Pfaff 3822-2/42 User manual

Instruction Manual
296-12-18 592/002
Betriebsanleitung engl. 01.06
3822
This instruction manual applies to machines from the
following serial numbers onwards:
# 2719930
-2/42
-2/44

This instruction manual applies to all versions and subclasses listed under
"Specifications".
Reprinting, copying or translation of PFAFF instruction manuals, whether in whole or in part, is
not permitted without our prior permission and not without written indication of the source.
PFAFF Industrie Maschinen AG
Postfach 3020
D-67653 Kaiserslautern
Königstr. 154
D-67655 Kaiserslautern

Index
Contents ................................................................................. Chapter - Page
1Safety ........................................................................................................................... 1 - 1
1.01 Directives ...................................................................................................................... 1 - 1
1.02 General notes on safety ................................................................................................ 1 - 1
1.03 Safety symbols ............................................................................................................. 1 -2
1.04 Important points for the user ........................................................................................ 1 - 2
1.05 Operating and specialist personnel ............................................................................... 1 - 3
1.05.01 Operating personnel ...................................................................................................... 1- 3
1.05.02 Specialist personnel ......................................................................................................1- 3
1.06 Danger .......................................................................................................................... 1 - 4
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 Pedal ............................................................................................................................. 7 - 1
7.03 Presser bar lifter ............................................................................................................ 7 - 2
7.04 Knee Switch ..................................................................................................................7- 2
7.05 Left knee switch ........................................................................................................... 7 -3
7.06 Control panel ................................................................................................................. 7 - 3
7.07 Keyboard ....................................................................................................................... 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 Tightening the V-belt .....................................................................................................8- 2
8.01.03 Fitting the top V-belt guard ............................................................................................ 8 -2
8.01.04 Mounting the bottom V-belt guard ................................................................................ 8 - 3
8.01.05 Fitting the synchronizer ................................................................................................. 8- 3
8.01.06 Connecting the plug-in connections and earth cables ................................................... 8 - 4
8.01.07 Fitting the reel stand ..................................................................................................... 8 - 5
8.02 Commissioning ............................................................................................................. 8 - 6
8.03 Switching the machine on/off ....................................................................................... 8 - 6

Index
Contents ................................................................................. Chapter - Page
9Preparation .................................................................................................................. 9 - 1
9.01 Inserting the needle ...................................................................................................... 9 - 1
9.02 Winding the bobbin thread, adjusting the thread tension .............................................. 9 - 2
9.03 Removing/inserting the bobbin case ............................................................................. 9 - 3
9.04 Threading the bobbin case, adjusting the thread tension .............................................. 9 - 3
9.05 Oberfaden einfädeln ...................................................................................................... 9 - 4
9.06 Oberfadenspannung regulieren ..................................................................................... 9 - 4
9.07 Selecting the program number ...................................................................................... 9 - 5
9.08 Inputting fullness...........................................................................................................9- 6
9.09 Entering / altering the code number .............................................................................. 9 - 7
9.10 Adjusting the control panel ............................................................................................ 9 - 9
10 Sewing ....................................................................................................................... 10 -1
10.01 Manual sewing ............................................................................................................ 10 - 1
10.01.01 Entering the seam start and seam end in manual sewing mode................................. 10 - 3
10.01.02 Selecting the material type ......................................................................................... 10 - 4
10.02 Sewing with fixed programs ....................................................................................... 10 - 5
10.03 Programmed sewing ................................................................................................... 10 - 7
10.03.01 Program interruption ................................................................................................... 10 -9
10.04 Error messages ........................................................................................................... 10 - 9
11 Input ...........................................................................................................................11- 1
11.01 Seam program input ................................................................................................... 11 - 2
11.01.01 Basic settings for seam program input ....................................................................... 11 - 2
11.01.02 Seam program input with the "Creating/adjusting a program" function ....................... 11 - 4
11.01.03 Entering the actual and required length of the seam section ...................................... 11 - 6
11.01.04 Seam program input with the "Creating/adjusting a program" function ....................... 11 - 7
11.01.05 Entering the functions at the beginning of the seam during seam programming ........ 11 - 9
11.01.06 Entering the functions at the end of seam section during seam programming ........... 11 - 10
11.02 Examples of how to create a seam program .............................................................. 11 - 12
11.02.01 Example of a seam program input with the "creating/adjusting a program" ....................
11.02.02 Example of a seam program input using the "teach-in" function .................................. 11 - 18
11.03 Seam program administration ..................................................................................... 11 - 22
12Care and Maintenance .............................................................................................. 12 - 1
12.01 Cleaning the machine .................................................................................................. 12 - 1
12.02 Oil level of the machine .............................................................................................. 12 - 2
12.03 Cleaning/lubricating the top feed joints ....................................................................... 12 - 2
12.04 Checking/adjusting the air pressure ............................................................................ 12 - 3
12.05 Cleaning the air filter of the air-filter/lubricator............................................................. 12 - 3
13 Adjustment ................................................................................................................ 13 - 1
13.01 Notes on adjustment................................................................................................... 13 - 1
13.02 Tools, gauges and other accessories .......................................................................... 13 - 1
13.03 Abbreviations .............................................................................................................. 13 -1

Index
Contents ................................................................................. Chapter - Page
13.04 Control and adjustment aids ....................................................................................... 13 - 2
13.05 Adjusting the basic machine ....................................................................................... 13 - 3
13.05.01 Basic position of the machine ..................................................................................... 13 - 3
13.05.02 Preliminary adjustment of the needle height ............................................................... 13 - 4
13.05.03 Needle in needle-hole centre....................................................................................... 13 - 5
13.05.04 Neutral position of the bottom feed dog ..................................................................... 13 - 6
13.05.05 Feeding motion of the bottom feed dog ..................................................................... 13 - 7
13.05.06 Lifting motion of the bottom feed dog ........................................................................ 13 - 8
13.05.07 Height of the bottom feed dog .................................................................................... 13 - 9
13.05.08 Clearance between presser foot and needle plate ...................................................... 13 - 10
13.05.09 Stop in relation to the presser foot .............................................................................. 13 - 11
13.05.10 Top feed driving and connecting lever ......................................................................... 13 - 12
13.05.11 Neutral position of the top feed dog ............................................................................ 13 - 13
13.05.12 Feeding motion of the top feed dog ............................................................................ 13 - 14
13.05.13 Front linkage rod to top feed drive .............................................................................. 13 - 15
13.05.14 Top feed stroke ........................................................................................................... 13 - 16
13.05.15 Lifting motion of the top feed dog ............................................................................... 13 - 17
13.05.16 Stitch length adjustment ............................................................................................. 13 - 18
13.05.17 Stitch length limitation ................................................................................................ 13 -19
13.05.18 Basic setting of the differential adjustment device ..................................................... 13 - 20
13.05.19 Eccentric hook shaft bearing and hook-to-needle clearance ........................................ 13 - 21
13.05.20 Needle bar rise, readjustment of the needle height and bobbin case position stop .... 13 - 22
13.05.21 Bobbin opener height .................................................................................................. 13 - 23
13.05.22 Adjustment of the bobbin opener ................................................................................ 13 - 24
13.05.23 Bobbin case opener .................................................................................................... 13 - 25
13.05.24 Needle thread tension release .................................................................................... 13 - 26
13.05.25 Thread check spring .................................................................................................... 13 - 27
13.05.26 Bobbin winder ............................................................................................................. 13 - 28
13.05.27 Position of the top feed dog in relation to the sewing foot.......................................... 13 - 29
13.05.28 Top feed dog and sewing foot pressure ...................................................................... 13 - 30
13.05.29 Stitch condensation .................................................................................................... 13 - 31
13.06 Adjusting the thread trimmer ...................................................................................... 13 - 32
13.06.01 Pre-adjusting the control cam ..................................................................................... 13 - 32
13.06.02 Roller lever .................................................................................................................. 13 - 33
13.06.03 Pawl ............................................................................................................................ 13 - 34
13.06.04 Engaging solenoid ....................................................................................................... 13 -35
13.06.05 Release lever ..............................................................................................................13-36
13.06.06 Engaging lever ............................................................................................................ 13 - 37
13.06.07 Lateral adjusting of the thread catcher ........................................................................ 13 - 38
13.06.08 Front reversal point of the thread catcher ................................................................... 13 - 39
13.06.09 Re-adjusting the control cam ...................................................................................... 13 - 40
13.06.10 Retaining spring .......................................................................................................... 13 - 41
13.06.11 Knife to needle clearance ............................................................................................ 13 - 42
13.06.12 Manual trimming control ............................................................................................. 13 - 43

Index
Contents ................................................................................. Chapter - Page
13.06.13 Tension release of needle thread ................................................................................ 13 - 44
13.06.14 Attaching and removing the thread trimming unit ....................................................... 13 - 45
13.07 Adjusting the edge trimming device on the PFAFF 3822-2/42 .................................... 13 - 46
13.07.01 Knife stroke ................................................................................................................. 13 - 46
13.07.02 Neutral position of the knife stroke ............................................................................. 13 - 47
13.07.03 Knife height ................................................................................................................. 13 - 48
13.07.04 Aligning the knife ........................................................................................................ 13 - 49
13.07.05 Adjusting the stop eccentric ....................................................................................... 13 - 50
13.08 Adjusting the feathered trimming device on the PFAFF 3822-2/44 ............................. 13 - 51
13.08.01 Top stroke motion of the knife .................................................................................... 13 - 51
13.08.02 Cutting angle of the front knife ................................................................................... 13 - 52
13.08.03 Cutting position of the front knife ............................................................................... 13 - 53
13.08.04 Cutting pressure of the front knife .............................................................................. 13 - 54
13.08.05 Knife stroke zero point ................................................................................................ 13 - 55
13.08.06 Side position of the back knife in relation to the hook knife ........................................ 13 - 56
13.08.07 Cutting angle of the back knife in relation to the hook knife ........................................ 13 - 57
13.08.08 Cutting pressure between the back knife and the hook knife ..................................... 13 - 58
13.08.09 Cutting depth of the back knife ................................................................................... 13 - 59
13.08.10 Cutting depth of the front knife ................................................................................... 13 - 60
13.08.11 Trimming margin ......................................................................................................... 13 -61
13.08.12 Sensor control of the hook knife ................................................................................. 13 - 62
13.08.13 Air-blast tube for separating the material plies ............................................................ 13 - 63
13.08.14 Air-blast tube for cutting waste ................................................................................... 13 - 64
13.09 Parameter settings ...................................................................................................... 13 - 65
13.09.01 Overview of the parameter functions ......................................................................... 13 - 65
13.07.02 Example of a parameter input ..................................................................................... 13 - 66
13.09.03 List of parameters ....................................................................................................... 13-67
13.10 Sewing motor errors ................................................................................................... 13 - 69
13.11 Explanation of the error messages.............................................................................. 13 - 70
13.12 Table of inputs ............................................................................................................ 13 -71
13.13 Table of outputs .......................................................................................................... 13 - 71
13.14 Service menu .............................................................................................................. 13 - 72
13.15 Carry out a cold start ................................................................................................... 13 - 73
13.16 Internet update of the machine software .................................................................... 13 - 74
14 Wearing parts ............................................................................................................ 14 - 1
15 Circuit diagrams ........................................................................................................ 15 - 2

1 - 1
Safety
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 disconnected 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
disconnected 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!

1 - 2
Safety
●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 ac-
cept 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!
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.
I
Caution
Do not operate without finger guard and safety devices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.

1 - 3
Safety
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 mach-
ine and for removing any disturbances in the sewing area.
The operating staff are obliged to observe the following points, and must:
●always observe the notes on safety in this instruction manual!
●avoid using any working methods which adversely effect the safety of the machine!
●avoid wearing loose-fitting clothing or jewelry such as necklaces or rings!
●also ensure that only authorized persons are allowed near the danger area of the
machine!
●immediately report to the user any changes to the machine that may affect its safety!
1.05.02 Technical staff
Technical staff are persons who have been trained in electrical engineering, electronics,
pneumatics and mechanical engineering. They are responsible for lubricating, servicing,
repairing and adjusting the machine.
The technical staff are obliged to observe the following points, and must:
●always observe the notes on safety in this instruction manual!
●switch off the on/off switch before carrying out adjustment and repair work and ensure it
cannot be switched on again unintentionally!
●never work on parts or equipment still connected to the power supply! Exceptions to this
are only permissible according to regulations EN 50110;
●disconnected the machine from the compressed air supply when carrying out
maintenance or repair work on pneumatic equipment!
Exceptions to this are only permissible for function checks;
●replace all safety covers after carrying out maintenance or repair work!

1 - 4
Safety
1.06 Danger warnings
A working area of 1 m must be kept free both in front of and behind the mach-
ine, so that easy access is possible at all times.
Never put your hands in the sewing area during sewing!
Danger of injury by the needle!
While setting or adjusting the machine do not leave any objects on the table nor
in the needle plate area! Objects may be trapped or slung out of the mach-ine!
Do not operate the machine without take-up lever guard 1!
Danger of injury by movement of take-up lever!
Do not operate the machine without finger guard 2!
Danger of injury by the needle!
Do not operate the machine without belt guards 3and 4!
Danger of injury by rotating drive belt!
Do not operate the machine without tilt lock 5!
Danger of crushing between the sewing head and table top!
Do not place hands in the cutting area between needle plate and knife!
Danger of injury from the cutting motion of the knife!
Fig. 1 - 01
1
3
2
4
54-66a
5

Proper use
2 - 1
2 Proper use
The PFAFF 3822-2/42, -2/44 are integrated workplaces for run-stitching and trimming the
edges of jackets, coats and costumes.
Machine type Equipment
PFAFF 3822-2/42 Edge trimmer and touch-screen control panel
PFAFF 3822-2/44 Edge trimmer for feathered trimming and touch-screen control
panel
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
Max. speed
3822-2/42 ...................................................................................................... 4000 s.p.m.-1◆
3822-2/44 ...................................................................................................... 3200 s.p.m.-1◆
Trimming margin
3822-1/32; -1/42 .............................................................................................. 5, 6 or 7 mm
3822-1/34; -1/44 ............................................................................................. 6.5 x 3.5 mm
Stitch length
With fullness setting ”0”: ....................................................................................... 2.7 mm
With stitch condensation: ....................................................................................... 1.6 mm
Needle system: ........................................................................................................ 134 KK
Needle size (Nm) in 1/100 mm: ....................................................................................... 80
Presser foot clearance: .............................................................................................. 7 mm
Connection data:
Operating voltage: ............................................230 V ± 10%, 50/60 Hz, alternating voltage
Max. power: ............................................................................................................. 400 VA
Fuse protection: ............................................................................................ 1 x 16 A, inert
Working air pressure: .................................................................................................. 6 bar
Air consumption (on the Pfaff 3801-3/07 and the PFAFF 3801-3/071): ......................... 40 l/work cycle
Noise data:
Emission sound pressure level at the workplace with
a sewing speed of 2400 spm: .................................................................... LpA < 75 dB(A) ■
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)
Machine dimensions:
Length: .................................................................................................... approx. 1365 mm
Width: ....................................................................................................... approx. 950 mm
Height(with reel stand): ........................................................................... approx. 1700 mm
Net weight: .................................................................................................. approx. 140 kg
▲Subject to technical alterations
◆Depending on the material, work 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 mat-
erials.
The electrical equipment comprises plastic materials and copper.
●The machine is to be disposed of according to the locally valid pollution control regula-
tions; 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 this machine comprise paper, cardboard and VCE fibre. Proper dis-
posal 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)

7 - 1
Controls
7.02 Pedal
0= Neutral position
+1 = Lower presser foot
+2 = Sewing
-1 = Raise presser foot
-2 = Trim threads
Fig. 7 - 02
0
-1 -2
+1
+2
Fig. 7 - 01
7 Controls
7.01 Main switch
●The machine is switched on or off by
turning main switch 1.
1

Controls
7 - 2
49-021
7.03 Presser bar lifter
●The presser foot is raised by turning
lever 1.
Fig. 7 - 03
1
7.04 Knee Switch
Manual sewing:
●By operating knee switch 1 it is possible
to alternate between two pre-set
amounts of fullness.
Programmed sewing:
●By operating knee switch 1the amounts
of fullness are changed according to the
program selected.
Fig. 7 - 04
1

7 - 3
Controls
49-09
7.05 Left knee switch
●By operating knee switch 11
11
1, the knife for
feathered trimming can be switched on
or off.
1
Fig. 7 - 05
7.06 Control panel
The current operating conditions are
displayed on control panel 1. Operation
takes place in a constant dialogue between
the control unit and the operator. For this
purpose, depending on the operating
condition of the machine, different symbols
and/or texts are displayed. If the symbols or
texts are framed, these show functions
which can be selected by pressing the
appropriate position on the monitor. By
pressing the corresponding function this is
carried out or switched on or off
immediately, or a further menu appears, e.g.
for entering a value. Activated functions are
shown with inverted symbols. Unframed
symbols or texts are only used for display
purposes and cannot be selected by
pressing.
Fig. 7 - 06
117
-
001
1

Controls
7 - 4
7.07 Keyboard
The keyboard 1is used for the quick operation of the machine during sewing and when
selecting the fullness. With the corresponding LED of the 20 keys, active key functions are
displayed (Function active = LED lit).
Stitch condensation
The stitch condensation is
switched on and off by pressing a
key. (When programming the
seam: Sew the seam section with
condensed stitches)
Reverse sewing
Press the key to switch on the
reverse sewing function.
(For seam programming: Sew
seam section in reverse)
Edge trimming device
The edge trimming device is
switched on and off by pressing a
key.
Hook knife
●The device for feathered trimming is switched on and off by pressing a key (same
function as left knee switch).
Bartack inversion
●Programmed bartacks can be suppressed by pressing a key.
Number keys (0 – 12)
●The previously allocated amount of fullness is called up by pressing a key.
●When two neighbouring number keys are pressed simultaneously, the corresponding
average value is selected.
The keyboard is pre-set with the following values:
Key 0: No fullness will be applied
Key 6: Selects the max. fullness for the bottom material ply.
Key 12: Selects the max. fullness for the top material ply.
Key 0 + 1: Selects the min. fullness for the bottom material ply.
Key 0 + 7: Selects the min. fullness for the top material ply.
The basic setting is set e.g. after a cold start, see Chapter 13.15 Carry out a
cold start.
Correction value + / correction value –
●By pressing a key, the value for the selected fullness is increased or reduced in 2 steps.
Fig. 7 - 07
11
1

8 - 1
Mounting and commissioning the machine
117
-
002
Fig. 8 - 01
11
2
8 Mounting and commissioning the machine
The machine must only be mounted and commissioned by qualified personnel!
All relevant safety regulations are to be observed!
If the machine is delivered without a table, you must make sure that the frame
and the table top which you intend to use can hold the weight of the machine
and the motor. It must be ensured that the supporting structure is sufficiently
sturdy, including during all sewing operations.
8.01 Mounting
The necessary supply connections for the electrical and pneumatic systems must be
available at the machine’s location, see Chapter 3 Specifications.
There must be a stable and horizontal surface and adequate lighting at the machine’s
location.
The method of packaging used requires that the table top be lowered for
transport. The following is a description of how to adjust the height of the
table top.
8.01.01 Adjusting the table-top height
●Loosen screws 1and 2and set the desired table-top height.
●Tighten screws 1well.
●Adjust the position of the pedal so that you can operate it comfortably and tighten
screw 2.