Pfaff 3734-12, 3734-31 Instruction Manual

3734 -12/31

Instruction Manual

This instruction manual applies to machines from the

following serial numbers onwards:

# 2721275

296-12-18 935/002
Betriebsanleitung engl. 02.06

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

Contents

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

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 3734-12/31 ......................................................................................................... 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

Safety ............................................................................................................................ 1- 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 Roller presser ............................................................................... 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 toothed belt / Basic position of the machine drive unit ........................... 8 - 5

Contents

.02.05 Mounting the belt guard of the flange motor ................................................................ 8 - 6

8

8.02.06 Connecting the safety switch ....................................................................................... 8 - 7

8.02.07 Checking the function of the start inhibitor ................................................................... 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

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

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 roller presser and feed wheel ...................................................... 12 - 9

Contents

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

04.08 Roller presser .............................................................................................................. 12 - 10

12.

12.04.09 Puller ........................................................................................................................... 12 - 11

12.04.10 Tension release and tension control ............................................................................ 12 - 12

12.04.11 Höhenniveauschalter des Rollfußes ............................................................................ 12 - 13

12.04.12 Automatic presser foot lift .......................................................................................... 12 - 14

12.04.13 Retainer ...................................................................................................................... 12 - 15

12.04.14 Thread check spring .................................................................................................... 12 - 16

12.04.15 Bobbin winder ............................................................................................................ 12 - 17

12.04.16 Roller presser pressure ............................................................................................... 12 - 18

12.04.17 Locking the set value transmitter ................................................................................ 12 - 19

12.04.18 Lubrication .................................................................................................................. 12 - 20

12.04.19 Re-engage safety coupling .......................................................................................... 12 - 21

12.05 Adjusting the thread trimmer –900/81......................................................................... 12 - 22

12.05.01 Resting position of the roller lever / radial position of the control cam ........................ 12 - 22

12.05.02 Position of the thread catcher holder .......................................................................... 12 - 23

12.05.03 Distance between thread catcher and needle plate .................................................... 12 - 24

12.05.04 Position of the thread catcher ..................................................................................... 12 - 25

12.05.05 Knife position and knife pressure ................................................................................ 12 - 26

12.05.06 Bobbin thread retaining spring .................................................................................... 12 - 27

12.05.07 Manual cutting test ..................................................................................................... 12 -28

12.06 Parameter settings...................................................................................................... 12 - 29

12.06.01 Overview of the parameter functions ......................................................................... 12 - 29

12.06.02 Parameter input example ............................................................................................ 12 - 30

12.06.03 List of parameters ....................................................................................................... 12-31

12.07 Explanation of the error messages.............................................................................. 12 - 34

12.08 Warning messages ..................................................................................................... 12 - 34

12.09 Carrying out a cold start .............................................................................................. 12 - 35

12.10 Internet update of the machine software.................................................................... 12 - 36

13 Wearing parts ............................................................................................................ 13 - 1

14 Circuit diagrams ........................................................................................................ 14 - 1

Safety

1 Safety

1

1.02 General notes on safety

.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!

● 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!

1 - 1

● 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.

1.03 Safety symbols

Danger!

Points to be observed.

Danger of injury for operating and specialist personnel!

Safety

Caution

Do not operate without finger guard and safety devices.

Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.

I

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.

1 - 2

Safety

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!

1 - 3

.06 Danger

1

Safety

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!

2

Fig. 1 - 01

3

1

4

63-021

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!

1 - 4

Proper use

2 Proper use

The PFAFF 3734-12/31 is a high-speed, single needle, postbed sewing machine (post to the

right of the needle) with forwards and reverse feeding feed-wheel and driven puller.

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!

2 - 1

3 Specifications

Specifications

3.01 PFAFF 3734-12/31

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, alternating voltage

Max. power consumption: ...................................................................................... 1,2 kVA

Fuse protection: ............................................................................................ 1 x 16 A, inert

▲

◆

Noise data:

Noise emission level at workplace with a sewing speed of 2700 spm: ..... L

(Noise measurement in accordance 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: ........................................................................................................... 120

< 80 dB(A)

pA

■

3 - 1

Disposal of machines

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!

4 - 1

Transport packaging and storage

5 Transport packaging and storage

.01 Transport to the customer’s premises

5

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 in-

dividual 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.

5 - 1

Explanation of the symbols

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)

6 - 1

77

005

7 Controls

.01 On/off switch

7

1

Controls

● Turn the machine on/off by turning

On/Off switch 1.

Fig. 7 - 01

7.02 Pedal

Fig. 7 - 02

-

0 = Neutral position

1 = Sewing

2 = Raise roller presser

3 = Trim thread and raise roller presser

01

1 + 4 = Variable application of fullness

4

7-004

3

2

7 - 1

Controls

7.03 Knee switch

● By operating knee switch 1 it is possible

to select 2 pre-set values for fullness.

1

Fig. 7 - 03

7.04 Lever for raising the roller presser

1

87-004

● Raise the roller presser by turning lever

1.

7 - 2

Fig. 7 - 04

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,

Controls

341 2

PM

2.5 2.5

5

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
key is held down longer, the values change more quickly.

the corresponding value 5

is changed slowly. If the +/-

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.

7 - 3

Controls

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 roller presser 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.

7 - 4

This key has no function.

Controls

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.

7 - 5

Mounting and commissioning the machine

87-007

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

2

8 - 1

1

2

Fig. 8 - 01

● 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.

1

8.01.02 Fitting the tilt lock

1

3

Mounting and commissioning the machine

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.

4

2

Fig. 8 - 02

8.01.03 Fitting the machine cover

4

Do not operate the machine
without tilt lock 1. Danger of

crushing between sewing head

and table top!

● Slide the slots of the lower section of the

cover 1 behind the heads of screws 2
and attach with screws 3, then tighten

4

screws 2 through the holes.

● Attach right and left cover sections with

screws 4.

4

3

Fig. 8 - 03

2

1

8 - 2

Mounting and commissioning the machine

77

011

8.02 Mounting the flange motor

8.02.01 Mounting the flange motor to the bearing plate

7

2

3

1

8

3

6

-

4

Fig. 8 - 04

● 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

3

..

.

..

5

8.02.02 Mounting the flange motor to the machine

● Attach bearing plate 1 of motor 2 to the

3

2

3

1

Fig. 8 - 05

machine case with screws 3 (only tighten
screws 3 slightly).

8 - 3

Mounting and commissioning the machine

8.02.03 Connecting the plug-in connections and earth cables

0

3

81-090

2

A

B

63-011

1

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

● Fasten the earth cable of the main switch to earth point A.

and earth point A

with an earth cable.

C

8 - 4

Mounting and commissioning the machine

8.02.04 Mounting the toothed belt / Basic position of the machine drive unit

● Switch on the machine.

2.5 2.5

2 x

● Press TE/Speed

● Select the parameter group "600" by pressing the corresponding +/- key.

No

key twice to select the input mode.

TE

No VAL
101 II

TE

No
600

● Confirm the selection by pressing the corresponding +/- key.

● Enter the code number, see Chapter 9.08 Entering/changing the code number.

8 - 5

TE

No VAL
603 11

● Select the parameter group "603" by pressing the corresponding +/- key.

● Turn the motor shaft by hand until value "11" appears in the display.

● Turn the balance wheel in sewing direction until the needle point descending from above,

is level with the top edge of the needle plate.

● Taking care not to turn the motor shaft 4 (Fig. 8 - 07) or the machine, fit synchronous

belt 5.

Mounting and commissioning the machine

77 014

7

7

Fig. 8 - 07

● 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 sewing direction until the needle point descending from above,

is level with the top edge of the needle plate and re-check the value. A tolerance of
± 2 increments is allowed.

● Conclude the adjustment of the sewing motor by pressing the TE/Speed

8.02.05 Mounting the belt guard of the flange motor

77-012

5

key.

6

4

Fig. 8 - 08

● Attach belt guard 1 with screws 2 and 3.

1

2

3

8 - 6

Mounting and commissioning the machine

8.02.06 Connecting the safety switch

● Connect plug 1 of safety switch 2 as

2

1

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

8.02.07 Checking the function of the start inhibitor

STOP

2.5 2.5

● 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

● After the sewing head has been set upright, the machine is ready for operation again.

33

3.

33

8 - 7

Mounting and commissioning the machine

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

8.04 Commissioning

● Clean the machine thoroughly and then oil it, or fill in oil, see Chapter 11 Care and

Maintenance.

● Examine the machine, in particular the electric cables, for any damage.

● Have a qualified person check whether the motor can be driven with the existing power

voltage.

If there are any differences, the machine must definitely not be operated!

The machine must only be connected to a suitably earthed socket!

● When the machine is running, the balance wheel must turn towards the operator. If this is not the

case, have the motor adjusted by specialist staff, see Chapter 12.06 Parameter settings.

8.05 Switching the machine on/off

● Switch on the machine, see Chapter 7.01 Main switch.

8 - 8

Setting up

9 Setting up

9.01 Inserting the needle

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

Special 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.

Switch the machine off!

Danger of injury if the machine

is started accidentally!

1

Fig. 9 - 01

2

● Raise the roller presser 1.

● Pull down roller presser 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 roller

presser back into position.

The choice of needle depends on the model of the machine and the thread and
material used ( see Chapter 3.02 Needles and threads ).

Only use needles from the

system intended for the
machine, see Chapter 3

Specifications.

9 - 1

9.02 Winding the bobbin thread, adjusting the thread tension

4

Setting up

_

+

6

1

3

2

5

Fig. 9 - 02

● 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 roller
presser and the feed wheel should be switched off by pressing the Stop

This function of the Stop

● 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.

key is only available in the manual sewing mode.

key.

9 - 2

Setting up

9.03 Removing / Inserting the bobbin case

Maschine ausschalten!

1

2

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.

Switch the machine off!

Danger of injury if the machine

is started accidentally!

Fig. 9 - 03

87-012

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

spring 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

5 cm

+

-

9 - 3

1

Fig. 9 - 04

Setting up

9.05 Threading the needle thread / Adjusting the needle thread tension

1

Fig. 9 - 05

2

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.

9 - 4

Setting up

9.06 Entering the stitch length

9.06.01 Entering the standard 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.

● Switch on the machine.

After the machine has been switched on, the current values of the stitch lengths for the

roller presser and the feed wheel are shown on the display.

2.5 2.5

● Set the stitch length ( feed stroke ) for the roller presser 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.

PM

2

1 1 2.6 2.5

● Switch on the machine and press the PM

mode.

key to move into the programmed sewing

9 - 5

● Select the program number (1 or 2) by pressing the corresponding +/- key.

● Set the stitch length (feed stroke) for the roller presser by pressing the corresponding +/-

key.

● Set the stitch length (feed stroke) for the feed wheel by pressing the corresponding

+/- key.

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.

2.5 2.5

Setting up

2 x

No

VAL

● Press the TE/Speed key twice to call up the parameter input function.

TE

No VAL
101 II

● Select parameter “107“ by pressing the corresponding +/- key.

● By pressing the corresponding +/- key, set the maximum stitch length for the fullness

pedal (left pedal).

3

TE

No VAL
107 4.0

● 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

9 - 6

Setting up

9.07 Entering the start and end backtacks

● Switch on the machine.

2.5 2.5

● 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

PM

A B C D

1 1 1 1

● By pressing the corresponding +/- key select the desired value for the number of forward

A

stitches (A) of the start backtack.

● By pressing the corresponding +/- key select the desired value for the number of reverse

B

stitches (B) of the start backtack.

● By pressing the corresponding +/- key select the desired value for the number of reverse

C

stitches (C) of the end backtack.

● By pressing the corresponding +/- key select the desired value for the number of forward

D

stitches (D) of the end backtack.

switch to the input menu for the start and end backtacks.

9 - 7

● Switch back to the stitch length input menu by pressing the Scroll key.

9.08 Entering/changing the code number

● Switch on the machine.

2.5 2.5

Setting up

2 x

● Press the TE/Speed key twice to call up the parameter input function.

TE

No VAL
101 II

● By pressing the corresponding +/- key select the parameter group "800".

No

TE

No
800

● Confirm the selection by pressing the corresponding +/- key.

1 5

TE

0

CODE: 1500

1

● 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.

9 - 8

Setting up

TE

No VAL
801 0

● By pressing the corresponding +/- key select the parameter "810".

No

TE

No
810 1500

● Confirm the selection by pressing the corresponding +/- key.

1 2 3 4 5 6 7 8

TE

CODE: 1500

9
0

1

● 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.

9 - 9

Setting up

9.09 Switching on/adjusting the bobbin thread control with reverse stitch
count

● Switch on the machine.

2.5 2.5

2 x

No

VAL

● Press the TE/Speed key twice to call up the parameter input function.

TE

No VAL
101 II

● Select parameter „105“ by pressing the corresponding +/- key.

● By pressing the corresponding +/- key set the number of stitches to be sewn with one

bobbin.

3

TE

No VAL
105 100

● 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.

9 - 10

Sewing

10 Sewing

10.01 Manual 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

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.

After the machine has been switched on (Chapter 7.01 Main switch) and the manual
sewing mode has been selected with the PM

stitch length, also see Chapter 9.06 Entering the stitch length.

key, the display appears for entering the

and programmed sewing. To

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

ABCD

3333

Further functions in manual sewing, also see Chapter 7.05.02 Function keys:

Start backtacks on/off Roller presser raised on/off

End backtacks on/off Roller presser raised at end of seam on/off

key.

10 - 1

Needle position raised on/off Thread trimming on/off

Sewing is carried out with the pedal functions, see Chapter 7.02 Pedal.

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

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

number, seam section and stitch length.

. .

. The seam programs are designed as cyclic running programs and are terminated

. .

1 1 2.6 2.5

Sewing

key, the display appears for selecting the program

PM

2

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

PM

ABCD
3333

key.

Further functions in programmed sewing, also see Chapter 7.05.02 Function keys:

Backtack suppression on/off Roller presser raised on/off

Start backtacks on/off Roller presser 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.

10 - 2

Sewing

10.03 Altering seam programs

● Switch on the machine.

● Select the programmed sewing mode with the PM key.

PM

2

1 1 2.6 2.5

● 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

roller presser.

● By pressing the corresponding +/- key select desired value for the stitch length of the

feed wheel.

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.

ERROR

E001

PRESS TE-SPEED

10 - 3

● Eliminate the error.

● Confirm error elimination by pressing the TE/Speed

key.

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

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.

Care and maintenance

2

3

Fig. 11 - 01

5 mm

Switch the machine off!

Danger of injury if the machine

is started accidentally!

● Bring the needle bar to its highest

1

87-014

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.

● Remove the puller cover and clean the

puller gears daily, several times if in

continuous operation.

11 - 1

Care and maintenance

11.02 Oiling the hook

Switch the machine off!

Danger of injury if the machine

is started accidentally!

Fig. 11 - 02

11.03 Checking the oil levels

● Pour 1-2 drops

1

87-015

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).

of oil into hole 1 of the

Before each operation check

the oil levels..

Fig. 11 - 03

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.

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.

11 - 2

11 - 2

11.04 Lubricating the bevel gears

1

Care and maintenance

63-012

Fig. 11 - 04

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.

11 - 3

Adjustment

12 Adjustment

12.01 Notes on 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!

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

12 - 1

12.04 Adjusting the basic machine

.04.01 Positioning the needle in the direction of sewing

12

Requirement

The needle must penetrate the middle of the needle hole as viewed in the direction of

sewing.

Adjustment

3

Fig. 12 - 01

3

1

2

87-018

● 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.

12 - 2

Adjustment

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.

4

3

4

63-019

1

4

4

2

2

87-058

12 - 3

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.

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.

Adjustment

2

1

21 mm

Fig. 12 - 03

● Move the needle bar 1 ( screw 2 ) in accordance with the requirement without turning it.

12 - 4

Adjustment

61-028

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 7 must lightly touch the needle.

10

7

5

3

2

1

8

9

5

12

4

4

86-009

87-019

11

6

7

12 - 5

0,8 - 1 mm

Fig. 12 - 04

● Loosen screws 1, 2, 3, 4 and 5.

● Bring the needle bar to 2.0 after b.d.c.

● Place the adjustment pin in hole 6 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 7.

● Adjust the needle height according to requirement 2.

87-022

● Adjust the hook post according to requirement 1 and tighten screws 4.

● Taking the play of the bevel gear into account, tighten screws 2.

● Remove the adjustment pin from hole 6.

● Install the retaining collar 8 on bevel gear 9 and tighten screws 1 and 3.

● Tighten screws 5 on both sides of the post.

● Align needle guard 7 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.

Adjustment

12 - 6

Adjustment

87-024

12.04.05 Height and stroke of the bobbin case opener

Requirement

1. The top edges of the bobbin case opener 1

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

plate recess.

1

and bobbin case base 3 should be on one

from the back edge of the needle

3

Fig. 12 - 05

1

2

0,3 - 0,5 mm

87-025

87-026

12 - 7

● 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.

87-027

12.04.06 Height of the feed wheel

Requirement
The feed wheel should jut 0.4 mm out of the needle plate.

Adjustment

0,4 mm

Fig. 12 - 06

1

3

2

● Swing out the roller presser.

● Loosen screw 1.

● Adjust the eccentric ( screw 3 ), which is accessible through hole 2, in accordance with

the requirement.

● Tighten screw 1.

12 - 8

Adjustment

12.04.07 Clearance between roller presser and feed wheel

Requirement

When lever 1 is raised, the clearance between feed band and feed wheel should be 7 mm.

7 mm

1

2

Fig. 12 - 07

● Raise lever 1.

● Adjust the presser bar ( screws 2

that the roller presser is parallel to the feed wheel.

) in accordance with the requirement, making sure

12 - 9

12.04.08 Roller presser

Requirement

When the roller presser 1 touches the feed wheel 6,

1. Seen in the direction of sewing, the roller presser should be parallel to the feed wheel 6,

2. Seen in the direction of sewing, the centre of the roller presser should be approx.
2 mm in front of the needle,

3. Seen crosswise to the direction of sewing, the roller presser should be as close as

possible to the needle.

Adjustment

2

2 mm

5

4

Fig. 12 - 08

● Raise the roller presser 1.

● Adjust roller presser 1 (screw 2 and 3) in accordance with requirement 1

● Adjust bracket 4 (screw 5) in accordance with requirement 3.

3

6

and 2.

1

12 - 10

Adjustment

12.04.09 Puller

Requirement

The puller 1

the puller should move freely.

should be positioned horizontally to the needle plate and the toothed belt of

Fig. 12 - 09

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

2

1

12 - 11

12.04.10 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 3 mm thick, the two tension disks 9 should be at least 0.5 mm

apart.

2. When the roller presser is touching the material, for materials over 3 mm thick, the
second thread tension unit 10

should be switched on ( solenoid 6

9

87-038

Adjustment

is released ).

8

0,5 mm

10

7

6

2

3

4

5

1

Fig. 12 - 10

● Raise lever 1 and adjust screw 2 ( nut 3

● Raise the roller presser with the automatic presser foot lift or with the knee lever and

adjust catch 4 ( screw 5

● Press solenoid 6 as far as possible.

● Adjust bracket 7 (screws 8) in accordance with requirement 1.

) in accordance with requirement 1.

) 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.

12 - 12

Adjustment

12.04.11 Roller presser height level switch

Requirement

1. There should be a space of approx. 1 mm between switch 1 and retaining collar 5.

2. When the roller presser is raised approx. 3mm
switch 1 should light up.

with the hand lever, the diode 6 of

6

5

1

4

2

3

12 - 13

Fig. 12 - 11

● Switch on the machine.

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

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

The height adjustment of switch 1 defines from which material thickness the

increased thread tension becomes effective. This adjustment may therefore

differ depending on the material.

12.04.12 Automatic presser foot lift

Requirement

When solenoid 1 is activated, lever 3 should drop automatically to raise the roller presser.

Adjustment

1

2

3

Fig. 12 - 12

● Adjust solenoid 1 ( screws 2

● Switch on the machine and check the requirement.

● Switch off the machine.

Depending on the material thickness, the clearance between roller presser and
feed wheel can be increased up to 10 mm by moving the solenoid 1 to the

right.

) in accordance with the requirement.

87-034

12 - 14

Adjustment

12.04.13 Retainer

Requirement

The retainer 3 should just rest on the material, so that the material does not start fluttering

during sewing.

3

Fig. 12 - 13

● Adjust pin 1( screw 2 ) according to the requirement.

1

2

12 - 15

12.04.14 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.

Adjustment

4

5

6

+

7 mm

1

2

7

3

Fig. 12 - 14

● 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 ).

-

12 - 16

Adjustment

12.04.15 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.

5

3

Fig. 12 - 15

2

1

1 mm

4

11-28a

12 - 17

● Move drive wheel 1 ( screws 2 ) in accordance with requirement 1.

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

12.04.16 Roller presser pressure

Requirement

The material should be fed without difficulty. No pressure marks should be visible on the

material.

Adjustment

+

-

Fig. 12 - 16

● Adjust screw 1 ( under a cover ) in accordance with the requirement.

1

If the roller presser pressure is low enough, the lowering speed of the roller

presser can be increased with parameter "202".

The maximum pressure is 25 N.

12 - 18

Adjustment

12.04.17 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 - 17

● Adjust screw 1 in accordance with the requirement.

1

12 - 19

87-040

12.04.18 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.

Adjustment

1

Fig. 12 - 18

● 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.

12 - 20

Adjustment

12.04.19 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.

2

1

87-041

12 - 21

Fig. 12 - 19

● Remove jammed thread.

● Hold coupling 1 with screw 2 and turn the balance wheel, until you feel coupling 1 snap

back into place again.

Adjustment

12.05 Adjusting the thread trimmer –900/81

.05.01 Resting position of the roller lever / radial position of the control cam

12

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

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.

away from control cam 3.

0,3 mm

7

4

3

1

6

Fig. 12 - 20

● 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.

5

12 - 22

Adjustment

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

should be the same ( see arrow ).

and the outer edge of the thread catcher holder 1

1

3

4

1

2

2

1

4

Fig. 12 - 21

● 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.

12 - 23

12.05.03 Distance between thread catcher and needle plate

Requirement

During its swivel movement thread catcher 1

( see arrow ).

should not pass the edge of the needle plate

Adjustment

1

1

2

1

87-043

2

Fig. 12 - 22

● Move thread catcher 1 ( screws 2, two screws ) parallel to the thread catcher holder in

accordance with the requirement.

12 - 24

Adjustment

12.05.04 Position of the thread catcher

Requirement

1. The bottom edge of the thread catcher 1
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

should be at a distance of 0.1 mm from the

behind the edge of the knife.

3

5

2,5 - 3 mm

87-046

1

0,1mm

1

5

87-045

12 - 25

1

86-044

2

4

Fig. 12 - 23

● 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.

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.

Adjustment

87-047

Fig. 12 - 24

● Move knife 1 ( screws 2 ) in accordance with requirement 1

with requirement 2.

2

1

87-048

or swivel it in accordance

12 - 26

Adjustment

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

bobbin thread should be held reliably after the cutting operation.

3

2

1

3

4

63-035

87-049

1

Fig. 12 - 25

● Adjust bobbin thread clamp spring 1 ( screws 2 ) in accordance with requirement 1.

● Adjust the tension in accordance with requirement 2

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.

by bending side 4 of the bobbin

63-034

12 - 27

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
1st and 3rd stitches. If necessary, correct the tension.

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
hook 4.

3. After the trimming action, both the needle thread and the bobbin thread must be
perfectly cut and bobbin thread 3

is in its front position, bobbin thread 3

retained.

3

2

1

Adjustment

must be held reliably by

3

Fig. 12 - 26

● Sew a few stitches.

● Turn off the on/off switch.

● Carry out the cutting operation manually.

● Check requirement 1

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.

and 2, and if necessary readjust thread catcher 1

4

61-108

in accordance

12 - 28

Adjustment

12.06 Parameter settings

.06.01 Overview of the parameter functions

12

2x

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

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

)

12 - 29

12.06.02 Parameter input example

● Switch on the machine

Adjustment

2x

● Select input mode by pressing TE/Speed

TE

No VAL
101 II

● Select parameter group "500" by pressing the corresponding +/- key

No

TE

No
500

key twice.

..

.

..

● Confirm selection by pressing the corresponding +/- key.

● Enter the code number, see Chapter 9.08 Entering/changing the code number.

No

VAL

TE

No VAL
501 3500

● 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 - 30

Adjustment

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

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 12000

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 0329/....

110 Display software version of V004H202

the control panel

111 Display software version of the V35

sewing drive

112 Key tone of the control panel

I = off, II = on II

113 Horn for section change II

I = off, II = on

2 202 Lowering speed roller presser

I = slow, II = quick II

12 - 31

203 Puller I = OFF, II = ON I

3 301 Position take-up lever t.d.c 0 – 127 2

302 Position needle lowered 0 - 127 20

303 Position cutting solenoid “on“ 0 - 127 20

304 Position cutting solenoid “tacting“ 0 - 127 103

305 Position cutting solenoid “off“ 0 – 127 123

Adjustment

Group Parameter Description Setting Set

range value

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 roller presser [s] 0.01 – 1.50 0.02

402 Start delay after lowering roller presser [s] 0.01 – 1.50 0.15

403 Set lift roller presser [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 roller presser

and feed wheel

602 Display inputs

0123456789ABCDEF
0: not assigned (E16)
1: not assigned (E15)
2: Coding intermittent (E14)
3: not assigned (E13)
4: not assigned (E12)
5: not assigned (E11)
6: not assigned (E10)
7: not assigned (E9)
8: not assigned (E8)
9: Bobbin thread error (E7)
A: Knee switch (E6)
B: not assigned (E5)
C: not assigned (E4)
D: not assigned (E3)
E: not assigned (E2)
F: not assigned (E1)

603 Basic position of the machine drive unit 11 ± 2

( see Chap. 8.02.04 )

604 Carry out cold start ( see Chap. 12.09 )

605 Stitch formation check by turning the

balance wheel

12 - 32

Adjustment

Group Parameter Description Setting Set

range value

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 – 35 35

712 Positioning speed 3 – 25 18

713 Acceleration ramp 1 – 50 35

714 Brake ramp 1 – 50 30

715 Reference position 0 – 127 20

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

12 - 33

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

8 809 Right of access program creation 0 – 1 1

810 Enter access code 0 - 9999 1500

12.07 Explanation of the error messages

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

Adjustment

range value

12.08 Warning messages

Message Description

Warning 2 Bobbin thread error

12 - 34

Adjustment

12

.09 Carrying out a cold start

● Switch on the machine.

2x

● Press the TE/Speed key twice to select the input mode.

TE

No VAL
101 II

● Select parameter group "600" by pressing the corresponding +/- key.

No

TE

No
600

● Confirm selection by pressing the corresponding +/- key.

● Enter the code number, see Chapter 9.08 Entering/changing the code number.

No

RESET

TE

No
604 RESET

● 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.

..

.

..

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.de/pfaff/de/service/downloads

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.

Adjustment

● 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.

1

● 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.

Fig. 12 - 27

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.

● Press the "OK" button.

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.

12 - 36

Wearing parts

13 Wearing parts

This is a list of the most important wearing parts.

A detailed parts list for the complete machine is included with the accessories.

In case of loss, the parts list can be downloaded from the internet address
www.pfaff-industrial.com/pfaff/en/service/downloads As an alternative to

the internet download the parts lists can also be ordered in book form

under part no. 296-12-18 935.

15-120 006-05

91-175 690-05

91-263 430-91 (A, B)

91-263 392-91

91-176 329-05

11-108 093-15

91-173 664-15

91-118 308-05

91-000 390-05

91-000 928-15

91-010 166-05

13 - 1

91-263 397-01

11-330 085-15

91-000 452-15

(2x)

91-263 429-91 (A; B)

91-000 529-15 (3x)

91-263 428-05 (A; B)

91-018 293-05

System 134-35

91-140 945-05 (A; B)

91-263 427-05

For Subclass -900/81

Wearing parts

91-263 139-05

11-108 093-15 (2x)

99-137 151-45

11-130 092-15 (2x)

12-315 080-15 (2x)

11-108 846-15 (2x)

91-263 348-05

91-263 294-05

91-171 049-05

95-774 464-25

91-700 996-15

91-171 042-05

13 - 2

Circuit diagrams

14 Circuit diagrams

Reference list for circuit diagrams

A1 Controller Quick P 320MS

A2 Control panel S2

A14 Sewing head identification (OTE)

B10 Initiator material height

H1 Sewing lamp

H20 LED Stitch counter (option)

M1 Sewing motor

M2 Stepping motor feed wheel

M3 Stepping motor roller presser

M45 Pullermotor

Q1 Main switch

R45 Resistance 330 ohm

S1 Pedal set value transmitter

S2 Pedal 2 Fullness

X30 Initiator material height

X31 Key row

X34 Start inhibitor

X36 Knee switch (program)

X41 -910/..Automatic presser foot lift

X42 -900/..Thread trimmer

X43 Thread tension 2

X44 Thread tension 1

X45 R45 Resistor + Pullermotor

Y1 -910/..Automatic presser foot lift

Y2 -900/..Thread trimmer

Y3 Thread tension 2

Y4 Thread tension 1

S21 Manual backtacking key (option)

S22 Single stitch switch (option)

S23 Needle position change switch (option)

S24 Start inhibitor switch

S26 Knee switch (program)

XP1 Pedal set value transmitter

XP2 Pedal 2 Fullness

X1 Mains plug

X1A RS232 – interface 1 (Control panel BDF S2)

X1B VSS Sewing head identification

X3 Incremental transmitter ( sewing motor )

X4A Stepping motor feed wheel

X4B Stepping motor roller presser

X5 Inputs

X8 Sewing motor

X11B Pedal set value transmitter and

fullness

14 - 1

X13 Outputs

X20 Stepping motor feed wheel

X21 Stepping motor roller presser

91-191 492-95

Part 1

Version 25.08.05

General plan - circuit diagrams

14 - 2

General plan - circuit diagrams

Version 25.08.05

91-191 442-95

Part 2

14 - 3

91-191 492-95

Part 3 Version 25.08.05

General plan - circuit diagrams

14 - 4

General plan - circuit diagrams

Version 25.08.05

91-191 442-95

Part 4

14 - 5

Notice

PFAFF Industrie Maschinen AG

Postfach 3020

D-67653 Kaiserslautern

Königstr. 154

D-67655 Kaiserslautern

Telefon: [phone]

Telefax: (0631) 17202

E-Mail: [e-mail]

Gedruckt in der BRD
Printed in Germany
Imprimé en R.F.A.
Impreso en la R.F.A.