-20/02
3538
INSTRUCTION MANUAL
-30/02
This instruction manual applies to machines
from the following serial numbers onwards: 2 804 345
and software version 0437/001.
296-12-19 292/002
Instruction Manual engl. 10.15
This instruction manual applies to 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 under order no. 296-12-19 293/002.
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
Table of Contents
Contents ..................................................................................................Page
1 Safety .................................................................................................................................... 5
1.01 Directives ............................................................................................................................... 5
1.02 General safety instructions ....................................................................................................5
1.03 Safety symbols ...................................................................................................................... 6
1.04 Special points of attention for the owner-operator ................................................................6
1.05 Operating personnel and technical staff ................................................................................7
1.05.01 Operating personnel .............................................................................................................. 7
1.05.02 Technical staff ........................................................................................................................ 7
1.06 Danger warnings ....................................................................................................................8
2 Proper Use ............................................................................................................................9
3 Technical Data
................................................................................................................. 10
3.01 PFAFF 3538 ......................................................................................................................... 10
4 Disposal of the Machine .................................................................................................... 11
5 Transport, Packaging and Storage ...................................................................................12
5.01 Transport to the customer’s premises ................................................................................ 12
5.02 Transport within the customer’s premises .......................................................................... 12
5.03 Disposal of the packaging materials .................................................................................... 12
5.04 Storage ................................................................................................................................ 12
6 Work Symbols ....................................................................................................................13
7 Operating Controls ............................................................................................................14
7.01 Main switch ........................................................................................................................ 14
7.02 Light barrier ..........................................................................................................................14
7.03 Stop button .......................................................................................................................... 15
7.04 Control panel ........................................................................................................................16
7.04.01 Symbols on the display ........................................................................................................ 17
7.04.02 Plus/minus keys ................................................................................................................... 17
7.04.03 Function keys ....................................................................................................................... 18
8 Set-up and Initial Commissioning ....................................................................................20
8.01 Set-up .................................................................................................................................. 20
8.01.01 Aligning the machine .......................................................................................................... 20
8.01.02 Mounting the reel stand ...................................................................................................... 21
8.02 Connecting the plug-in connections and ground cable ........................................................22
8.03 Initial start-up ....................................................................................................................... 23
8.04 Switching the machine on/off ............................................................................................. 23
Table of Contents
Contents ..................................................................................................Page
9 Set-up .................................................................................................................................. 24
9.01 Inserting the needle ............................................................................................................. 24
9.02 Threading the needle / adjusting the needle thread ............................................................ 25
10 Input .................................................................................................................................... 26
10.01 Sewing – automatic mode ...................................................................................................27
10.02 Sewing – Unit with cutter and rack ......................................................................................28
10.03 Input mode .......................................................................................................................... 29
10.04 Input mode ..........................................................................................................................31
10.09 Parameter list ....................................................................................................................... 32
10.10 Error messages .................................................................................................................... 36
11 Maintenance and Care .......................................................................................................38
11.01 Maintenance intervals .......................................................................................................... 38
11.02 Cleaning the machine .......................................................................................................... 38
11.03 Checking / topping up the oil level of the oil tank for the front parts ................................... 39
11.04 Checking / topping up the oil level of the gear mechanism ................................................. 40
11.05 Checking / setting the air pressure ......................................................................................41
11.06 Emptying / cleaning the maintenance unit’s water tank ...................................................... 41
12 Wearing Parts .....................................................................................................................42
Safety
1 Safety
1
.01 Directives
The machine was built in compliance with the European regulations specifi ed in the declara-
tion of conformity and declaration of incorporation.
As a supplement to this instruction manual, please also observe the generally applicable, le-
gal and other regulations and legislation – also in the country of use – and the valid environ-
mental 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 manufactur-
er before starting up the machine!
Always follow the hazard and safety instructions attached to the machine!
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,
sewing foot, needle plate, feed dog etc.) and when threading, leaving the workstation, or
performing maintenance!
The daily maintenance work may only be carried out by suitably qualifi ed personnel!
Repairs and special maintenance work may only be carried out by technical staff or peo-
ple with appropriate training!
Unless otherwise stated, the machine must be isolated from the power supply and pneu-
matic supplies before any servicing work or repairs are performed! The only permitted
exceptions are for adjustment work and functional tests by appropriately trained techni-
cal staff!
Work on electrical equipment may only be carried out by qualifi ed technical staff!
Work on parts and equipment under voltage is not permitted!
Exceptions are regulated by the EN 50110 standards.
Modifi cations and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
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.
5
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.
Danger of hands being crushed!
Caution!
Do not operate without fi nger guard and safety covers!
Turn off the main switch before threading, changing the
bobbin or needle, cleaning etc!
I
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 oper-
ating personnel at all times. The instruction manual must have been read before the ini-
tial start-up.
The operating personnel and technical staff must be instructed about the machine’s safe-
ty covers and about safe working methods.
The owner-operator may only operate the machine in a fl awless 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.
6
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:
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-fi tting 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 before starting any adjustment or repair work and secure it
against reactivation!
Working on live parts and equipment is prohibited!
Exceptions are regulated by the EN 50110 standards.
Unless otherwise stated, the machine must be isolated from the power supply and pneu-
matic supplies before any servicing work or repairs are performed!
Exceptions are permitted solely for function tests.
Reattach the safety covers following repair and maintenance work!
7
Safety
1.06 Danger warnings
A work area of 1 m must be kept around the machine during operation to en-
sure 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 fl ying around!
Danger of hands being crushed!
3
Fig. 1 - 01
2
1
Do not operate the machine without the protective cover 1!
Risk of injury from the feed band!
Do not operate the machine without the take-up lever guard 2!
Risk of injury due to movement of the take-up lever!
Do not operate the machine without the belt guard 3!
Risk of injury due to the rotating driving belt!
8
2 Proper Use
The PFAFF 3538 is a sewing machine for effi ciently hemming pocket openings.
Proper Use
Any usage not approved by the manufacturer is deemed misuse! The manufac-
turer shall assume no liability for damage caused by misuse! Proper use also
includes compliance with the operating, maintenance, adjustment and repair
measures specifi ed by the manufacturer!
9
Technical Data
3 Technical Data
3
.01 PFAFF 3538
Stitch type: ....................................................................................................... 401 (chainstitch)
Design B: ......................................................... for the machining of medium-weight materials
Design C: ...........................................................for the machining of medium-heavy materials
Needle thickness: ........................................................................................................ 80 – 140
Needle system: ................................................................................................................ 62x57
Thread thickness max. ........................................................................................................ 11/3
Speed max.: ................................................................................................. 4000 stitches/min.
Stitch length max: ..........................................................................................................4.5 mm
Noise data:
Noise emission level at workplace with a sewing speed of n = 2400 min-1: ...... LpA = 75 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1,ISO 11204, ISO 3744,
ISO 4871)
Motor data: ................................................................................. see motor instruction manual
Air consumption per switching cycle: ...........................................................................0.146 Nl
Net weight of sewing head with stand: ............................................................. approx. 308 kg
Gross weight of sewing head with stand: ......................................................... approx. 521 kg
Subject to alterations
KpA = 2.5 dB
10
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 pro-
tection regulations, with a specialised company being contracted if necessary.
Please ensure that parts coated with lubricants are disposed of separately in ac-
cordance with the locally valid environmental protection regulations!
11
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 fl eece. 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 fi lm.
12
Work Symbols
6 Work Symbols
Activities to be performed or important information in this instruction manual are empha-
sised 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)
13
Operating Controls
7 Operating Controls
7
.01 Main switch
1
Turning the main switch 1 switches the
machine on and off.
Fig. 7 - 01
7.02 Light barrier
The LED in the light barrier indicates the
following status:
– LED lights up green = Reception indica-
tor (If there is no sewing material below
it).
– LED fl ashes green or yellow = Setting
aid/soiling indicator.
– LED lights up yellow = Output indicator
(if there is no sewing material below it).
14
Fig. 7 - 02
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