Pfaff 2438 plusline User manual

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!

Specifications
3 - 1
3 Specifications▲
Stitch type: .................................................................................................. 301 (lockstitch)
Max. sewing speed: .......................................................................................... 4500 spm ◆
Max. stitch length .................................................................................................... 2.5 mm
Needle system: ........................................................................................................ 438 KK
Needle size in 1/100 mm: .................................................................................................80
Effective balance wheel diameter: ............................................................................ 65 mm
Presser foot clearance: .......................................................................................... 7 - 9 mm
Clearance width: .................................................................................................... 260 mm
Clearance height: .................................................................................................... 130 mm
Sewing head dimensions:
Length: ............................................................................................................. ca. 535 mm
Width: ............................................................................................................... ca. 265 mm
Height (above table): ......................................................................................... ca. 330 mm
Bed plate dimensions: ...................................................................................476 x 177 mm
Connection data:
Operating voltage: ........................................................................... 230 V ± 10%, 50/60 Hz
Max. power consumption: ....................................................................................... 1.2 kVA
Fuse protection: ............................................................................................. 1 x 16 A, inert
Noise data:
Noise emission level at workplace with a sewing speed of 2800 spm: ...... LpA < 80 dB(A) ■
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)
Net weight of sewing head: ................................................................................... ca. 48 kg
Gross weight of sewing head: ............................................................................... ca. 56 kg
▲Subject to alterations
◆ Depending on the material, operation and stitch length
■ KpA = 2.5 dB

Disposal of machine
4 - 1
4 Disposal of Machine
●Proper disposal of the machine is the responsibility of the customer.
●The materials used for the machine are steel, aluminium, brass and 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, a specialist ist to be commissioned.
Care must be taken that parts soiled with lubricants are disposed of separately
according to the locally valid pollution control regulations!

Transportation, packing and storage
5 - 1
5 Transportation, packing and storage
5.01 Transportation to customer’s premises
All machines are delivered completely packed.
5.02 Transportation inside the customer’s premises
The manufacturer cannot be made liable for transportation inside the customer's premises nor
to other operating locations. It must be ensured that the machines are only transported in an
upright position.
5.03 Disposal of packing materials
The packing materials of these machines consist of paper, cardboard and VCE-fibre.
Proper disposal of the packing material is the responsibility of the customer.
5.04 Storage
If the machine is not in use, it can be stored as it is for a period of up to six months, but it
should be protected against dust and moisture.
If the machine is stored for longer periods, the individual parts, especially the surfaces of
moving parts, must be protected against corrosion, e.g. by a film of oil.

Explanation of symbols
6 - 1
6 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)

Controls
7 - 1
77
-
005
81-003
7.02 Keys on the machine head
●By operating 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 machine is switched on or off by
turning the main switch 1.
1
3
2
1

Controls
7 - 2
81-004
7.03 Pedal
0= Neutral position
1= Sewing
2= Raise presser foot
3= Trim thread/reset bobbin thread
control or remaining bobbin
thread count function
Fig. 7 - 03
0
1
23
7.04 Lever for raising presser foot
●The presser foot is raised by turning
lever 1.
Fig. 7 - 04
1

Controls
7 - 3
81
-
105
Fig. 7 - 05
4
M
L
R
2
1
3
7.05 Adjustment lever for zigzag stitch and needle position
●The zigzag stitch adjustment lever 1is
used for adjusting the width of the zigzag
stitch.
●To change the position of the adjustment
lever, the locking lever 2must be pressed
against the adjustment lever 1.
The current zigzag-stitch width
can be seen on scale 3.
●By turning the needle-position adjustment
lever 4the required needle position can be
set.
L= needle-position left
M= needle-position center
R= needle-position right
7.06 Bobbin thread control
●When the remaining thread quantity is
reached LED 1flashes.
After thread trimming a bobbin
symbol appears on the display
with the number of remaining
stitches. To enter the number of
remaining stitches, see Chapter
9.10 Setting the remaining
stitches for the bobbin thread
control.
Fig. 7 - 06
1

Controls
7 - 4
2.0
SPEED
7.07 Control panel
The control panel is used to create and alter seam programs, enter parameter values and read
error messages and service settings.
The control panel consists of display 1and the function keys described below. The display 1
consists of a two-line alpha-numerical LCD display with 16 symbols per line. The special
symbols 2, 3, and texts 4show the respective status of the function keys and the operating
status of the machine.
The control panels switches on all LCD-segments and the horn automatically for a short time
during the power-on phase, after which the lettering PFAFF appears on the display, until the
higher ranking control unit sends commands to the control panel.
7.07.01 Screen displays
●Activated functions are displayed with a triangular marking 2below 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 the status of the machine, see also Chapter 10 Sewing.
●During the parameter input the selected parameter number with the corresponding value is
displayed, see Chapter 13.12 Parameter settings.
●During the seam program input the inputs are carried out in relevant input menus, see
Chapter 11.01 Seam program input.
7.07.02 Function keys
The function keys described below are used basically to switch machine functions on and off.
If a corresponding value has to be set for the activated function, this is carried out with the
corresponding +/- key. For example, by pressing and holding the +/- key 5, the numerical
value 6shown above the key is changed slowly to begin with. If the +/- key 5 is held down
longer, the numerical value 6is changed more quickly.
5
1
24 3
6

Controls
7 - 5
Start backtacks
●If this key is pressed, the backtacks at the beginning of the seam (start backtacks) are
switched on or off. The number of forward stitches (A) or reverse stitches (B) for the start
backtacks can be changed by pressing the +/- key underneath. To convert from double
backtack to single backtack set the number of stitches for the corresponding seam section
at zero.
End backtacks
●If this key is pressed, the backtacks at the end of the seam (end backtacks) are switched
on or off. The number of reverse stitches (C) or forward stitches (D) can be changed by
pressing the +/- key underneath. To convert from double backtack to single backtack set
the number of stitches for the corresponding seam section at zero.
Needle position
●If this key is pressed the "needle raised after sewing stop" function is switched on or off.
When the function is switched on, the needle positions at t.d.c. after sewing stops.
Foot position 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 trimming
●If this key is pressed the "foot raised after thread trimming" function is switched on or off.
When the function is switched on, the presser foot is raised after thread trimming.
Thread trimmer
●If this key is pressed the thread trimming function is switched on or off.
Speed
●If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the current seam section is sewn at the speed entered irrespective of the
pedal position.
Reverse sewing
●If this key is pressed the corresponding function is switched on or off. When the function
is switched during programmed sewing, the corresponding seam section is sewn in
reverse.
Manual seam end
●If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the move to the next seam section is not carried out by stitch counting or
sensor, but manually with the use of the pedal (position "-2").

Controls
7 - 6
Programmed stop
●If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the machine stops automatically at the end of a seam section.
Sensor
●If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the move to the next seam section is carried out by sensor.
Stitch counting
●If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the machine moves to the next seam section after sewing the number of
stitches entered.
TE/Speed
●If this key is pressed once while the machine is in the sewing mode, the input menu for
the maximum speed is selected. If no input is made within 5 seconds, the sewing mode
is selected again.
●If 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, the altered
values are stored and the sewing mode is selected.
Scrolling
●If this key is pressed the machine scrolls among the displays (parameters), if more than 4
parameters are directly accessible in the sewing mode.
PM
●If this key is pressed the programmed sewing function is switched on or off. When the
function is switched on, the letters "PM" appear on the display of the control panel. The
parameters related to the program are shown in the alpha-numerical part of the display.
F1
●If this key is pressed the service menu is selected, see Chapter 13.14 Service functions.
F2
No function
F3
●If this key is pressed the adjustment of the light barrier is started, see Chapter 13.10
Adjustment of the transmitted light sensors.
F4
●If this key is pressed, the next bartack is not sewn.