Pfaff 421E1 User manual

Instruction Manual
296-12-18395/002
Betriebsanleitung engl. 04.98
421E1
1421E1
This instruction manual applies to machines from the
following serial numbers onwards:
PFAFF 421 E1 # 2546845
PFAFF 1421 E1 # 2541850

The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or in
part, is only permitted with our previous authorisation and with written reference to the
source.
G.M. PFAFF KAISERSLAUTERN
INDUSTRIEMASCHINEN AG
Postfach 3020
D-67653 Kaiserslautern
Königstr. 154
D-67655 Kaiserslautern
Editing / Illustrations
HAAS-Publikationen GmbH
D-53840 Troisdorf
This Instruction Manual is valid for all models and subclasses listed in the
chapter "Specifications".

Contents
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
3.01 PFAFF 421E1 ............................................................................................................. 3 - 1
3.02 Needle and thread PFAFF 421E1 ............................................................................... 3 - 2
3.03 Needle and thread PFAFF 421E1 ............................................................................... 3 - 2
3.04 Possible models......................................................................................................... 3 - 2
4Disposal of the machine .......................................................................................... 4 - 1
5Transport, packaging and storage .......................................................................... 5 - 1
5.01 Transport to the customer ......................................................................................... 5 - 1
5.02 Transport within the customer's premises ................................................................ 5 - 1
5.03 Disposal of the packaging .......................................................................................... 5 - 1
5.04 Storage ......................................................................................................................5- 1
6Explanation of the symbols..................................................................................... 6 - 1
7Controls .................................................................................................................... 7 - 1
7.01 On/off switch ............................................................................................................. 7 - 1
7.02 Keys on the machine head......................................................................................... 7 - 1
7.03 Pedal .......................................................................................................................... 7 - 2
7.04 Knee switch ............................................................................................................... 7 - 2
7.05 Knee lever.................................................................................................................. 7- 3
7.06 Lever for lifting the roller presser............................................................................... 7 - 3
7.07 Control panel.............................................................................................................. 7 -4
7.07.01 Display ....................................................................................................................... 7 - 4
7.07.02 Operation-mode keys................................................................................................. 7 - 5
7.07.03 Function keys.............................................................................................................7- 5
7.07.04 Number keys ............................................................................................................. 7 -5
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 tilt lock ...................................................................................................... 8 - 2
8.01.03 Adjusting the V-belt tension ....................................................................................... 8 - 2
8.01.04 Mounting the upper V-belt guard ............................................................................... 8 - 3
8.01.05 Mounting the lower V-belt guard ............................................................................... 8 - 3
8.01.06 Mounting the synchronizer ........................................................................................ 8 - 4

Contents
Contents ...............................................................................Chapter - Page
8.01.07 Mounting the spool holder ......................................................................................... 8 - 4
8.02 Commissioning the machine...................................................................................... 8 - 5
8.03 Turning the machine on/off........................................................................................ 8 - 5
9Preparation ............................................................................................................... 9 - 1
9.01 Inserting the needle ................................................................................................... 9 - 1
9.02 Winding the bobbin thread, adjusting the thread pre-tension .................................... 9 - 2
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 Adjusting the stitch length ......................................................................................... 9 - 5
9.07 Selecting a language .................................................................................................. 9 - 6
10 Sewing.................................................................................................................... 10 - 1
10.01 Manual sewing ........................................................................................................ 10 - 1
10.02 Sewing with the fixed programs .............................................................................. 10 - 2
10.03 Programmed sewing................................................................................................ 10 - 4
10.04 Decorative seams .................................................................................................... 10 - 5
10.05 Program interruption ................................................................................................ 10 - 5
10.06 Error messages........................................................................................................ 10 - 5
11 Programming ......................................................................................................... 11 - 1
11.01 Symbols in the status bar ........................................................................................ 11 - 1
11.02 Symbols in the text and graphic fields ..................................................................... 11 - 2
11.03 Symbols in the pictogram bar .................................................................................. 11 - 3
11.04 Summary of the functions in SEWING mode .......................................................... 11 - 4
11.05 Summary of the functions in INPUT mode .............................................................. 11 - 5
11.06 Summary of the functions in Teach In ..................................................................... 11 - 6
11.07 Summary of the functions in program administration .............................................. 11 - 7
11.08 Summary of the functions in the input menu .......................................................... 11 - 7
11.09 Summary of the service functions ........................................................................... 11 - 8
11.10 Selection of functions from menu levels ................................................................. 11 - 8
11.11 Creating seam programs.......................................................................................... 11 -11
11.11.01 Altering fixed programs............................................................................................ 11 -11
11.11.02 Programming ........................................................................................................... 11 -12
11.11.03 Teach In ................................................................................................................... 11 -14
11.12 Bartack menu........................................................................................................... 11 -16
11.13 Zielstichmenü........................................................................................................... 11 -17
11.14 Seam section end .................................................................................................... 11 -18
11.15 Programming examples ........................................................................................... 11 -19
11.15.01 Example of seam programming ............................................................................... 11 -19
11.15.02 Example for programming a decorative seam.......................................................... 11 -29
11.15.03 Example of Teach In programming .......................................................................... 11 -32
12 Care and maintenance........................................................................................... 12 - 1
12.01 Cleaning ................................................................................................................... 12- 1

Contents
Contents...............................................................................Chapter - Page
12.02 Filling the oil reservoir .............................................................................................. 12 - 2
12.03 Lubricating the bevel gears...................................................................................... 12 - 2
12.04 Cleaning the air filter on the control box .................................................................. 12 - 3
13 Adjustment ............................................................................................................. 13 - 1
13.01 Notes on adjusting ................................................................................................... 13 - 1
13.02 Tools, gauges and other accessories for adjusting .................................................. 13 - 1
13.03 Abbreviations ........................................................................................................... 13 - 1
13.04 Adjusting the basic machine................................................................................. 13 - 2
13.04.01 Adjusting the synchronizer....................................................................................... 13 - 2
13.04.02 Positioning the needle in the direction of sewing .................................................... 13 - 4
13.04.03 Setting the machine configuration ........................................................................... 13 - 5
13.04.04 Positioning the needle across the direction of sewing............................................. 13 - 6
13.04.05 Limiting the needle bar frame .................................................................................. 13 - 7
13.04.06 Preadjusting the needle height ................................................................................ 13 - 8
13.04.07 Hook-to-needle clearance, needle rise, needle height and needle guard ................. 13 - 9
13.04.08 Balancing weight...................................................................................................... 13 -11
13.04.09 Bobbin-case-opener eccentric and retaining lug....................................................... 13 - 12
13.04.10 Bobbin case opener position.................................................................................... 13 -13
13.04.11 Feed wheel .............................................................................................................. 13-14
13.04.12 Clearance between roller presser and feed wheel................................................... 13 -15
13.04.13 Roller presser........................................................................................................... 13 -16
13.04.14 Automatic presser-foot lifter .................................................................................... 13 -17
13.04.15 Knee lever................................................................................................................13 -18
13.04.16 Tension release........................................................................................................ 13 -19
13.04.17 Thread check spring................................................................................................. 13 -20
13.04.18 Bobbin winder.......................................................................................................... 13 -21
13.04.19 Roller presser pressure............................................................................................ 13 -22
13.05 Adjusting the thread trimmer -900/61 .................................................................. 13 -23
13.05.01 Preadjusting the control cam ................................................................................... 13 -23
13.05.02 Roller lever............................................................................................................... 13 -24
13.05.03 Engaging solenoid.................................................................................................... 13 -25
13.05.04 Actuating lever......................................................................................................... 13-26
13.05.05 Connecting rod......................................................................................................... 13 -27
13.05.06 Thread-catcher height .............................................................................................. 13 - 28
13.05.07 Thread-catcher position............................................................................................ 13 -29
13.05.08 Knife pressure.......................................................................................................... 13-30
13.05.09 Bobbin-thread clamp spring ..................................................................................... 13 -31
13.05.10 Control cam final adjustment ................................................................................... 13 -32
13.05.11 Manual cutting test .................................................................................................. 13 -33
13.05.12 Tension release (during trimming process) .............................................................. 13 -34
13.05.13 Stop positions .......................................................................................................... 13-35
13.06 Parameter adjustments ......................................................................................... 13 -36
13.06.01 Adjusting positions................................................................................................... 13 - 36
13.06.02 Adjusting the counter............................................................................................... 13 -37
13.06.03 Adjusting speeds ..................................................................................................... 13 -37

Safety
1 Safety
1.01 Directives
This machine is constructed in accordance with the European regulations contained in the
conformity and manufacturer’s declarations.
In addition to this Instruction Manual, observe also all generally accepted, statutory and
other regulations and legal requirements and all valid environmental protection regulations!
The regionally valid regulations of the social insurance society for occupational accidents or
other supervisory organisations are to be strictly adhered to!
1.02 General notes on safety
●This machine may only be operated by adequately trained operators and only after
having completely read and understood the Instruction Manual!
●All Notes on Safety and Instruction Manuals of the motor manufacturer are to be read
before operating the machine!
●The danger and safety instructions on the machine itself are to be followed!
●This machine may only be used for the purpose for which it is intended and may not be
operated without its safety devices. All safety regulations relevant to its operation are to
be adhered to.
●When exchanging sewing tools (e.g. needle, roller presser, needle plate or bobbin),
when threading the machine, when leaving the machine unattended and during
maintenance work, the machine is to be separated from the power supply by switching
off the On/Off switch or by removing the plug from the mains!
●Everyday maintenance work is only to be carried out by appropriately trained personnel!
●Repairs and special maintenance work may only be carried out by qualified service staff
or appropriately trained personnel!
●Work on electrical equipment may only be carried out by appropriately trained personnel!
●Work is not permitted on parts and equipment which are connected to the power
supply! Exceptions to this are only to be found in the regulations EN 50110.
●Modifications and alterations to the machine may only be carried out under observance
of all the relevant safety regulations!
●Only spare parts which have been approved by us are to be used for repairs! We
expressly point out that any replacement parts or accessories which are not supplied by
us have not been tested and approved by us. The installation and/or use of any such
products can lead to negative changes in the structural characteristics of the machine.
We shall not be liable for any damage which may be caused by non-original parts.
1 - 1

Safety
1.03 Safety symbols
Danger!
Points to be observed.
Danger of injury for operating and specialist personnel!
1 - 2
1.04 Important points for the user
●This Instruction Manual is a component part of the machine and must be available to the
operating personnel at all times.
●The Instruction Manual must be read before operating the machine for the first time.
●The operating and specialist personnel is to be instructed as to the safety equipment of
the machine and regarding safe work methods.
●It is the duty of the user to only operate the machine in perfect running order.
●It is the obligation of the user to ensure that none of the safety mechanisms are
removed or deactivated.
●It is the obligation of the user to ensure that only authorized persons operate and work
on the machine.
Further information can be obtained at your PFAFF agent.
I
Caution
Do not operate without finger guard and safety devices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.

Safety
1.05 Operating and specialist personnel
1.05.01 Operating personnel
Operating personnel are persons responsible for the equipping, operating and cleaning of
the machine as well as taking care of faults arising in the sewing area.
The operating personnel is obliged to observe the following points and must:
●always observe the Notes on Safety in the Instruction Manual!
●never use any working methods which could limit the level of safety in using the
machine!
●not wear loose-fitting clothing or jewellery such as chains or rings!
●also ensure that only authorized persons have access to the potentially dangerous area
around the machine!
●always immediately report to the person responsible any changes in the machine which
may limit its safety!
1.05.02 Specialist personnel
Specialist personnel are persons with a specialist education in the fields of electrics,
electronics and mechanics. They are responsible for the lubrication, maintenance, repair and
adjustment of the machine.
The specialist personnel is obliged to observe the following points and must:
●always observe the Notes on Safety in the Instruction Manual!
●switch off the On/Off switch before carrying out adjustments or repairs and ensure that
it cannot be switched on again unintentionally!
●never work on parts which are still connected to the power supply! Exceptions are
contained only in the regulations EN 50110.
●replace the protective coverings and close the electrical control box after all repairs or
maintenance work!
1 - 3

Safety
1.06 Danger
A working area of 1 meter is to be kept free both in front of and behind the
machine while it is in operation so that it is always easily accessible.
Never reach into the sewing area while sewing! Danger of injury by the needle!
Never leave objects on the table or in the needle plate area while adjusting the
machine settings! Objects can become trapped or be slung away! Danger of
injury!
1 - 4
Do not operate the machine without the take-up lever guard 1!
Danger of injury due to the the motion of the take-up lever!
Do not operate the machine without its belt guards 2 and 3!
Danger of injury due to the rotating V-belt!
Do not operate the machine without tilt lock 4!
Danger of crushing between sewing head and table top!
2
1 1
2
1
Fig. 1 - 01
3
4

Proper use
2 Proper use
The PFAFF 421E1 is a high speed, single needle sewing machine with forwards and reverse
feeding feed-wheel and roller presser as well as a feed-synchronized needle.
The Pfaff 1421E1 is a single-needle high-speed seamer with compound feed, forward- and
reverse-feeding wheel feed and roller presser, and large sewing hook.
These machines are used for sewing lockstitch seams in the leather and upholstery
industries.
Any and all uses of this machine which have not been approved of by the
manufacturer are considered to be inappropriate! The manufacturer cannot be
held liable for any damage caused by the inappropriate use of the machine! The
appropriate use of the machine includes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!
2 - 1

Specifications
3 - 1
3 Specifications
3.01 PFAFF 421E1, 1421E1 ▲
Stitch type:.................................................................................................. 301 (lockstitch)
Needle system PFAFF 421E1: ...................................................................................... 134
Needle system PFAFF 1421E1: ............................................................................... 134-35
Handwheel eff. dia.:................................................................................................. 65 mm
Clearance under the roller presser: ............................................................................ 7 mm
Clearance width: .................................................................................................... 245 mm
Clearance height: ................................................................................................... 115 mm
Dimensions of sewing head:
Length:...................................................................................................... approx. 615 mm
Width: ....................................................................................................... approx. 240 mm
Height (above table):................................................................................. approx. 320 mm
Bedplate:...................................................................................................... 518 x 177 mm
Max. speed: ..................................................................................................4000 Sti/min ◆
Electrical data:
Operating voltage:..........................................................................230 V ± 10%, 50/60 Hz
Max. output: ...........................................................................................................1.2 kVA
Fuse protection: ............................................................................ 1 x 16 A, delayed action
Software: ...................................................................................Version 79-0011 0200/010
Working noise level:
Emission at workplace at n = 2500 spm: 80 dB(A): .............................................. 80 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1)
Net weight of machine head:........................................................................ approx. 61 kg
Gross weight of machine head: .................................................................... approx. 71 kg
▲Subject to alteration
◆ Varies according to material, work process and stitch length

Specifications
3 - 2
3.02 Needle and thread PFAFF 421E1
Model
B 40 - 40 100 134
B/C 20 - 30 120 134
A 60 - 60 70 134
needle system
Thread thickness ( Nm ) max. synthetic
Needle
thickness
in
1/100 mm
3.03 Needle and thread PFAFF 1421E1
Model
needle system
Thread thickness ( Nm ) max. synthetic
Needle
thickness
in
1/100 mm
B 40 - 40 100 134 - 35
B/C 20 - 30 120 134 - 35
▲or comparable thicknesses of other thread types
▲or comparable thicknesses of other thread types
3.04 Possible models
Model A (only PFAFF 421E1) ................................................ For processing fine materials
Model B ......................................................................... For processing medium materials
Model B/C..........................................For processing medium to medium/heavy materials

Disposal of machine waste
4 - 1
4 Disposal of machines
●The proper disposal of machines is the responsibility of the customer.
●The materials used in the machines are steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
●The machine is to be disposed of in accordance with the locally valid
environmental protection regulations. If necessary, a specialist is to be commissioned.
Special care is to be taken that parts soiled with lubricants are separately
disposed of in accordance with the locally valid pollution control regulations!

Transport packaging and storage
5 - 1
5 Transport packaging and storage
5.01 Transport to the customer’s premises
Within Germany, complete machines (with table and motor) are delivered without packaging.
Machines without a table (sewing head with motor only) and machines for export are
packaged.
5.02 Transport within the customer’s premises
The manufacturer bears no liability for transport within the customer’s premises.
Always ensure that the machine is only transported upright.
5.03 Disposal of the packaging
The packaging of the machines consists of paper, cardboard and VCE fibre.
The proper disposal of the packaging is the responsibility of the customer.
5.04 Storage
The machines can be stored for up to 6 months if not in use. During this time they should
be protected from dust and moisture.
For longer storage the individual parts of the machines, especially the moving parts, should
be protected against corrosion, e.g. by a film of oil.

Explanation of the symbols
6 Explanation of the symbols
In the following section of this Instruction Manual, certain tasks or important pieces of
information are accentuated by symbols.
The symbols used have the following meanings:
Note, information
Cleaning, care
Lubrication, greasing
Servicing, repairing, adjustment, maintenance
(only to be carried out by specialist personnel)
6 - 1

Controls
Fig. 7 - 01
7 Controls
7.01 On/off switch
●Turn the machine on/off by turning
On/Off switch 1.
Fig. 7 - 02
7.02 Keys on the machine head
●Different functions are triggered by
pressing the different keys.
Key 1: reverse sewing
Key 2: sews one stitch with half stitch
length.
Key 3: sews one stitch with full stitch
length.
0
1
7 - 1
2
1 1
123

Controls
7.03 Pedal
●Different functions are triggered by
different pedal positions.
0= Machine stop
1= Sew
2= Raise roller-presser
3= Trim thread and raise roller
presser
Other pedal functions can also
be programmed (see
chapter 11 Programming)
Fig. 7 - 03
0
1
23
7.04 Knee switch
●By activating the knee switch 1the end
of the seam segment can be signalized
during programmed sewing.
The function of the knee
switch 1must be switched on
using the control panel (see
chapter 11 Programming).
Fig. 7 - 04
1
7 - 2

Controls
7.05 Knee lever
●The roller presser is raised by pressing
the knee lever 1in the direction of the
arrow.
1
Fig. 7 - 05
7.06 Lever for lifting the roller presser
●The roller presser is raised by turning
lever 1.
Fig. 7 - 06
7 - 3
1

Controls
7.07.01 Display
In the basic screen the messages in the display are divided into three sections:
Status bar
The status bar is in the upper section of the display. Here, up to 5 pictograms with the
corresponding values can be displayed (e.g. program number, number of seam section,
stitch length etc.).
Text field
The text field is in the middle section of the screen, in which messages are displayed in
2 lines. Stylized seam sections can also be shown here with information about start and end
bartacks, sewing direction and seam section end.
Pictogram bar
The pictogram bar can be found at the bottom of the display. Here, symbols are displayed
whose corresponding function can be called up via the number keys. Active functions are
shown by a symbol displayed on a dark background.
Normal symbol (function not active)
Symbol on dark background (function active)
7.07 Control panel
The control panel consists of the display and two key panels.
Enter
1 2 3456 7 890
Clear
Esc
-+
Fig. 7 - 07
7 - 4

Controls
7.07.02 Operation-mode keys
There are two operation modes. The selected mode can be seen by the light emitting diode
in the respective key.
SEWING mode
INPUT mode
7.07.03 Function keys
Arrow keys (right/left)
- Change menu bars.
- for positioning the cursor when entering several values in one line
Plus/Minus keys
- for raising and lowering input values
Esc key
- for interrupting functions without taking on the value inputted
- for returning to superordinate menu functions
- for error acknowledgement after an error message
Clear key
- for returning the input value to 0
- for error acknowledgement after an error message
Enter key
- for confirming an input value
- for error acknowledgement after an error message
7.07.04 Number keys
Esc
Clear
Enter
7 - 5
1
2
3
4 5 6
7
8
9
0
Below the display there is a row of number keys (1-0).
Depending on the current operating mode, these keys have the following functions:
- carrying out the function shown by the symbol displayed above the number key
- inputting a numerical value
- selecting functions or the next level of the menu
Double click = pressing a key twice in rapid succession