Pfaff 5489 User manual

INSTRUCTION MANUAL
5489
296-12-18 991/002
Betriebsanleitung engl. 07.11
This instruction manual applies to machines
from the following serial numbers onwards:
# 2 768 477

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

Index
Contents ..................................................................................Page
1Safety .................................................................................................................................... 5
1.01 Regulations ............................................................................................................................ 5
1.02 General notes on safety......................................................................................................... 5
1.03 Safety symbols ...................................................................................................................... 6
1.04 Important notes for the user.................................................................................................. 6
1.05 Notes for operating and technical staff .................................................................................. 7
1.05.01 Operating staff ....................................................................................................................... 7
1.05.02 Technical staff ........................................................................................................................ 7
1.06 Danger warnings.................................................................................................................... 8
2Proper use............................................................................................................................. 9
3Specifications ..................................................................................................................... 10
3.01 PFAFF 5489.......................................................................................................................... 10
3.02 Models and work aids ......................................................................................................... 10
4Disposal of Machine ...........................................................................................................11
5Transportation, packing and storage................................................................................ 12
5.01 Transportation to customer‘s premises ............................................................................... 12
5.02 Transportation inside the customer‘s premises................................................................... 12
5.03 Disposal of packing materials ..............................................................................................12
5.04 Storage ................................................................................................................................ 12
6Explanation of symbols..................................................................................................... 13
7Controls .............................................................................................................................. 14
7.01 Main switch ......................................................................................................................... 14
7.02 Pedal .................................................................................................................................... 14
7.03 Keys on the machine head................................................................................................... 15
7.04 Raising the presser foot....................................................................................................... 15
7.05 Thread tension release lever................................................................................................ 16
7.06 Reverse feed lever ............................................................................................................... 16
7.07 Stitch length and Differential feed levers ............................................................................. 17
7.08 Control panel........................................................................................................................ 17
7.09 Puller (-948/26)..................................................................................................................... 17
8Installation and commissioning ....................................................................................... 18
8.01 Installation............................................................................................................................ 18
8.01.01 Adjusting the table-top height.............................................................................................. 18
8.01.02 Assembling the motor P40 ED ............................................................................................ 19
8.01.03 Tightening the V-belt ............................................................................................................ 19
8.01.04 Mounting the bottom V-belt guard ....................................................................................... 20

Index
Contents ..................................................................................Page
8.01.05 Fitting the upper belt guard.................................................................................................. 20
8.01.06 Fitting the synchronizer........................................................................................................ 21
8.01.07 Fitting the reel stand ............................................................................................................ 21
8.02 Connecting the plug-in connections and earth cables ......................................................... 22
8.03 Commissioning .................................................................................................................... 23
8.04 Switching the machine on/off .............................................................................................. 23
8.05 Basic position of the machine drive unit P40ED ................................................................. 24
9Setting up ........................................................................................................................... 25
9.01 Inserting the needle ..................................................................................................................25
9.02 Threading the needle thread and regulating its tension ........................................................26
9.03 Threading the looper thread and regulating its tension ....................................................... 27
9.04 Adjusting the differential feed .............................................................................................. 28
10 Care and maintenance....................................................................................................... 29
10.01 Servicing and maintenance intervals ................................................................................... 29
10.02 Cleaning the machine .......................................................................................................... 29
10.03 Lubricating ........................................................................................................................... 30
10.04 Checking/regulating the air pressure ................................................................................... 31
10.05 Emptying/cleaning the water bowl of the air filter/regulator................................................ 31

5
Safety
1 Safety
1.01 Directives
The machine has been constructed in accordance with the requirements listed in the
EC Declaration of Conformity and the Declaration of Incorporation.
In addition to this Instruction Manual, also observe 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 organizations 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 be-
fore 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 and bobbin),
when threading the machine, when leaving the machine unattended and during mainte-
nance 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!
The only exceptions to this rule are 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 express-
ly 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 are not liable
for any damage which may be caused by non-original parts.

Safety
6
I
1.03 Safety symbols
Danger!
Special points to observe.
Danger of injury 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.
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
7
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, re-
pairing 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 mainte-
nance 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!

Safety
8
Fig. 1 - 01
2
1
3
4
Do not operate the machine without take-up lever guard 1!
Danger of injury from the movement of the take-up lever!
Do not operate the machine without belt guard 2and 3!
Danger of injury by running drive belts!
Do not operate the machine without finger guard 4!
Danger of injury by the needle!
1.06 Danger warnings
A working area of 1mmust 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 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 machine!

9
Proper use
2 Proper use
The PFAFF 5489 is an ultra-high-speed chainstitch sewing machine with differential bottom
feed for production of chainstitch seams.
The machine is intended for commercial (industrial) use.
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
10
3 Specifications ◆
3.01 PFAFF 5489
Stitch type:..................................................................................... 401 (two-thread chainstitch)
Needle system:............................................................................................................. 4463-35
Model :.....................................................................................................................................B
Needle thickness in 1/100 mm: .................................................................................... 80 - 100
Max. stitch length: .........................................................................................................4,5 mm
Max.thread size (synthetic):.............................................................................................. 40/3▲
Dimensions of the machine:
Length:............................................................................................................. approx. 580 mm
Breadth: ........................................................................................................... approx. 177 mm
Height (above table): ........................................................................................ approx. 265 mm
Clear workspace width: ................................................................................................260 mm
Clear workspace height: ...............................................................................................130 mm
Noise data:
Noise emission level at workplace with a sewing speed of 4800 spm: ............ LpA < 83 dB(A)■
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO
Motor data: .................................................................... See instruction manual for the motor
Working pressure:.............................................................................................................. 6 bar
Air consumption per switch cycle: ............................................................................. ~ 0,146 ll
Net weight (sewing head):....................................................................................approx. 39 kg
Gross weight (sewing head): ..................................................................................approx. 47 k
◆Subject to alterations
3.02 Models and work aids
Model B: ................................................................................For sewing medium materials
Mögliche Zusatzeinrichtungen:
Possible work aids:
Subclass -900/71.......................................................................................... Thread trimmer
Subclass -910/.. ..............................................................................................Automatic foot lift
Subclass -917/.. .........................................................................Stitch condensation system
Subclass -918/14.. ........................................................................................Various controls
Subclass -948/26.................................................................................................. Puller feed
Subclass -971/.. ......................................................................................... Photocell control
▲synthetic, or other sizes of comparable thread types
■K
pA = 2,5dB

11
Disposal of Machine
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 regula-ti-
ons; 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
12
5 Transportation, packing and storage
5.01 Transportation to customer‘s premises
The 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
13
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
14
7.02 Pedal
●With the on/off switch on
0 = Machine stop
+1 = sewing, up to maximum speed
-1 = Raise presser foot
-2 = Raise puller roller
(on machines with -948/26)
-3= Trim thread
( on machines with -900/..)
1
Fig. 7 - 01
Fig. 7 - 02
0+1
-1 -2 -3
7 Controls
7.01 Main switch
●The machine is switched on or off by
turning main switch 1.

Controls
15
Fig. 7 - 04
7.04 Raising the presser foot
Fig. 7 - 04a
Fig. 7 - 03
7.03 Keys on the machine head
●As long as key 1 is pressed during
sewing, the machine sews in reverse.
●Keys 2 can be used for parameter set-
tings (see parameter 748 and 446 in the
instruction manual for the motor).
2
1

Controls
16
Fig. 7 - 05
7.06 Reverse feed lever
●To sew condensed stitches, press lever 1
down.
Fig. 7 - 05
1
7.05 Thread tension release lever
●To release the thread tension push lever 1
downwards.
1

Controls
17
7.07 Stitch length and Differential feed levers
●To set the stitch length, press lever 1 a
little to the right and move it to the re-
quired stitch length.
●Adjustment levers 1 and 2 are used to
adjust the differential feed stroke (also
see Chapter 9.04 Adjusting the differen-
tial feed.
Fig. 7 - 07
1
2
3
7.08 Control panel
The description can be found in the separate instruction manual for the motor.
7.09 Puller (-948/26)
The description can be found in the separate instruction manual for the Puller.

18
Installation and commissioning
Fig. 8 - 01
2
11
●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.
8 Installation and commissioning
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, it must be ensured 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 Installation
The site where the machine is installed must be provided with suitable connections for the
electric current, see Chapter 3Specifications.
It must also be ensured that the standing surface of the machine site is firm and horizontal,
and that sufficient lighting is provided.
The method of packaging used requires that the table top be lowered for trans-
port. The following is a description of how to adjust the height of the table top.
8.01.01 Adjusting the table-top height

19
Installation and commissioning
Fig. 8 - 03
Fig. 8 - 02
1
4
2
3
1
2
8.01.03 Tightening the V-belt
●Fit the V-belt.
●Loosen nut 1and tighten the V-belt by
turning motor mounting 2.
●Tighten nut 1.
8.01.02 Assembling the motor P40 ED
●Assemble motor mounting 1, motor 2, belt guard support 3and belt pulley 4as shown in
Fig. 8-02.

20
Installation and commissioning
Fig. 8 - 04
Fig. 8 - 05
2
3
16
4
5
1
2
3
4
2
●Push belt guard halves 1and 2with their
slots behind the heads of screws 3and 4.
●Fit spacing sleeve 5on screw 6and wind
screw 6in a few turns.
●Making sure that the lug on belt guard
half 2is between belt guard half 1and
spacing sleeve 5, position the belt guard
and tighten screws 3, 4and 6.
8.01.05 Fitting the upper belt guard
8.01.04 Mounting the bottom V-belt guard
●Loosen screws 2and adjust belt guard support 1so that the motor pulley and V-belt run
freely.
●Tighten screws 2.
●Fasten belt guard 3with screw 4.