Pfaff creative 4874 User manual

4874
SERVICE MANUAL

TABLE OF CONTENTS
1
A.  General directions and recommendations
B.  Recommendations
C.1-2. Mechanical sewing disorders
D.1-3. Test program - test of LCD display
E.1-2. Test program - tension settings - fine tuning
F.1-2. Error code
G.1-3. Gauge for the after - sales service
1. Removing back cover
2.  Removing front cover
3.a-e.  Removing LCD UNIT and connections for Main & LCDPCB
4.a-b. Angular position of balance weights and position of eccentrics
5.a-b. Height and alignment of cloth presser bar
6.a-b. Height and orientation of needle bar in relation to the needle plate holes
7.  Height - clearance - angular position of lower looper
8.  Clearance of needle guards
9.a-b.  Timing of lower looper
10.  Angular position of upper looper
11.  Clearance and timing of upper looper to lower looper
12.a-d. Chain looper : angular position - clearance - orbital timing - clearance of 
 chain needles guards
13. Chain looper thread take up rotary cam
14. Height of feed dog
15.a-b.  Moving cutter and vertical feed timing
16.a-b.  Horizontal feed timing against chainstitch needle
17. Adjustment for differential feed unit operated with stepping motor
18.  Position of fixed cutter and cutting width dial setting
19.  Position of loopers threads take up lever
20.  Position of the stitch width finger
21.  Lateral and front covers safety device
22.a-b.  Adjustment of setting position for en-sensor and slit-plate
23.  Adjustment for stitch length unit operated with step motor
24.  Timing adjustment for Top Cover Triangle Thread Guide and Top Cover 
 Hook
25.  Adjustment of threads take up lever for Top cover and Deco cover
26.  Installing of Deco unit
27.a-b.  Adjustment for Deco unit
28.  Cover hem stitch being pulled

TABLE OF CONTENTS 2
29.a-b.  Irregular loop formation on the chain needles (cover hems)
30.  Cover hem stitch formation (Narrow & Wide)
31.  Triple cover hem stitch formation
32.a-c.  Top cover stitch formation (Prog.21~23)
33.a-g.  Deco cover stitch formation (Prog.24~30)

GENERAL DIRECTIONS AND RECOMMENDATIONS A
Safety
For safety reasons, the sewing machine must be disconnected from the mains:
- Whenever the machine is left unattended
- Whenever preparing the machine for sewing
- Whenever servicing
- Whenever replacing mechanical or electrical parts or accessories
Needles
Usually needles of the system 130/705 H may be used. However, in certain cases stitch
quality may be improved by using type ELX 705 needles.
Choose needle size Nm 80 for sheer materials and Nm 90 for normal or thick materials.
Threads
Choose a good quality polyester thread or blended thread.
Lubrication
Besides the 2 oiling points marked in red, the machine is equipped with self-lubrication
bearings and parts. Lubricate the machine as follows: when using it for the first time - if it
has not been used for some time - when it has been intensively during 7 to 8 hours.

RECOMMENDATIONS B
1. Never connect the machine to a different voltage than tha t marked on the specification
plate.
2. For safety reasons, never perform any repairs on the powe r supply circuit without first
removing the mains lead from the machine.
3. Before replacing the LCD display PCB unit, check by means of the test program.
4. Never plug in or run the machine unless all the connections are correctly set.
5. After replacing the main control PCB unit, it is necessar y to recheck the speeds. Use a
small screwdriver with insulated blade to avoid short-circuits.
6. When changing the light bulb, it is neccessary to disconnect the mains lead.

MECHANICAL SEWING DISORDERS C1
First of all, please refer to the paragraph entitled "maintenance" in the instruction manual,
especially when machine does not turn freely by turning the flywheel by hand. If necessary,
check and adjust tightness of motor belt.
Given below are the most frequent disorders. In most cases, they can be remedied by
checking the adjustments in the following order. However, before checking the adjustments,
make sure that the threading is correct and that all the thread passages are okay.
1. Skipped overlock stitches
Check and adjust if necessary:
- Needle bent or with a dull point - replace needle
- Needle not set correctly - refer to "changing the needle" in the instruction manual
- Burrs on upper or lower looper - polish
- Burrs on stitch tongue - polish
- Excessive tension on the needle thread
- Height and orientation of needle bar
- Clearance between point of lower loopers and needle
- Clearance between upper and lower loopers
- Timing of upper and lower loopers against needle
- Feed timing
2. Skipped chainstitches - Cover hems
Check and adjust if necessary:
- Needle and chain looper thread tensions not balanced
- Needle bent or with a dull point - replace needle
- Needle not set correctly - refer to "changing the needle" in the instruction manual
- Burr on chain looper - replace or polish
- Dull blade edge on moving cutter - replace
- Chain looper needle clearance
- Chain needle guard clearance
- Angular position of chain looper
- Orbital timing of chain looper
- Chain thread take up lever timing
- Height and orientation of needle bar
- Needle plate spring plate bent
- Clearance and position between back of chain looper and need le L0
Note: For more information, see pages 28-31.

MECHANICAL SEWING DISORDERS C2
3. Thread breakage
Before checking the adjustment, make sure of the good quality of the thread and the needle,
the correctness of threading and the smoothness of all the thread passages. Quite often, an
injury to thread passage is the cause of thread breakage. If all these points are in order, check
the following:
- Dull point of needle or bent needle - replace.
- Dull or burred point of looper - replace.
- Scratch or injury on stitch tongue of needle plate - replace.
- Too strong thread tension.
- Unsmooth or injured edge of needle hole on needle plate (thread breakage of chain stitches)
- replace.
4. Irregular stitches
- Inadequate setting of thread tensions - re-adjust.
- Unsmooth thread passage - polish.
- Height of feed dog.
- Position of looper thread take up levers and thread guides.
- Dull blade edge of moving cutter - replace.
- Injury on needle plate face or presser foot sole - replace.
- Incorrect alignment of pulled-up thread antenna with spool pins - reset it at correct position
to align to spool pins.
5. Breakage of needle
Check and adjust if necessary
- Dull point of needle or bent needle - replace.
- Incorrect placement of needle - refer to "changing the needle" in the instruction manual.
- Clearance of needle guard and (chain needle).
- Incorrect alignment of needle holes of presser foot and needle plate.
- Clearance from needle to lower looper.
- Clearance between the upper and lower loopers.
- Feed timing.
- Horizontal feed timing against chain-stitch needle.

TEST PROGRAM - TEST OF LCD DISPLAY D1
PROG.
1 2 3 45
Access to the test program
1. Switch off the machine.
2. While pressing key "2" and "3" simultaneously, switch on the machine.
3. The matrix pattern turns to "LCD test mode".
4. Press "1", the step motors will rotate to their minimum position and the number "12" will
appear on the display.
Tension value can be checked and adjusted as a manner shown in the page E1.

TEST PROGRAM - TEST OF LCD DISPLAY D2
5. Press "1" again, the step motors will rotate to their maximum position and the number "48"
will appear on the display.
Tension value can be checked and adjusted as a manner shown in the page E1.
6. Press "1" again, the display becomes
7. Press "1" again, the display becomes
8. Press "1" again, the display becomes
9. Press "1" again, the display becomes

TEST PROGRAM - TEST OF LCD DISPLAY D3
10. Press "1" again, the display becomes
11. Press "1" again, the display becomes
12.Press "1" again, nothing is displayed
13. Press "1" again, all symbols are displayed
14. Press "1" again, Program version number is displayed

Note: It is also possible to proceed with above tests in reverse sequence by pressing key "2"
instead of key "1".

TEST PROGRAM-THREAD TENSION SETTING-DIAL TENSION
FINE TUNING E1
e
d
Test program for minimum dial tension (step 4 in page D1) and maximum
dial tension (step 5 in page D2 ).
The following manners are used for the setting of step motors (dial tensions).
a) Step 4
    The step motors will rotate to its minimum position. Check the tension value by pulling
    a polyeter thread #60/3 in the direction of "e" as drawing below. Make sure that each
   tension is set at 5 to 15 gr.
b) Step 5
   The step motors will rotate to its maximum position. Check the tension value in the same
   manner as mentioned in the step 4. Make sure that each tension is set at 40 to 50 gr.
c) If not, adjust the tension(s) with the fine tuning dial "d".
Note: The fine tuning can be executed without removing the covers by using a point of
needle, as shown in the drawing below.
d) Fine tuning with dial "d"may be executed as follows:
i) If thread tension appeared as strong (stitch becomes tight),dial "d" should turn to the 
 direction of with the point of needle.
ii) To the contrary, if it appeared as not eough strong,dial "d" should turn to the direction 
   of with thepoint of needle.

FINE TUNING OF DIAL TENSION FOR TOP-COVER & DECO-COVER E2
e
d
1. At the indication of Dial Tension Number "4", secure the tension value of thread shouldbe
15 to 20 gr.(with polyester thread #30)
2. If the thread tension is higher than expected( stitch becomes tight.), adjust tensions with
 fine tuning dial "d" to turn it in the direction of with the point of needle.
3. If it is lower than expected( stitch becomes loose), adjust tensions with the fine tuningDial
"d" to turn it in the direction of with the point of needle.

ERROR CODE F1
Step motor for D.F.(DFM)
Ref. to Page 3 and 17
Step motor,middle gear and D.F. gear for
D.F.
Ref. to Page 17 Fig. 1
D.F. Sensor P.C.B (DFS)
Ref. to Page 17 Fig. 1
DECO Sensor P.C.B (DCS)
Ref. to Page 26 Fig. 1,27b Fig. 4
Miter gear
Ref. to Page 27b Fig. 4
DECO Step motor (DCM)
Ref. to Page 3, 26 and 27
Blue &Yellow Decorative Thread Guides dose not return to
initial point and turn all the way to left or right.
Step motor turns, Blue &Yellow Decorative Thread Guides
does not move.
DECO Step motor does not turn.
Same as Phenomenon for S.L. Sensor P.C.B
All gears driven by Step motor do not smoothly turn.
7
8
1
2
3
4
5
Place in problem Phenomenon
Error
Code
Step motor DT-1
Step motor DT-2
Step motor DT-3
Step motor DT-4
Step motor DT-5
Ref. to Page 3
Sensor of DT(DTS)
Ref. to Page 3
Step motor for S.L.(SLM)
Ref. to Page 3 and 23
Step motor with same number of Error code does not turn.
(Example: Error No.3 showed on the display, DT-3 does not
turn however DT-1 & DT-2 are normal.)
Although a notch of the shelter disk crossed a sensor, the
disk does not reverse its course and turn all the way.
Step motor does not turn.
Step motor’s pinion gear,middle gear and feed regulator’s
gear do not smoothly turn.
Step motor and the middle gear(idle) and Feed
regulator gear.
Ref. to Page 23
S.L. sensor P.C.B(SLS)
Ref. to Page 23 Although a shelter disk (driven by middle gear) crossed sensor, middle gear does not reverse its course and turn all the way.
6
Step motor for D.F. does not turn.

Defective connection at the connector on the LCD
P.C.B.
Gearing between Step motor’s pinion gear and
middle gear is out of mesh.(tight)
Same as Cause of failure and Measure for S.L. Sensor P.C.B.
Failure of DECO Step motor.
Measure
Lead wire from Step motor.
Defective connection at the connector on the LCD
P.C.B
Loosing of set screws for miter gear.
Failure of DECO Step motor.
Lead wire cut off. (burn out) Replacing lead wire and or DECO Sensor.
Replacing DECO Sensor.
Refer. to Manual Part.1
Connecting the connector properly.
Preplacing DECO Step motor and or lead wirte.
Replacing DECO Step motor.
Decreasing the tension of D.F. spring.
Adjusting setting position of D.F. Unit.
Adjusting the setting position of Step motor.
Tension of D.F. spring is strong.(Page 17 Fig.1-S)
Gearing between middle gear and D.F. gear is out
of mesh. (tight)
Lead wire of Step motor for D.F. cut off (burn out)
Failure of Step motor for D.F. Replacing Step motor for D.F.
Replacing lead wire and or Step motor for D.F.
Connect repeatedly with connectors.
Failure of DECO Step motor.
Lead wire of Step motor for D.F. cut off. (burn out)
Defective connection at the connector on the LCD
P.C.B. and at the connectors from other compo-
nents.
Failure of sensor.
Lead wire cut off.
Defective connection at the connector on the LCD
P.C.B
Replacing the Step motor.
Replacing the lead wire and or the Step motor.
Connect repeatedly with connectors.
Replacing a P.C.B of sensor.
Replacing lead wire and or a P.C.B of sensor.
Connect repeatedly with connector.
Cause of failure
Lead wire of Step motor cut off. (burn out)
Defective connection at the connector on the LCD
P.C.B.
Gearing between Step motor pinion gear and mid-
dle gear (Fig.1-C) is out of mesh. (may be tight)
Gearing between middle gear(Fig 1-C) and Feed
regulator gear (Fig.1-B) is out of mesh. (may be
tight)
Replacing the Step motor.
Connect repeatedly with connector.
Adjust its gearing properly with moving set position.
Adjust set position of S.L. regulating unit, so that it may
secure proper gearing. (Two set screws for SL Unit must be
loosen. Fig.2-D)
Replacing S.L. Sensor P.C.B
Replacing S.L. Sensor P.C.B
Connect repeatedly with connector.
Replacing lead wire and or the Step motor.
Defective connection at the connector on the LCD
P.C.B
Lead wire cut off. (burn out)
Failure of S.L. Sensor.
Failure of Step motor.
ERROR CODE F2

GAUGE FOR THE AFTER-SALES SERVICE G1
665
47.3
3.21.3
12
1.5
4.7 2.8
12
Dimension Use
Gauge No. 109894.7mm Height of cloth presser bar
 12.0mm Height of needle bar
 2.8mm Angular position of lower looper to needle
 65.0mm Height of lower looper
 6.0mm Angular position of upper looper to needle
 1.5mm Chain looper angular position
 47.3mm Position of upper looper thread take up lever
 1.3mm Height of feed dogs
 3.2mm Position of feed dogs
 Dimension Use
Gauge No. 11687 6.0mm For the adjustment of setting position of 
  Yellow Decorative Thread Guide(height of 
  the same from the surface of the needle plate 
  and position of the point of the Blue and 
  Yellow Decorative Thread Guides). 
  (Page.26-Fig.2)

6.0
40

GAUGE FOR THE AFTER-SALES SERVICE G2
84.3
1.2
6
3.5
50
Dimension Use
Gauge No. 1168484.3mm For the adjustment of initial point for  
  Blue & Yellow Decorative Thread Guides 
 1.2mm and for setting position of the DECO UNIT 
  sensor (Page.23-Fig.1,Page.27b-Fig.6,7,9)
 3.5mm For the setting of stitch length unit
  (setting the both gears(Page.23-Fig.1B&C))
 6mm Height of Yellow Decorative Thread Guide 
  from thesurface of needle plate
 Dimension Use
Gauge No. 11685 3.98mm For the setting of Differential Feed UNIT
  (setting the both gears)
  (Page.17-Fig.1-C&D)   
 Dimension Use
Gauge No. 11686 6.8mm For the setting of Differential Feed UNIT
  (setting the position of feed rock lever,back
  and differential regulator slide block  
  (Page.17-Fig.2-B)) 

6.8
3.98

GAUGE FOR THE AFTER-SALES SERVICE G3
22.6
Dimension Use
Gauge No. 11691 For the adjustment of setting position of 
  EN-Sensor (measuring the clearance  
  between out side of a projected arc of slit-
  plate and the bottom of U shaped part of 
  EN-Sensor ) Ref.to Page 22a & b

 
 Dimension Use
Gauge No. 11692  For the adjustment of setting position of the 
  slit-plate. Ref. to Page 22a & b.   
 
8.116
20
25
Thickness = 0.2mm
4.5

REMOVING BACK COVER 1
2
b
c
d
3
d
f
e
5
4
f
f
aa
a
1
1. Remove mains lead.
2. Remove base plate unit "1" (screws "a").
3. Remove knobs "b" and screw caps and screws "c".
4. Remove side cover "2".
5. Remove top cover "3" with screws "d".
6. Remove lamp cover "4" with screw "e".
7. Remove screw caps and screws "f".
8. Remove back cover unit "5".