Pfaff 3582-2/01 Instruction Manual

Instruction Manual

3582-2/01

296-12-18 572/002
Betriebsanleitung engl. 03.2002

This instruction manual applies to machines from the

following serial numbers onwards:

# 006141101

This instruction manual applies to all versions and subclasses listed under
"Specifications".

Reprinting, copying or translation of PFAFF instruction manuals, whether in whole or in part,

is not permitted without our prior permission and not without written indication of the

source.

PFAFF Industrie Maschinen AG

Postfach 3020

D-67653 Kaiserslautern

Königstr. 154

D-67655 Kaiserslautern

Editing/illustrations

HAAS-Publikationen GmbH

D-53840 Troisdorf

Table of contents

Contents ..........................................................................................Chapter

Register 01

Safety ........................................................................................................................... 1

Register 02

Proper use .................................................................................................................... 2

Specifications ............................................................................................................... 3

Disposal of the machine ............................................................................................... 4

Transport, packaging and storage ................................................................................. 5

Explanation of the symbols .......................................................................................... 6

Register 03

Controls ........................................................................................................................ 7

Register 04

Mounting and commissioning the machine .................................................................. 8

Register 05

Preparation ................................................................................................................... 9

Register 06

Sewing ....................................................................................................................... 10

Register 07

Care and maintenance ................................................................................................ 11

Adjustment ................................................................................................................. 12

Register 08

Circuit diagrams ......................................................................................................... 13

Register 09

Parts list .........................................................................................................................

Register 10

Miscellaneous ................................................................................................................

Register 01

Contents .......................................................................................... Chapter

1

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

1.01 Directives .................................................................................................................. 1- 1

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

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

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

1.05 Operating and specialist personnel ........................................................................... 1 - 3

1.05.01 Operating personnel .................................................................................................. 1 - 3

1.05.02 Specialist personnel .................................................................................................. 1 - 3

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

1 - 1

Safety

1 Safety

1.01 Regulations

This machine is constructed in accordance with the European regulations indicated in the

conformity and manufacturer's declarations.

In addition to this instruction manual, please also observe all generally accepted, statutory

and other legal requirements, including those of the user's country, and the applicable pol-

lution control regulations!

The valid regulations of the regional social insurance society for occupational accidents or

other supervisory authorities are to be strictly adhered to!

1.02 General notes on safety

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

instruction manual has been fully read and understood!

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

before the machine is put into operation!

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

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

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

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

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

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

removing the plug from the mains!

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

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

staff or persons with appropriate training!

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

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

function checks are carried out by appropriately trained technical staff!

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

qualified to do so!

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

exceptions to this are specified in regulations EN 50110.

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

all relevant safety regulations!

1 - 2

Safety

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

special attention to the fact that spare parts and accessories not supplied by us have not

been subjected to testing nor approval by us. Fitting and/or use of any such parts may

cause negative changes to the design characteristics of the machine. We shall not ac-

cept any liability for damage caused by the use of non-original parts.

1.03 1.03 Safety symbols

Danger!

Special points to observe.

Danger of injury to operating or technical staff!

Danger: Laser beam!

Caution

Do not operate without finger guard and safety devices.

Before threading, changing bobbin and needle, cleaning

etc. switch off main switch.

1.04 Important notes for the user

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

to the operating staff at all times.

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

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

ine and on safe working methods.

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

● The user must ensure that none of the safety devices are removed nor put out of work-

ing order.

● The user must ensure that only authorized persons operate and work on the machine.

For further information please refer to your PFAFF agency.

I

1 - 3

Safety

1.05 Notes for operating and technical staff

1.05.01 Operating staff

Operating staff are the persons responsible for setting up, operating and cleaning the mach-

ine and for removing any disturbances in the sewing area.

The operating staff are obliged to observe the following points, and must:

● always observe the notes on safety in this instruction manual!

● avoid using any working methods which adversely effect the safety of the machine!

● avoid wearing loose-fitting clothing or jewelry such as necklaces or rings!

● also ensure that only authorized persons are allowed near the danger area of the

machine!

● immediately report to the user any changes to the machine that may affect its safety!

1.05.02 Technical staff

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

pneumatics and mechanical engineering. They are responsible for lubricating, servicing,

repairing and adjusting the machine.

The technical staff are obliged to observe the following points, and must:

● always observe the notes on safety in this instruction manual!

● switch off the on/off switch before carrying out adjustment and repair work and ensure it

cannot be switched on again unintentionally!

● never work on parts or equipment still connected to the power supply! Exceptions to this

are only permissible according to regulations EN 50110;

● isolate the machine from the compressed air supply when carrying out maintenance or

repair work on pneumatic equipment!

Exceptions to this are only permissible for function checks;

● replace all safety covers after carrying out maintenance or repair work!

1 - 4

Safety

1.06 Danger warnings

A working area of 1 m must be kept free both in front of and behind the mach-

ine, so that easy access is possible at all times.

Never put your hands in the sewing area during sewing!

Danger of injury by the needle!

Do not leave any objects on the table during adjustment work!

Objects can be caught in the machine or flung out!

Danger of injury!

1 - 5

Safety

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

Danger of injury due to movement of the take-up lever!

Do not operate the machine without covers 2 and 3!

Danger of injury from running drive belts!

Do not switch on the machine when cover plate 4 is retracted!

Danger of injury in hook area!

During operation do not place hands in the swing area of stacker 5!

Danger of injury from the moving arms of the stacker.

During operation do not look into the positioning device 6 !

Danger of injury from laser beams!

Fig. 1 - 01

2

3

5

4

6

1

Register 02

Contents ..........................................................................................Chapter

2

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

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

4 Disposal of the machine .......................................................................................... 4 - 1

5 Transport, packaging and storage .......................................................................... 5 - 1

5.01 Transport to the customer’s premises ....................................................................... 5 - 1

5.02 Transport within the customer’s premises ................................................................ 5 - 1

5.03 Disposal of the packaging .......................................................................................... 5 - 1

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

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

Proper use

2 - 1

2 Proper use

The PFAFF 3582-2/01 is a mechanised sewing unit for manufacturing plackets and pocket

piping in the clothing industry

Any and all uses of this machine which have not been approved of by the

manufacturer are considered to be inappropriate! The manufacturer cannot be

held liable for any damage caused by the inappropriate use of the machine!

The appropriate use of the machine means that all operational, adjustment,

maintenance and repair measures required by the manufacturer are to be

observed!

Specifications

3 - 1

3 Specifications

▲

Specifications

Speed: ............................................................................................................... 2100 s.p.m.

Stitch length: ........................................................................................................... 2.5 mm

Stitch type: .................................................................................................................... 301

Needle system: ............................................................................................................. 134

Needle size: .................................................................................................... 80 – 100 Nm

Sewing motor: .......................................................................... See Motor Service Manual

Connection voltage: .......................................................................... 230 V, 50 – 60 Hz A/C

Power requirement: ................................................................................................. 1.2 kW

Working air pressure: ...........................................................................................min. 6 bar

Air consumption: ............................................................................... approx. 5 l/work cycle

Noise data:

Emission sound level at the workplace at a speed of 2000 spm: ................ L

pA =

74 dB(A)

■

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

Machine dimensions:

Length: .................................................................................................... approx. 1300 mm

Width: ..................................................................................................... approx. 1200 mm

Height: .................................................................................................... approx. 1300 mm

Table height: .......................................................................................................... 850 mm

Net weight: ............................................................................................................... 234 kg

▲

Subject to technical alterations

■

KpA = 2,5 dB , ∆LI = 4 dB

Disposal of the machine

4 - 1

4 Disposal of the machine

● The proper disposal of the machine is the responsibility of the customer.

● The materials used for the machine are steel, aluminium, brass and various plastics.

The electrical equipment consists of plastics and copper.

● The machine must be disposed of in accordance with applicable local environmental

protection regulations. If necessary, a specialist is to be commissioned.

Special care is to be taken that parts soiled by lubricants are separately

disposed of in accordance with the applicable local environmental protection

regulations!

Transport, packaging and storage

5 - 1

5 Transport, packaging and storage

5.01 Transport to the customer’s premises

Within Germany, machines are delivered without packaging.

Machines for export are packaged.

5.02 Transport within the customer’s premises

The manufacturer bears no liability for transport within the customer’s premises or to the

location of use.

The machine may only be transported in an upright position.

5.03 Disposal of the packaging

The packaging of these machines consists of paper, cardboard and VCE fiber.

The proper disposal of the packaging is the responsibility of the customer.

5.04 Storage

The machine can be stored for up to 6 months if not in use. During this time it should be

protected from dust and moisture.

For longer storage the individual parts of the machine, especially the moving parts, should

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

Explanation of the symbols

6 - 1

6 Explanation of the symbols

In this Instruction Manual, tasks to be carried out and important information are drawn to

your attention by symbols. The symbols have the following meanings:

Note, information

Cleaning, care

Lubrication

Servicing, repairing, adjustment, maintenance

(only to be carried out by specialist personnel)

Register 03

Contents ............................................................................... Chapter - Page

7

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

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

7.02 Catch of the folding unit .............................................................................................. 7 - 2

7.03 Balance wheel ............................................................................................................ 7 - 3

7.04 Control panel .............................................................................................................. 7 -4

7.05 Foot switch ................................................................................................................ 7 -7

7 - 1

Controls

Fig. 7 - 01

7 Controls

7.01 Main switch

● Switch the machine on or off by turning

main switch 1.

The motor control switch 2

must always be switched on.

2

1

7 - 2

Controls

7.02 Catch of the folding unit

Fig. 7 - 03

● After lifting catch 1 the folding unit can be retracted.

1

7 - 3

Controls

● Balance wheel 1 is used to adjust the needle bar, e.g. when changing the needle.

When sewing begins, the needle bar must be positioned 1 mm after t.d.c. If
necessary, set the needle bar in the right position using balance wheel 1 (LED 2

must be on).

7.03 Balance wheel

Fig. 7 - 04

1

2

7 - 4

Controls

7.04 Control panel

Fig. 7 - 05

The machine’s control panel consists of a touch screen monitor 1 where the functions can

be selected by touching the appropriate function symbol.

The display on the monitor is dependent on the operating condition of the machine. In

addition to function symbols, fields are also displayed, where it is possible to enter a value

(e.g. the length of the pocket) after touching the screen. Symbols for error signals and

operating conditions (e.g. amount of remaining thread) are also displayed.

● When the machine is switched on the start display screen appears.

● When the monitor screen is touched, the basic display screen for controlling the machine

appears. The functions on the basic display screen are used to enter further functions of

the machine control.

1

7 - 5

Controls

Explanation of the symbols

Flap

By touching this symbol a menu is opened for entering the required flap.
Further functions of this menu are explained in Chapter 9.07 Entering flap values.

Cycle

By touching this symbol a menu is opened for entering a work cycle.
Further functions of this menu are explained in Chapter 9.09 Entering work cycle.

Pocket (1-4)

By touching this symbol a menu is opened for entering the appropriate pocket.

4 different pockets can be entered. Further functions of this menu are explained in

Chapter 9.08 Entering pocket values.

Main clamp forwards

By touching this symbol the main clamp is moved forwards.

Main clamp backwards

By touching this symbol the main clamp is moved backwards.

Technics/Service

By touching this symbol the service level of the control system is opened.

Basic display screen

7 - 6

Controls

Explanation of further symbols:

Below further symbols are explained, which are displayed in different operating conditions.

The functions shown are the same in every operating condition.

Needle thread and bobbin thread knife

With this function the threads can be cut and trapped.

● Press once: Needle thread trap is opened, the bobbin thread is cut and the cutter closed.

● Press again: Thread trap is closed and the needle threads are cut. Bobbin thread cutter

opens.

Feeding interface on/off

This function switches the interface tape feed on or off.

Interface knife

This function is used to feed and cut the interface tape.

Corner knife on/off

When this symbol is touched, the corner knife function is switched on or off.

When the centre knife is switched off, the corner knifes are automatically switched off too.

Centre knife on/off

When this symbol is touched, the centre knife function is switched on or off.

When the centre knife is switched off, the corner knifes are automatically switched off too.

Open/close thread tension

By touching this symbol, the thread tension unit is opened or closed.

Thread remaining

This symbol is used to display the amount of thread remaining.

Piece counter

This symbol is used to display the number of pockets sewn, or the number of work cycles.

7 - 7

Controls

7.05 Foot switch

● The function of the foot switch 1

depends on the setting in the machine

configuration.

● With foot switch 2 the functions carried
out with foot switch 1 are cancelled step

by step.

● After sewing starts, a sewing stop is
carried out by operating foot switch 2.

Fig. 7 - 06

1

2

Standard functions of foot switch 1:

Number of operations/steps Function

1 Move main clamps forwards

2 Lower both main clamps

3 Lower folding unit/engage folding slide

4 Close left flap clamp

5 Close right flap clamp

6 Sewing start

7 - 8

Controls

On the control panel the functions of foot switch 1 can be adapted to various requirements

when placing the workpiece as follows.

● Switch on the machine.

● Select the basic screen display by touching the monitor screen.

● Select the service level by touching the symbol technics/service.

● Select the menu for machine configuration by touching the appropriate symbol.

Using the symbols displayed on the screen, the functions of the foot switch can be altered

as follows.

● Both flap clamps are closed at the same time.

● First the left and then the right flap clamp is closed.

Number of operations/steps functions

1 Move main clamps forwards

2 Lower both main clamps

3 Lower folding unit/engage folding slide

4 Close left flap clamp

5 Close right flap clamp

6 Sewing start

Number of operations/steps functions

1 Move main clamps forwards

2 Lower both main clamps

3 Lower folding unit/engage folding slide

4 Close both flap clamps

5 Sewing start

7 - 9

Controls

● First the right and then the left flap clamp is closed.

● Both main clamps are lowered at the same time.

Number of operations/steps functions

1 Move main clamps forwards

2 Lower both main clamps

3 Lower folding unit/engage folding slide

4 Close right flap clamp

5 Close left flap clamp

6 Sewing start

● The right main clamp is lowered after the left main clamp.

Number of operations/steps functions

1 Move main clamps forwards

2 Lower both main clamps

3 Lower folding unit/engage folding slide

4 Close left flap clamp

5 Close right flap clamp

6 Sewing start

Number of operations/steps functions

1 Move main clamps forwards

2 Lower left main clamp

3 Lower right main clamp

4 Lower folding unit/engage folding slide

5 Close left flap clamp

6 Close right flap clamp

7 Sewing start

7 - 10

Controls

● With the function More a menu for selecting further functions is opened.

● The stacker function is generally switched off.

When the stacker function is switched off, the automatic material

recognition function of the main clamp is also switched off.

● Switch on stacker function.

● Switch off vacuum and stamp.

● Switch on vacuum and stamp.

The vacuum is used to retain the workpiece on the cover plate.

When the vacuum is switched on, the functions of the foot switch are

altered as follows.

● Switch off needle thread monitor.

● Switch on needle thread monitor.

Number of operations/steps functions

1 Switch on suction (vacuum or stamp)

2 Move main clamps forwards

3 Switch off suction (vacuum or stamp)

4 Lower both main clamps

5 Lower folding unit/engage folding slide

6 Close left flap clamp

7 Close right flap clamp

8 Sewing start

● Return to the basic display screen with the Exit function.

Register 04

Contents ............................................................................... Chapter - Page

8

Installation and commissioning .................................................................................. 8- 1

8.01 Installation .................................................................................................................. 8 - 1

8.01.01 Mounting the bearing plate ......................................................................................... 8 - 2

8.01.02 Connecting the vacuum system ................................................................................. 8 - 2

8.01.03 Mounting the stacker .................................................................................................. 8 - 3

8.01.04 Mounting the reel stand .............................................................................................. 8 - 4

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

8.03 Switching the machine on/off ..................................................................................... 8 - 5

8.04 PC interfaces .............................................................................................................. 8 -6

Installation and commissioning

8 - 1

8 Installation and commissioning

After unpacking the machine, examine it for any transport damages. If there are any

damages, inform the carrier and your local PFAFF agency.

The machine must only be installed and commissioned by qualified personnel!

All relevant safety regulations must be strictly adhered to!

8.01 Installation

Suitable connections for electricity and compressed air must be available at the installation

site (see Chapter 3 Specifications).

● Lift the machine off the transport pallet with a fork-lift.

● Just above the floor, align the machine until it is level and adjust the four legs accordingly

before setting the machine down onto the floor.

Fig. 8 - 01

Installation and commissioning

8 - 2

8.01.02 Connecting the vacuum system

● Place the tube delivered for the vacuum

system on the connection piece and fa­sten it with clip 1.

Fig. 8 - 03

8.01.01 Mounting the bearing plate

● Attach the bearing plate 1 to the sewing
table with screws 2.

Fig. 8 - 02

1

1

2

2

Installation and commissioning

8 - 3

8

.01.03 Mounting the stacker

Fig. 8 - 04

● Attach the stacker 1 to the frame with screws 2 (four screws).

● Connect pneumatic tubes as shown in the circuit diagram.

2

1

Installation and commissioning

8 - 4

Fig. 8 - 05

8.01.04 Mounting the reel stand

● Mount the reel stand as shown in the above illustration.

8.02 Commissioning

● Clean the entire machine thoroughly, checking the electric leads and pneumatic

connection tubes for any damage.

● Check whether the machine can be operated with the available electricity supply (see

Chapter 3 Specifications). If there are any irregularities do not operate the machine
under any circumstances!

● Have the machine connected to the mains by qualified staff.

● Oil the machine or pour in oil (see Chapter 11 Care and Maintenance).

● Connect the machine to the compressed air supply.

● The manometer on the air filter should show a pressure of 6 bar. If necessary, adjust to

this value (see Chapter 11.04 Checking/adjusting the air pressure).

Installation and commissioning

8 - 5

8

.03 Switching the machine on/off

Fig. 8 - 06

● Open the main air supply 1.

● Check the air pressure and adjust if necessary (see Chapter 11.04 Checking/adjusting

the air pressure).

● Turn main switch 2 to position "I".

Switch 3 of the motor control unit must always be switched on.

● To switch off the machine, turn main switch 2 to position "0" and close the main air
supply 1.

1

Fig. 8 - 07

zu

auf

2

3

Installation and commissioning

8 - 6

8.04 PC interfaces

Fig. 8 - 08

Fig. 8 - 09

● Parallel interface 1 on control panel.

● Serial interface 2 on control unit in switch box.

1

2

Register 05

Contents ...............................................................................Chapter - Page

9

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

9.01 Inserting the needles .................................................................................................. 9 - 1

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

9.03 Changing the bobbin / adjusting the bobbin thread tension .......................................... 9 - 3

9.04 Threading the needle thread / adjusting the needle thread tension ............................... 9 - 4

9.05 Changing the interfacing tape ..................................................................................... 9 - 5

9.06 Display settings .......................................................................................................... 9 - 6

9.06.01 Selecting the language ................................................................................................ 9 - 6

9.06.02 Adjusting the contrast setting ..................................................................................... 9 - 6

9.07 Entering the flap values .............................................................................................. 9 - 7

9.08 Entering pocket values ............................................................................................... 9 - 10

9.09 Entering the work cycle .............................................................................................. 9 - 11

9.10 Changing the folding unit ............................................................................................ 9 - 12

9.11 Switch on bobbin thread counter / enter bobbin thread length ..................................... 9 - 13

9 - 1

Setting up

9 Setting up

All instructions and regulations in this instruction manual must be observed.

Special attention must be given to all safety regulations!

All setting-up work must only be done by personnel with the necessary

training.

9.01 Inserting the needles

Switch the machine off!

Danger of injury if the machine

suddenly starts running!

Only use needles from System 134!

● Retract the folding unit.

● Loosen screws 1 and insert needles 2 as

far as possible into the needle bar.

● Align needles 2 as shown in the adjacent
illustration and tighten screws 1.

● Swing in the folding unit and let it snap

into place.

Fig. 9 - 01

1

1

2

2

9 - 2

Setting up

9.02 Winding the bobbin thread / adjusting the preliminary thread tension

● Place empty bobbin 1 on spindle 2.

● Thread up as shown in Fig. 9-02 and wind the thread around bobbin 1 a few times in a

clockwise direction.

● Engage the bobbin winder by pressing lever 3 in the direction shown by the arrow.

Bobbin 1 is filled during sewing.

● The tension of the thread on bobbin 1 can be set on screw 4.

● The bobbin winder will stop automatically, when there is enough thread on bobbin 1.

The adjustment of the amount of thread is described in Chapter 12
Adjustment.

Fig. 9 - 02

71-065

71-052

1

2

3

4

5

9 - 3

Setting up

9.03 Changing the bobbin / adjusting the bobbin thread tension

Fig. 9 - 03

● Once the number of stitches entered beforehand has been reached, the corresponding

symbol appears on the screen and the sewing operation stops, see Chapter 10.02 Error
signals.

● To change the bobbin, switch off the machine.

● Open the folding unit and cover plate.

● Pull up latch 1 and remove the empty bobbin.

● Place the filled bobbin in the hook, so that it moves in the direction of the arrow when the

thread is pulled out.

● Close down latch 1.

● First lead the thread through slot 2 and then around the finger of the bobbin case.

● Adjust the bobbin thread tension by turning screw 3.

● Replace the folding unit and the cover plate.

● Acknowledge the bobbin change by pressing the error signal.

1

3

2

+

-

9 - 4

Setting up

9.04 Threading the needle thread / adjusting the needle thread tension

Fig. 9 - 04

● Switch off the machine.

● Retract the folding unit.

● Thread both needle threads as shown in the above illustration.

● Adjust the needle thread tension by turning knurled screws 1 and 2.

1

2

+

-

9 - 5

Setting up

9.05 Changing the interfacing tape

Fig. 9 - 05

● Insert the interfacing tape as shown in Fig. 9-05.

● Switch on the machine.

● Select the basic display by touching the screen.

● Select one of the Pocket functions by touching the appropriate symbol.

● Touch the feed/cut interface function.

● The interface is fed and cut.

● Move back to the basic display with the Exit function.

1

9 - 6

Setting up

9.06 Display settings

9.06.01 Selecting the language

● Switch on the machine.

● Select the basic display by touching the screen.

● Select the Technics/Service function by touching the appropriate symbol.

● Select the Display function.

● Select the choice of languages by touching the appropriate symbol.

● Select the desired language by touching it.

● Move back to the basic display with the Exit function.

9.06.02 Adjusting the contrast setting

● Switch on the machine.

● Select the basic display by touching the screen.

● Select the Technics/Service function by touching the appropriate symbol.

● Select the Display function.

● By touching the appropriate symbol, the screen setting can be made darker or brighter.

● The selected setting can be saved by touching the appropriate symbol.

● Move back to the basic display with the Exit function.

9 - 7

Setting up

9.07 Entering the flap values

● Switch on the machine.

● Select the basic display by touching the screen.

● Select the menu for entering the flap values by touching the appropriate symbol.

Basic display for entering flaps

For the fields described below, a number field can be selected by touching the

appropriate field. The appropriate value can then be entered by touch. To

conclude the entry, press Enter.

● Enter the required value for the distance of the corner knife from the beginning of the

seam in the top field.

● Enter the required value for the distance of the corner knife from the end of the seam in

the bottom field.

● Enter the required distance to the flap edge for the beginning of the seam in the top field.

The flap will be recognized by the sensor.

● Enter the required distance to the flap edge for the end of the seam in the bottom field.

The flap will be recognized by the sensor.

● After touching the symbol, a menu for entering the flap length appears. The flap length

must be entered on the number field.

9 - 8

Setting up

● After the flap length has been entered, an extended menu can be selected with the Extra

function. Here the distance to the flap is set, at which the main clamp moves at a

reduced speed until the flap has been sewn on.

● To move back to the basic display for entering the flap, press the Exit function.

In the extended menu two different flaps (e.g. left and right flap) can be

entered. The flaps can then be selected separately or processed alternately. In

this case the flap to be processed first must be selected.

● Select the extended menu for entering the flap with the Extra function.

● Enter the values for the flaps as described above.

● With the off/on function select either alternate (on) or separate (off) processing.

9 - 9

Setting up

● By touching the appropriate flap symbol, select which flap is to be sewn (OFF), or which

flap is to be sewn first when the flaps are sewn alternately (ON).

The functions of the other symbols are not dependent on the menu and are
described in Chapter 7.04 Control panel.

Left front jacket section,

back positioning point

(inactive)

Right front jacket section,

front positioning point

(active)

9 - 10

Setting up

9.08 Entering pocket values

● Switch on the machine.

● Select the basic display by touching the screen.

● Select the menu for entering the appropriate pocket value by touching one of the

symbols.

4 pockets can be entered independent of each other. The entry described

below is the same for all pockets.

Basic display for entering pockets

For the fields described below, a number field can be selected by touching the

appropriate field. The appropriate value can then be entered by touch. To

conclude the entry, press Enter.

● Enter the required value for the distance of the corner knife from the beginning of the

seam in the top field.

● Enter the required value for the distance of the corner knife from the end of the seam in

the bottom field.

● Enter the required pocket length in this field.

9 - 11

Setting up

● By touching the appropriate field, set the positioning point for the pocket. The screen

display corresponds to the projection of the positioning point on the cover plate of the

machine. The selected positioning point is shown by the “finger”.

The functions of the other symbols are not dependent on the menu and are
described in Chapter 7.04 Control panel.

9.09 Entering the work cycle

If values have been set for at least 2 pockets, these can be combined in one work cycle, so

that in one operation up to 4 different pockets can be sewn automatically one after the

other.

● Switch on the machine.

● Select the basic display by touching the screen.

● By touching the appropriate symbol select the menu for entering the work cycle.

● By touching the appropriate field select the desired pocket.

● Switch the stacking function for the selected pockets on or off as required.

9 - 12

Setting up

9.10 Changing the folding unit

Fig. 9 - 06

● Switch off the machine.

● Loosen screws 1.

● Pull the folding unit 2 out of its holder and insert the desired folding unit, e.g. folding unit

for single piping.

The folding unit (single or double piping) is recognized automatically.

1

2

9 - 13

Setting up

9.11 Switch on bobbin thread counter / enter bobbin thread length

● Switch on the machine.

● Select the basic display by touching the screen.

● By touching the appropriate symbol select the Technics/Service function.

● Select the Options function.

● By touching the appropriate symbol select the next menu.

● By touching the appropriate symbol select the next menu.

● By touching the appropriate symbol the bobbin thread count function is switched on. The

thread length is entered by touching the number field using a number keyboard.

● By touching the appropriate symbol the bobbin thread count function is switched off.

● Use the Exit function to return to the basic display.

Register 06

Contents ...............................................................................Chapter - Page

10

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

10.01 Re-setting the piece counter .................................................................................... 10 - 1

10.02 Error signals ............................................................................................................. 10 -2

Sewing

10 - 1

10 Sewing

The machine must be installed and connected in accordance with Chapter 8 Installation and
Commissioning.

● Setting up the machine, see Chapter 9 Setting up.

● By operating the foot switch, insert the material step by step and trigger off the sewing

start.

10.01 Re-setting the piece counter

● Switch on the machine.

● By touching the screen, select the basic display.

● By touching the appropriate symbol, select the Technics/Service function.

● Select the piece counter function.

● By touching the appropriate symbol, set the piece counter at zero.

● Use the Exit function to jump back to the basic display.

Sewing

10 - 2

10

.02 Error signals

The following symbols may appear on the screen during sewing. They indicate the

corresponding errors.

Symbol Error Correction

Flap seam switched on but no Insert flap

flap inserted.

Thread error. Re-thread needle thread.

Carry out sewing start.

Incorrect needle position. Turn balance wheel until error

signal goes off.

Bobbin thread counter has run out. Change the bobbin. Acknowledge

correction by touching the

symbol.

Folding unit open. Close folding unit.

Machine stop with left foot switch. Operate right foot switch. Return

main clamp without sewing.

Register 07

Contents ............................................................................... Chapter - Page

11 Care and maintenance ........................................................................................... 11 - 1

11.01 Cleaning the machine ............................................................................................... 11 - 2

11.02 Cleaning the hook .................................................................................................... 11 - 3

11.03 Checking the oil level ............................................................................................... 11 - 3

11.04 Checking/adjusting the air pressure ......................................................................... 11 - 4

11.05 Cleaning the air filter of the air-filter/lubricator .......................................................... 11 - 4

11.06 Greasing the clamp guide ........................................................................................ 11 - 5

12 Adjustment ............................................................................................................. 12 - 1

12.01 Notes on adjustment ................................................................................................ 12 - 1

12.02 Tools, gauges and other accessories ....................................................................... 12 - 1

12.03 Abbreviations ........................................................................................................... 12 - 1

12.04 Opening up the sewing head ................................................................................... 12 - 2

12.05.01 Preliminary adjustment of the needle height ............................................................ 12 - 3

12.05.02 Position of the needles to the needle hole ............................................................... 12 - 4

12.05.03 Needle bar rise, needle height, hook-to-needle clearance and needle guard ............ 12 - 5

12.05.04 Bobbin case opener stroke ...................................................................................... 12 - 7

12.05.05 Position of the bobbin thread cutter ......................................................................... 12 - 8

12.05.06 Position of the needle thread cutter ......................................................................... 12 - 9

12.05.07 Cutting device of the interfacing feed unit ............................................................... 12 - 10

12.05.08 Basic position of the middle knife ............................................................................ 12 - 11

12.05.09 Knife pressure and angle of the middle knife blade .................................................. 12 - 12

12.05.10 Height of the middle knife ........................................................................................ 12 - 13

12.05.11 Middle knife motion ................................................................................................. 12 - 14

12.05.12 Needle thread tension release ................................................................................. 12 - 15

12.05.13 Thread check spring ................................................................................................. 12 - 16

12.05.14 Hook lubrication ....................................................................................................... 12 -17

12.05.15 Setting the reference point ...................................................................................... 12 - 18

12.05.16 Adjusting the laser points ......................................................................................... 12 - 19

12.05.17 Height and lateral adjustment of the folding unit ...................................................... 12 - 20

12.05.18 Folding unit to needle clearance ............................................................................... 12 - 21

12.05.19 Position of the flap retainers .................................................................................... 12 - 22

12.05.20 Flap retainer to needle clearance ............................................................................. 12 - 23

12.05.21 Height of the main clamps ....................................................................................... 12 - 24

12.05.22 Distance of both main clamps from the folding unit ................................................. 12 - 25

12.05.23 Adjusting the fold slider............................................................................................ 12 - 26

12.05.24 Adjusting the flap clamps ......................................................................................... 12 - 27

12.05.25 Basic position of the main clamps ............................................................................ 12 - 28

12.05.26 Preliminary adjustment of the mitre knives .............................................................. 12 - 29

12.05.27 Adjusting the mitre knives ....................................................................................... 12 - 30

12.05.28 Adjusting the sensors .............................................................................................. 12 - 31

12.05.29 Summary of the functions in the service menu ....................................................... 12 - 32

11 - 1

Care and maintenance

11 Care and maintenance

Clean the entire machine .............................................................................. once a week

Clean the hook compartment ............................................................... several times daily

Check the oil level ................................................................................... daily, before use

Grease the clamp guides .......................................................................... every 2 months

Check the air pressure ............................................................................ daily, before use

Clean the air filter of the air filter/lubricator ................................................ when required

These maintenance intervals are calculated for the average running time of a

single shift operation. If the machine is operated more than this, shorter

intervals are recommended.

11 - 2

Care and maintenance

11.01 Cleaning the machine

The required cleaning intervals for the machine depend on the following factors:

● Single or multi-shift operation

● Amount of dust caused by the workpiece

Optimum cleaning instructions can therefore only be given for each case individually.

Fig. 11 - 01

To avoid interruptions following cleaning work is recommended for single-shift operation:

● Clean the hook compartment and needle area of the sewing head several times daily.

● Clean the entire machine at least once a week.

Switch off the machine.

Turn off the compressed air.

11 - 3

Care and maintenance

11.02 Cleaning the hook

● Remove screws 1.

● Remove hook gib 2.

● Turn the balance wheel until the edge of

the bobbin case is positioned vertically

below the bobbin opener.

● Remove bobbin case 3.

● Clean the hook race.

● Insert the bobbin case 3.

● Screw on hook gib 2.

11.03 Checking the oil level

Switch off the machine!

● Check the oil level through the inspection

glass 1 daily before use.

● If the oil level is below the marking, oil

must be poured in through hole 2, until

the oil level rises again between the top

and bottom marking on inspection glass 1.

Only use oil with a mean

viscosity of 22.0 mm²/s at 40ºC

and a density of 0.865 g/cm³ at

15º C!

We recommend PFAFF

sewing machine oil, part no.

280-1-120 144.

Fig. 10 - 03

1

2

Fig. 11 - 02

1

2

3

11 - 4

Care and maintenance

10

12

0

6

4

2

8

16

14

100

50

150

0

200

230

Fig. 10 - 02

11.05 Cleaning the air filter of the air-filter/lubricator

Switch the machine off!

Disconnect the air hose at the

air-filter/lubricator.

To drain water bowl 1:

● Water bowl 1 drains itself automatically

when the compressed-air hose is discon-

nected from the air-filter/lubricator.

Cleaning filter 2:

● Unscrew water bowl 1.

● Take out filter 2.

● Clean filter 2 with compressed air or iso-

propyl alcohol (part No. 95-665 735-91).

● Screw in filter 2 and screw on water

bowl 1.

Fig. 10 - 03

2

1

10

12

0

6

4

2

8

16

14

100

50

150

0

200

230

1

2

11.04 Checking/adjusting the air pressure

● Before operating the machine, always

check the air pressure on gauge1.

● Gauge 1 must show a pressure of 6 bar.

● If necessary adjust to this reading.

● To do so, pull knob 2 upwards and turn it

so that the gauge shows a pressure of 6

bar.

11 - 5

Care and maintenance

11.06 Greasing the clamp guide

Switch off the machine and

take precautions to prevent it

being switched on again!

Only use Isoflex Topas L32

heavy-duty grease, part no.

280-1-110 210.

● Grease the guides with a grease nipple

using a grease gun every 2 months for

single-shift operation and once a month

for two-shift operation.

Fig. 11 - 08

1

There are more grease nipples on the machine, which ought to be greased with

a grease gun at regular intervals.

Adjustment

12 - 1

12 Adjustment

12.01 Notes on adjustment

All following adjustments are based on a fully assembled machine and may only be carried

out by expert staff trained for this purpose.

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

adjustments, are not mentioned in the text.

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

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

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

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

loosened before adjustment and tightened again afterwards.

12.02 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 6 to 22 mm

● 1 set of Allan keys from 1.5 to 6 mm

● 1 universal screwdriver with exchangeable blades

● 1 metal ruler

● 1 needle rise gauge, Part no. 61-111 600-01

● 1 screw clamp, Part no. 08-880 137 00

● Sewing threads and test material

● Needles

12.03 Abbreviations

t.d.c. = top dead centre

b.d.c. = bottom dead centre

Adjustment

12 - 2

12.04 Opening up the sewing head

Turn off the compressed air supply!

Switch off the machine and take measures to prevent it being switched on

again!

The opened sewing head must be prevented from falling back down with support 6!

If the sewing head falls down suddenly there is a danger of being crushed between

the sewing head and table top!

Fig. 12 - 01

● Remove cover 1 (screws 2, 4 ea).

● Remove cover 3 (screws 4).

● Unscrew screw 5 and swing out the cover plate.

● Swing the control panel aside. If necessary loosen the terminal screws.

● Open up the sewing head and protect it from falling back down with support 6.

● To replace the sewing head repeat the steps in reverse order.

71-001

71-013

5

71-019

3

4

4

6

71-020

1

2

2

Adjustment

12 - 3

71-029

12.05.01 Preliminary adjustment of the needle height

Requirement

When the needle bar is at t.d.c. there should be a distance of approx. 15 mm between the

needle points and the needle plate.

● Without twisting it, adjust needle bar 1 (screw 2) in accordance with the requirement.

Fig. 12- 02

2

1

71-027

15 mm

Adjustment

12 - 4

3

1

12.05.02 Position of the needles to the needle hole

Requirement

Both needles should enter the respective needle holes in the centre.

● Adjust needle bar 1 (screw 2) in accordance with the requirement.

● If necessary, adjust needle bar 1 (screw 3) in accordance with the requirement.

Fig. 12 - 03

71-003

2

Adjustment

12 - 5

12.05.03 Needle bar rise, needle height, hook-to-needle clearance and needle guard

Requirement

When the needle bar is positioned 2.2 after b.d.c. (needle bar rise)

1. The top edge of the needle eye should be 1.0 mm below the hook point

2. The hook point, at a distance of 0.05 – 0.10 mm from the needle, should be positioned at

needle centre

3. Needle guard 5 should be touching the needle lightly.

Needle bar rise

● Loosen screws 1.

● Position the needle bar at b.d.c.

● In this position slide the 2.2 mm thick feeler of the needle rise gauge directly under the

needle bar bearing.

● Move screw clamp (part no. 08-880 137 00) to touch the feeler gauge and screw tightly

onto the needle bar.

● Remove the feeler and turn balance wheel 6 in the direction of the arrow, until the screw

clamp fits tightly.

● Set the hook tip towards the centre of the needle and tighten the fastening screws of the

bevel gear 1, taking the backlash into consideration.

Fig. 12 - 04

6

71-017

1

1

Adjustment

12 - 6

71-031

Fig. 12 - 04

Needle height

● Without twisting it, adjust the needle bar (screw 3) in accordance with the requirement 1.
Hook to needle clearance

● Loosen the screws of the hook gear drive through the installation holes (arrows).

● Adjust the hook bearing (screws 4) in accordance with requirement 2, taking care that the

needle is not deflected by needle guard 5.

● Control the movement of the lifting eccentric.

Needle guard

● Bring the needle bar into the needle rise position by turning the balance wheel.

● Align needle guard 5 in accordance with requirement 3.

1,0 mm

4

4

4

4

73-013

0,05 - 0,1 mm

5

71-032

3

Adjustment

12 - 7

70-028

12.05.04 Bobbin case opener stroke

Requirement

At the end of the back stroke of the bobbin opener, the catch 3 of the bobbin case should be
at such a distance from the edge of the recess of the needle plate 4 that the thread can

pass through unhindered.

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

Fig. 12 - 05

2

1

3

4

Adjustment

12 - 8

12.05.05 Position of the bobbin thread cutter

Requirement

Bobbin thread cutter 1 should

1. Be positioned in the centre of the needle plate cutout and

2. Must not jut out above the edge of the table top.

● Adjust bobbin thread cutter 1 (screw 2) in accordance with requirement 1.

● Adjust bobbin thread cutter 1 (screw 3) in accordance with requirement 2.

Fig. 12 - 06

2

3

71-033

1

Adjustment

12 - 9

71-018

12.05.06 Position of the needle thread cutter

Requirement

The needle thread cutter should be positioned in the centre between the needles at a
distance of 3 mm from the needle plate (extended thread catcher 3) and catch the

thread reliably.

● Adjust needle thread cutter 1 (screws 2) in accordance with the requirement.

Fig. 12 - 07

2

71-034

1

2

3 mm

Adjustment

12 - 10

71-005

12.05.07 Cutting device of the interfacing feed unit

Requirement

1. The interfacing should be cut smoothly with the lowest possible cutting pressure.

2. The roller lever should be activated when the bottom knife is lowered.

● Adjust knife holder 1 (screws 2) in accordance with requirement 1.

● Adjust screw 3 (nut 4) in accordance with requirement 2.

Fig. 12 - 08

71-006

1

2

2

4

3

Adjustment

12 - 11

71-002

12.05.08 Basic position of the middle knife

Requirement
The top edge of the cylinder 1 should be approx. 70 mm above the top edge of the machine.

● Adjust cylinder 1 in accordance with the requirement.

Fig. 12 - 09

71-058

1

70 mm

Adjustment

12 - 12

12.05.09 Knife pressure and angle of the middle knife blade

Requirement

1. Middle knife 4 should cut smoothly with the lowest possible knife pressure.

2. Middle knife 4 should be at a slight angle to the counter knife.

● Adjust knife holder 1 (screw 2) in accordance with requirement 1.

● Adjust knife holder 1 (screws 3) in accordance with requirement 2.

Fig. 12 - 10

7

3-011

3

1

2

4

Adjustment

12 - 13

71-037

12.05.10 Height of the middle knife

Requirement

When the middle knife 5 is at its b.d.c.

1. The bottom edge of the knife holding bar 1 should be 40 mm above the edge of the cast-

iron machine head.

2. Cylinder 7 should slot into the corresponding groove of the knife holding bar 1.

3. The top edge of middle knife 5 should be 0.5 mm below the needle plate cutout.

● Adjust knife holding bar 1 (screw 2) in accordance with requirement 1.

● Move cylinder bracket 3 (screw 4) in accordance with requirement 2.

● Adjust middle knife 5 (screws 6) in accordance with requirement 3.

Fig. 12 - 11

1

7

4

3

40 mm

71-038

6

5

0,5 mm

2

Adjustment

12 - 14

71-053

12.05.11 Middle knife motion

Requirement
When the needle bar is at b.d.c., the middle knife 3 should be at the bottom of its stroke.

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

Fig. 12 - 12

71-039

3

2

1

Adjustment

12 - 15

71-056

12.05.12 Needle thread tension release

Requirement
Tension disks 3 should be 0.5 mm apart when the thread tension is released.

● Align pressure plate 1 in accordance with the requirement.

The distance of 0.5 mm is a minimum distance and can be over 1 mm when
thick threads are used. If the thread tension is effective, the release pin 3 should

not be under stress

Fig. 12 - 13

3

3

71-054

71-055

0,5 mm

1

2

1

3

Adjustment

12 - 16

71-021

3

1

2

12.05.13 Thread check spring

Requirement

The movement of the thread check spring 3 should have come to an end when the needle

point penetrates the material (spring stroke approx. 7 mm).

● Adjust guide stop 1 (screw 2) in accordance with the requirement.

For technical reasons it may be necessary to deviate from the specified spring

stroke or from the spring tension.

Fig. 12 - 14

Adjustment

12 - 17

71-040

12.05.14 Hook lubrication

Requirement

After a running time of 10 seconds, a fine oil film should be visible on a paper strip held next

to the hook.

● Adjust screws 1 in accordance with the requirement.

Fig. 12 - 15

1

Adjustment

12 - 18

12.05.15 Setting the reference point

Requirement
When the needle bar is positioned 1 mm after t.d.c., LED 2 should be on.

● Bring toothed belt wheel 1 into the position in accordance with the requirement and fit the

toothed belt.

Fig. 12 - 16

1

2

Adjustment

12 - 19

71-059

12.05.16 Adjusting the laser points

Requirement

1. The distance from the needle centre to the front edge of the first laser cross should be

110 mm.

2. The distance from the centre of the middle laser cross to the outer edges of each of the

outer laser crosses should be 90 mm.

3. All three laser crosses should be in alignment with the centre of the middle knife.

● Adjust the positioning aids 1 (screws 2 and 3) in accordance with the requirements.

Fig. 12 - 18

2

3

1

2

2

1

1

3

110 mm

90 mm

90 mm

Adjustment

12 - 20

71-060

12.05.17 Height and lateral adjustment of the folding unit

Requirement

When lowered, folding unit 3 should be

1. At a distance of 1.5 - 2.3 mm (depending on the material) from the cover plate.

2. Parallel to the top edge of the cover plate and centred to the needles and

3. Parallel to the outer edge of the cover plate.

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

● Swing or shift folding unit 3 (screw 4) in accordance with requirements 2 and 3.

Fig. 12 - 19

2

1

3

(=)

(=)

1,5 - 2,3 mm

1,5 - 2,3 mm

71-062

4

Adjustment

12 - 21

7

1-063

12.05.18 Folding unit to needle clearance

Requirement

When lowered, folding unit 1 should be at a distance of 3 mm from the rear edge of the

needle.

● Shift folding unit 1 (screws 2) in accordance with the requirement.

Fig. 12 - 20

71-011

2

3 mm

1

Adjustment

12 - 22

12.05.19 Position of the flap retainers

Requirement

1. Flap retainer 5 should be approx. 1 mm above the work surface.

2. The spring pressure should be set so that the flap is held reliably.

● Turn screw 1 (nut 2) in accordance with requirement 1.

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

Carry out the adjustment of the second flap retainer in the same way.

Fig. 12 - 21

1

2

3

4

5

1 mm

Adjustment

12 - 23

12.05.20 Flap retainer to needle clearance

Requirement

When the folding unit is lowered, the back edge of the flap retainer 1 should be at a distance
of 1 mm behind the edge of the needle.

● Shift flap retainer 1 (screws 2) in accordance with the requirement.

Carry out the adjustment of the second flap retainer in the same way.

Fig. 12 - 22

1

2

2

1 mm

Adjustment

12 - 24

71-012

12.05.21 Height of the main clamps

Requirement
The front edge of the main clamps 3 should be at a height of 21 mm above the cover plate.

● Adjust piston rods 1 (nuts 2) in accordance with the requirement.

71-052

3

3

21 mm

2

1

1

Fig. 12 - 23

Adjustment

12 - 25

71-064

12.05.22 Distance of both main clamps from the folding unit

Requirement

Both main clamps 1 and 5 should be

1. Parallel to the folding unit over their entire length and

2. At a distance of 0.5 mm from the folding unit.

Left main clamp

● Align main clamp 5 (screws 6) in accordance with requirement 1.

● Insert folding unit for double piping.

● Adjust adjustment ring 7 (screws 8) in accordance with requirement 2.

● Insert folding unit for single piping.

● Making sure that main clamp 1 is touching adjustment ring 9, adjust adjustment ring 9

(screws 10) in accordance with requirement 2.

Right main clamp

● Align main clamp 1 (screws 2) in accordance with requirement 1.

● Adjust adjustment rings 3 (screws 4) in accordance with requirement 2.

Fig. 12 - 24

2

3

3

4

4

1

6

7

8

9

10

5

71-050

0,5 mm 0,5 mm

Adjustment

12 - 26

12.05.23 Adjusting the fold slider

Requirement

1. Fold sliders 1 should extend 4 mm, parallel to the main clamp.

2. When retracted, the fold sliders should be positioned behind the edge of the main

clamp.

● Adjust fold slider 1 (screws 2) in accordance with requirement 1.

● Adjust fold slider 1 (nut 3) in accordance with requirement 2.

Repeat the adjustment of the second fold slider in the same way.

Fig. 12 - 25

1

2

3

2

Adjustment

12 - 27

12.05.24 Adjusting the flap clamps

Requirement
The flap clamps 1 should hold the flaps reliably over the entire length.

● Adjust flap clamp 1 (screw 2) in accordance with the requirement.

● Adjust flap clamp pressure with piston rod 3 (nut 4) in accordance with requirement.

Repeat the adjustment of the second flap clamp in the same way.

Fig. 12 - 26

1

2

3

4

Adjustment

12 - 28

71-048

12.05.25 Basic position of the main clamps

Requirement

1. In the basic position the main clamps 3 should be at a distance of 302 mm from the

centre of the needle.

2. Initiator 1 should be at a distance of 0.3 mm from the contact surface.

● Adjust initiator 1 (nuts 2) in accordance with the requirements.

Fig. 12 - 27

302 mm

0,3 mm

2

1

3

Adjustment

12 - 29

12.05.26 Preliminary adjustment of the mitre knives

Requirement

1. The distance between the needle and the tip of the right mitre knife 1 should be approx.
185 mm.

2. The distance between the tips of mitre knives 1 and 2 should be approx. 45 mm.

● Remove compressed air tube.

● Push mitre knives 1 and 2 upwards by hand.

● Adjust mitre knife 1 (screws 3) in accordance with requirement 1.

● Adjust mitre knife 2 (screws 4) in accordance with requirement 2.

Fig. 12 - 28a

1

3

2

4

18545

Adjustment

12 - 30

71-049

12.05.27 Adjusting the mitre knives

Requirement

The cut of the mitre knives should be

1. Centred to the seam,

2. Should not be distorted and

3. Should have a distance on the right and left of approx. 0.5 mm to the seam.

● Adjust bracket 1 (screws 2) in accordance with requirement 1.

● Adjust mitre knives 3 (screws 4) in accordance with requirement 2.

● Adjust cylinder 5 (screws 6) in accordance with requirement 3.

Fig. 12 - 28b

3

4

2

3

4

1

2

71-057

0,5 mm

0,5 mm

6

6

5

5

Adjustment

12 - 31

71-061

12.05.28 Adjusting the sensors

Requirement

1. Sensor 1 must be directed to the centre of the reflection surface of the folding unit over

the entire length.

2. The two LEDs 4 and 5 must be on.

● Adjust sensor 1 (screws 2) in accordance with requirement 1.

● Adjust potentiometer 3 in accordance with requirement 2.

Fig. 12 - 29

2

71-051

1

3
5

4

2

2

Adjustment

12 - 32

A - Needle thread cutter / clamp

B - Middle knife

C Interfacing feed

D - Stacker (time)

E - 2

nd

service level (code entry required, 8 x “9”)

F - back to basic display

Closing order of the flap clamps (see Chapter 7.05 Foot switch)

Closing order of the main clamps (see Chapter 7.05 Foot switch)

A - Clamp speed and clamp insertion to seam beginning

B - Bartacking

C - (R1)

Clamp speed, position for cutting needle thread and path to first mitre cut

(R2)

Clamp speed and path to second mitre cut

D - Speed “reverse clamp” and rear end position of the clamps

H - Setting safety length flap

Encoder – seam length correction

12.05.29 Summary of the functions in the service menu

Select the service menu with the Technics/Service function .

Sensor and stacker on/off (see Chapter 7.05 Foot switch)

Vacuum and trouser stamp on/off (see Chapter 7.05 Foot switch)

Needle thread monitor on/off (see Chapter 7.05 Foot switch)

Bobbin thread counter on/off

Service settings (code entry required, 8 x “1”)

Output test

Backtacking settings

Back to basic display

Select/reset piece counter

Display setting (language(contrast)

Adjustment flaps / main clamps

Machine information

Register 08

Contents ................................................................................. Chapter - Page

13

Pneumatics circuit diagramc ....................................................................................... 13 - 1

Circuit diagrams .......................................................................................................... 13 - 8

13 - 1

Solenoid valve Connection Designation

Y16 C6 Quick adjustment main clamp

Y15 Q2.6 Vacuum/option stamp

Y14 Q2.5 Interfacing feed

Y13 A/B Q2.4 Stacker forwards/reverse A = 2-arm stacker,

B = 3-arm stacker

Y10 Q2.1 Left flap clamp

Y9 Q2.0 Right flap clamp

Y8 Q1.1 Left main clamp

Y7 Q1.0 Right main clamp

Y6 Q0.7 Fold slider

Y5 Q0.6 Thread clamp up and cut

Y4 Q0.5 Middle knife carrier

Y3 Q0.4 Switch on middle knife

Y2 Q0.3 Raise/lower folding unit

Y1 Q0.2 Thread tension release

Y12 Q2.3 Front mitre knife

Y11 Q2.2 Back mitre knife

For the Vacuum and Stacker functions, the menu options must be switched to

ON

Reference list for the diagrams of the pneumatic systems

13 - 2

Version 01.01.2002

Pneumatics circuit diagram

Part 1

Q0.2 Q0.3 Q0.4 Q0.5

Y1 Y2

Y3

Y4

2

2

2

3

3

4

4

41

1

13 - 3

Pneumatics circuit diagram

Part 2

Version 01.01.2002

6

677

88

Q0.6

Y5 Y6

Y7

Y8

Q0.7

Q1.0

Q1.1

55

13 - 4

Version 01.01.2002

Pneumatics circuit diagram

Part 3

99

10

10

Q2.0 Q2.1

Y9

Y10

99

10

16

16

C6

Y16

16

12

12

Q2.3

Y12

12

11

11

Q2.2

Y11

11

13 - 5

Pneumatics circuit diagram

Part 4

Version 01.01.2002

20-50

A0 20-150

B0

a0

b0

13

13

Q2.4

Y13A

13 - 6

Version 01.01.2002

Pneumatics circuit diagram

Part 5

C1 20-50 A0

20-150

B0

b0C1

a0

4

2

3

1

5

Q2.4

13

13

Y13B

13 - 7

Pneumatics circuit diagram

Part 6

Version 01.01.2002

a0

A0

14 14

Q2.5

Y14

Q2.6

Option

Y15

13 - 8

Reference list for the circuit diagrams

S1 Main switch

DRV1: Controller for clamp drive motor

DRV2: Controller for QUICK-Mini-Stop

M1: Clamp drive motor

M2: QUICK-Mini-Stop motor

C1: Control card Servo –motor

C2: Control card QUICK-Mini-Stop motor

C3: Relay, reduced speed for backtacks

C4: Amplifier for thread monitor

C5: Amplifier for thread monitor

C6: Relay, quick adjustment for double- or single-piping

C10: Motherboard

PLC: SIEMENS CPU 224 S7

Outlet (EM 222 DC)

PANEL: Control panel (HITECH LCD SCREEN 1711)

POINTER: Marking lamps

SERVO

SW: Switch for clamp reference point

FLAP

FOTOSEL: Sensor for flap recognition (PNP Type +24 DC)

HEAD:

COVER SW: Safety switch folder retracted

DOUBLE-

SINGLE SW: Switch for folder (single-/double piping)

NEEDLE

POSITION SW: Needle position switch on balance wheel

PEDAL SW: Pedal switch

13 - 9

Version 01.01.2002

Circuit diagrams

13 - 10

General Plan Inputs

Version 01.01.2002

13 - 11

Version 01.01.2002

General Plan Inputs/Outputs