Pfaff 2438 plusline Instruction Manual Download Page 14

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Explanation of symbols

6 - 1

Explanation of symbols

In this instruction manual, work to be carried out or important information is accentuated by

symbols. These symbols have the following meanings:

Note, information

Cleaning, care

Lubrication

Maintenance, repairs, adjustment, service work

(only to be carried out by technical staff)

Summary of Contents for 2438 plusline

Page 1: ...RUCTION MANUAL 296 12 18 708 002 Betriebsanleitung engl 06 09 This instruction manual applies to machines from the following serial numbers 2 657 257 and software version 0307 001 onwards 2438 Industr...

Page 2: ...eci cations The reprinting copying or translation of PFAFF Instruction Manuals whether in whole or in part is only permitted with our previous authorization and with written reference to the source PF...

Page 3: ...symbols 6 1 7 Controls 7 1 7 01 Main switch 7 1 7 02 Keys on the machine head 7 1 7 03 Pedal 7 2 7 04 Lever for raising presser foot 7 2 7 05 Adjustment lever for zigzag stitch and needle position 7 3...

Page 4: ...lter lubricator 12 4 12 05 Checking adjusting the air pressure 12 4 13 Adjustment 13 1 13 01 Notesonadjustment 13 1 13 02 Tools gauges and other accessories for adjusting 13 1 13 03 Abbreviations 13 1...

Page 5: ...32 13 05 31 Spuler 13 34 13 06 Adjustingthethreadtrimmer 13 35 13 06 01 Axial position of the control cam 13 35 13 06 02 Preliminary adjustment of the control cam 13 36 13 06 03 Position of the threa...

Page 6: ...rated without its safety devices all regulations relevant to safety must be adhered to When part sets are changed e g needle presser foot needle plate feed dog or bob bin during threading when the wor...

Page 7: ...te without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off main switch I 1 04 Important notes for the user This instruction manual belongs to the eq...

Page 8: ...occurring on the machine which may affect its safety must be reported to the user immediately 1 05 02 Technical staff Technical staff are persons who have been trained in electrical engineering electr...

Page 9: ...Fig 1 01 Do not operate the machine without the take up lever guard 1 Danger of injury through the movement of the take up lever Do not operate the machine without finger guard 2 Danger of injury fro...

Page 10: ...bels on linings in industry Any use of these machines which is not approved by the manufacturer shall be considered as improper use The manufacturer shall not be liable for any dam age arising out of...

Page 11: ...dth ca 265 mm Height above table ca 330 mm Bed plate dimensions 476 x 177 mm Connectiondata Operatingvoltage 230 V 10 50 60 Hz Max power consumption 1 2 kVA Fuseprotection 1 x 16 A inert Noise data No...

Page 12: ...nd various plastic materials The electrical equipment comprises plastic materials and copper The machine is to be disposed of according to the locally valid pollution control regulations if necessary...

Page 13: ...e machines are only transported in an uprightposition 5 03 Disposal of packing materials The packing materials of these machines consist of paper cardboard and VCE fibre Proper disposal of the packing...

Page 14: ...struction manual work to be carried out or important information is accentuated by symbols These symbols have the following meanings Note information Cleaning care Lubrication Maintenance repairs adju...

Page 15: ...ng the respective key the following functions are carried out Key 1 Reverse sewing Key 2 Raise needle without thread trimming Key 3 Sew single stitch Fig 7 02 Fig 7 01 7 Controls 7 01 Main switch The...

Page 16: ...Neutralposition 1 Sewing 2 Raise presser foot 3 Trimthread resetbobbinthread controlorremainingbobbin threadcountfunction Fig 7 03 0 1 2 3 7 04 Lever for raising presser foot The presser foot is rais...

Page 17: ...t zigzag stitch width can be seen on scale 3 Byturningtheneedle positionadjustment lever 4 the required needle position can be set L needle positionleft M needle positioncenter R needle positionright...

Page 18: ...unctions are displayed with a triangular marking 2 below or next to the respective function key In the sewing mode all relevant sewing data is displayed and these can be changed directly depending on...

Page 19: ...after stop If this key is pressed the foot raised after sewing stop function is switched on or off When the function is switched on the presser foot is raised after sewing stops Foot position after t...

Page 20: ...this key is pressed twice within 5 seconds while the machine is in the sewing mode the machine switches to parameter input If this key is pressed once while the machine is in the parameter input mode...

Page 21: ...otor 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 l...

Page 22: ...nce sleeve 4 into tapped hole 5 Making sure that the bracket 6 is behind slot 7 and in front of distance sleeve 4 adjust the belt guard Tighten screws 1 and 2 accessible through holes 8 and 9 and scre...

Page 23: ...4 Connect plugs 1 6 as labelled in the control box Screw the earth cable from the sewing head to earth point A Screw the earth cable 7 from the motor to earth point B Connect earth point C and earth p...

Page 24: ...sted by qualified personnel Parameter 800 Connect the machine to the compressed air system The pressure gauge should show a pressure of 6 bar If necessary adjust the value see Chapter 12 05 Checking a...

Page 25: ...witch is off when the sewing head is tilted over and activated by switch lug 2 when the sewing head is upright Checking the start inhibitor 8 04 Mounting checking the start inhibitor Fig 8 07 Switch t...

Page 26: ...rk the machine must be isolated from its power supply by turning off the on off switch or removing the machine plug from the electric power socket 9 01 Inserting the needle Switch off the machine Dang...

Page 27: ...same time The bobbin is filled during sewing If the machine is only operated for winding without sewing a bobbin case must be inserted in the hook Otherwise the hook can be damaged by the thread jammi...

Page 28: ...rt bobbin case 1 until you feel it click into place 81 097 9 04 Threading the bobbin case Adjusting the bobbin thread tension Fig 9 04 2 1 Insert bobbin 1 into bobbin case 2 as shown in the above illu...

Page 29: ...ad Adjusting the needle thread tension Switch off the machine Danger of injury if the machine is started accidentally Thread the needle thread as show in the above illustration Adjust the needle threa...

Page 30: ...ting can be read from scale 3 Set the stitch position by turning stitch position lever 4 L stitch position on left M stitch position in the middle R stitch position on the right M L R 4 3 2 1 Fig 9 07...

Page 31: ...ssing 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 sti...

Page 32: ...in thread has been used up there is still a little thread on the bobbin Switch on the machine Press the TE Speed key twice to enter the parameter input function 2 x Select the parameter 760 by pressin...

Page 33: ...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 07 Entering the stitch length If the backtack functi...

Page 34: ...seam section and stitch length If other functions such as sensor or stitch count have been activated it is possible to switch to other displays for entering corresponding values by pressing the scrol...

Page 35: ...ort instructions An error message is caused by incorrect settings faulty elements or seam programs as well as by overload conditions For an explanation of the error codes see Chapter 13 13 Explanation...

Page 36: ...in the following example 11 Input In this chapter the input of seam programs is described 11 01 Seam program input Switch on the machine Press the PM key to call up programmed sewing The text PM must...

Page 37: ...he text PM must appear on the display 15 0 2 0 PM Selecting the program number Select program number 7 with the corresponding key 7 0 2 0 PM 1 7 0 1 6 0 0 2 7 1 1 6 0 0 3 7 2 1 6 0 0 4 7 3 1 6 0 0 5 7...

Page 38: ...Press the scroll key to enter the seam depth 0 0 PM Set the value for the seam depth at 0 with the corresponding key 0 0 PM Press the scroll key to select the first seam section 7 0 1 6 PM The values...

Page 39: ...ect seam section 1 with the corresponding key 7 1 1 6 PM Selecting the functions for seam section 1 The machine should stop at the end of the seam section The end of the seam section should be recogni...

Page 40: ...tically at the end of the seam section Press the sensor key for recognition of the end of the seam section by sensor 7 3 1 6 PM 7 2 1 6 PM Selecting seam section 3 Select seam section 3 with the corre...

Page 41: ...presser foot should rise after thread trimming The seam depth should be 0 input made in seam section 0 Press the programmed stop key to stop the machine automatically at the end of the seam section P...

Page 42: ...hine automatically at the end of the seam section Press the thread trimming key for automatic trimming of the thread a the end of the seam section Press foot position after trimming to raise the press...

Page 43: ...y By setting the stitch length in seam section 6 at zero seam section 5 is recognised as the last seam section in the seam program and the seam program input is finished Sewing a test seam Select seam...

Page 44: ...Input 11 9 11 03 Program recording forms 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 E Step A B C D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 E Step A B C D...

Page 45: ...Input 11 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 E Step A B C D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 E Step A B C D...

Page 46: ...or Cleaning the air filter lubricator This maintenance interval if for an average machine running time in a single shift operation If the machine running times are longer shorter maintenance intervals...

Page 47: ...3 at 15 C Lay the machine head on its back Fill the oil reservoir 1 up to the upper marking 3 through hole 2 Before operating the machine for the first time or after longer stationary periods add a fe...

Page 48: ...top marking 2 Tighten screw 1 Never allow the oil level to sink below the minimum mark 3 Danger of damage to the machine To fill in larger quantities of oil e g when filling for the first time before...

Page 49: ...bowl 1 Take out filter 2 Clean filter 2 with compressed air or isopropyl alkohol part No 95 665 735 91 Screw in filter 2 and screw on water bowl 1 Fig 12 06 10 12 0 6 4 2 8 16 14 100 50 150 0 200 230...

Page 50: ...e 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...

Page 51: ...nd the bearing plate thus blocking the machine Hole 1 2 0 mm after the bottom dead center of the needle bar 2 0 past tdc Hole 2 Top dead center of the needle bar tdc Hole 3 0 25 mm after the top dead...

Page 52: ...r to b d c Adjust the balance weight 1 screw 2 in accordance with the requirement 13 05 Adjusting the basic machine 13 05 01 Balancing weight Requirement With the needle bar at bdc the largest eccentr...

Page 53: ...and screw 3 in accordance with the requirement 3 2 1 13 05 02 Centering the needle in the needle hole in sewing direction Requirement With the zigzag setting at 0 and the needle position set at middle...

Page 54: ...4 turn eccentric pin 4 in accordance with the requirement and tighten nut 3 Push guide bar 5 downwards and then upwards as far as possible Bushing 6 must not move laterally during this movement readj...

Page 55: ...o be locked in any position Fig 13 05 Loosen screw 2 Press locking lever 1 against the zigzag stitch adjustment lever 3 Turn pivot pin 4 as far as possible to the left Release locking lever 1 Locking...

Page 56: ...achine off Move screw 5 to the right until it touches and then tighten it Loosen screws 7 and move scale 1 in accordance with requirement 2 Tighten screws 7 Screw 6 remains loose for the following adj...

Page 57: ...sewing direction Requirement With the zigzag stitch set at 0 and the needle position setting at middle the needle must enter the center of the needle hole as seen across the direction of sewing 1 Fig...

Page 58: ...n scale 2 Fig 13 08 Turn the zigzag stitch adjustment lever 3 in accordance with the requirement Move screw 4 upwards until it touches and then tighten it If the machine is equipped with a needle plat...

Page 59: ...t the zigzag eccentric 1 is at a distance of approx 5 mm from the inside right wall of the case 13 05 08 Zigzag stitch motion Requirement When the needle bar is at tdc coming from the right bdc hole 2...

Page 60: ...rate the paper to the right and left by turning the balancewheel back and forth Without turning it move zigzag stitch eccentric 3 screw 4 in accordance with the requirement 13 05 09 Needle penetration...

Page 61: ...titch adjustment lever 4 at 0 and move the needle position adjustment lever 3 to the right left until the needle is exactly over the perforations made in the last step For the left needle position bri...

Page 62: ...on the start inhibitor again Switch off the machine 13 05 11 Zero position of the bottom feed dog with closed gear box Requirement 1 When the stitch length is set at 0 the shaft crank 3 should not car...

Page 63: ...th set at 0 the bottom feed dog must not carry out any feeding motion when the balance wheel is turned 2 1 3 Switch on the machine Set parameter 834 at 0 While continuously turning the balance wheel a...

Page 64: ...0 past tdc hole 4 the bottom feed dog must not move when the reverse feed lever is pressed While continuously operating the reverse feed control adjust feeding eccentric 1 screws 2 in accordance with...

Page 65: ...stitch length set at 0 and the needle bar position at 0 25 mm past tdc hole 3 the bottom feed dog must be at its upper point of reversal 2 1 Fig 13 15 Adjust feed lifting eccentric 1 screw 2 in accor...

Page 66: ...accordance with the requirement and so that drive belt 4 is in the centre of bobbin opener drive wheel 3 13 05 15 Drive belt in the gearbox housing Requirement Drive belt 4 must be tightened so that t...

Page 67: ...ring bracket adjustment gauge It must be possible to read the numbers 438 439 from the front Move or turn hook bearing bracket 4 in accordance with the requirement Tighten screw 2 Adjust the bobbin ca...

Page 68: ...cation Requirement When the machine is running at full speed after about 10 seconds a fine oil streak should be visible on a strip of paper held over the needle plate cutout Adjust screw 1 in accordan...

Page 69: ...equirement With the needle bar at tdc hole 2 the distance between the point of the needle and the needle plate must be 19 mm 81 034 Fig 13 19 1 Without turning it adjust the needle bar screws 1 in acc...

Page 70: ...nger Requirement 1 With the needle position set at middle the zigzag stitch setting at 0 and the needle bar position 2 0 past bdc hole 1 the hook point must be in the middle of the needle and the dist...

Page 71: ...zigzag stitch set at 0 the needle position set at left and the hook point in the middle of the needle the top edge of the needle eye must be 0 5 mm underneath the hook point Fig 13 21 Without turning...

Page 72: ...bin opener 1 is touching clamp crank 3 13 05 21 Bobbin case opener position Requirement 1 There must be a clearance of 0 5 mm between the top edge of the bobbin case opener and the inner edge of the b...

Page 73: ...ase opener motion Requirement With the needle bar 2 0 past bdc hole 1 the bobbin case opener 3 must be at its right point of reversal 3 1 2 Fig 13 23 Adjust bobbin opener eccentric 1 screws 2 in accor...

Page 74: ...touching the feed dog height adjustment gauge along its entire length 2 1 3 4 Fig 13 24 Position the feed dog adjustment gauge underneath the presser foot with the cutout facing downwards Lower the p...

Page 75: ...tment lever at 0 and the stitch position adjustment lever at centre Let the presser foot drop onto the needle plate and reduce the pressure on the presser bar by turning screws 1 Place the feed dog ad...

Page 76: ...rement Even at top sewing speed the material should be fed without problems There should be no pressure marks on the material Turn screw 1 in accordance with the requirement The presser foot pressure...

Page 77: ...the needle bar at bdc the top edge of the thread guide hole must be at the same height as the bottom edge of the thread diverter 81 040 Fig 13 27 2 1 Adjust thread guide bar 1 screw 2 according to th...

Page 78: ...r the presser foot with its recess facing downwards Lower the presser foot onto the gauge Loosen nut 1 and turn screw 2 out a few turns Move the knee lever to the right until a noticeable resistance i...

Page 79: ...y Requirement When lightly pressing the knee lever there should be a noticeable play between nut 1 and fork 3 1 2 3 Adjust nut 1 nut 2 in accordance with the requirement and lock it with nut 2 The kne...

Page 80: ...values in accordance with the requirement The permissible values for parameter 834 are 1 0 or 1 If the zero point of the feed regulator cannot be set by selecting one of the permissible values the mec...

Page 81: ...l stitch length x 100 Stitch length 2 2 mm Stitch length 2 0 mm Stitch length 1 6 mm Stitch length 1 4 mm 56 0 78 52 0 77 55 5 79 51 5 78 55 0 80 51 0 78 54 5 81 50 5 79 54 0 81 50 0 80 42 0 76 53 5 8...

Page 82: ...adjustment of the reverse stitch length is carried out as described in the above work steps with the reverse feed key pressed More information about selecting and changing parameters and explanations...

Page 83: ...n accordance with requirement3 13 05 31 Bobbin winder Requirement 1 When the bobbin winder is switched on the bobbin winder spindle should be driven reliably whereby the friction wheel 5 should not to...

Page 84: ...of the control cam Requirement 1 Roller 5 should be at a distance of 0 3 mm from the control cam 1 2 Adjustment ring 3 should be touching the control cam 1 Fig 13 31 Shift control cam 1 screw 2 and ad...

Page 85: ...needle rise position hole 1 the roller lever 4 should lock into the corresponding groove of the control cam 2 The control cam 1 should be touching adjustment ring 3 Fig 13 32 Turn control cam 1 screws...

Page 86: ...50 3 3 1 2 4 6 Fig 13 33 Turn linkage rod 1 nuts 2 left and right thread in accordance with the requirement During the cutting test remove linkage rod 1 loosen screws 3 and remove mounting plate 4 Ca...

Page 87: ...t edge of the bobbin case position finger 4 the thread catcher 5 should begin moving forwards 2 The control cam 1 should be touching adjustment ring 6 Bring the needle bar to b d c Turn control cam 1...

Page 88: ...should be at least 0 5 mm apart 2 When the thread trimmer is in its neutral position and the sewing foot is positioned on the needle plate the tension should be fully effective Fig 13 35 Unscrew the...

Page 89: ...per 3 should not touch anything during its motion 2 With the take up lever at t d c when the engaging solenoid 4 is activated the thread wiper 3 should have approx 1 mm clearance under the needle poin...

Page 90: ...e tip of the thread wiper 5 should be approx 1 1 5 mm to the right of the needle 2 At its front point of reversal thread wiper 5 should be approx 2 mm in front of the needle Without twisting it move h...

Page 91: ...tch surface 4 when the main drive of the machine is at position 15 Switch on the machine Select parameter 702 see Chapter 13 12 Parameter settings Turn the balance wheel until the needle is at its rig...

Page 92: ...ters PS2 and PS1 should display the same value same receiving power Switch on the machine Select the PS function from the service menu see Chapter 13 14 Service functions Adjust light transmitter 1 sc...

Page 93: ...y Move the material ply to and fro under the sensors for a short time To end the adjustment for the material ply press on the corresponding key To start the adjustment for the material ply with label...

Page 94: ...in thread monitor Place the bobbin in the bobbin case and the bobbin case in the hook Switch on the machine Select the TM function from the service menu see Chapter 13 14 Service functions Pull the bo...

Page 95: ...cked to avoid the machine starting accidentally Select the desired parameter e g 660 bobbin thread control by pressing the corresponding plus minus key With the corresponding plus minus key set the de...

Page 96: ...OFF 107 Pedal controlled speed start backtacks ON limited with parameter 105 OFF limited with parameter 607 C ON OFF OFF 108 End backtacks in reverse C 0 9 3 109 End backtacks forwards C 0 9 3 110 End...

Page 97: ...min 1 10 mm B 10 50 10 325 Edge guide position max 1 10 mm B 165 185 185 4 419 Bartacks ON inverted OFF suppressed C ON OFF ON 478 Corner stitch ON accurate OFF fast C ON OFF ON 492 Number of seam pro...

Page 98: ...mp 2 off 0 B 0 2 1 7 700 Logical zero mark increments B 0 127 0 702 Needle position needle lowered B 0 30 15 703 Needle position take up lever raised B 100 127 113 705 Needle position end of cutting s...

Page 99: ...760 Stitch count to bobbin thread monitor machine stop in needle lowered position A 0 50000 1000 761 Extension thread tension release pull thread ms B 0 2550 0 791 Stitch count delay for start backtac...

Page 100: ...864 Proportional amplification of the speed control general B 0 2500 500 880 Starting current main drive C 1 10 10 881 Filter parameter for position controller C 0 12 5 884 Proportional amplification...

Page 101: ...current reduction of stepping motor axis 2 B 15 48 39 958 Current reduction time stepping motor axis 2 B 0 2500 2000 978 Delay power off stepping motor 2 C 0 99 0 979 Delay power off stepping motor 1...

Page 102: ...thread monitoring E062 Short circuit 24V E063 Overload switch power supply E064 Network monitoring E065 Extint low in operation E066 Short circuit E067 Power off E068 Extint low in operation E069 No...

Page 103: ...n E158 Stepping motor frequency E170 Incorrect main drive transmission E171 Logical zero mark invalid E172 Communication error main drive E175 Main drive start E200 Brake path too short E201 Main driv...

Page 104: ...4 ON SERVICE The individual service functions are shown under FKT and can be selected with the corresponding key Overview of the service functions FKT IN Read out inputs With the corresponding key the...

Page 105: ...ys the value for the speed is changed accordingly By selecting the type SC and entering the desired value with the corresponding keys the value for the stitch count is changed accordingly RES Carry ou...

Page 106: ...ction Plugmarking Signalmarking X15 1 Sensors current source UFW P7 3 X15 2 Sensors DLS outside LS2 P5 3 analog X15 3 Sensors DLS inside LS1 P5 6 analog X15 4 Sensors ZZ Sensor 2438 E9 E9 Port_E9 X15...

Page 107: ...ADTC X3 5 incr transm 5V X3 6 incr transm 5V X3 7 incr transm Gnd X3 8 incr transm Ext SyMa 180 EXTSM_MINI X3 9 incr transm Gnd Stepping motor 1 edge guide Pin No Comment Function Plugmarking Signalm...

Page 108: ...9 SN solenoid Y2 24V 24V X13 20 WI solenoid Y3 24V 24V X13 21 24V 24V X13 22 RAFI LED H1 24V 24V X13 23 24V 24V X13 24 A13 O13 X13 25 A12 O12 Inputs Pin No Comment Function Plugmarking Signalmarking X...

Page 109: ...ent 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 cont...

Page 110: ...complete machine under part no 296 12 18 708 91 701 179 15 System 134 11 108 174 25 95 774 443 05 91 100 296 25 3x 11 108 174 15 2x 91 000 390 05 91 000 250 15 91 009 026 05 91 225 227 05 3x 11 174 91...

Page 111: ...Wearing parts 14 2 99 137 151 45 91 171 049 05 91 171 042 05...

Page 112: ...included in A4 S11 VR by hand backtack included in A4 S12 Needle position included in A4 S13 Knee switch single stitch S14 Startinhibitor S15 2nd knee switch H1 Sewing lamp H10 Bobbin thread alarm in...

Page 113: ...15 2 Circuit diagram View Version 23 01 03...

Page 114: ...15 3 91 191 445 95 Part 1 Version 29 01 02 Circuit diagram...

Page 115: ...15 4 Circuit diagram Version 29 01 02 91 191 445 95 Part 2...

Page 116: ...15 5 91 191 445 95 Part 3 Version 29 01 02 Circuit diagram...

Page 117: ...15 6 Circuit diagram Version 29 01 02 91 191 445 95 Part 4...

Page 118: ...und Maschinen AG is an authorized licensee of the PFAFF trademark PFAFF Industriesysteme und Maschinen AG Hans Geiger Str 12 IG Nord D 67661 Kaiserslautern Telefon 49 6301 3205 0 Telefax 49 6301 3205...

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Summary of Contents for 2438 plusline

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Pfaff 2438 plusline, Instruction Manual, Page: 14 / 118

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Summary of Contents for 2438 plusline

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