Pfaff 2438 plusline Manuale utente
INSTRUCTION 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
Industrial
®
This Instruction Manual is valid for all models and subclasses listed in the
chapter "Specifications ".
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.
PFAFF Industriesysteme
und Maschinen AG
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
Contents
Contents ................................................................................. Chapter – Page
1Safety ............................................................................................................................ 1 - 1
1.01 Regulations ................................................................................................................... 1 - 1
1.02 General notes on safety ................................................................................................. 1 - 1
1.03 Safety symbols ............................................................................................................. 1 -2
1.04 Important notes for the user .......................................................................................... 1 - 2
1.05 Notes for operating and technical staff........................................................................... 1 - 3
1.05.01 Operating staff ............................................................................................................... 1 - 3
1.05.02 Technical staff ............................................................................................................... 1 -3
1.06 Danger warnings ........................................................................................................... 1 - 4
2Proper use .................................................................................................................... 2 -1
3Specifications .............................................................................................................. 3 - 1
4Disposal of Machine .................................................................................................... 4 - 1
5Transportation, packing and storage ......................................................................... 5 - 1
5.01 Transportation to customer’s premises ......................................................................... 5 - 1
5.02 Transportation inside the customer’s premises ............................................................. 5 - 1
5.03 Disposal of packing materials ........................................................................................ 5 - 1
5.04 Storage .......................................................................................................................... 5 - 1
6Explanation of symbols ............................................................................................... 6 - 1
7Controls........................................................................................................................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
7.06 Bobbin thread control ..................................................................................................... 7 - 3
7.07 Control panel ................................................................................................................. 7 - 4
7.07.01 Screen displays ............................................................................................................. 7 - 4
7.07.02 Function keys ................................................................................................................ 7 - 4
8Mounting 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 machine cover .............................................................................................. 8 - 2
8.01.03 Fitting the reel stand ...................................................................................................... 8 - 2
8.01.04 Connecting the plug-in connections and earth cables..................................................... 8 - 3
8.02 Commissioning ............................................................................................................. 8 - 4
8.03 Switching the machine on/off ........................................................................................ 8 - 4
8.04 Mounting/checking the start inhibitor ............................................................................. 8 - 5
9Setting up..................................................................................................................... 9- 1
9.01 Inserting the needle ....................................................................................................... 9 -1
9.02 Winding the bobbin thread / adjusting the primary thread tension .................................. 9 - 2
Contents
Contents ................................................................................. Chapter – Page
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 Setting the zigzag stitch and the stitch position ............................................................. 9 - 5
9.07 Entering the stitch length ............................................................................................... 9 - 5
9.08 Entering the start and end backtacks ............................................................................. 9 - 6
9.09 Entering the maximum speed ........................................................................................ 9 - 7
9.10 Setting the remaining stitches for the bobbin thread control ........................................... 9 - 7
10 Sewing ........................................................................................................................10- 1
10.01 Manual sewing .............................................................................................................10 -1
10.02 Programmed sewing ....................................................................................................10 - 2
10.03 Error messages ............................................................................................................10 -3
11 Input ............................................................................................................................11 - 1
11.01 Seam program input .....................................................................................................11 - 1
11.02 Example of a seam program input ................................................................................11 - 1
11.03 Program recording forms ..............................................................................................11 - 9
12 Care and maintenance ................................................................................................ 12 - 1
12.01 Cleaning .......................................................................................................................12 - 1
12.02 Lubricating the hook ..................................................................................................... 12 - 2
12.03 Oiling the zigzag drive ...................................................................................................12 -3
12.04 Cleaning the air filter of the air-filter / lubricator .............................................................12 - 4
12.05 Checking/adjusting the air pressure ..............................................................................12 - 4
13 Adjustment ..................................................................................................................13 - 1
13.01 Notes on adjustment ....................................................................................................13 - 1
13.02 Tools, gauges and other accessories for adjusting .......................................................13 - 1
13.03 Abbreviations ................................................................................................................13 - 1
13.04 Check and adjustment aid ............................................................................................13 - 2
13.05 Adjusting the basic machine ........................................................................................13 - 3
13.05.01 Balancing weight ..........................................................................................................13 - 3
13.05.02 Centering the needle in the needle hole (in sewing direction) .......................................13 - 4
13.05.03 Parallel guiding of the needle bar ..................................................................................13 - 5
13.05.04 Locking lever ................................................................................................................13 -6
13.05.05 Zero stitch and zigzag stitch scale ...............................................................................13 - 7
13.05.06 Centering the needle in the needle hole (crosswise to sewing direction) .....................13 - 8
13.05.07 Zigzag stitch width .......................................................................................................13 - 9
13.05.08 Zigzag stitch motion .....................................................................................................13 - 10
13.05.09 Needle penetration symmetry ......................................................................................13 - 11
13.05.10 Needle position adjustment lever .................................................................................13 - 12
13.05.11 Zero position of the bottom feed dog (with closed gear box) .........................................13 - 13
13.05.12 Zeroing the bottom feed (with open gearbox) ............................................................... 13 - 14
13.05.13 Feeding motion of the bottom feed dog ........................................................................ 13 - 15
13.05.14 Lifting motion of the bottom feed dog ...........................................................................13 - 16
13.05.15 Drive belt in the gearbox housing .................................................................................13 - 17
Contents
Contents ................................................................................. Chapter – Page
13.05.16 Hook bearing bracket ...................................................................................................13 - 18
13.05.17 Hook lubrication ............................................................................................................13 - 19
13.05.18 Pre-adjusting the needle height ....................................................................................13 - 20
13.05.19 Needle rise, hook-to-needle clearance and bobbin case positioning-finger ...................13 - 21
13.05.20 Final adjustment of the needle height ...........................................................................13 - 22
13.05.21 Bobbin case opener position ........................................................................................13 - 23
13.05.22 Bobbin case opener motion ..........................................................................................13 - 24
13.05.23 Bottom feed dog height ................................................................................................13 - 25
13.05.24 Presser foot to needle plate clearance .......................................................................... 13 - 26
13.05.25 Presser foot pressure ................................................................................................... 13 - 27
13.05.26 Thread diverter pin ........................................................................................................13 - 28
13.05.27 Limiting the knee lever stroke ......................................................................................13 - 29
13.05.28 Knee lever play .............................................................................................................13 - 30
13.05.29 Setting the zero point of the feed regulator .................................................................... 13 - 31
13.05.30 Stitch length adjustment forwards and in reverse .........................................................13 - 32
13.05.31 Spuler ...........................................................................................................................13 - 34
13.06 Adjusting the thread trimmer ........................................................................................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 thread catcher and cutting test ..............................................................13 - 37
13.06.04 Readjustment of the control cam..................................................................................13 - 38
13.06.05 Needle thread tension release .......................................................................................13 - 39
13.07 Adjusting the thread wiper –909/04 ...............................................................................13 - 40
13.07.01 Thread wiper motion .....................................................................................................13 - 40
13.07.02 Position of the thread wiper ..........................................................................................13 - 41
13.08 Adjusting the zigzag sensor ..........................................................................................13 - 42
13.09 Aligning the light transmitter .........................................................................................13 - 43
13.10 Adjustment of the transmitted light sensors .................................................................13 - 44
13.11 Function control of the bobbin thread monitor ...............................................................13 - 45
13.12 Parameter settings .......................................................................................................13 - 46
13.12.01 Example of a parameter input .......................................................................................13 - 46
13.12.02 List of parameters ........................................................................................................13 - 47
13.13 Explanation of the error messages ...............................................................................13 - 54
13.14 Service functions ..........................................................................................................13-55
13.15 Internet update of the machine software ......................................................................13 - 60
14 Wearing parts .............................................................................................................14 - 1
15 Circuit diagrams .........................................................................................................15 - 1
Safety
1 - 1
1 Safety
1.01 Regulations
This machine is constructed in accordance with the European regulations indicated in the
conformity and manufacturer's declarations.
In addition to this instruction manual, please also observe all generally accepted, statutory
and other legal requirements, including those of the user's country, and the applicable pol-
lution control regulations!
The valid regulations of the regional social insurance society for occupational accidents or
other supervisory authorities are to be strictly adhered to!
1.02 General notes on safety
●The machine must only be operated by adequately trained operators and only when the
instruction manual has been fully read and understood!
●All notices on safety and the instruction manual of the motor manufacturer are to be read
before the machine is put into operation!
●All notes on the machine concerning danger and safety must be observed!
●The machine must be used for the purpose for which it is intended and must not be
operated without its safety devices; all regulations relevant to safety must be adhered to.
●When part sets are changed (e.g. needle, presser foot, needle plate, feed dog or bob-bin),
during threading, when the workplace is left unattended and during maintenance work, the
machine must be isolated from the power supply by turning off the on/off switch or
removing the plug from the mains!
●Daily maintenance work must only be carried out by appropriately trained persons!
●Repairs and special maintenance work must only be carried out by qualified technical staff
or persons with appropriate training!
●During maintenance or repairs on the pneumatic system the machine must be isolated
from the compressed air supply! The only exception to this is when adjustments or
function checks are carried out by appropriately trained technical staff!
●Work on the electrical equipment must only be carried out by technical staff who are
qualified to do so!
●Work on parts or equipment connected to the power supply is not permitted! The only
exceptions to this are specified in regulations EN 50110.
●Conversion or modification of the machine must only be carried out under observation of
all relevant safety regulations!
Safety
1 - 2
●Only spare parts which have been approved by us are to be used for repairs! We draw
special attention to the fact that spare parts and accessories not supplied by us have not
been subjected to testing nor approval by us. Fitting and/or use of any such parts may
cause negative changes to the design characteristics of the machine. We shall not accept
any liability for damage caused by the use of non-original parts.
1.03 Safety symbols
Danger!
Special points to observe.
Danger of injury to operating or technical staff!
Electric voltage!
Danger to operating or technical staff!
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 notes for the user
●This instruction manual belongs to the equipment of the machine and must be available to
the operating staff at all times.
This instruction manual must be read before the machine is operated for the first time.
●Both operating and technical staff must be instructed on the safety devices of the mach-
ine and on safe working methods.
●It is the duty of the user to operate the machine in perfect running order only.
●The user must ensure that none of the safety devices are removed nor put out of work-ing
order.
●The user must ensure that only authorized persons operate and work on the machine.
For further information please refer to your PFAFF agency.
Safety
1 - 3
1.05 Notes for operating and technical staff
1.05.01 Operating staff
Operating staff are the persons responsible for setting up, operating and cleaning the machine
and for eliminating any malfunctioning in the sewing area.
The operating staff is obliged to observe the following points:
●The notes on safety in this instruction manual must always be observed!
●Any working methods, which adversely affect the safety of the machine, must be
avoided.!
●Loose-fitting clothing should be avoided. No jewellery, such as chains and rings, should be
worn!
●Ensure that only authorised persons enter the danger area of the machine!
●Any changes 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/electronics and
mechanical engineering. They are responsible for lubricating, servicing, repairing and adjusting
the machine.
The technical staff is obliged to observe the following points:
●The notes on safety in this instruction manual must always be observed!
●Before carrying out any adjustment or repair work the main switch must be switched off
and measures taken to prevent it from being switched on again!
●Never work on parts or equipment still connected to the power supply! Exceptions are only
permissible in accordance with the regulations EN 50110.
●All safety covers must be replaced after the completion of maintenance or repair work!
Safety
1 - 4
81
-
001
1.06 Danger warnings
A working area of 1 m must be kept free both in front of and behind the machine,
so that easy access is possible at all times.
Never put your hands in the needle area during sewing!
Danger of injury by the needle!
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 from the movement of the needle!
Do not operate the machine without machine covers 3and 4!
Danger of injury from moving belts!
Do not operate the machine without start inhibitor 5!
Danger of injury if the machine is started accidentally!
81-002
1
2
3
45
Proper use
2 - 1
2 Proper use
The PFAFF 2438 is a high-speed zigzag machine with bottom feed and automatic material
edge detector.
The machine is used for sewing labels 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 improper use! Proper use shall also be considered to include
compliance with the operation, adjustment, service and repair measures speci-
fied by the manufacturer!
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