Pfaff 2481-980/30 PLUSLINE Guide

296-12-19 273/002
Adjustment manual in English 05.16
This instruction manual applies to machines
from the serial number 2809 573 and
software version 0307/010 onwards.
ADJUSTMENT MANUAL
2481
-3/01-980/30

Reprinting, reproduction and/or translation of PFAFF instruction
manuals (including parts thereof) is only permitted with our prior
agreement and citation of the source.
PFAFF Industriesysteme
und Maschinen GmbH
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern

Table of Contents
Contents ..................................................................................Page
15 Adjustment ........................................................................................................................... 5
15.01 Notes on adjustment ............................................................................................................. 5
15.02 Tools, gauges and other accessories .................................................................................... 5
15.03 Abbreviations ......................................................................................................................... 5
15.04 Explanation of symbols.......................................................................................................... 5
15.05 Checking and adjustment aid................................................................................................. 6
15.06 Adjusting basic machine ........................................................................................................ 7
15.06.01 Machine drive home position ................................................................................................ 7
15.06.02 Pre-calibrating the needle height ........................................................................................... 8
15.06.03 Bottom transporter zero position........................................................................................... 9
15.06.04 Needle transport zero position............................................................................................. 10
15.06.05 Bottom transporter sliding movement................................................................................. 11
15.06.06 Needle transport sliding motion........................................................................................... 12
15.06.07 Bottom transporter lifting movement .................................................................................. 13
15.06.08 Bottom transporter height / position in stitch platen cutout ................................................ 14
15.06.09 Needle in needle hole centre............................................................................................... 15
15.06.10 Hook shaft bearing and spur gear clearance........................................................................ 16
15.06.11 Hook lubrication .................................................................................................................. 17
15.06.12 Needle bar rise, hook-to-needle clearance, needle height and bobbin case position finger 18
15.06.13 Thread check spring and slack thread regulator .................................................................. 20
15.06.14 Passage under sewing foot ................................................................................................. 21
15.06.15 Adjusting the feed regulator zero position........................................................................... 22
15.06.16 Stitch length adjustment forwards and backwards ............................................................. 23
15.06.17 Bobbin winder...................................................................................................................... 24
15.06.18 Mechanical stitch length limitation ...................................................................................... 25
15.06.19 Sewing foot pressure .......................................................................................................... 26
15.07 Adjusting thread trimmer -900/24........................................................................................ 27
15.07.01 Pre-calibrating solenoid setting / control cam ...................................................................... 27
15.07.02 Aligning thread catcher laterally........................................................................................... 28
15.07.03 Knife position ....................................................................................................................... 29
15.07.04 Front turning point of thread catcher ................................................................................... 30
15.07.05 Manual cutting control ......................................................................................................... 31
15.07.06 Needle thread tension release............................................................................................. 32
15.07.07 Re-calibrating control cam ................................................................................................... 33
15.08 Aligning transmitted light transmitter .................................................................................. 34
15.09 Adjusting transmitted light sensors ..................................................................................... 35

Table of Contents
Contents ..................................................................................Page
15.10 Functional check of bobbin thread monitor ......................................................................... 36
15.11 Adjusting electric edge guide .............................................................................................. 37
15.12 Parameter settings .............................................................................................................. 38
15.12.01 Overview of parameter functions ........................................................................................ 38
15.12.02 Example of a parameter entry ............................................................................................. 39
15.12.03 Selecting user level.............................................................................................................. 40
15.12.04 List of parameters................................................................................................................ 41
15.13 Error messages and description .......................................................................................... 47
15.14 Sewing motor errors............................................................................................................ 48
15.15 Service menu....................................................................................................................... 49
15.16 Internet update of machine software .................................................................................. 50
16 Circuit Diagrams ................................................................................................................ 51
16.01 Block diagram of PFAFF 2481 with control unit P322 ED.................................................... 51
16.02 Circuit diagrams ................................................................................................................... 52
16.03 Plug connections ................................................................................................................. 57

Adjustment
5
15 Adjustment
Observe and comply with all instructions in the operating manual’s chapter 1
Safety! In particular make sure that all safety covers are installed again correct-
ly after making adjustments, see chapter 1.06 Operating manual hazard infor-
mation!
Unless otherwise stated, the machine must be disconnected from the power
supply before all adjustment work!
Risk of injury due to accidental machine start-up!
No screw clamp may be fastened to the needle bar with the
PFAFF 2481-980/30!
This may damage the special needle bar coating.
15.01 Notes on adjustment
All adjustments in this manual are based on a fully assembled machine and may only be car-
ried out by technical staff trained for this purpose. Machine covers, which have to be re-
moved 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 ma-
chines that have to be completely adjusted. Both the preceding and following chapters must
be observed if only specific individual work steps are carried out. Screws and nuts indicated
in brackets ( ) are fastenings for machine parts, which must be loosened before any adjust-
ment and tightened again afterwards.
15.02 Tools, gauges and other accessories
O1set of screwdrivers with knife widths of 2to 10 mm
O1set of wrenches with jaw widths from 7to 14 mm
O1set of Allen keys of 1.5to 6mm
O1feed dog setting gauge (order no. 61-111 639-71)
O1setting gauge (order no. 61-111 639-73)
O1adjustment pin (5mm diameter), order no. 13-033 346-05
O1metal ruler (order no. 08-880 218-00)
OThread and testing material
15.03 Abbreviations
t.d.c. = top dead centre
b.d.c. = bottom dead centre
15.04 Explanation of symbols
Activities to be performed or important information in this adjustment manual are empha-
sised by symbols. The symbols used have the following meaning:
Note, information
Maintenance, repairs, adjustment, service work
(only to be carried out by technical staff)

Adjustment
6
15.05 Checking and adjustment aid
The adjustment pin 1(order no. 13-033 346-05) and the adjustment gauge 3
(order no. 61-111 639-73) if necessary can be used to fix the required positions
during the adjustment.
Needle bar positioned 1.8 mm after b.d.c.
OTurn the handwheel until the needle bar is approximately in the required position.
OPush the adjustment pin 1into the hole.
OMove the handwheel gently back and forwards until the adjustment pin 1engages in the
crank 2.
Needle bar positioned 0.6 mm after b.d.c.
OMove the needle bar approximately into the required position.
OFit the adjustment gauge 3to the studs 4and 5ensuring the right side (for a 30 mm or
36 mm needle bar stroke).
Fig. 15 - 01
1
2
4
5
3

Adjustment
7
15.06 Adjusting basic machine
15.06.01 Machine drive home position
This setting is only required if the toothed belt 2has been dismantled.
Rule
The markings 3 and 4 should be aligned if the needle bar is positioned 0.6 mm after b.d.c.
Fig. 15 - 02
OMove the needle bar to 0.6mm after b.d.c.
OTurn the toothed belt wheel 1according to the rule and slide on the toothed belt 2.
Make sure that the shaft flange, shock absorber and motor flange are in the
right position when installing the motor!
The second toothed belt wheel screw 1is a balance cup screw
3
41
2

Adjustment
8
15.06.02 Pre-calibrating the needle height
Rule
The marking on the needle bar 1 should be flush with the lower edge of the needle bar
frame 3 when the needle bar is positioned 1.8 mm after b.d.c.
Fig. 15 - 03
OMove the needle bar to 1.8mm after b.d.c. and fix with the adjustment pin, see chapter
15.05 Checking and adjustment aid.
OAdjust the needle bar 1( screw 2) without twisting according to the rule.
2
1
3

Adjustment
9
15.06.03 Bottom transporter zero position
Rule
At stitch length regulation “0”
1. The marking on the toothed segment 1 should be in the centre of the shaft of the gear
wheel 3,
2. The cranks 4 and 6 should be aligned and the bottom transporter should not move
when turning the handwheel.
Fig. 15 - 04
OSwitch the machine on.
OSet the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
OMake sure that parameter 834 is set to “0”, see chapter 15.11 Parameter settings.
OAdjust the toothed segment 1( screws 2) without the gear wheel 3according to rule 1.
OTurn the crank 4( screws 5) according to rule 2.
OSwitch the machine off.
6
5
4
1
2
2
3
0.0

Adjustment
10
15.06.04 Needle transport zero position
Rule
The needle bar should not move when turning the handwheel with stitch length regulation
“0”.
OSwitch the machine on.
OSet the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
OMake sure that parameter 834 is set to “0”, see chapter 15.11 Parameter settings.
OTurn the crank 1( screw 2) according to the rule.
OSwitch the machine off.
Fig. 15 - 05
2
1
0.0

Adjustment
11
15.06.05 Bottom transporter sliding movement
Rule
When the needle bar is positioned 0.6 mm after b.d.c., the bottom transporter should not
move when the shaft 3 is rotated back and forth.
Fig. 15 - 06
OMove the needle bar to a position 0.6mm after b.d.c.
OTurn the eccentric 1( screws 2), without moving it sideways according to the rule.
3
1
2
2

Adjustment
12
15.06.06 Needle transport sliding motion
Rule
When the needle bar is positioned 0.6 mm after b.d.c., the needle should not move when
the shaft 4 is rotated back and forth.
Fig. 15 - 07
OMove the needle bar to a position 0.6mm after b.d.c.
OTurn the eccentric 1( screws 2) until the adjustment pin 3engages according to the
rule.
1
2
3
3
2

Adjustment
13
15.06.07 Bottom transporter lifting movement
Rule
When the needle bar is positioned 0.6 mm after b.d.c. and with stitch length regulation “0”,
1. the bottom transporter should be in its upper turning point and
2. the control cam 3 should abut the feed lifting eccentric 1.
OSwitch the machine on.
OSet the stitch length to “0” and move the needle bar to a position 0.6mm after b.d.c.
OTurn the handwheel until the feed regulator motor responds.
OTurn the eccentric 1( screws 2) according to rule 1.
OAdjust the control cam 3( screws 4) according to rule 2 and switch off the machine.
0.0
Fig. 15 - 08
1
2
4
3

Adjustment
14
15.06.08 Bottom transporter height / position in stitch platen cutout
Rule
In its upper turning point and with stitch length regulation “0” the bottom transporter 1 should
1. be in the centre of the stitch platen cutout looking from the side and in the feeding di-
rection and
2. abut the feed dog setting gauge 2 along its entire length.
6
7
3
5
4
Fig. 15 - 09
2
1
OTurn on machine and set the stitch length to “0”.
OTurn the handwheel until the feed regulator motor responds.
OMove the bottom transporter 1 to its upper turning point.
ORaise the sewing foot, move the feed dog setting gauge 2 over the stitch platen cut-
out with the arrow in the sewing direction and the front edge flush with the stitch platen
edge and lower the sewing foot.
OAdjust the bottom transporter carrier 3 ( screw 4 ) according to rule 1.
OLoosen the screws 5and 6
OAdjust the bottom transporter carrier 3 and eccentric 7 according to rule 2.
OTighten the screws 5and 6
OSwitch the machine off.
0.0

Adjustment
15
15.06.09 Needle in needle hole centre
Rule
The needle should pierce the centre of the needle hole exactly.
Fig. 15 - 10
2
1
3
OSwitch the machine on.
OSet the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
OInsert the needle into the needle hole by turning the handwheel.
OAdjust the needle bar frame 1( screws 2and 3) according to the rule.
OSwitch the machine off.
0.0

Adjustment
16
15.06.10 Hook shaft bearing and spur gear clearance
Rule
1. The front edge of the hook shaft 5 should be 14.5 mm away from the needle midpoint;
the groove in the hook shaft bearing 1 (see arrow) should be parallel to the bed plate
and point away from the sewing direction.
2. There should be minimal yet noticeable play between the plastic pinion 3and the steel
wheel 4. This play should be approximately the same for a 360° turn.
3. The steel wheel 4 should align with the plastic pinion 3.
3
Fig. 15 - 11
4
2
14.5 mm
OAlign the hook shaft bearing 1( screw 2) according to rule 1.
OSet the steel wheel 4with the eccentric bush of the hook shaft bearing 1according to
rule 2and tighten the screw 2.
OAdjust the plastic pinion 3( screws 6) according to rule 3 and tighten the screws 6.
6
1

Adjustment
17
15.06.11 Hook lubrication
Rule
1. The centrifugal disc 1 should be 1.5 mm in front of the oil distributor ring 3.
2. A light oil strip should appear on a paper strip held over the needle plate cutout after
approximately 10 seconds when the machine is running at full speed.
Fig. 15 - 12
The setting is only required if the wick is replaced.
Make sure that the new wick is impregnated with oil when replacing the wick.
OAdjust the centrifugal disc 1( screw 2) according to rule 1.
OCheck rule 2 and adjust the centrifugal disc 1if necessary.
1.5 mm
2
1
3

Adjustment
18
15.06.12 Needle bar rise, hook-to-needle clearance, needle height and bobbin case
position finger
Rule
When the needle is positioned 1.8 mm after b.d.c.,
1. The tip of the hook 6 should be at the needle midpoint and be a distance of 0.05 mm -
0.1 mm from the fillet of the needle and
2. The upper edge of the eye of the needle should be 0.8 mm under the tip of the hook.
3. There should be a clearance of 0.5 mm between the lug of the bobbin case position
finger 4and the base of the stop groove.
Fig. 15 - 13
0.05 - 0.1 mm
6
10.5 mm
4
2
3
0.8 mm
5
4
OSwitch the machine on.
OSet the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
OSwitch the machine off.
0.0

Adjustment
19
OUse the adjustment pin to move the needle bar to 1.8mm after b.d.c.
OAdjust the hook according to rule 1
OTighten the screws 1.
OAdjust the needle bar 2( screw 3), without twisting according to rule 2.
OAlign the bobbin case position finger 4( screw 5) according to rule 3.

Adjustment
20
15.06.13 Thread check spring and slack thread regulator
Rule
1. The movement of the thread check spring should be finished when the needle point
punctures the material (spring deflection: approx. 7 mm).
2. The thread check spring should have moved approx. 1 mm when forming the maxi-
mum thread loop while passing the thread around the hook.
Fig. 15 - 14
OTurn the thread tension 1( screw 2) according to rule 1.
OAdjust the slack thread regulator 3( screws 4) according to rule 2.
It may be necessary to deviate from the specified spring deflection for reasons
relating to the sewing technology.
Adjust the slack thread regulator 3( screw 4) by “ + “ (= more thread) or “ - “
(= less thread).
7 mm
4
3
-
1
+
2