
You can enter correction values for the current seam program after calling up the
appropriate function within seam programming. The value for the uncut material fold length
can also be specified for single-point and tapered darts.
Enter or alter the correction values for dart length L1, dart depth L3 and waist depth L4.
Enter or change the value for the uncut material fold length.
Conclude the input of the correction values.
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Input
11.02.06 Concluding seam programming
The seam programming can be concluded by pressing the appropriate function once all the
details for the programming have been entered.
Description of the functions
Esc
The input is interrupted and the machine moves back to the initial status of the
programming function.
Discard alterations
All program alterations are cancelled.
Save as...
The number block opens to enter any program number if this function is pressed.
Enter
All program alterations are stored under the current program number.
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Input
11.03 Program management
The program management function is used to manage seam programs as well as configura-
tion and machine data. Files can be selected, copied and deleted from the machine memory
or from an SD card.
Switch the machine on.
Call up input mode.
Call up program management.
Both data carriers with the corresponding files appear on the display:
- Machine memory ("C:\DATA") is currently selected
- SD card ( ) is currently inserted
The data carrier is selected by touching the appropriate box. The content of the appropriate
data carrier is also updated. The selected data carrier is shown inversely and the selected
files are shown in red:
The seam programs are stored at a different level to the storage of the configu-
ration and machine data to avoid the accidental processing of the configuration
and machine data.
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Input
Description of the functions
Input mode
This function is used to change the initial status of input mode.
Update drives
This function is used to update (reimport) the drives.
Conclude input
This function is used to conclude the input and the machine switches to sewing mode.
Data selection
These functions are used to mark the desired files in the current drive. Individual files are
selected with the arrow keys. Several files can be selected at one time with the arrow keys
in combination with the lock key (S).
Copy
This function is used to copy the files selected from the current data carrier to the second
data carrier.
Delete
This function is used to delete the selected files.
MDAT/CONF
This function is used to call up the level for the configuration and machine data.
The current settings and the machine configuration are stored in the files "MDAT3519" and
"CONF3519. In this way, the machine data can be copied onto an SD card as a backup or
several machines with the same designation can be configured quickly by reading the ma-
chine data.
Format
This function is used to format the inserted SD card.
All data on the SD card is deleted in the course of the formatting process!
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Input
11.04 Rights of access
The functions that can be called up with the control panel are classified by code numbers
and can be protected from unauthorised access. To this end, the control unit differentiates
between three user groups (user 1, 2 and 3), all of which can be assigned a corresponding
PIN. If a function is selected for which the user does not have authorisation, the user is
requested to input a PIN. The selected function is carried out after the appropriate PIN has
been entered. In addition to the 3 user groups, the control unit also recognises the so-called
"super user" who has a key switch to access all functions and who is authorised to stipulate
the rights of access.
Enter the key switch and switch on the machine.
Call up input mode.
Call up the menu for inputting the rights of access.
Description of the functions
Input mode
This function is used to change the initial status of input mode.
Conclude input
This function is used to conclude the input and the machine switches to sewing mode.
PIN input
These functions can be used to stipulate an individual PIN for each user.
Function selection
These functions are used to select the code number for the function to be locked or
released.
Lock/release functions
These functions are used to lock or release the selected function for the appropriate users.
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Input
Allocation of the code numbers
Code
Function Symbol
Program number selection
Correct program - 1
Input 2
Create program 3
Program management 4
Parameter settings 5
Parameter group 100
General settings
Parameter group 200
Seam parameters
Parameter group 300
Sewing motor positions
Parameter group 400
Times
Parameter group 500
Counters
- 6
- 7
- 8
- 9
- 10
num-
ber
Standard setting
User 1 User 2 User 3
0
Parameter group 600 - 11
Parameter group 700
Sewing motor
Parameter group 800 - 13
Parameter group 900
Sewing motor
Info 15
Reset daily piece counter 16
Reset bobbin thread
stitch counter
Delete operating hours
counter
Delete production hours
counter
Country settings 20
Rights of access 21
- 12
- 14
17
18
19
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Input
Code
Function Symbol
Service
Run cold start 23
Configure machine 24
Load software 25
Set control panel contrast 26
Thread trimmer sequence 27
Needle position 28
num-
ber
22
Standard setting
User 1 User 2 User 3
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Maintenance and Care
12 Maintenance and Care
12
.01 Maintenance intervals
Clean the whole machine ......................................................................................... weekly
Clean the needle area ............................................................................ several times a day
Clean the hook area ............................................................................... several times a day
Clean the blower air filter .................................................................................... as required
Clean the maintenance unit air filter (air filter) .................................................... as required
Check the air pressure ......................................................................... daily, before start-up
Check the oil level ................................................................................ daily, before start-up
Lubricate the trimmer .......................................................................... daily, before start-up
Lubricate the stacker drive ................................................................................ twice a year
These maintenance intervals are based on an average running time of a single
shift operation. Shorter maintenance intervals are recommended for increased
running times.
12.02 Cleaning the entire machine
The required cleaning cycle for the machine depends on the following factors:
Single or multi-shift operation
Dust formation caused by the workpieces
Optimal cleaning instructions can therefore only be defined on a case-by-case basis.
Disconnect the machine from the electricity mains by shutting off the main
switch or removing the mains plug!
Risk of injury due to accidental machine start-up!
Clean the whole machine at least once a week.
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Maintenance and Care
12.03 Cleaning the needle area and hook area
Fig. 12 - 01
Switch the machine on.
Call up the threading aid function.
The transport rail moves out of the needle area, the presser foot is lowered and the
sewing start is disengaged.
Press both start keys at the same time, see chapter 7.07 Start keys.
The infeed table moves forward and the hook area of the sewing head becomes
accessible.
Clean the hook and hook area several times a day.
Move the machine to the last position prior to the cleaning
or
Move the machine to home position.
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Maintenance and Care
.04 Cleaning the blower air filter
12
As required:
Remove the cover 1.
Remove the filter element and blow it
out with compressed air.
Insert the cleaned filter element and
replace the cover 1.
1
Fig. 12 - 02
12.05 Cleaning the maintenance unit air filter
8
6
4
50
2
0
10
100
150
12
200
14
230
0
16
Emptying the water tank:
2
1
Cleaning the filter:
Switch off the machine!
Push the slide closure on the
maintenance unit downwards,
see chapter 8.02 Initial start-
up.
The water tank 1 empties itself
automatically after the compressed air
tube for the maintenance unit has been
removed.
Unscrew the water tank 1 and take out
the filter 2.
Fig. 12 - 03
Clean the filter 2 with compressed air or
isopropyl alcohol
(order no. 95-665 735-91).
Screw in the filter 2 and screw on the
water tank 1.
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Maintenance and Care
.06 Checking / setting the air pressure
12
Check the air pressure on the
2
manometer 1 before every start-up.
The manometer 1 must show a pressure
of 6 bar.
Fig. 12 - 04
8
6
4
50
2
0
10
100
150
12
200
14
230
0
16
To do this, pull up the button 2 and turn
it so that the manometer 1 shows a
pressure of 6 bar.
1
Adjust this value if needed.
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Maintenance and Care
12.07 Checking the oil level
2
3
Fig. 12 - 05
1
Switch off the machine!
Risk of injury due to accidental machine start-up!
The oil reservoir 1 must always have oil in it!
Danger of machine damage!
Check the oil level daily, add oil through the hole 2 as needed up to the line as a
maximum.
The oil tank 3 serves solely for topping up the oil reservoir 1 and not for
displaying the oil level.
Only use oil with a centre viscosity of 22.0 mm²/s at 40 °C and a density of
0.865 g/cm³ at 15 °C.
We recommend PFAFF-sewing machine oil part no. 280-1-120 144.
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Maintenance and Care
12.08 Lubricating the trimmer
1
Fig. 12 - 06
Switch off the machine!
Risk of injury due to accidental machine start-up!
Add a drop of silicone oil through the hole 1 into the trimmer before every start-up.
Only use oil with a density of 0.810 g/cm³ at 21 °C.
We recommend PFAFF sewing machine oil part no. 280-1-120 217.
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Maintenance and Care
12.09 Lubricating the stacker drive
1
Fig. 12 - 07
Switch off the machine!
Risk of injury due to accidental machine start-up!
Clean and then lubricate the track 1 twice a year.
Only use Isoflex Topas L32 high-performance grease, order no. 280-1-120 210.
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Adjustment
13 Adjustment
13.01 Notes on adjustment
No screw clamp may be fastened to the needle bar with the PFAFF 3519-4/01!
This may damage the special needle bar coating.
All adjustments in this manual are based on a fully assembled machine and may only be
carried out by technical 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 that have to be completely adjusted. Both the preceding and following chapters
must be observed if only specific individual work steps are carried out.
The screws and nuts indicated in brackets ( ) are fastenings for machine parts, which must
be loosened before any adjustment and tightened again afterwards.
Unless otherwise stated, the machine must be disconnected from the electric
and pneumatic supplies for all adjustment work!
Risk of injury due to accidental machine start-up!
13.02 Tools, gauges and other accessories
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 Allen keys from 1.5 to 6 mm
1 open-ended wrench with 22 mm wrench size
1 metal ruler, order no. 08-880 218-00
1 adjustment gauge, (order no. 95-752 474-05)
1 setting gauge for the hook drive belt tension, order no. 61-111 639-76
1 setting gauge for the infeed table needles, (order no. 95-743 776-15)
Thread and testing material
13.03 Abbreviations
t.d.c. = top dead centre
b.d.c. = bottom dead centre
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Adjustment
13.04 Sewing head service position
The sewing head can be pulled out of the machine stand for maintenance and
adjustment work.
3
1
4
2
5
2
Fig. 13 - 01
Switch off the machine!
Risk of injury due to accidental machine start-up!
Move the sewing head into home position.
Open the cover 1 and the tensioning lever on the loading clamp.
Loosen the screws 2 and push the loading clamp in the direction of the arrow until it
stops.
Raise the frame 3 and hook in the support 4.
Open the tensioning lever 5.
Pull the sewing back until it stops and tilt if necessary.
Tilt the sewing head with both hands!
Risk of crushing between the sewing head and the machine stand!
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Adjustment
Move the sewing head to the operating position.
Move the sewing head to its upright position using both hands!
Risk of crushing between the sewing head and the machine stand!
Move the sewing head to its upright position and push into the machine stand until it
stop.
Close the tensioning lever 5.
Fold down the support 4 and pivot the frame 3 downwards.
Push back the loading clamp until it stops.
Close the tensioning lever on the loading clamp.
Tighten the screws 2 and close the cover 1.
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Adjustment
13.05 Adjusting the sewing head
13
.05.01 Adjustment aid
The adjustment gauge 1 (order no. 95-752 474-05) can be used to fix the needle
bar in the needle rise position (needle bar is positioned 1.8 mm after b.d.c.).
1
Fig. 13 - 02
Turn the handwheel until the needle bar is approximately in the required position.
Fit the adjustment gauge 1 as shown in Fig. 13-02; move the handwheel gently back and
forwards if necessary until the adjustment gauge 1 fits properly.
69
Page 70
Adjustment
13.05.02 Machine drive home position
This setting is only made if the toothed belt 2 has been dismantled.
Rule
The markings 3 and 4 should be aligned if the needle bar is positioned 1.8 mm after b.d.c.
2
4
1
3
70
Fig. 13 - 03
Move the needle bar to a position 1.8 mm after b.d.c., see chapter 13.05.01 Adjustment
aid.
Turn the toothed belt wheel 1 according to the rule and slide on the toothed belt 2.
Make sure that the shaft flange, shock absorber and motor flange are in the
right position when installing the motor!
Page 71
Adjustment
13.05.03 Needle in needle hole centre
Rule
The needle should pierce the centre of the needle hole exactly.
1
4
3
2
Fig. 13 - 04
Move the needle directly over the needle hole.
Loosen the screws 1, 2 and 3.
Adjust the needle bar frame 4 according to the rule.
Tighten the screw 2 and gently tighten the screw 3.
Use the screw 1 to pull the internal guide pin up to the eye of the needle bar frame 4 and
tighten it.
Turn the handwheel a few turns so that the needle bar frame 4 is not under tension.
Tighten the screw 3.
71
Page 72
Adjustment
13.05.04 Hook shaft bearing and spur gear clearance
Rule
1. The front edge of the hook shaft 5 should be 14.5 mm away from the needle midpoint,
the groove in the hook shaft bearing 1 (see arrow) should be parallel to the bed plate
and point away from the sewing direction.
2. There should be minimal yet noticeable play between the plastic pinion 3 and the steel
wheel 4. This play should be approximately the same for a 360° turn.
3. The steel wheel 4 should align with the plastic pinion 3.
Fig. 13 - 05
4
2
3
6
14.5 mm
1
72
Align the hook shaft bearing 1 (screw 2) according to rule 1.
Set the steel wheel 4 with the eccentric bush of the hook shaft bearing 1 according to
rule 2 and tighten the screw 2.
Adjust the plastic pinion 3 (screws 6) according to rule 3 and tighten the screws 6.
Page 73
Adjustment
13.05.05 Hook lubrication
Rule
1. The centrifugal disc 1 should be 1.5 mm in front of the oil distributor ring 3.
2. A light oil strip should appear on a paper strip held over the needle plate cutout after
approximately 10 seconds when the machine is running at full speed.
1.5 mm
3
2
1
Fig. 13 - 06
The setting is only required if the wick is replaced.
Make sure that the new wick is impregnated with oil when replacing the wick.
Adjust the centrifugal disc 1 (screw 2) according to rule 1.
Check rule 2 and adjust the centrifugal disc 1 if necessary.
73
Page 74
Adjustment
13.05.06 Needle bar rise, hook-to-needle clearance, needle height and bobbin case
position finger
Rule
With the needle bar positioned 1.8 mm after b.d.c.
1. The tip of the hook 6 should be at the needle midpoint and be a distance of 0.05 mm -
0.1 mm from the scarf of the needle and
2. the upper edge of the eye of the needle should be 0.8 mm under the tip of the hook.
3. There should be a clearance of 0.5 mm between the lug of the bobbin case position
finger 4 and the base of the stop groove.
0.8 mm
0.05 - 0.1 mm
4
1
0.5 mm
6
3
5
74
4
2
Fig. 13 - 07
Move the needle bar to a position 1.8 mm after b.d.c., see chapter 13.05.01
Adjustment aid.
Adjust the hook according to rule 1.
Tighten the screws 1.
Adjust the needle bar 2 (screw 3) without twisting according to rule 2.
Align the bobbin case position finger 4 (screw 5) according to rule3.
Page 75
Adjustment
13.05.07 Thread check spring and slack thread regulator
Rule
1. The movement of the thread check spring should be finished when the needle point
punctures the material (spring deflection: approx. 7 mm).
2. The thread check spring should have moved approx. 1 mm when forming the
maximum thread loop while passing the thread around the hook.
4
4
-
+
3
2
Fig. 13 - 08
Turn the thread tension 1 (screw 2) according to rule 1.
Adjust the slack thread regulator 3 (screws 4) according to rule 2.
1
7 mm
It may be necessary to deviate from the specified spring deflection for reasons
relating to the sewing technology.
Adjust the slack thread regulator 3 (screw 4) by “+“ (= more thread) o “-”
(= less thread).
75
Page 76
Adjustment
13.05.08 Bobbin winder
Rule
1. When the bobbin winder is switched on, the drive wheel 1 should be moved easily.
2. When the bobbin winder is switched off, the friction wheel 5 must not touch the drive
wheel 1.
3. The bobbin winder should switch off automatically if the fill amount of the bobbin is
approx. 1 mm away from the edge of the bobbin.
5
2
4
Fig. 13 - 09
1
2
3
76
Adjust the drive wheel 1 (screws 2) according to rules 1 and 2.
Adjust the bolt 3 (screw 4) according to rule 3.
Page 77
Adjustment
13.06 Adjusting the thread trimmer
13
.06.01 Pre-adjusting the control cam
Rule
When the needle bar is at t.d.c. the surface 1 of the control cam should be parallel to the
bed plate.
2
Fig. 13 - 10
Turn the control cam (screws 2) according to the rule.
1
77
Page 78
Adjustment
13.06.02 Roller lever setting
Rule
1. When the cylinder 3 is fully extended, the roller of the roller lever 4 should be a
distance of 0.1 mm from the highest point of the control cam 5.
2. The cylinder 3 should be parallel to the front edge of the bed plate.
1
2
3
5
4
5
78
4
0.1 mm
Fig. 13 - 11
Turn or adjust the eccentric 1 (screw 2) according to the rules.
Page 79
Adjustment
13.06.03 Aligning the thread trimmer laterally
Rule
1. The tip of the thread catcher 5 should point exactly at the needle midpoint.
2. The thread catcher 5 should be horizontal and not touch at any position as it moves.
5
6
6
5
3
1
2
Fig. 13 - 12
Remove the knife 1 (screw 2).
4
4
Move the needle bar to b.d.c.
Loosen the stop 3 (screws 4).
Manually position the thread catcher 5 (screws 6) in front of the needle and align
according to the rules.
79
Page 80
Adjustment
13.06.04 Knife position
Rule
1. There should be a clearance of 4 mm between the knife edge and the needle.
2. The right edge of the knife 1 should not protrude beyond the right edge of the thread
catcher (see arrow).
3
4 mm
Fig. 13 - 13
Move the needle bar to b.d.c.
1
12
80
Slide the knife 1 under the locking tab and align according to rule 1.
Gently tighten the screw 2 .
Manually adjust the thread catcher carrier 3 until the cutting tip in the thread catcher is
positioned just in front of the knife edge.
Align the knife 1 according to rule 2 and tighten the screw 2 .
Page 81
Adjustment
13.06.05 Front turning point of the thread catcher
Rule
When the thread catcher 5 is in the front turning point, the rear edge of the thread
catcher cutout should be 1 mm in front of the bobbin case position finger 6.
3
6
5
1 mm
Fig. 13 - 14
Swivel the roller lever 1 to the lowest point of the control cam 2.
2
4
1
Adjust the thread catcher carrier 3 (screw 4) according to the rule.
81
Page 82
Adjustment
13.06.06 Manual cutting control
Rule
Two threads must be cut cleanly on both the left and right in the thread catcher cutout 1.
2
2
1
4
5
5
3
Fig. 13 - 15
Fit the needle plate.
Manually move the thread catcher 1 to its front turning point.
1
82
Pull a double-up length of thread and hook it in the thread catcher cutout.
Carry out the cutting operation manually.
If the threads are not cut according to the rule, align the thread catcher 1 (screws 2) to
the knife 3 accordingly.
Move the stop 4 until it abuts the thread catcher 1 and tighten the screws 5.
Chapter 13.06.03 Checking and if necessary adjusting the lateral alignment of the
thread catcher.
Page 83
Adjustment
13.08.07 Control cam (recalibrating)
Rule
If the end of the thread guard 3 is positioned 2 mm behind the centre of the lug on the
bobbin case position finger 4, there should also be a clearance of 2 mm between the tip
of the thread catcher 6 and the centre of the lug.
5
1
3
2 mm
2
4
6
2 mm
Fig. 13 - 16
Move the needle bar to b.d.c.
Manually press the roller lever 1 onto the control cam 2 and turn the handwheel until
there is a clearance of 2 mm between the end of the thread guard 3 and the middle of
the lug on the bobbin case position finger 4.
If required, turn the control cam 2 (screws 5) according to the rule.
83
Page 84
Adjustment
13.07 Adjusting the loading plate
13
.07.01 Basic setting of the loading plate height
Rule
The loading plate 3 should be centred between the strips 4 and 5 and be parallel to the
bars 4 and 5.
4
==
3
5
1
1
84
1
Fig. 13 - 17
Turn the screws 1 (screws 2) according to the rule.
2
1
2
Page 85
Adjustment
13.07.02 Loading plate position
Rule
The loading plate 1 should be parallel to the rail 3.
2
2
2
2
2
2
2
1
3
Fig. 13 - 18
Remove the cover plate of the loading plate 1.
Retract the loading plate 1 manually.
Adjust the loading plate 1 (screws 2) according to the rule.
Fit the cover plate.
85
Page 86
Adjustment
13.07.03 Insertion depth of the loading plate
Rule
1. There should be a clearance of 12 mm between the front edge of the plate and the
needle hole centre when the loading plate is retracted.
2. The screws 1 should rest on the stops when the loading plate is extended.
3
3
2
1
12 mm
4
1
2
86
Fig. 13 - 19
Screw in the screws 1 (nuts 2) until they no longer touch the stops.
Adjust the cylinder (screws 3 on the cylinder bracket 4) according to rule 1.
Turn the screws 1 (nuts 2) according to rule 2.
Page 87
Adjustment
13.08 Aligning the sewing head
13
.08.01 Sewing head height
Rule
The upper edge of the sewing machine bed plate should have a clearance of 0.5 mm to
the surface plate 5.
1
4
1
3
2
3
2
0.5 mm
5
Fig. 13 - 20
Move the sewing head to the service position, see chapter 13.04 Sewing head service
position.
Loosen the screws 1.
Turn the screws 2 (nuts 3) according to the rule making sure that the bars 4 are
horizontal.
Tighten the screws 1.
Move the sewing head back to the operating position.
87
Page 88
Adjustment
13.08.02 Aligning the sewing head laterally
Rule
1. There should be a clearance of 50 mm between the front edge of the spreader 5 and
the needle hole centre.
2. The sewing head should be at a right angle to the loading plate.
5
2
4
Fig. 13 - 21
1
2
2
4
3
4
88
Adjust the rail 1 (screws 2) according to the rules.
Place the rail 3 (screws 4) parallel on the sewing head so that there is no play.
Page 89
Adjustment
13.09 Aligning the surface plate
Rule
1. The surface plate 1 should be parallel to the front edge of the loading plate.
2. There should be a clearance of 1 mm between the needle plate insert and the surface
plate 1.
1 mm
1
2
2
Fig. 13 - 23
Adjust the surface plate 1 (screws 2, under the surface plate) according to the rules.
2
2
89
Page 90
Adjustment
13.10 Adjusting the positioning tube
13
.10.01 Presetting the positioning tube
Rule
The bracket 1 should be parallel to the bracket 3 when the positioning tube is in the upper
position.
2
1
3
2
3
1
90
Fig. 13 - 23
Adjust the bracket 1 (screw 2) according to the rule.
Page 91
Adjustment
13.10.02 Front final position of the positioning tube
Rule
The positioning tube 1 should rest parallel on the loading plate in its front final position.
2
2
2
2
Fig. 13 - 24
Adjust the positioning tube 1 (screws 2) according to the rule.
1
1
91
Page 92
Adjustment
13.10.03 Height and alignment of the positioning tube
Rule
When the positioning tube 3 is in the front final position
1. its top edge should maintain a distance of 18.9 mm to the upper edge of the loading
plate and
2. the corresponding holes on the marking should be centred in relation to the loading
plate needles.
2
18.9 mm
4
Fig. 13 - 25
1
4
3
3
92
Adjust the stop 1 (screw 2) according to rule 1.
Turn or adjust the positioning tube 3 (two screws 4 respectively) according to rule 2.
Page 93
Adjustment
13.11 Height of the needles
Rule
There should be a clearance of 4 mm between the needle points and the front edge of
the loading plate 1 when the needles are extended.
Fig. 13 - 26
4 mm
1
2
Remove the cover plate of the loading plate 1.
Extend the needles.
Adjust the needles (screws 2) according to the rule.
The cover plate remains dismantled for additional settings.
93
Page 94
Adjustment
13.12 Adjusting the spreader
Rule
1. When retracted, the spreader 1 should be flush with the front edge of the loading
plate
2. When extended, the spreader 1 should be recessed by 3 mm.
3
1
2
2
Fig. 13 - 27
Adjust the spreader 1 (screws 2) according to rule 1.
Turn the yoke head (nut) of the cylinder 3 according to rule 2.
94
Page 95
Adjustment
13.13 Adjusting the table extension
Rule
When extended, the front edge of the table extension 1 should be flush with the front
edge of the loading plate.
3
4
2
1
2
Fig. 13 - 28
Adjust the table extension 1 (screws 2) according to the rule.
If necessary, the clearance between the retracted table extension 1 and the
loading plate can be changed according to the incision depth on the screw 3
(nut 4).
95
Page 96
Adjustment
13.14 Adjusting the loading clamp
13
.14.01 Loading clamp height
Rule
1. The claws of the loading clamp should touch the retracted loading plate
simultaneously from the top and bottom.
2. The claws should be parallel to the loading plate.
3
3
96
1
2
1
2
Fig. 13 - 29
Turn the feed regular post 1 (nuts 2 and screws 3) according to the rules.
Page 97
Adjustment
13.14.02 Position of the loading clamp
Rule
1. The inner claws of the loading clamp should touch the retracted loading plate
6 - 7 mm behind the front edge.
2. The clearance between the left claw edge of the loading clamp and the needle hole
centre should be 50 mm.
2
2
3
Fig. 13 - 30
1
3
6 - 7 mm
1
3
Adjust the loading clamp (screws 1) according to rule 1.
Adjust the bracket 2 (screws 3) according to rule 2.
97
Page 98
Adjustment
13.15 Adjusting the brushes
13
.15.01 Adjusting the long brushes
Rule
1. The closed brushes 1 should rest parallel on the loading plate and close far enough
that the material ail so that the material is smoothed out properly; in doing so, the
loading plate should retract directly in the middle between the brushes 1.
2. The open brushes 1 should have a clearance of approx. 10 mm from each other.
2
2
2
3
4
1
10 mm
5
1
6
98
Fig. 13 - 31
Adjust the brushes 1 (screws 2), the screw 3 (nut 4) and the screw 5 (nut 6) according to
the rules.
The closing of the brushes 1 is dependent on the material and must be
adjusted according to the sewing result.
Page 99
Adjustment
13.15.02 Adjusting the short brushes
Rule
1. The upper and lower brush should rest directly on or against the loading plate when
the brushes are closed.
2. The upper and lower brush should each have a clearance of approx. 4 mm to the
loading plate when the brushes are open.
1
3
Fig. 13 - 32
4
2
6
7
8
5
Adjusting the upper brush:
Turn the screw 1 (nut 2) according to rule 1.
Turn the screw 3 (nut 4) according to rule 2.
Adjusting the lower brush:
Adjust the cylinder bracket 5 (nut 6) according to rule 1.
Turn the screw 7 (nut 8) according to rule 2.
The closing of the brushes is dependent on the material and must be adjusted
according to the sewing result.
99
Page 100
Adjustment
13.16 Adjusting the knife unit
13
.16.01 Presetting the knife unit
Rule
1. The rear edge of the retracted thread catcher should tilt forward approx. 2°.
(The centre of the screw 6 is almost flush with the outer edge of the screw 7.)
2. Rest the thread catcher on the fold of the material (with an average material
thickness).
3. The highest points of the knife should rest on the material when the thread catcher is
retracted.
6
1
2
7
5
4
4
100
3
Fig. 13 - 33
Turn the piston rod 1 (nut 2) according to rule 1.
Adjust the stop 3 (screws 4) according to rule 2.
Adjust the knife unit (screws 5) according to rule 3.
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