Page 1
Instruction Manual
3734 -12/21
296-12-18 750/002
Betriebsanleitung dtsch. 09.03
This instruction manual applies to machines from the
following serial numbers onwards:
# 2648486
Page 2
This instruction manual applies to all versions and subclasses listed under
"Specifications".
The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or in
part, is only permitted with our previous authorisation and with written reference to the
source.
PFAFF Industrie Maschinen AG
Postfach 3020
D-67653 Kaiserslautern
Königstr. 154
D-67655 Kaiserslautern
Redaktion / Illustration
HAAS-Publikationen GmbH
D-53840 Troisdorf
Page 3
Contents
Contents ..................................................................................Chapter - Page
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
2 Proper use .................................................................................................................... 2 -1
3 Specifications .............................................................................................................. 3 - 1
3.01 PFAFF 3734-12/21 ......................................................................................................... 3 - 1
3.02 Model, needles and threads........................................................................................... 3 - 2
4 Disposal of machines .................................................................................................. 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
7 Controls .................................................................................................... 7- 1
7.01 On/off switch................................................................................................................. 7 - 1
7.02 Pedal ............................................................................................................................. 7 - 1
7.03 Knee switch ..................................................................................................................7- 2
7.04 Lever for raising the feed band ...................................................................................... 7 - 2
7.05 Control panel ................................................................................................................. 7 - 3
7.05.01 Displays on the screen .................................................................................................. 7 - 3
7.05.02 Function keys ................................................................................................................ 7 - 3
8 Mounting and commissioning the machine .............................................................. 8 - 1
8.01 Mounting ....................................................................................................................... 8 - 1
8.01.01 Adjusting the table-top height ........................................................................................ 8 - 1
8.01.02 Fitting the tilt lock .......................................................................................................... 8 -2
8.01.03 Fitting the machine cover .............................................................................................. 8 - 2
8.02 Mounting the flange motor ............................................................................................. 8 - 3
8.02.01 Mounting the flange motor to the bearing plate .............................................................. 8 - 3
8.02.02 Mounting the flange motor to the machine .................................................................... 8 - 3
8.02.03 Connecting the plug-in connections and earth cables ..................................................... 8 - 4
8.02.04 Mounting the belt guard of the flange motor .................................................................. 8 - 5
Page 4
Contents
Contents ..................................................................................Chapter - Page
8.02.05 Connecting the safety switch ........................................................................................ 8 - 6
8.02.06 Checking the function of the start inhibitor .................................................................... 8 - 6
8.02.07 Basic position of the machine drive unit ........................................................................ 8 - 7
8.03 Fitting the reel stand ...................................................................................................... 8- 8
8.04 Commissioning ............................................................................................................. 8 - 8
8.05 Switching the machine on/off........................................................................................ 8 - 8
9 Setting up ..................................................................................................................... 9- 1
9.01 Inserting the needle ....................................................................................................... 9 -1
9.02 Winding the bobbin thread, adjusting the thread tension ................................................ 9 - 2
9.03 Removing / Inserting the bobbin case............................................................................ 9 - 3
9.04 Threading the bobbin case / Adjusting the bobbin thread tension ................................... 9 - 3
9.05 Threading the needle thread / Adjusting the needle thread tension ................................. 9 - 4
9.06 Entering the stitch length............................................................................................... 9 - 5
9.06.01 Entering the standard stitch length ................................................................................ 9 - 5
9.06.02 Entering a second stitch length or amount of fullness .................................................... 9 - 5
9.06.03 Entering the fullness area for the pedal adjustment ....................................................... 9 - 6
9.07 Entering the start and end backtacks............................................................................. 9 - 7
9.08 Entering/changing the code number ............................................................................... 9 - 8
9.09 Switching on/adjusting the bobbin thread control with reverse stitch count .................. 9 - 10
10 Sewing ........................................................................................................................10- 1
10.01 Manual sewing ............................................................................................................. 10 -1
10.02 Programmed sewing .................................................................................................... 10 - 2
10.03 Altering seam programs ............................................................................................... 10 - 3
10.04 Error messages ............................................................................................................10 -4
11 Care and maintenance ............................................................................................... 11 - 1
11.01 Cleaning ....................................................................................................................... 11 - 1
11.02 Oiling the hook ............................................................................................................. 11 - 2
11.03 Checking the oil levels ................................................................................................. 11 - 2
11.04 Lubricating the bevel gears ........................................................................................... 11 - 3
12 Adjustment ..................................................................................................................12 - 1
12.01 Notes on adjustment ....................................................................................................12 - 1
12.02 Werkzeuge, Lehren und sonstige Hilfsmittel ................................................................. 12 - 1
12.03 Abbreviations ................................................................................................................12 - 1
12.04 Adjusting the basic machine ......................................................................................... 12 - 2
12.04.01 Positioning the needle in the direction of sewing...........................................................12 - 2
12.04.02 Positioning the needle across the direction of sewing ...................................................12 - 3
12.04.03 Preadjusting the needle height ......................................................................................12 - 4
12.04.04 Needle rise, hook-to-needle clearance, needle height and needle guard ........................ 12 - 5
12.04.05 Height and stroke of the bobbin case opener ................................................................12 - 7
12.04.06 Height of the feed wheel .............................................................................................. 12 - 8
12.04.07 Clearance between feed band and feed wheel .............................................................12 - 9
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Contents
Contents ..................................................................................Chapter - Page
12.04.08 Adjusting the feed band ................................................................................................12 - 10
12.04.09 Changing the feed band ................................................................................................12 - 11
12.04.10 Automatic presser foot lift ............................................................................................12 - 12
12.04.11 Retainer ........................................................................................................................12 - 13
12.04.12 Tension release and tension control .............................................................................12 - 14
12.04.13 Thread check spring ..................................................................................................... 12 - 15
12.04.14 Bobbin winder .............................................................................................................12 - 16
12.04.15 Feed band pressure ...................................................................................................... 12 - 17
12.04.16 Locking the set value transmitter ................................................................................. 12 - 18
12.04.17 Lubrication ....................................................................................................................12 - 19
12.04.18 Re-engage safety coupling ........................................................................................... 12 - 20
12.05 Adjusting the thread trimmer –900/81 ...........................................................................12 - 21
12.05.01 Resting position of the roller lever / radial position of the control cam ........................... 12 - 21
12.05.02 Position of the thread catcher holder .............................................................................12 - 22
12.05.03 Distance between thread catcher and needle plate .......................................................12 - 23
12.05.04 Position of the thread catcher .......................................................................................12 - 24
12.05.05 Knife position and knife pressure .................................................................................. 12 - 25
12.05.06 Bobbin thread retaining spring .......................................................................................12 - 26
12.05.07 Manual cutting test ..................................................................................................... 12 - 27
12.06 Parameter settings ....................................................................................................... 12 - 28
12.06.01 Overview of the parameter functions ...........................................................................12 - 29
12.06.02 Parameter input example ..............................................................................................12 - 29
12.06.03 List of parameters ........................................................................................................ 12 - 30
12.07 Explanation of the error messages ...............................................................................12 - 33
12.08 Warning messages ......................................................................................................12 - 33
12.09 Carrying out a cold start ............................................................................................... 12 - 34
12.10 Internet update of the machine software ...................................................................... 12 - 35
13 Wearing parts ............................................................................................................. 13 - 1
14 Circuit diagrams ......................................................................................................... 14 - 1
Page 6
Safety
1 - 1
1 Safety
1.01 Directives
This machine is constructed in accordance with the European regulations contained in the
conformity and manufacturer’s declarations.
In addition to this Instruction Manual, observe also all generally accepted, statutory and other
regulations and legal requirements and all valid environmental protection regulations!
The regionally valid regulations of the social insurance society for occupational accidents or
other supervisory organisations are to be strictly adhered to!
1.02 General notes on safety
● This machine may only be operated by adequately trained operators and only after having
completely read and understood the Instruction Manual!
● All Notes on Safety and Instruction Manuals of the motor manufacturer are to be read
before operating the machine!
● The danger and safety instructions on the machine itself are to be followed!
● This machine may only be used for the purpose for which it is intended and may not be
operated without its safety devices. All safety regulations relevant to its operation are to be
adhered to.
● When exchanging sewing tools (e.g. needle, roller presser, needle plate, or bobbin), when
threading the machine, when leaving the machine unattended and during maintenance
work, the machine is to be separated from the power supply by switching off the On/Off
switch or by removing the plug from the mains!
● Everyday maintenance work is only to be carried out by appropriately trained personnel!
● Repairs and special maintenance work may only be carried out by qualified service staff or
appropriately trained personnel!
● Work on electrical equipment may only be carried out by appropriately trained personnel!
● Work is not permitted on parts and equipment which are connected to the power supply!
Exceptions to this are only to be found in the regulations EN 50110.
● Modifications and alterations to the machine may only be carried out under observance of
all the relevant safety regulations!
● Only spare parts which have been approved by us are to be used for repairs! We
expressly point out that any replacement parts or accessories which are not supplied by
us have not been tested and approved by us. The installation and/or use of any such
products can lead to negative changes in the structural characteristics of the machine. We
shall not be liable for any damage which may be caused by non-original parts.
Page 7
Safety
1 - 2
1.03 Safety symbols
Danger!
Points to be observed.
Danger of injury for operating and specialist personnel!
1.04 Important points for the user
● This Instruction Manual is a component part of the machine and must be available to the
operating personnel at all times.
● The Instruction Manual must be read before operating the machine for the first time.
● The operating and specialist personnel is to be instructed as to the safety equipment of the
machine and regarding safe work methods.
● It is the duty of the user to only operate the machine in perfect running order.
● It is the obligation of the user to ensure that none of the safety mechanisms are removed
or deactivated.
● It is the obligation of the user to ensure that only authorized persons operate and work on
the machine.
Further information can be obtained at your PFAFF agent.
Caution
Do not operate without finger guard and safety devices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.
I
Page 8
Safety
1 - 3
1.05 Operating and specialist personnel
1.05.01 Operating personnel
Operating personnel are persons responsible for the equipping, operating and cleaning of the
machine as well as taking care of faults arising in the sewing area.
The operating personnel is obliged to observe the following points and must:
● always observe the Notes on Safety in the Instruction Manual!
● never use any working methods which could limit the level of safety in using the machine!
● not wear loose-fitting clothing or jewellery such as chains or rings!
● also ensure that only authorized persons have access to the potentially dangerous area
around the machine!
● always immediately report to the person responsible any changes in the machine which
may limit its safety!
1.05.02 Specialist personnel
Specialist personnel are persons with a specialist education in the fields of electrics,
electronics and mechanics. They are responsible for the lubrication, maintenance, repair and
adjustment of the machine.
The specialist personnel is obliged to observe the following points and must:
● always observe the Notes on Safety in the Instruction Manual!
● switch off the On/Off switch before carrying out adjustments or repairs and ensure that it
cannot be switched on again unintentionally!
● never work on parts which are still connected to the power supply! Exceptions are
contained only in the regulations EN 50110.
● replace the protective coverings and close the electrical control box after all repairs or
maintenance work!
Page 9
Safety
1 - 4
1.06 Danger
A working area of 1 meter is to be kept free both in front of and behind the
machine while it is in operation so that it is always easily accessible.
Never reach into the sewing area while sewing! Danger of injury by the needle!
Never leave objects on the table or in the needle plate area while adjusting the
machine settings! Objects can become trapped or be slung away! Danger of
injury!
Do not operate the machine without support 1!
Danger due to top-heavy sewing head!
Machine can tip over backwards when tilted!
Do not operate the machine without its take-up-lever guard 2!
Danger of injury due to the motion of the take-up lever!
Do not operate the machine without cover 3!
Danger of injury from moving drive belts!
Do not operate the machine without tilt lock 4!
Danger of crushing between sewing head and table top!
2
3
4
Fig. 1 - 01
63-021
1
Page 10
Proper use
2 - 1
2 Proper use
The PFAFF 3734-2/21 is a high-speed, single needle, postbed sewing machine (post to the
right of the needle) with forwards and reverse feeding feed-wheel and roller presser.
This machine is used for sewing lockstitch seams 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 includes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!
Page 11
Specifications
3 - 1
3 Specifications
3.01 PFAFF 3734-12/21
▲
Stitch type: ................................................................................................ 301 ( lockstitch )
Roller presser clearance: ............................................................................................ 9 mm
Clearance width: .................................................................................................... 245 mm
Clearance height: .................................................................................................... 115 mm
Post height: ............................................................................................................ 180 mm
Sewing head dimensions:
Length: ....................................................................................................... approx. 615 mm
Width: ......................................................................................................... approx. 240 mm
Height ( above table ): ................................................................................ approx. 500 mm
Bed-plate dimensions: ................................................................................... 518 x 177 mm
Max. speed: ................................................................................................... 3500 s.p.m.
◆
Connection data:
Operating voltage: ........................................................................... 230 V ± 10%, 50/60 Hz
Max. power consumption: ....................................................................................... 1,2 kVA
Fuse protection: ............................................................................................. 1 x 16 A, inert
Noise data:
Emission sound level at the workplace at a speed of 2700 spm: ......................... 80 dB(A)
■
( Noise measurement in acc. with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871 )
Net weight of sewing head: ............................................................................ approx. 61 kg
Gross weight of sewing head: ........................................................................ approx. 71 kg
▲
Subject to alternation
◆
Varies according to material, work process and stitch length
■
KpA = 2,5 dB
3.02 Model, needles and threads
Model: ............................................................................................................................... A
Needle system: ......................................................................................................... 134-35
Needle size in 1/100 mm: .................................................................................................80
Max. thread size synthetic *: .................................................................................... 60 - 60
*
Or comparable thicknesses of other thread types
Page 12
Disposal of machines
4 - 1
4 Disposal of machines
● The proper disposal of machines is the responsibility of the customer.
● The materials used in the machines are steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
● The machine is to be disposed of in accordance with the locally valid
environmental protection regulations. If necessary, a specialist is to be commissioned.
Special care is to be taken that parts soiled with lubricants are separately
disposed of in accordance with the locally valid pollution control regulations!
Page 13
Transport packaging and storage
5 - 1
5 Transport packaging and storage
5.01 Transport to the customer’s premises
All machines are delivered completely packed.
5.02 Transport within the customer’s premises
The manufacturer bears no liability for transport within the customer’s premises or to the indi-
vidual locations of use.
Always ensure that the machine is only transported upright.
5.03 Disposal of the packaging
The packaging of these machines consists of paper, cardboard and VCE fibre.
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.
Page 14
Explanation of the symbols
6 - 1
6 Explanation of the symbols
In the following section of this Instruction Manual, certain tasks or important pieces of
information are accentuated by symbols.
The symbols used have the following meanings:
Note, information
Cleaning, care
Lubrication, greasing
Servicing, repairing, adjustment, maintenance
(only to be carried out by specialist personnel)
Page 15
Controls
7 - 1
7.02 Pedal
0 = Neutral position
1 = Sewing
2 = Raise roller presser
3 = Trim thread and raise roller presser
1 + 4 = Variable application of fullness
7-004
77
-
005
Fig. 7 - 01
7 Controls
7.01 On/off switch
● Turn the machine on/off by turning
On/Off switch 1.
Fig. 7 - 02
4
01
3
2
1
Page 16
Controls
7 - 2
87-006
87-004
7.04 Lever for raising the feed band
● Raise the feed band by turning lever 1.
Fig. 7 - 04
7.03 Knee switch
● By operating knee switch 1 it is possible
to select 2 pre-set values for fullness.
Fig. 7 - 03
1
1
Page 17
Controls
7 - 3
7.05 Control panel
The control panel consists of display 1 and the function keys described below. Display 1
consists of a two-row, alpha-numerical display with 16 symbols per row. The special
symbols 3 and texts 4 show the respective status of the function keys and the operating
modes of the machine.
During the power-on phase the control panel automatically switches on all LCD segments
and a beep tone for a short time. Afterwards the lettering PFAFF appears on the display, until
the higher-ranking control unit sends commands to the control panel.
7.05.01 Displays on the screen
● Activated functions are shown with a triangular symbol 2 below or next to the respective
function key.
● In sewing mode all relevant sewing data is displayed and can be changed directly
depending on the machine status, also see Chapter 10 Sewing.
● When entering the parameters, the selected parameter number with the corresponding
parameter value is displayed, see Chapter 12.06 Parameter settings.
7.05.02 Function keys
The function keys described below are used basically to switch the machine functions on and
off.
If a value must be given for the activated function, this is entered with the relevant +/- key.
By pressing down the relevant +/- key the corresponding value 5 is changed slowly. If the +/-
key is held down longer, the values change more quickly.
Start backtacks
● By pressing this key, the backtacking function at the beginning of the seam (start
backtacks) is switched on or off. The number of forward stitches (A) or reverse stitches
(B) for the start backtacks can be changed in each case by pressing the +/- key
underneath. To convert from double backtacks to single backtacks the relevant number of
stitches for the seam segment is set at zero.
● When entering the code number, the key corresponds to the number 1.
2.5 2.5
PM
5
341 2
Page 18
Controls
7 - 4
End backtacks
● By pressing this key, the backtacking function at the end of the seam (end backtacks) is
switched on or off. The number of reverse stitches (C) or forward stitches (D) can be
changed in each case by pressing the +/- key underneath. To convert from double
backtacks to single backtacks the relevant number of stitches for the seam segment is
set at zero.
● When entering the code number, the key corresponds to the number 2.
Needle position
● By pressing this key the function "Needle raised after sewing stop" is switched on or off.
When the function is switched on, the needle positions at t.d.c. after sewing stops.
● When entering the code number, the key corresponds to the number 3.
Foot position after stop
● By pressing this key the function "Foot raised after sewing stop" is switched on or off.
When the function is switched on, the sewing foot is raised after sewing stops.
● When entering the code number, the key corresponds to the number 4.
Foot position after trimming
● By pressing this key the function "Foot raised after thread trimming" is switched on or off.
When the function is switched on, the sewing foot is raised after sewing thread trimming.
● When entering the code number, the key corresponds to the number 5.
Thread trimmer
● By pressing this key the thread trimming function is switched on or off.
● When entering the code number, the key corresponds to the number 6.
● When entering the code number, the key corresponds to the number 7.
● When entering the code number, the key corresponds to the number 8.
● When entering the code number, the key corresponds to the number 9.
Stop
● By pressing this key the corresponding function is switched on or off. If the function is
activated, the feed band and feed wheel drive are switched off, in order to e.g. fill the
bobbin thread spool outside the sewing operation.
● When entering the code number, this key corresponds to the number 0.
This key has no function.
This key has no function.
Page 19
Controls
7 - 5
TE/Speed
● By pressing this key once the speed limitation for sewing mode is activated.
By pressing the key twice ( within 5 seconds ) the machine switches to parameter input mode.
In the parameter input mode the lettering "TE" is displayed on the control panel. In the alpha-
numerical section of the display the parameters are listed with their corresponding values, see
Chapter 12.06 Parameter settings.
Scrolling
● When this key is pressed, it is possible to scroll through the input menus on the display.
PM
● By pressing this key the Programmed Sewing function is switched on or off. When the
function is switched on, the lettering “PM“ appears in the display of the control panel.
The parameters of the programs are shown in the alpha-numerical section of the display.
F1
This key has no function.
F2
This key has no function.
F3
This key has no function.
F4
● After this key has been pressed, the next bartack will not be sewn.
Page 20
Mounting and commissioning the machine
8 - 1
8 Mounting and commissioning the machine
The machine must only be mounted and commissioned by qualified personnel!
All relevant safety regulations are to be observed!
If the machine is delivered without a table, it must be ensured that the frame
and the table top which you intend to use can hold the weight of the machine
and the motor, even while sewing.
8.01 Mounting
The necessary electricity supply must be available at the machine’s location.
There must be a stable and horizontal surface and adequate lighting at the
machine’s location.
Due to reasons of packaging, the table top is lowered for transport.
The following is a description of how to adjust the height of the table top.
8.01.01 Adjusting the table-top height
● Loosen screws 1 and 2 and set the desired table-top height
● Tighten screws 1 well.
● Adjust the position of the pedal so that you can operate it comfortably and
tighten screw 2.
Fig. 8 - 01
87
-
007
1
1
2
2
Page 21
Mounting and commissioning the machine
8 - 2
Fig. 8 - 02
8.01.02 Fitting the tilt lock
Switch off the machine!
Danger of injury if the machine
is the machine is started
accidentally!
● Screw on the tilt lock parts 1 and 2,
provided in the accessories, using
screws 3 and 4.
Do not operate the machine
without tilt lock 1. Danger of
crushing between sewing head
and table top!
1
2
3
4
8.01.03 Fitting the machine cover
● Slide the slots of the lower section of the
cover 1 behind the heads of screws 2 and
attach with screws 3, then tighten
screws 2 through the holes.
● Attach right and left cover sections with
screws 4.
4
1
2
3
4
4
Fig. 8 - 03
Page 22
Mounting and commissioning the machine
8 - 3
8.02.02 Mounting the flange motor to the machine
● Attach bearing plate 1 of motor 2 to the
machine case with screws 3 (only tighten
screws 3 slightly).
Fig. 8 - 05
2
3
1
3
77
-
011
8.02 Mounting the flange motor
8.02.01 Mounting the flange motor to the bearing plate
Fig. 8 - 04
1
3
2
3
● Attach bearing plate 1 to motor 2 with screws 3 as shown in Fig. 8 - 04.
● Remove the wedge from motor shaft 4.
● Attach angle bracket 5 with screws 6.
● Fit toothed belt wheel 7 to the motor shaft 4, so that the point of the screw is located in
the groove of the motor shaft.
● Screw threaded stud 8 into the bearing plate 1.
4
5
8
3
6
7
Page 23
Mounting and commissioning the machine
8 - 4
0
81-090
8.02.03 Connecting the plug-in connections and earth cables
Fig. 8 - 06
● Connect all plugs as labelled to the control box 1.
● Screw the earth cable from the sewing head to earth point A.
● Screw the earth cable 2 from the motor to earth point B.
● Connect earth point C and earth point A with an earth cable.
● Fasten the earth cable of the main switch to earth point A.
A
63-011
B
2
C
1
3
Page 24
Mounting and commissioning the machine
8 - 5
Fig. 8 - 07
77-012
4
5
7
7
6
● Taking care not to turn the motor shaft 4 or the machine, fit synchronous belt 5.
● Swing the bearing plate 6 of the motor, so that the belt 5 is tightened.
● In this position tighten screws 7.
● Turn the balance wheel in the direction of sewing, until the needle point is on a level with
the top edge of the needle plate and check the value again. A tolerance of ± 2 increments
is permitted.
● Conclude the adjustment of the sewing motor by pressing the TE/Speed key.
77 014
8.02.04 Mounting the belt guard of the flange motor
● Attach belt guard 1 with screws 2 and 3.
Fig. 8 - 08
1
2
3
Page 25
Mounting and commissioning the machine
8 - 6
8.02.05 Connecting the safety switch
● Connect plug 1 of safety switch 2 as
shown in Fig. 8-09.
When the sewing head is tilted
back, the safety switch
prevents the machine starting
when the main switch is on.
Fig. 8 - 09
1
2
8.02.06 Checking the function of the start inhibitor
● Switch the machine on at the main switch and tilt back the sewing head.
The error message „STOP“ must appear on the control panel.
● If the message does not appear, check the setting of switch 3.
● After the sewing head has been set upright, the machine is ready for operation again.
2.5 2.5
STOP
Page 26
Mounting and commissioning the machine
8 - 7
8.02.07 Basic position of the machine drive unit
● Switch on the machine.
● Press TE/Speed key twice to select the input mode.
2.5 2.5
2 x
No VAL
101 II
TE
● Select the parameter group "600" by pressing the corresponding +/- key.
No
No
600
TE
● Confirm the selection by pressing the corresponding +/- key.
● Enter the code number, see Chapter 9.08 Entering/changing the code number.
● Select the parameter group "603" by pressing the corresponding +/- key.
● Turn the balance wheel in the direction of sewing, until the needle point is on a level with
the top edge of the needle plate.
● Turn the motor shaft by hand until value "11" appears in the display.ht.
No VAL
603 11
TE
Page 27
Mounting and commissioning the machine
8 - 8
8.04 Commissioning
● Examine the machine, in particular the electric cables, for any damage.
● Clean the machine thoroughly and then oil it, or fill in oil, see Chapter 11 Care and
Maintenance..
● Have qualified personnel check whether the machine can be operated with the available
voltage and whether it is connected properly in the terminal box. If there are any
irregularities do not operate the machine under any circumstances.
8.05 Switching the machine on/off
● Switch on the machine, see Chapter 7.01 Main switch.
8.03 Fitting the reel stand
● Fit the reel stand as shown in Fig. 8-10.
● Afterwards insert the stand in the hole in
the table top and secure it with the nuts
provided.
Fig. 8 - 10
Page 28
Setting up
9 - 1
9 Setting up
All instructions and regulations in this instruction manual must be observed. Spe-
cial attention must be paid to all safety regulations!
All setting-up work must only be carried out by personnel with the appropriate
training. For all setting-up work the machine must be disconnected from its po-
wer supply by turning off the on/off switch, or removing the plug from the electric
power socket.
9.01 Inserting the needle
Switch the machine off!
Danger of injury if the machine
is started accidentally!
Only use needles of system 134-35.
● Raise the feed band 1.
● Pull down feed band 1 a little and swing it
towards the left.
● Loosen screw 2 and insert the needle as
far as possible. The long needle groove
must be facing towards the left.
● Tighten screw 2 and swing the feed band
back into position.
Fig. 9 - 01
The choice of needle depends on the model of the machine and the thread and
material used ( see Chapter 3.02 Needles and threads ).
1
2
Page 29
Setting up
9 - 2
● Place an empty bobbin 1 onto bobbin winder spindle 2.
● Thread the bobbin in accordance with Fig. 9 - 02 and wind it clockwise around bobbin 1
a few times.
● Switch on the bobbin winder by pressing the bobbin winder spindle 2 and lever 3 at the
same time.
The bobbin is filled during sewing.
If the bobbin is filled outside the sewing operation, the drive for the feed band
and the feed wheel should be switched off by pressing the Stop key. This
function of the Stop key is only available in the manual sewing mode.
● The tension of the thread on bobbin 1 can be adjusted with knurled screw 4.
● The bobbin winder stops automatically when bobbin 1 is full.
If the thread is wound unevenly:
● Loosen nut 5.
● Turn thread guide 6 accordingly.
● Tighten nut 5.
9.02 Winding the bobbin thread, adjusting the thread tension
2
1
4
_
+
Fig. 9 - 02
5
6
3
Page 30
Setting up
9 - 3
9.03 Removing / Inserting the bobbin case
Maschine ausschalten!
Switch the machine off!
Danger of injury if the machine
is started accidentally!
Removing the bobbin case:
● Open the post cap.
● Raise latch 1 and remove bobbin case 2.
Inserting the bobbin case:
● Insert bobbin case 2.
● Close the latch and close the post cap.
Fig. 9 - 03
9.04 Threading the bobbin case / Adjusting the bobbin thread tension
● Insert the bobbin into the bobbin case 1.
● Pass the thread through the slot under sp-
ring 2.
● Pass the thread through the notch.
● Adjust the thread tension by turning
screw 3.
When the thread is pulled, the
bobbin must rotate in the
direction of the arrow.
2
-
+
1
5 cm
Fig. 9 - 04
87-012
1
2
Page 31
Setting up
9 - 4
9.05 Threading the needle thread / Adjusting the needle thread tension
Switch the machine off!
Danger of injury if the machine is started accidentally!
● Thread needle thread as shown in Fig. 9-05.
● Adjust the needle thread tension by turning knurled screws 1 and 2.
Fig. 9 - 05
87
-
013
1
2
Page 32
Setting up
9 - 5
9.06 Entering the stitch length
The stitch length is determined by adjusting the feed strokes of the feed band and the feed
wheel. When applying fullness, the feed stroke of the feed band must be larger or smaller
that the feed stroke of the feed wheel.
9.06.01 Entering the standard stitch length
● Switch on the machine.
After the machine has been switched on, the current values of the stitch lengths for the
feed band and the feed wheel are shown on the display.
● Set the stitch length ( feed stroke ) for the feed band by pressing the corresponding
+/- key.
● Set the stitch length ( feed stroke ) for the feed wheel by pressing the corresponding
+/- key.
9.06.02 Entering a second stitch length or amount of fullness
With the PM key, in addition to the standard stitch length a second stitch length or fullness
setting can be determined. In the programmed sewing mode ( text “PM“ on the display ) it
is possible to switch from one setting to the other by operating the knee switch.
● Switch on the machine and press the PM key to move into the programmed sewing
mode.
● Select the program number (1 or 2) by pressing the corresponding +/- key.
● Set the stitch length (feed stroke) for the feed band by pressing the corresponding +/- key.
● Set the stitch length (feed stroke) for the feed wheel by pressing the corresponding
+/- key.
2
1 1 2.6 2.5
PM
2.5 2.5
Page 33
Setting up
9 - 6
9.06.03 Entering the fullness area for the pedal adjustment
With parameter “107“ it is possible to stipulate the maximum stitch length, which can be
called up in infinite variations with the fullness pedal (left pedal).
● Switch on the machine.
● Press the TE/Speed key twice to call up the parameter input function.
3
2 x
No VAL
101 II
TE
● Select parameter “107“ by pressing the corresponding +/- key.
No
No VAL
107 4.0
TE
2.5 2.5
VAL
● By pressing the corresponding +/- key, set the maximum stitch length for the fullness
pedal (left pedal).
● Conclude the parameter input by pressing the TE/Speed key. The value enter is stored.
When the fullness pedal is activated, a bar display appears on the screen which shows
the actual amount of fullness in the fullness area entered, dependent on the pedal setting.
2.5 2.5
Page 34
Setting up
9 - 7
9.07 Entering the start and end backtacks
● Switch on the machine.
● Switch on the relevant function by pressing the Start backtack and/or End backtack keys.
( Arrow appears under the corresponding function key )
● By pressing the Scroll key switch to the input menu for the start and end backtacks.
2.5 2.5
A B C D
1 1 1 1
PM
A
B
C
D
● By pressing the corresponding +/- key select the desired value for the number of forward
stitches (A) of the start backtack.
● By pressing the corresponding +/- key select the desired value for the number of reverse
stitches (B) of the start backtack.
● By pressing the corresponding +/- key select the desired value for the number of reverse
stitches (C) of the end backtack.
● By pressing the corresponding +/- key select the desired value for the number of forward
stitches (D) of the end backtack.
● Switch back to the stitch length input menu by pressing the Scroll key.
Page 35
Setting up
9 - 8
9.08 Entering/changing the code number
● Switch on the machine.
● Press the TE/Speed key twice to call up the parameter input function.
● Enter the code number by pressing the corresponding keys ( factory code setting is "1500"),
also see Chapter 7.05.02 Key functions.
● Conclude code input by pressing the corresponding +/- key.
The code input is stored until the machine is switched off at the main switch. As
long as the machine is not switched off, there is free access to all parameters
without having to enter the code number again.
2.5 2.5
2 x
No VAL
101 II
TE
● By pressing the corresponding +/- key select the parameter group "800".
No
No
800
TE
● Confirm the selection by pressing the corresponding +/- key.
CODE: 1500
TE
1 5
1
0
Page 36
Setting up
9 - 9
● Enter the desired code by pressing the corresponding keys, also see Chapter 7.05.02
Key functions.
● Conclude the input by pressing the corresponding +/- key. The new code number is stored
and the parameter input concluded.
No VAL
801 0
TE
● By pressing the corresponding +/- key select the parameter "810".
No
No
810 1500
TE
● Confirm the selection by pressing the corresponding +/- key.
CODE: 1500
TE
1 2 3 4 5 6 7 8
1
9
0
Page 37
Setting up
9 - 10
9.09 Switching on/adjusting the bobbin thread control with reverse stitch
count
● Switch on the machine.
● Press the TE/Speed key twice to call up the parameter input function.
● By pressing the corresponding +/- key set the number of stitches to be sewn with one
bobbin.
● Conclude the parameter input by pressing the TE/Speed key. The value enter is stored.
To activate the stitch counting function, the value of parameter "104" must be set
at "1".
Shortly before the number of stitches entered have been sewn, the signal
"WARNING 2" appears on the display after the thread has been trimmed, also
see Chapter 12.08 Warning signals.
To be able to continue sewing after the bobbin has been changed, the error
elimination must be acknowledged by pressing any key on the control panel.
3
2 x
No VAL
101 II
TE
● Select parameter „105“ by pressing the corresponding +/- key.
No
No VAL
105 100
TE
2.5 2.5
VAL
Page 38
Sewing
10 - 1
10 Sewing
In the sewing mode all relevant settings for the sewing operation are displayed. Functions
can be switched on or off by pressing a key. Values for start and end backtacks or stitch
placement can be changed directly.
In this mode a difference is made between manual sewing and programmed sewing. To
change from manual to programmed sewing, press the PM key. In programmed sewing the
text „PM“ appears on the display. Under the program numbers 1 – 2 seam programs are
stored, which can each altered, see Chapter 10.03 Altering seam programs.
10.01 Manual sewing
After the machine has been switched on (Chapter 7.01 Main switch) and the manual
sewing mode has been selected with the PM key, the display appears for entering the stitch
length, also see Chapter 9.06 Entering the stitch length.
2.5 2.5
If the backtack function is switched on, the display appears for entering the backtack values,
also see Chapter 9.07 Entering the start and end backtacks.
It is possible to switch from one display to the other by pressing the scroll key.
ABCD
3333
Further functions in manual sewing, also see Chapter 7.05.02 Function keys:
Start backtacks on/off Feed band raised on/off
End backtacks on/off Feed band raised at end of seam on/off
Needle position raised on/off Thread trimming on/off
Sewing is carried out with the pedal functions, see Chapter 7.02 Pedal.
Page 39
Sewing
10 - 2
10.02 Programmed sewing
In programmed sewing seam programs (program numbers 1 and 2) can be called up and
altered if necessary. These seam programs are used for the quick and easy production of
seams with different stitch lengths or amounts of fullness. With the knee switch function it
is possible to move to each of the 2 or 3 seams sections, also see Chapter 7.03 Knee
switch. The seam programs are designed as cyclic running programs and are terminated
with the pedal function, also see Chapter 7.02 Pedal.
After the machine has been switched on (Chapter 7.01 Main switch) and programmed
sewing has been selected with the PM key, the display appears for selecting the program
number, seam section and stitch length.
2
1 1 2.6 2.5
PM
Further functions in programmed sewing, also see Chapter 7.05.02 Function keys:
Backtack suppression on/off Feed band raised on/off
Start backtacks on/off Feed band raised after thread trimming on/
off
End backtacks on/off
Thread trimming on/off
Needle position raised on/off
Sewing is carried out with the pedal functions, see Chapter 7.02 Pedal.
When the backtack function is activated, the display for entering the backtack values
appears, also see Chapter 9.07 Entering the start and end backtacks.
It is possible to switch to other displays by pressing the scroll key.
ABCD
3333
PM
Page 40
Sewing
10 - 3
● With the corresponding +/- key select the seam program to be altered.
● With the corresponding +/- key select the seam section of the seam program which is to
be altered.
● By pressing the corresponding +/- key select desired value for the stitch length of the feed
band.
● By pressing the corresponding +/- key select desired value for the stitch length of the feed
wheel.
10.03 Altering seam programs
● Switch on the machine.
● Select the programmed sewing mode with the PM key.
2
1 1 2.6 2.5
PM
10.04 Error messages
If an error occurs, the text „ERROR“ appears on the display, together with an error code and
short instructions. An error message is caused by incorrect settings, defective elements or
seam programs and by overload conditions.
For an explanation of the error codes see Chapter 12.07 Explanation of the error
messages.
● Eliminate the error.
● Confirm error elimination by pressing the TE/Speed key.
ERROR
E001
PRESS TE-SPEED
Page 41
Care and maintenance
11 - 1
These maintenance intervals are calculated for the average running time of a sin-
gle shift operation. If the machine is operated more than this, shorter intervals
are recommended.
11.01 Cleaning
Clean the hook, hook compartment and toothed wheel 3 daily, several times if in continuous use.
Switch the machine off!
Danger of injury if the machine
is started accidentally!
● Bring the needle bar to its highest
position.
● Open the post cap and remove the bobbin
case cap and the bobbin.
● Unscrew hook gib 1.
● Turn the handwheel until the point of bob-
bin case 2 penetrates into the groove of
the hook race approx. 5 mm.
● Remove bobbin case 2.
● Clean the hook race with paraffin.
● When inserting the bobbin case 2, ensure
that the horn of the bobbin
case 2 engages in the groove of the
needle plate.
● Screw hook gib 1 back on and close the
post cap.
● Clean the gearwheel of the feed band
daily, several times if in continuous use
(see arrow).
Switch the machine off!
Danger of injury if the machine
is started accidentally!
87-014
11 Care and maintenance
Cleaning ..................................................... daily, several times if in continuous operation
Oiling the hook ................................................................................ daily, before operation
Checking the oil levels .................................................................... daily, before operation
Lubricating the bevel gears ............................................................................. once a year
Fig. 11 - 01
5 mm
1
2
3
Page 42
Care and maintenance
11 - 2
87-015
11 - 2
Fig. 11 - 02
11.02 Oiling the hook
Switch the machine off!
Danger of injury if the machine
is started accidentally!
● Pour 1-2 drops of oil into hole 1 of the
hook gib daily.
● Before commissioning the machine, and
after long periods out of operation, pour a
few drops of oil into the hook race (see
arrow).
11.03 Checking the oil levels
Before each operation check
the oil levels..
Oil must always be visible in
the reserve tanks 1 and 2.
● If necessary, fill in oil through the
respective hole of the reserve tank.
Fig. 11 - 03
1
2
Use only oil with a mean 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 Best.-Nr. 280-1-120 144.
1
Page 43
Care and maintenance
11 - 3
Switch the machine off!
Danger of injury if the machine is started accidentally!
● All bevel gears must be supplied with new grease once a year.
● Tilt the sewing head back onto the support.
● To set the sewing head upright, press tilt lock 1 backwards and set the sewing head
upright using both hands.
Use both hands to set the sewing head upright!
Danger of crushing between the sewing head and the table top!
We recommend PFAFF sodium grease with a dripping point of approx. 150C,
Order No. 280-1-120 243.
Fig. 11 - 04
11.04 Lubricating the bevel gears
63-012
1
Page 44
Adjustment
12 - 1
12 Adjustment
Unless stated otherwise, during all adjustment work the machine must be
disconnected from the electric and pneumatic power supply!
Danger of injury if the machine is started accidentally!
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, nuts indicated in brackets ( ) are fastenings for machine parts, which must be
loosened before adjustment and tightened again afterwards.
12.02 Werkzeuge, Lehren und sonstige Hilfsmittel
● 1 set of screwdrivers with blade widths from 2 to 10 mm
● 1 set of wrenches with jaw widths from 7 to 13 mm
● 1 set of Allen keys from 1.5 to 6 mm
● 1 adjustable clamp ( part no. 08-880 137 00 )
● 1 metal ruler ( part no. 08-880 218-00 )
● 1 locking pin for needle bar rise ( part no. 61-111 641-39 )
● Needles, system 134-35 R
● Threads and test material.
12.03 Abbreviations
TDC = top dead center
BDC = bottom dead center
Page 45
Adjustment
12 - 2
87-017
12.04 Adjusting the basic machine
12.04.01 Positioning the needle in the direction of sewing
Requirement
The needle must penetrate the middle of the needle hole as viewed in the direction of
sewing.
Fig. 12 - 01
● Move the needle bar frame 1 ( screws 2 and 3 ) in accordance with the requirement.
Screws 3 are accessible through the holes on the back of the housing.
3
3
87-018
2
1
Page 46
Adjustment
12 - 3
87-058
12.04.02 Positioning the needle across the direction of sewing
Requirement
The needle must penetrate the middle of the needle hole as viewed across the direction of
sewing.
Fig. 12 - 02
● Move the feed wheel post 1 ( screws 2, 3 and 4 ) in accordance with the requirement.
Screws 4 remain loosened for the following adjustments.
63-019
3
4
1
2
2
4
4
4
Page 47
Adjustment
12 - 4
12.04.03 Preadjusting the needle height
Requirement
With the needle bar at TDC there must be approx. 21 mm between the point of the needle
and the needle plate.
Fig. 12 - 03
● Move the needle bar 1 ( screw 2 ) in accordance with the requirement without turning it.
1
2
21 mm
Page 48
Adjustment
12 - 5
87-019
12.04.04 Needle rise, hook-to-needle clearance, needle height and needle guard
Requirement
When the needle bar is positioned at 2.0 mm after b.d.c.
1. The point of the hook must be pointing to the centre of the needle and have a clearance
of 0.05 – 0.1 mm to the needle.
2. The top edge of the needle eye must be 0.8 – 1.00 mm below the hook point and
3. The needle guard 9 must lightly touch the needle.
8
4
4
0,8 - 1 mm
11
12
61-028
1
3
2
6
7
87-022
5
Fig. 12 - 04
8
9
10
● Loosen screws 1, 2, 3 and 4.
● Bring the needle bar to 2.0 after b.d.c.
● Place the adjustment pin in hole 5 and apply pressure.
● Position the hook point towards the centre of the needle, taking care to ensure that the
needle is not deflected by needle guard 9.
● Adjust the needle height according to requirement 2.
● Adjust the hook post according to requirement 1 and tighten screws 4.
86-009
9
Page 49
Adjustment
12 - 6
● Taking the play of the bevel gear into account, tighten screws 2.
● Remove the adjustment pin from hole 5.
● Install the retaining collar 6 on bevel gear 7 and tighten screws 1 and 3.
● Tighten screws 8 on both sides of the post.
● Align needle guard 9 in accordance with requirement 3.
When changing the hook, care must be taken to ensure that the
markings 11 and 12 are on one side.
Page 50
Adjustment
12 - 7
7-026
12.04.05 Height and stroke of the bobbin case opener
Requirement
1. The top edges of the bobbin case opener 1 and bobbin case base 3 should be on one
level.
2. When the bobbin case opener 1 has deflected the bobbin case to its furthest point, the
catch of the bobbin case should be 0.3 – 0.5 mm from the back edge of the needle plate
recess.
Fig. 12 - 05
● Adjust bobbin case opener 1 ( screw 2 ) in accordance with requirement 1.
● Turn the balance wheel until the bobbin case opener has deflected the bobbin case to its
furthest point.
● Adjust bobbin case opener 1 ( screw 2 ) in accordance with requirement 2.
Depending on the thread size, a variation of the setting in Requirement 2 is
permitted.
1
2
87-024
3
1
87-025
0,3 - 0,5 mm
Page 51
Adjustment
12 - 8
87-027
12.04.06 Height of the feed wheel
Requirement
The feed wheel should jut 0.4 mm out of the needle plate.
1
2
3
● Swing out the feed band.
● Loosen screw 1.
● Adjust the eccentric ( screw 3 ), which is accessible through hole 2, in accordance with
the requirement.
● Tighten screw 1.
Fig. 12 - 06
0,4 mm
Page 52
Adjustment
12 - 9
12.04.07 Clearance between feed band and feed wheel
Requirement
When lever 1 is raised, the clearance between feed band and feed wheel should be 7 mm.
● Raise lever 1.
● Adjust the presser bar ( screws 2 ) in accordance with the requirement, making sure that
the feed band is parallel to the feed wheel.
Fig. 12 - 07
2
1
87-029
7 mm
Page 53
Adjustment
12 - 10
87-031
1
2
4
3
5
12.04.08 Adjusting the feed band
Requirement
Band feed 5 should be set so that
1. The centre of roller 6 is approx. 2.5 mm from the centre of feed wheel 7
2. The band feed 5, seen in the direction of sewing, is parallel to feed wheel 7 and the
seam runs directly below O-ring 8.
● Adjust holder 1 ( screw 2 ) in accordance with requirement 1.
● Adjust holder 3 ( screw 4 ) in accordance with requirement 2.
Fig. 12 - 08
8
6
7
2,5 mm
87-032
8
Page 54
Adjustment
12 - 11
12.04.09 Changing the feed band
● Loosen screw 1.
● Turn eccentric 2 toward the inside.
● Fit feed band 3 and tighten it with eccentric 2.
● Tighten screw 1.
Part numbers:
Feed band 91-189 210-95
0-ring 15-120 723-05
Fig. 12 - 09
1
3
2
Page 55
Adjustment
12 - 12
12.04.10 Automatic presser foot lift
Requirement
When solenoid 1 is activated, lever 3 should drop automatically to raise the feed band.
1
2
● Adjust solenoid 1 ( screws 2 ) in accordance with the requirement.
● Switch on the machine and check the requirement.
● Switch off the machine.
Depending on the material thickness, the clearance between feed band and feed
wheel can be increased up to 10 mm by moving the solenoid 1 to the right.
Fig. 12 - 10
87-034
3
Page 56
Adjustment
12 - 13
87-035
12.04.11 Retainer
Requirement
The retainer 3 should just rest on the material, so that the material does not start fluttering
during sewing.
● Adjust pin 1( screw 2 ) according to the requirement.
Fig. 12 - 11
1
2
3
Page 57
Adjustment
12 - 14
3
2
4
5
1
12.04.12 Tension release and tension control
Requirement
1. When lever 1 is raised, or when the automatic presser foot lift is activated and for
materials less than 2 mm thick, the two tension disks 10 should be at least 0.5 mm
apart.
2. When the feed band is touching the material, for materials over 2 mm thick, the second
thread tension unit 11 should be switched on ( solenoid 8 is released ).
● Raise lever 1 and adjust screw 2 ( nut 3 ) in accordance with requirement 1.
● Raise the feed band with the automatic presser foot lift or with the knee lever and adjust
catch 4 ( screw 5 ) in accordance with requirement 1.
● Adjust switch lug 6 ( screw 7 ) in accordance with requirement 2.
● Press solenoid 8 as far as possible.
● Adjust solenoid 8 ( screws 9 ) in accordance with requirement 1.
The position of the tension release unit can be changed with parameter "308",
see Chapter 12.06 Parameter settings.
The setting in requirement 2 is a basic setting, which can be changed
depending on the material thickness.
Fig. 12 - 12
87-038
0,5 mm
10
6
7
9
8
11
Page 58
Adjustment
12 - 15
12.04.13 Thread check spring
Requirements
1. The motion of the thread check spring 7 must be finished when needle point enters the
material ( spring stroke approx. 7 mm ).
2. When the thread loop is at its largest when going around the hook, the thread check spring must raise slightly from the workpiece rack 1.
Fig. 12 - 13
● Move workpiece rack 1 ( screw 2 ) in accordance with requirement 1.
● Turn screw 3 ( screw 4 ) to adjust the strength of the spring.
● Move the slack thread regulator 5 ( screw 6 ) in accordance with requirement 2.
Due to technical sewing reasons it may be necessary to deviate from the spring
stroke / spring strength mentioned here.Move the slack thread regulator 5
( screw 6 ) toward the "+" ( = more thread ) or toward the "-" ( = less thread ).
+
5
6
1
2
7
3
7 mm
4
-
Page 59
Adjustment
12 - 16
12.04.14 Bobbin winder
Requirements
1. With the bobbin winder on, the bobbin winder spindle must engage reliably. With the
bobbin winder off, the friction wheel 5 must not engage the drive wheel 1.
2. The bobbin winder must turn off automatically when the thread level is approx. 1 mm
from the edge of the bobbin.
2
1
5
Fig. 12 - 14
● Move drive wheel 1 ( screws 2 ) in accordance with requirement 1.
● Move pin 3 ( screw 4 ) in accordance with requirement 2.
11-28a
1 mm
4
3
Page 60
Adjustment
12 - 17
12.04.15 Feed band pressure
Requirement
The material should be fed without difficulty. No pressure marks should be visible on the
material.
Fig. 12 - 15
● Adjust screw 1 ( under a cover ) in accordance with the requirement.
If the feed band pressure is low enough, the lowering speed of the feed band
can be increased with parameter "202".
The maximum pressure is 25 N.
1
+
-
Page 61
Adjustment
12 - 18
12.04.16 Locking the set value transmitter
Requirement
The pedal for selecting the fullness ( left pedal ) should be held securely in every position
without being too stiff.
Fig. 12 - 16
● Adjust screw 1 in accordance with the requirement.
1
Page 62
Adjustment
12 - 19
87-040
12.04.17 Lubrication
Requirement
After a running time of 10 seconds a fine line of oil should form on a strip of paper held next
to the hook.
● Check whether oil has been filled in and that there is no air in the oil lines.
● Let the machine run for 2-3 min..
While the machine is running do not place hands in the needle or hook area!
Danger of injury from moving parts!
● With the machine running hold a strip of paper on the hook and check the requirement.
● If necessary, adjust the oil flow on screw 1.
1
Fig. 12 - 17
Page 63
Adjustment
12 - 20
12.04.18 Re-engage safety coupling
The coupling 1 is set by the manufacturer. When the thread jams, the coupling 1
disengages in order to avoid damage to the hooks.
A description of how to engage the coupling follows.
Fig. 12 - 18
● Remove jammed thread.
● Hold coupling 1 with screw 2 and turn the balance wheel, until you feel coupling 1 snap
back into place again.
87-041
1
2
Page 64
Adjustment
12 - 21
12.05 Adjusting the thread trimmer –900/81
12.05.01 Resting position of the roller lever / radial position of the control cam
Requirement
1. When the thread trimmer is in is resting position, lever 5 should be touching piston 6 and
the roller of roller lever 7 should be 0.3 mm away from control cam 3.
2. When the take-up lever is at t.d.c., control cam 3 should just have placed roller lever 7 in
its resting position.
Fig. 12 - 19
● Having made sure that piston 6 is positioned against the left stop, adjust magnet 1
( 2 screws ) in accordance with requirement 1.
● Adjust control cam 3 ( screws 4 ) in accordance with requirement 2.
3
4
1
7
6
5
0,3 mm
Page 65
Adjustment
12 - 22
12.05.02 Position of the thread catcher holder
Requirement
1. There should be a minimum amount of play between toothed wheel 3 and toothed
segment 4.
2. Both in the neutral position and the foremost position of the catcher, the distance
between the toothed segment 4 and the outer edge of the thread catcher holder 1
should be the same ( see arrow ).
Fig. 12 - 20
● Adjust the thread catcher holder 1 ( screws 2 ) according to the requirements.
If requirement 2 cannot be fulfilled, loosen screw 2 and move the toothed
segment 4 by one tooth.
3
4
1
1
4
2
2
1
Page 66
Adjustment
12 - 23
87-043
12.05.03 Distance between thread catcher and needle plate
Requirement
During its swivel movement thread catcher 1 should not pass the edge of the needle plate
( see arrow ).
Fig. 12 - 21
● Move thread catcher 1 ( screws 2, two screws ) parallel to the thread catcher holder in
accordance with the requirement.
1
2
1
1
2
Page 67
Adjustment
12 - 24
87-045
12.05.04 Position of the thread catcher
Requirement
1. The bottom edge of the thread catcher 1 should be at a distance of 0.1 mm from the
positioning finger of the bobbin case 5.
2. When the thread trimmer is in its neutral position, the rear edge of thread catcher should
be positioned approx. 2.5 – 3 mm behind the edge of the knife.
● Move thread catcher 1 ( screws 2, two screws ) in accordance with requirement 1.
● Turn thread catcher 1 ( screw 3 ) in accordance with requirement 2.
Thread catcher 1 must be parallel to the surface of the thread catcher holder 4.
Fig. 12 - 22
87-046
2,5 - 3 mm
0,1mm
5
1
2
1
4
1
5
86-044
3
Page 68
Adjustment
12 - 25
12.05.05 Knife position and knife pressure
Requirement
1. The knife 1 should be touching the needle plate.
2. The knife pressure should be set as low as possible but the cutting operation should still
be carried out reliably.
Fig. 12 - 23
● Move knife 1 ( screws 2 ) in accordance with requirement 1 or swivel it in accordance
with requirement 2.
87-047
87-048
2
1
Page 69
Adjustment
12 - 26
87-049
12.05.06 Bobbin thread retaining spring
Requirement
1. The bobbin thread clamp spring should be guided reliably in the thread groove of the
thread catcher 3.
2. The tension of the bobbin thread spring clamp should be as low as possible, but the bob-
bin thread should be held reliably after the cutting operation.
● Adjust bobbin thread clamp spring 1 ( screws 2 ) in accordance with requirement 1.
● Adjust the tension in accordance with requirement 2 by bending side 4 of the bobbin
thread clamp spring 1.
Control – requirement 1
● Switch off the machine and bring the take-up lever to its b.d.c.
● Engage and disengage the thread catcher 3 by hand and check requirement 1. Adjust if
necessary.
Control – requirement 2
● After the thread has been cut, sew a few stitches by turning the balance wheel, checking
whether the bobbin thread is drawn out of the bobbin thread clamp spring between the 1
st
and 3rd stitches. If necessary, correct the tension.
63-034
2
1
3
Fig. 12 - 24
63-035
1
4
3
Page 70
Adjustment
12 - 27
87-050
12.05.07 Manual cutting test
Requirement
1. When thread catcher 1 is on its forward stroke, it must not carry bobbin thread 3 forward
too.
2. When thread catcher 1 is in its front position, bobbin thread 3 must be held reliably by
hook 4.
3. After the trimming action, both the needle thread and the bobbin thread must be perfectly
cut and bobbin thread 3 retained.
● Sew a few stitches.
● Turn off the on/off switch.
● Carry out the cutting operation manually.
● Check requirement 1 and 2, and if necessary readjust thread catcher 1 in accordance with
Chapter 12.05.04 Position of the thread catcher.
● Check requirement 3, and if necessary readjust the bobbin thread retaining spring 2 in
accordance with Chapter 12.05.06 Bobbin thread retaining spring.
2
Fig. 12 - 25
61-108
3
4
3
1
Page 71
Adjustment
12 - 28
12.06 Parameter settings
12.06.01 Overview of the parameter functions
By pressing the TE/Speed key twice the input mode is called up. From the following
parameter groups parameters can be called up and altered. With a code the parameter
groups can be protected against unauthorised access.
2x
2x
Select parameter group ( appropriate +/- key )
100 Operator level
200 Mechanic level
300 Sewing motor positions
400 Times
500 Counters and speeds
600 Service
700 Sewing motor
800 Access rights
Page 72
Adjustment
12 - 29
2x
● Select the desired parameter, e.g. "501" by pressing the corresponding +/- key.
● Set the desired parameter value by pressing the corresponding +/- key.
●By pressing the TE/speed key, the value is taken over and the machine changes to the
sewing mode.
12.06.02 Parameter input example
● Switch on the machine
● Select input mode by pressing TE/Speed key twice.
● Select parameter group "500" by pressing the corresponding +/- key.
● Confirm selection by pressing the corresponding +/- key.
● Enter the code number, see Chapter 9.08 Entering/changing the code number.
No VAL
101 II
TE
No
No
500
TE
No VAL
501 3500
TE
No
VAL
Page 73
Adjustment
12 - 30
1 101 Start backtack, pedal-controlled
(I = OFF, II = ON) I
102 Reversing
(I = OFF, II = ON) I
103 Stitch placement
I = OFF, II = ON) I
104 Bobbin thread monitoring
( 0 = OFF, I = reverse counter,
2 = thread monitor ) 0 - 2 0
105 Bobbin thread reverse counter 0 -99999 30000
106 Remaining bobbin thread counter 0 -999 100
107 Maximum stitch length of 0.8 - 6.5 4.0
fullness pedal (mm)
108 Display software version of
main processor 0302/....
109 Display software version of
stepping motor processor 0305/....
110 Display software version of V004H202
the control panel
111 Key tone of the control panel
I = off, II = on II
112 Horn for section change I
I = off, II = on
2 202 Lowering speed feed band
I = quick, II = slow I
3 301 Position take-up lever t.d.c 0 – 127 2
302 Position needle lowered 0 - 127 32
303 Position cutting solenoid “on“ 0 - 127 32
304 Position cutting solenoid “tacting“ 0 - 127 103
305 Position cutting solenoid “off“ 0 – 127 123
12.06.03 List of parameters
The operator has free access to the “100“ parameters. Parameters “200“ –
“800“ can only be changed after entering a code number and many only be
changed by authorised personnel.
Group Parameter Description Setting Set
range value
Page 74
Adjustment
12 - 31
3 306 Reverse position 0 – 127 103
307 Placement stitch position 0 – 127 7
308 Position thread tension release 0 – 127 101
4 401 Delay time lifting feed band [s] 0.01 – 1.50 0.02
402 Start delay after lowering feed band [s] 0.01 – 1.50 0.15
403 Set lift feed band [s] 0.01 – 0.20 0.03
404 Tact thread cutting solenoid (%) 10 - 50 35
405 Time for cleaning thread monitor [s] 0.01 - 1.50 0,25
5 501 Maximum speed 100 – 3500 3500
502 Speed start backtack 100 – 1500 700
503 Speed end backtack 100 – 1500 700
504 Speed soft start 100 – 3500 1500
505 Soft start stitches 0 – 15 0
6 601 Move stepping motor feed band
and feed wheel
602 Display inputs
0123456789ABCDEF
0: Centre position needle (E16)
1: End position needle (E15)
2: Coding intermittent (E14)
3: not assigned (E13)
4: not assigned (E12)
5: not assigned (E11)
6: Stop docu system (E10)
7: Watchdog Dokusystem (E9)
8: Error docu system (E8)
9: Bobbin thread error (E7)
A: Knee switch (E6)
B: Sensor (E5)
C: Start inhibitor (E4)
D: Single stitch key on
machine head (E3)
E: Semi-stitch key on
machine head (E2)
F: Reverse stitch key on
machine head (E1)
603 Adjust sewing motor for sewing head
( see Chap. 8.02.03 )
604 Carry out cold start ( see Chap. 13.10 )
Group Parameter Description Setting Set
range value
Page 75
Adjustment
12 - 32
7 701 P-quota speed controller 1 – 50 30
702 I-quota speed controller 0 – 100 50
703 P-quota position controller 1 – 50 20
704 D-quota position controller 1 – 100 30
705 Time for position controller 0 – 100 25
706 P-quota position controller for rest brake 1 – 50 25
707 D-quota position controller for rest brake 1 – 50 15
708 Maximum moment for rest brake 0 – 100 0
709 Minimum machine speed 3 – 64 6
710 Maximum machine speed 1 – 35 35
711 Maximum motor speed 1 – 90 90
712 Positioning speed 3 – 25 18
713 Acceleration ramp 1 – 50 35
714 Brake ramp 1 – 50 30
715 Reference position 0 – 127 29
716 Time-out 0 – 255 40
717 Starting current motor 3 – 10 8
718 Anti-vibration filter 1 – 10 6
719 Rotation direction allocation 0 – 1 0
720 Reference position correction 0 – 127 64
8 801 Right of access function group 100 0 – 1 0
802 Right of access function group 200 0 – 1 1
803 Right of access function group 300 0 – 1 1
804 Right of access function group 400 0 – 1 1
805 Right of access function group 500 0 – 1 1
806 Right of access function group 600 0 – 1 1
807 Right of access function group 700 0 – 1 1
808 Right of access function group 800 0 – 1 1
Group Parameter Description Setting Set
range value
Page 76
Adjustment
12 - 33
Message Description
Error 1: System error
Error 2: Sewing motor
Error 3: Section
Error 4: End of section
Error 5: Pedal activated when machine switched on
Error 6: Communication error with stepping motor
processor
Error 7: End of ramp
Error 8: End position of needle drive not found
Error 9: Centre position of needle drive not found
Error 10: Error of stepping motor processor
Error 11: Stepping motor stepping frequency too high
Error 12: Error in sewing start deflection
Error 13: Error in docu-seam system
Error 14: Incorrect program number ( larger than 99 )
Error 15: Incorrect section number
Error 16: Memory full
Error 17: Incorrect stitch length
Error 19: Interface to external controller
Error 21: Power supply unit overloaded
Error 22: Mains voltage
Error 23: Power supply 24V too high/too low
Group Parameter Description Setting Set
range value
8 809 Right of access program creation 0 – 1 1
810 Enter access code 0 - 9999 1500
12.08 Warning messages
Message Description
Warning 2 Bobbin thread error
12.07 Explanation of the error messages
Page 77
Adjustment
12 - 34
2x
RESET
12.09 Carrying out a cold start
● Switch on the machine.
● Press the TE/Speed key twice to select the input mode.
● Select parameter group "600" by pressing the corresponding +/- key.
● Confirm selection by pressing the corresponding +/- key.
● Enter the code number, see Chapter 9.08 Entering/changing the code number.
● Select parameter "604" by pressing the corresponding +/- key.
● Carry out cold start by pressing the corresponding +/- key.
● Switch off the machine.
After a cold start all programmed values are reset to their status at the time of
delivery.
No VAL
101 II
TE
No
No
600
TE
No
604 RESET
TE
No
Page 78
Adjustment
12 - 35
12.10 Internet update of the machine software
The machine software can be updated with PFAFF flash programming. For this purpose the
PFP boot program and the appropriate control software for the machine type must be installed
on a PC. To transfer the data to the machine, the PC and the machine control unit must be
connected with an appropriate null modem cable ( part no. 91-291 998-91 ).
The PFP boot program and the control software of the machine type can be
downloaded from the PFAFF-homepage using the following path:
www.pfaff-industrial.com/de/service/download/steuerungssoftware.html
To update the machine software carry out the following steps:
While the machine software is being updated, no setting up, maintenance or
adjustment work may be carried out on the machine!
● Switch off the machine.
● Connect the PC (serial interface or
appropriate USB-adapter) and the
machine control unit (RS232). To do so
disconnect the plug of the control panel.
● Switch on the PC and start the PFP boot
program.
● Select the machine type.
● Press the "programming" button.
● Hold down boot key 1 and switch on the
machine.
● Press the "OK" button.
Fig. 13 - 47
1
The software update is carried out, the update progress is shown on the bar display of the
PFP boot program.
● During the up-dating procedure the machine must not be switched off.
● When the update has been completed, switch off the machine and end the PFP boot
program.
● End the connection between the PC and the machine control unit and reconnect the control
panel to the machine control unit.
● Switch on the machine.
A plausibility control is carried out and, if necessary, a cold start.
More information and assistance is at your disposal in the file "PFPHILFE.TXT",
which can be called up from the PFP boot program by pressing the "help" button.
Page 79
Wearing parts
13 - 1
11-108 093-15
91-173 664-15
91-176 329-05
13 Wearing parts
This list indicates the most important wearing parts.
You can request a detailed parts list for the complete machine under parts
number 296-12-17 750.
91-189 210-95
15-120 723-05
91-118 308-05
System 134-35
91-263 392-91
91-000 390-05
91-000 928-15
91-010 166-05
91-000 529-15 (3x)
91-119 408-05 (A; B)
91-263 397-01
91-263 261-05
91-000 452-15
(2x)
91-263 400-91 (A; B)
91-263 292-91 (A; B)
91-175 690-05
Page 80
Wearing parts
13 - 2
99-137 151-45
91-171 049-05
91-171 042-05
11-130 092-15 (2x)
12-315 080-15 (2x)
91-263 139-05
11-108 846-15 (2x)
91-263 348-05
11-108 093-15 (2x)
91-263 294-05
For Subclass -900/81
Page 81
14 - 1
Circuit diagrams
14 Circuit diagrams
Reference list for circuit diagrams
A1 Controller Quick P 320MS
A2 Control panel S2
A14 Sewing head identification
B10 Initiator material height
H1 Sewing lamp
H20 LED Stitch counter
M1 Sewing motor
M2 Stepping motor feed wheel
M3 Stepping motor roller presser
Q1 Main switch
S1 Pedal set value transmitter
S2 Pedal 2 Fullness
S20 Knee switch (program)
S21 Manual backtacking key
S22 Single stitch switch
S23 Needle position change switch
S24 Start inhibitor switch
X1 Mains plug
X1A RS232 – interface 1 Control panel S2
X1B Sewing head identification
X3 Incremental transmitter ( sewing motor )
X4A Stepping motor feed wheel
X4B Stepping motor roller presser
X5 Inputs
X8 Sewing motor
X11A CAN interface
X11B Pedal set value transmitter
X13 Outputs
Y1 -910/..Automatic presser foot lift
Y2 -900/..Thread trimmer
Y3 Thread tension
Y4 Thread tension
Y6 -926/04 Bobbin thread monitor
Page 82
14 - 2
General plan - circuit diagrams
Version 05.02.03
91-191 442-95
Part 1
Page 83
14 - 3
91-191 442-95
Part 2 Version 05.02.03
General plan - circuit diagrams
Page 84
14 - 4
General plan - circuit diagrams
Version 05.02.03
91-191 442-95
Part 3
Page 85
14 - 5
91-191 442-95
Part 4 Version 05.02.03
General plan - circuit diagrams
Page 86
PFAFF Industrie Maschinen AG
Postfach 3020
D-67653 Kaiserslautern
Königstr. 154
D-67655 Kaiserslautern
Telefon: (0631) 200-0
Telefax: (0631) 17202
E-Mail: info@pfaff-industrial.com
Gedruckt in der BRD
Printed in Germany
Imprimé en R.F.A.
Impreso en la R.F.A.
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