Service Manual 1st Release August 2001
Page Contents Foreword Notes on the sewing machine in relation to environment, handling, cleaning and safety Specifications off PFAFF machines Removing the housing covers 1 3 5 6 8 Adjustment instructions Feeding system 1. Adjustment of toothed belt tension 2. Adjustment of feed dog in sideways direction on Pfaff 1520 3. Adjustment of feed dog in sideways direction on Pfaff 1530-1540 4. Adjustment of feed dog height 5. Adjustment of presser bar height on Pfaff 1520 6.
Stitching off 34. Adjustment of needle threader 35. Adjustment of bobbin winder stop 36. Adjustment of bobbin thread tension 37. Adjustment of needle thread tension 38. Adjustment of thread check spring stroke 39. Adjustment of equal stitch length for left and right buttonhole seams 40. Adjustment of equal forward and reverse stitch length (for forward and reverse controlled utility stitches) 41. Making up a sewing sample 74 Repair Instructions 42. Removing and fitting the needle thread tension 43.
Foreword The purpose of this service manual is to assist you in quick and correct repair of the machines. Adjustments should only be made if the settings deviate from the requirements described in this manual. When checking or adjusting a machine, always proceed in the order of the worksteps prescribed. For easier reference, each workstep is identified by a number. Different operational procedures are indicated by a circle or a square.
For the proper adjustment of the machine, the following gauges and tools are required: z z z z z z z z z z z z z z z z z z z Needle rise gauge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-870136-01 Needle rise clamp: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-870137-01 Spacer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63-102600-18 Adjustment gauge for the bobbin case holder: . . . . .
Notes on the sewing machine in relation to environment, handling, cleaning and safety Environment: The recommended operating ranges are as follows: Ambient temperature -10°C to 40°C (50° to 104°F) Air humidity 20 % to 80 % This machine is a high-quality electro-mechanical device. It is designed for household purposes and should always be supervised when in use.
Specifications of PFAFF machines PFAFF 1540 Electronic free-arm utility stitch machine with 40 sewing programs (push buttons). A straight stitch program with 15 needle positions. A zigzag program with 15 needle positions. A buttonhole program with adjustable width. 37 utility stitches. High-ohm foot control (cold) with torque raising. Dual fabric feed. Needle threader. PFAFF 1530 Electronic free-arm utility stitch machine with 15 sewing programs (program dial).
z z z z z z z z z z z z z z z z z z Maintenance-free PFAFF transverse double-rotating hook Link take-up lever Linkage-type feed regulator Dual fabric feed Disengageable feed dog Needle threader Drive from motor to handwheel by flat-toothed belt 60-1000 stitches per minute Sintered metal bearings Oil for sintered metal bearings: BP Energol HLP 46 or HLP 80 No. 28-036550-09 Oil for sewing hook No.
Removing the housing covers Note: Before adjusting or repairing the machine, make sure to remove the housing covers as described in this manual. z z z z z z z z z z z z z z z 8 Disconnect the machine's main plug. Remove needle and presser foot. Remove detachable work support. Remove top cover. Switch on bobbin winder. Remove the two Torx screws of the housing insert.. Remove housing insert. Lay the machine on its back and remove the four fastening screws of the baseplate. Remove baseplate.
z Loosen the fastening screws 4, 5, 6 and 7 of the rear housing shell (fig. 3 and 4). z Loosen the snap connections by pressing with your thumb on the spots marked with arrows on the inner surface of the arm (fig. 5). z Remove the rear housing shell. z Remove motor cover.
z Loosen the fastening screws 8, 9, and 10 of the front housing shell (fig. 5 and 6). z Remove fastening screws 10 and 11.
z Remove fastening screw 12 (fig. 7). z Switch on the top key row of the utility stitch unit. z Carefully remove the front housing shell by lifting it off. The assembly must be carried out in reverse order.
Notes: 12
Feeding system 1. Adjustment of the toothed belt tension Requirement: The toothed belt must be so taut that the sewing hook has no play in its direction of rotation. However, it must be possible to turn the machine easily. Adjustment: z Loosen screw 1 (fig. 1) z Re-position tensioning roller 2 with a screwdriver as required. z Tighten screw 1. Check: z Check adjustment according to the "Requirement". z Press lightly against the middle of the toothed belt (250 g).
2. Adjustment of feed dog in sideways direction on Pfaff 1520 Requirement: The left and right clearance of the feed dog in the feed slot must be the same (fig. 2). Check: Carry out a visual check of the feed dog position. Adjustment: z z z z z z z z Loosen the two screws 3 and 4 (fig. 2a). Loosen screw 5. Detach spring 6. Re-position feed-dog driving shaft 7 with the two cylindrical pins 8 and 9 sideways until the feed dog is centered in the feed slot. Firmly tighten the two screws 3 and 4.
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3. Adjustment of feed dog in sideways direction on Pfaff 1530-1540 Requirement: The left and right clearance of the feed dog in the feed slot must be the same (fig. 3). Check: Carry out a visual check of the feed dog position. Adjustment: z z z z z z z z z z z z z z z z z z z z z z z z z z z Lay the machine on its back. Loosen screw 12 (fig. 4). Remove bolt 13 to the right. Loosen screw 5. Remove circlip 14. Remove bolt 11. Loosen both screws 3 and 4.
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4. Adjustment of feed dog height Requirement: At the highest working position of the feed dog, the tips of the feed dog teeth must protrude above the needle plate surface by 0.9 mm (fig. 6). Check: z z z z z z z Remove the needle. Remove the presser foot. Set the maximum stitch length. Place bridge gauge (63-112120-08) over the feed dog onto the needle plate. Turn the handwheel until the feed dog has reached its highest working position. Carry out a visual check.
5. Adjustment of presser bar height on Pfaff 1520 Requirement: With the presser bar lifter raised, there must be a clearance of 8 mm between the needle plate and the bottom of the zigzag foot. Check: z z z z z Raise the presser bar lifter. Fit the zigzag foot. Lower the feed dog. Fully raise the presser bar lifter and hold it there firmly. At the same time, insert presser foot gauge No. 63-114690-39 from the rear under the zigzag foot and into the cutouts of the needle plate (fig. 8).
6. Adjustment of presser bar height on Pfaff 1530-1540 Requirement: With the presser bar lifter raised, there must be a clearance of 8 mm between the needle plate and the bottom of the zigzag foot. Check: z z z z z Raise the presser bar lifter. Fit the zigzag foot. Lower the feed dog. Fully raise the presser bar lifter and hold it there firmly. At the same time, insert presser foot gauge No. 63-114690-39 from the rear under the zigzag foot and into the cutouts of the needle plate (fig. 9).
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7. Adjustment of top feed foot in sewing direction Requirement: The front edge of the top feed foot must be between the first and second tooth point of the center tooth row of the feed dog (fig. 11). Check: z z z z z z z Raise the presser bar lifter. Remove presser foot & presser foot holder. Set the maximum stitch length. Engage the top feed foot. Turn the handwheel until the rising feed dog is flush with the needle plate surface. Lower the presser bar lifter. Carry out a visual check.
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8. Adjustment of top feed foot height Requirement: At its highest working position the top feed foot must be 2 mm higher than the lower edge of the zigzag foot (fig. 13). Note: This adjustment must only be carried out when the height of the presser bar is set correctly! Check: z z z z z z z z z z Raise the presser bar lifter. Fit the zigzag foot. Engage the top feed. Turn the handwheel until the needle bar is at its lowest position. Caution: The handwheel must now no longer be turned! Lower the feed dog.
z Set guide piece 31 at a clearance of 0.2 mm from cross head 32 (fig. 14). z Tighten screw 25. Cross-check: z Turn the handwheel and check for clearance of 0.2 mm.
9. Adjustment of feed regulator cranks on Pfaff 1520 / 1530 Requirement: The feed regulator cranks must not have any axial play. Check: Move the feed regulator cranks laterally backwards and forwards (fig. 15). Adjustment: z z z z Loosen the two screws 5. Push feeding eccentric 33 to the right against the bearing. Push bolt 11 to the right until connecting bar 10 is in contact with edge 34 of feeding eccentric 33. Tighten the screws 5. Cross-check: z z z z 26 Set the stitch length graduated dial to "6".
10. Adjustment of feed regulator cranks on Pfaff 1540 Requirement: The feed regulator cranks must not have any axial play. Check: Move the feed regulator cranks laterally backwards and forwards (fig. 16). Adjustment: z z z z Loosen the two screws 5 and 36. Push feeding eccentric 33 to the right against the bearing. Push bolt 11 to the right until connecting bar 10 is in contact with edge 34 of feeding eccentric 33.
11. Zero point adjustment of stitch length regulator Requirement: When the stitch length graduated dial is set to "0", the feed dog should only move up and down. Check: z z z z Set the stitch length graduated dial to "0". Place a piece of fabric under the presser foot. Lower the presser foot. Operate the machine. The fabric must not be fed neither forwards nor backwards. Precondition 1: The dot markings on the toothed segments must be diametrically opposite each other (fig. 17).
Notes: 29
12. Timing of feed motion Operating sequence: When the rising needle has cleared the fabric, the feed dog moves up above the needle plate. The risen feed dog pushes the fabric to the rear. Shortly before the end of the feeding motion, the take-up lever is in its highest position (t.d.c). At a stitch length setting of 6 mm the feed dog now pushes another 0.6 mm more to the rear (feeding stroke).
z Turn the long drive shaft 45 clockwise until the line marks on edge 34 of feeding eccentric and connection rod 10 are opposite each other (fig. 19). Cross-check: z Turn the handwheel back and forth, until until the needle-rise clamp rests on the spacer. The line marks must now be opposite each other. z Tighten all three screws 44 very firmly.
Automatic utility-stitch unit 13. Replacing the automatic module on Pfaff 1520 - 1530 Removal: z z z z z z z z z z z z z z Disconnect the machine's mains plug. Remove the housing covers as described in this manual. Disconnect light plug 46 (fig. 22). Detach spring 47 at the top of the push-lever. Loosen screw 48. Remove circlip 49. Detach connecting lever 50. Remove circlip 51. Remove reverse button 52 together with bolt 53, connecting rod 54, plastic angle piece 55 and tension spring 47 (fig. 22).
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14. Adjustment of the locking disk Note: Carry out this adjustment only if compelling reasons exist. For this adjustment the automatic module has to be removed. Requirement: When the automatic module is switched off, lifting pin 66 should be exactly centered in the groove (fig. 24). Check: z Set adjustment dial 67 at the dot mark. z Move push-lever 68 back and forth. z Lifting pin 66 should now be exactly centered the groove and should not come into contact with the left wall of the groove during operation.
15. Replacing the zigzag-stitch unit on Pfaff 1520 - 1530 Removal: z z z z z z z z Disconnect the machine's mains plug. Remove the housing covers as described in this manual. Set stitch width adjustment dial 70 to "0" (fig. 26). Remove circlip 71 from connecting rod 72. Remove circlip 60. Remove connecting rod 65. Remove fastening screws 75. Carefully remove the zigzag unit from the machine. Fitting: z Insert bolt 76 of connecting rod 72 into joint piece 77 of the zigzag unit (fig. 26).
16. Basic position of setting eccentric for the sideways needle position Requirement: In its basic position the setting eccentric must point downwards (fig. 28). Adjustment: z z z z z z Set stitch width adjustment dial 70 to "0" (fig. 27). Set needle position adjustment dial 79 to "center". Switch the automatic unit to position "E". Loosen screw 73 (fig. 28). Rotate setting eccentric 74 downwards. Tighten screw 73.
17. Adjustment of needle penetration in needle plate slot Requirement: At straight stitch setting with needle position "center" the needle must be exactly in the center of the needle plate slot (fig. 30). Check: z z z z z Remove presser foot. Insert a new needle. Set stitch width adjustment dial 70 to "0" (fig. 32). Set needle position adjustment dial 79 to "center". Turn the handwheel and check the centered position of the needle.
18. Adjustment of the sideways movement of the needle bar Requirement: During zigzag sewing operation the sideways movement of the needle should stop above the highest possible fabric thickness. The sideways movement of the needle must start when the needle point is leaving the needle plate. It must be completed before the needle enters the fabric again, approx. 8 mm above the needle plate (fig. 33). When hole mark 80 is indicated on the automatic unit bracket (fig.
Cross-check: z As described under "Check".
19. Adjustment of the stop for the left needle position Requirement: At the widest zigzag stitch setting the crank should rest on the stop. Check: z z z z Set stitch width adjustment dial to "5". Set needle position adjustment dial to "center". Set the adjustment dial on the automatic unit to "E". Rotate the handwheel until the needle moves downward on the left side and is at a position of roughly 1 mm above the needle plate. z Crank 90 should now rest on stop 85.
Notes: 41
20. Adjustment of the feed reversing bar Requirement: At straight stitch or stretch stitch setting there must be a clearance of 0.2 mm between reversing bar 54 and the end of the lever of feeler 91 (fig. 39). Check: z z z z Set the adjustment dial for the automatic unit to "E". Move the stitch length adjustment dial to the stretch symbol, up to the stop. Rotate the handwheel until adjusting crank 39 is positioned fully to the front (fig. 40).
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21. Replacing the utility-stitch unit on Pfaff 1540 Removal: z z z z z z z z Loosen screw 5 (fig. 42). Remove circlip 14. Remove bolt 11. Remove circlip 92. Disconnect pull rod 93. Detach feed regulator cranks together with connecting rod 10 to the left. Loosen the three screws 94, 95 and 96. Remove the complete utility-stitch unit downwards. Note: Before fitting the automatic unit, make sure that the two dot marks on the toothed segments are exactly opposite each other (fig. 43).
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22. Adjustment of the gears in relation to each other Requirement: The two gears must not have any play, must not bind, and must be parallel to each other. Check: z Check for free running by turning the handwheel, check for lack of play by turning the gears back and forth and carry out a visual check of parallel configuration. Adjustment: z Loosen the three screws 94, 95 and 96 and adjust the two gears 97 and 98 so that they are parallel and have no play (fig. 43). z Tighten the three screws.
23. Replacing the zigzag-stitch unit on Pfaff 1540 Removal: z z z z z z z z z z Disconnect the machine's mains plug. Remove the housing covers as described in this manual. Set stitch width adjustment dial 70 to "0" (fig. 44). Remove circlip 71 from connecting rod 72. Remove circlip 92 (fig. 46). Detach pull rod 93 and remove it from the top. Remove the two circlips 99 (fig. 45). Remove plastic angle lever 100 from the front. Loosen fastening screws 75 (fig. 45).
24. Basic position of setting eccentric for the sideways needle position on Pfaff 1540 Requirement: In its basic position the setting eccentric must point upwards at a position approx. 45 degrees towards the left (fig. 47). Adjustment: z z z z z z Set stitch width adjustment dial 70 to "0" (fig. 47). Set needle position adjustment wheel 79 to "center". Press straight stitch and zigzag stitch button. Loosen screw 73 (fig. 49). Rotate setting eccentric 74 upwards and 45 degrees to the left.
25. Adjustment of needle penetration in needle plate slot on Pfaff 1540 Requirement: At straight stitch setting with needle position "center" the needle must be exactly in the center of the needle plate slot (fig. 30). Check: z z z z z z Remove presser foot. Insert a new needle. Set stitch width adjustment dial 70 to "0" (fig. 32). Set needle position adjustment dial 79 to "center". Press straight stitch and zigzag stitch button on the automatic utility-stitch unit.
26. Adjustment of the sideways movement of the needle bar on Pfaff 1540 Requirement: During zigzag sewing operation the sideways movement of the needle should stop above the highest possible fabric thickness. The sideways movement of the needle must start when the needle point is leaving the needle plate. It must be completed before the needle enters the fabric again, approx. 8 mm above the needle plate (fig. 50). Check: z z z z z Set stitch width adjustment dial to the maximum zigzag width.
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27. Adjustment of zigzag stitch penetration in needle plate slot on Pfaff 1540 Requirement: The widest zigzag stitches must have the same distance to the left and right edges of the needle plate slot (fig. 54). Check: z z z z z z Remove the presser foot. Insert a new needle. Set zigzag stitch adjustment dial to "5". Set needle position adjustment dial to "center". Press zigzag stitch button. Turn the handwheel and check the left and the right clearance in the slot.
28. Adjustment of the stop for the left needle position on Pfaff 1540 Requirement: When all push buttons are switched off, the needle must be approx. 0.2 mm further left than the widest zigzag stitch. The needle must not touch the needle plate. Check: z z z z Set stitch width adjustment dial to "5". Set needle position adjustment dial to "center". Press the zigzag stitch button.
Stitch forming parts (sewing hook) Foreword: The sewing hook adjustment consists basically of the three following adjustments: z Needle rise (sewing hook timing) z Needle bar height z Hook-to-needle clearance Needle rise (sewing hook timing): The needle rise is the movement by which the needle must rise from its lowest position until a thread loop has formed on the side of the needle on which the scarf is located.
55 Vertical rotary hook Large horizontal rotary hook Horizontal rotary hook Oscillating CB hook and beak shuttle Hook complete Hook complete.
29. Adjustment of needle clearance in needle slot in sewing direction Requirement: There must be a clearance of 0.2 mm between the rear edge of the needle shank and the rear edge of the needle plate slot (fig. 57).
Cross-check z Carry out a visual check at straight and zigzag stitch settings.
30. Adjustment of hook-to-needle clearance Requirement: At the straight stitch setting the clearance between the sewing hook point and the bottom of the scarf in the needle must be 0.05 mm (fig. 60). At the widest zigzag stitch setting, the sewing hook point must almost touch the needle. Check: z z z z z z z z z z Remove the needle. Remove presser foot and needle plate. Remove the bobbin case. Unscrew the bobbin case position finger.
30a. Adjustment of bevel gears Requirement: The bevel gears must move easily and without play. Adjustment: z Push bevel gear with lifting eccentric to the left until it rests on bevel gear 38 without play. z Tighten screw 37 on the surface of the drive shaft. Check: z As described under "Requirement".
31. Sewing hook timing Requirement: When the needle bar has moved 2.2 mm upwards from its lowest position, with the machine set for straight stitch and center needle position, the sewing hook point must be exactly behind the center line of the needle (fig. 62). Check: z z z z z z z z z z z z Remove presser foot and needle plate. Press the straight stitch button. Bring the needle bar to its lowest position by turning the handwheel.
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32. Adjustment of needle bar height This machine has a transverse double-rotating hook. At the right zigzag penetration, the sewing hook reaches the needle a little earlier and at the left penetration a little later than at the center penetration. As a result of this, the position of sewing hook at the right zigzag penetration is slightly higher above the needle eye than at the left zigzag-penetration (fig. 65).
33. Adjustment of bobbin case position finger Requirement: The clearance between the position finger and the bottom of the groove in the bobbin case base must be 0.7 mm. Check: z It must be possible to insert clearance gauge (00-880133-01) with ease but without play between the position finger and the bottom of the groove in the bobbin case base (fig. 68). Adjustment: z z z z Loosen the two screws 114. Insert clearance gauge.
Stitching off 34. Adjustment of needle threader Requirement: With the threader lever pushed fully down, prong 115 must pass through in the center between the top and bottom edge of the needle eye of a size 70 needle (fig. 69). The prong must have the same distance to either side of the walls of the needle eye. Check: z z z z Insert a new system 130/705 H, size 70 needle. Move the needle bar to its top position by turning the handwheel. Push threader lever 116 fully down and swivel it forwards.
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35. Adjustment of bobbin winder stop Requirement: The bobbin winder must stop when the thread has reached a level of 1 mm below the bobbin rim. Check: z Wind a bobbin and check that the winder stops as required. Adjustment: z Loosen screw 123 (fig. 72). z Position stop 124 to the left for less thread and to right for more thread. z Tighten screw 123. Cross-check: z Wind a bobbin and check that the winder stops as required.
36. Adjustment of bobbin thread tension Requirement: The force required for pulling cotton thread 50/2 or synthetic fiber thread 100/3 off the bobbin must be approximately 20-25 g. Check: z z z z When a threaded bobbin case hangs on its thread, it must not slide downwards by its own weight. Upon sharp upward movements of the hand, the thread must run off gradually (fig. 73). There must not be any thread waste under the tension spring. The tension spring must rest evenly and parallel on the bobbin case.
37. Adjustment of needle thread tension Requirement: Within the adjusting range from 3 to 5, the interlacing of needle thread and bobbin thread (cotton thread 50/2 or synthetic fiber thread 100/35) must take place approximately in the middle of the fabric (fig. 74). Check: z z z z z z z Set needle thread tension to "5". Press the button for the widest zigzag stitch. Set stitch length to "2.0". Place a piece of fabric under the zigzag foot and sew. Press the button for straight stitch.
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38. Adjustment of thread check spring stroke The thread check spring prevents the descending needle from piercing the slack needle thread. The needle thread is slackened by the descending take-up lever. Requirement: Thread check spring 126 must keep the needle thread taut at least until the needle point enters the fabric (fig. 77). The thread check spring must release the needle thread as soon as the lower edge of the needle eye enters the fabric. Check: z z z z z Press the straight stitch button.
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39. Adjustment of equal stitch length for left and right buttonhole seams Requirement: The stitch lengths of the left buttonhole seam and of the right buttonhole seam must be the same (fig. 78). Note: When the correct zero point has been set on the stitch length regulator, the stitch lengths of the buttonhole seams are normally the same (section 11 of this manual). Check: z Sew a buttonhole with gimp thread and compare the two stitch lengths.
40. Adjustment of equal forward and reverse stitch length (for forward and reverse controlled utility stitches) Requirement: The needle perforations for the honeycomb stitch must always take place in the same penetration holes for forward and reverse feed (fig. 82). Check: z Set the adjustment dial for the stitch length against the stop of the triple stitch symbol. z Press the button for honeycomb stitching (on Pfaff 1520 /1530 set the automatic unit adjustment dial to "F").
41. Making up a sewing sample When all sewing checks are completed and the machine sews perfectly, a sewing sample is to be made. This sewing sample should contain the most important stitch patterns that can be sewn on the repaired machine (fig. 83). If the customer has any particular requirements, these should be produced on a separate sample. The following is a sewing sample made on the PFAFF 1540 Stitch program Stitch length Presser foot No. 1 2 3 4 5 6 8 2.5 2.0 1.0 ||| ||| ||| approx. 0.
Repair Instructions 42. Removing and fitting the needle thread tension Removal: z z z z z z z Remove the needle thread tension. Press the two plastic noses 131 together and remove tension dial 132 (fig. 93). Remove spring disk 133. Turn knurled nut 125 out of guide 134. Remove guide 134. Remove knurled nut 125 and pressure spring 135. Pull out or knock out cemented tension stud 136 complete with pressure piece 137 and the three tension disks 138, 139 and 140.
43. Changing the pressure spring in the handwheel release Removing the handwheel release z Remove plastic cap 141 using clearance gauge 00-880 133-01 (fig. 94). z Remove metal screw 142. z Pull out handwheel release disk 143 and take out pawl 144, clutch piece 145 and pressure spring 146. Fitting the handwheel release z Turn handwheel 147 and clutch disk 148 until the hole in the handwheel and the cutout in the clutch disk are facing downwards (fig. 95).
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44. Removing and fitting the sewing hook Removal: z z z z z z z z Remove the needle. Unscrew the presser foot. Remove the bobbin case. Remove the bobbin case position finger. Remove the three screws with springs from behind (fig. 100). Remove the bobbin case base with sewing hook gib (fig. 101). Turn the sewing hook gib to the left or to the right out of the bobbin case base (fig. 102). Clean the sewing hook, bobbin case base and hook gib.
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46. Changing the toothed belt Removal: z z z z z z z z z z z z z z Disconnect the machine lead cord. Remove needle and presser foot. Remove detachable work support. Remove top cover. Switch on bobbin winder. Remove the two Torx screws of the housing insert. Remove the housing insert. Remove the four retaining screws of the baseplate. Place the baseplate aside. Loosen screw 152 in arm shaft crank 153 (fig. 106). Loosen screw 1 on tensioning roller 2. Remove screw 154 on the upper toothed belt sprocket 155.
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47. Adjusting the arm shaft crank z Press the straight stitch button. z Carefully loosen screw 152 on arm shaft crank 153 just enough to allow the arm shaft crank to be turned on its shaft (fig. 107). z Raise the needle bar and insert the needle. z Firmly hold arm shaft crank 153 using the left hand. z At the same time, turn the handwheel with your right hand until the feed dog is at the bottom and the sewing hook point is centered between the feed dog rows.
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48. Changing the bevel gears Note: Always change bevel gears in pairs. Removal: z z z z z z z z z z z z z z z z z z z z z z z z z z Remove the housing covers as described in this manual. Remove the synchronizer from the shaft to the right. Loosen the two screws 101 on small gear 97 (fig. 110). Remove small gear 97 from the hook driving shaft 45 to the right. Disconnect pull-spring 6 (fig. 111). Loosen screw 19. Remove the feed-dog lowering mechanism.
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Refitting: z Set the new bevel gear with the lifting eccentric onto the sewing hook bearing. z Insert hook shaft bushing 109 and tighten screw 110 lightly (fig. 110). z Insert the small hook driving shaft with the small bevel gear 111 and the two plastic washers. Note: The large surface of hook shaft bushing 109 must face to the right. z z z z z z z Insert set screw 160 and fasten the hook bearing (fig. 111). Insert sewing hook 44 and tighten one of screws 108 (fig. 112).
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49. Changing the motor Note: The motor must be replaced as a complete unit. Removal: z z z z z z z Disconnect the machine lead cord Remove the detachable work support. Remove the housing covers as described in this manual. Remove the right-hand motor retaining screw 57 (fig. 113). Disconnect light plug 46. Remove the second motor retaining screw 56. Lift motor sprocket 58 out of toothed belt 59 and remove the motor to the front.
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50. Changing the motor circuit board on motor types UUS 390 and UUS 393 Note: Capacitor and master switch must always be replaced with the circuit board. Removal: z z z z z Remove the motor in accordance with section 49 of this manual. Slightly raise the two locking tabs 163 and remove cover 162 (fig. 114). Unsolder the two cables at points 168. Remove the three screws 165. Remove circuit board 164. Refitting: z z z z z z z 90 Solder the two cables to points 168 at the top of the new circuit board.
51. Changing the carbon brushes on motor types UUS 390 and UUS 393 Removal: z z z z z z Remove the motor in accordance with point 49of this manual. Slightly raise the two locking tabs 163 and remove cover 162 (fig. 115). Unscrew the two groove nuts 170. Pull the motor apart and remove end shield 171. Detach the torsion springs and remove carbon brushes 169. Clean the collector and the motor. Refitting: z z z z z z z Insert the two new carbon brushes and re-attach the torsion springs.
52. Changing the motor pinion Note: The motor pinion must only be removed when a rotor is exchanged. Removal: z Remove the motor in accordance with point 49 of this manual. z Insert two screwdrivers of the same width between pinion 58 and the motor bearing (fig. 116). z Rotate the two screwdrivers in opposite directions, thus prizing pinion 58 off the shaft. Note: The old motor pinion gear is no longer usable.
53. Changing the motor toothed belt Removal: z z z z z z z z Disconnect the machine lead cord Remove the housing covers as described in this manual. Remove the two screws 56 and 57 of the motor (fig. 117). Disengage the handwheel. Remove plastic cap 141. Remove handwheel screw 142 (fig. 118). Remove the complete handwheel. Remove toothed belt 59. Refitting: z z z z z z z z Insert the new toothed belt 59 and press it up until there is enough space for the handwheel (fig. 117).
54. Changing the circuit board in foot control AE 010 Removal: z z z z z z z Turn the foot control so that it is resting on pedal 175. Insert a screwdriver with a wide blade on the side opposite to the cables (fig. 119). Turn the screwdriver while removing pedal 175 upwards. Carefully remove cables 177 from the circuit board (fig. 119). Remove pressure piece 174 and spring 173. Remove the two Phillips screws 176. Remove the complete circuit board.
55. Changing the mains connections in foot control AE 010 Note: When changing connections it is compulsory to use original PFAFF connection cables, as only these are approved. Removal: z z z z z z z Turn the foot control so that it is resting on pedal 175. Insert a screwdriver with a wide blade on the side opposite to the cables (fig. 120). Turn the screwdriver while removing pedal 175 upwards. Carefully remove mains connection cables or machine cables 177 from the circuit board (fig. 120).
Safety test 56. Electrical safety test According to the German law on safe machine operation of June 24, 1986, VDE regulations are the recognized rules in the field of electrical engineering and form the basis for electrical safety tests of technical appliances. The required electrical tests for the appliances are laid down in paragraph 4 of the regulations for repair, modification and testing of electrical appliances (VDE 0701 date of issue 10.86).
IV Simulated leakage current test: Milliampere = mA z z z z Leave sewing machine plug in tester connection. Use clamp to attach test lead of testing appliance M 5013 to presser bar. Set testing range switch at "20 mA" (fig. 124). Meter reading: 0.50 mA maximum.
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58. Simulated leakage current measurements of complete motors with ABB Metrawatt M 5013 V Simulated leakage current measurements of complete motors z When exchanging complete motors or motor parts (windings, rotors or capacitors), the complete motor must be measured for leakage current before fitting in the machine. z Set testing range switch at "20 mA" (fig. 125). z Screw nut No. 92-320 068-05 to the motor. z Connect auxiliary angle plug No. 29-924 800-04 to the motor plug.
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B. & Th. Göb ImageDesign, e-mail: info@tg-imagedesign.de, www.tg-imagedesign.com PFAFF GmbH Amalienbadstraße 36 D-76227 Karlsruhe Phone +49 (0)721/4001-0 Telefax +49 (0)721/4001-513 E-Mail: info@pfaff.com http://www.pfaff.de Printed in Germany Technische Änderungen vorbehalten Subject to alterations in design Sous toute réserve de modifications techniques Salvo modificaciones técniche Druckerei Gablenz GmbH Stettiner Straße 17 76356 Weingarten © 2003 copyright VSM-Group AB All rights reserved.
