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Pfaff 1520 Sewing Machine User Manual

1. Rest fehft noch Fig 118 93 54 Changing the circuit board in foot control AE 010 Removal 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 Refitting e Insert the complete new circuit board making sure that the switch fits into the guide of the pre selection slide Insert the two Phillips screws 176 and firmly tighten Turn the potentiometer counter clockwise until the crank journal is at the top e In this position insert spring 173 and pressure piece 174 e Connect cables 187 to the printed circuit board e Refit pedal 175 Use a screwdriver with a wide blade to press the pedal a little aside and insert it downwards 6 Carry out a functional test e Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metrawatt M 5013 94 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 e Turn the foot control so that it is resting on pedal 175 e Insert a screwdriver
2. 2 gt x LT Fig 77 71 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 buttonho le seams are normally the same section 11 of this manual Check e Sew a buttonhole with gimp thread and compare the two stitch lengths Adjustment e If right buttonhole seam has longer stitch length than left one fig 79 turn setting eccentric slightly to the front in direction A fig 81 e If left buttonhole seam has longer stitch length than right one fig 80 turn setting eccentric slightly to the rear in direction B fig 81 Cross check Sew a buttonhole with gimp thread and check the stitch length Fig 78 Fig 79 Fig 80 Fig 81 72 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 Set the adjustment dial for the stitch length against the stop of the triple stitch symbol Press the button for honeycomb stitching on Pfaff 1520 1530 set the automatic unit adjustment dial to
3. Tighten screw 78 Note When setting eccentric 74 is in its basic position connecting lever 50 must be parallel to the automatic unit adjustment dial Fig 28 36 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 e Remove presser foot Insert a new needle Set stitch width adjustment dial 70 to O fig 32 e Set needle position adjustment dial 79 to center e Turn the handwheel and check the centered position of the needle Adjustment Loosen the three screws 75 on the zigzag stitch unit by just 1 8 of a turn e Turn the handwheel until the needle point is level with the surface of the needle plate fig 31 e Move the zigzag stitch unit to the left or right until the needle is exactly in the center of the needle plate slot fig 32 Note The zigzag stitch unit should now be parallel to the arm shaft and clear it by 3 0 mm e Tighten the three screws 75 Cross check The needle must be exactly in the center of the needle plate slot 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
4. Place two layers of linen fabric under the presser foot and sew the honeycomb stitch Adjustment e Loosen hexagon head screw 129 by just 1 8 of a turn using a 5 5 mm spanner fig 82 Loosen screw 130 by approx 2 turns e Tighten screw 129 just a little Sew the honeycomb stitch The stitch length of the honeycomb stitch should now be a bit too long e Loosen screw 129 e Tighten screw 130 just a little Slightly tighten screw 129 Sew the honeycomb stitch and check needle perforations Continue adjusting screws 129 and 130 until the needle enters the same perforations Tighten screw 129 securely Cross check Sew the honeycomb stitch and the stretch triple straight stitch and check whether the needle always ent ers the same perforations 1 n 7 0 2 uu TH 1 ga HU 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 Straight stitch 2 5 Zigzag foot 0 2 Zigzag stitch 2 0 Zigzag foot 0 3 Decorative stretch stitch 1 0 Zigzag foot 4 Honeycomb stitch
5. Lateral adjustment e Use button 116 to turn the threader prong 115 to the front into the needle eye e Loosen screw 120 by just 1 8 of a turn fig 70 e Move prong bracket 121 laterally until prong 115 is precisely centered in the needle eye e Tighten screw 120 Cross check 2 Use the button to move threader prong 115 to the rear and to the front again At the same time carry out a visual check of the lateral position of the prong e Rotate pull spring 117 by two full turns counter clockwise and engage it in hook 122 in such a way that the body of the spring is positioned outwards to the left fig 71 This ensures that the threader is swung automatically backwards e Operate the threader button and carry out a visual and functional check 64 Fig 70 Sn TL 123 16 f SN L L fr ME ge e R 1 2108 HS 0y lt A NOL io gt Fig 71 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 Wind a bobbin and check that the winder stops as required Adjustment Loosen screw 123 fig 72 Position stop 124 to the left for less thread and to right for more thread Tighten screw 123 Cross check e Wind a bobbin and check that the winder stops as required 4 125 Fig 72 66 36 Adjustment of bo
6. SS NM 80 9 NM 100 ES 0 2 mm Fig 57 md i 77292222222 1 Fig 58 57 Fig 59 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 Remove the needle e Remove presser foot and needle plate Remove the bobbin case e Unscrew the bobbin case position finger Remove sewing hook gib with bobbin case base by unscrewing the three screws Insert a new system 130 705 H size 80 needle O Press the straight stitch button Turn the handwheel until the hook point is exactly opposite the center line of the needle Check the clearance between the hook point and the bottom of the needle scarf e Check the axial play of hook 107 to hook shaft bushing 109 Adjustment e If the hook shaft has axial play loosen the two screws 108 fig 61 e Push bevel gear 111 with the shaft to the front and sewing hook 108 to the rear e Tighten the two screws 108 e Loosen screw 112 in the lifting eccentric by 2 3 turns Loosen screw 110 slightly Turn handwheel and sewing hook until the hook point is exactly opposite the center line of the needle scarf e Shift the sewing hook tog
7. e Remove the needle rise clamp e Tighten screw 152 on arm shaft crank 153 until arm shaft 157 has no play and the needle rise move ment is correct To this end reposition the needle rise clamp and check e Refit the needle plate e Adjust the sideways movement of the needle bar in accordance with section 18 1520 30 or section 25 1540 Fold the baseplate against the machine and fasten it with the four screws e Insert the housing insert and fasten it with the two screws e Then the following items have to be checked and adjusted on the machine Adjustment of bobbin thread tension section 34 e Adjustment of needle thread tension section 35 Adjustment of thread check spring stroke section 36 Adjustment of equal forward and reverse stitch length for utility stitches Section 38 e Carry out an electronic safety test in accordance to VDE 0701 using testing appliance ABB Metrawatt M 5013 82 ET AT 7 116 1 n E TUT z ra m Io Ll 95 Fig 109 83 48 Changing the bevel gears Note Always change bevel gears in pairs Removal 84 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
8. e Turn the sewing hook gib to the left or to the right out of the bobbin case base fig 102 e Clean the sewing hook bobbin case base and hook gib Fitting e Turn the handwheel until the opening of the sewing hook faces to the left fig 103 e Turn the sewing hook gib to the left into the bobbin case base fig 104 e Insert the bobbin case base complete with sewing hook gib into the sewing hook fig 105 e Secure the sewing hook gib from behind with three screws with springs fig 100 e Screw on and adjust the bobbin case position finger 45 Cleaning and oiling the machine Note The machine is equipped with sintered bearings and components and is therefore maintenance free for the user Only the sewing hook should be lubricated once in a while with normal sewing machine oil After repair work the service engineer should oil the machine with BP Energol HLP 46 or HLP 80 and the sewing hook with normal sewing machine oil Sintered bearings and components must not be cleaned with gasoline petroleum kerosene thinners trichlorethylene etc 78 46 Changing the toothed belt Removal 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
9. Loosen screw 19 Remove the feed dog lowering mechanism Set the adjustment dial for the stitch length control to Loosen screw 5 Remove washer 14 Remove bolt 11 Remove the two screws 114 of bobbin case position finger 113 Place bobbin case position finger 113 and the leaf spring aside Loosen the two screws 108 on the sewing hook fig 112 Remove the entire sewing hook 107 to the top Remove the entire connecting bar 10 from actuating crank 39 fig 111 Move connecting bar 10 as far as possible to the left Push driving eccentric 33 to the left Knock out hollow pin 161 fig 110 Remove the circlip with a screwdriver Push the plastic washer a little to the left Remove screw 112 of the lifting eccentric fig 111 Loosen the three screws 44 of the lower belt sprocket fig 110 Move hook driving shaft 45 fully to the right Remove set screw 160 at the sewing hook bearing and push the latter fully to the left fig 111 Turn the sewing hook bearing a little and remove the small hook driving shaft along with the small bevel gear 111 Remove screw 110 at the sewing hook bearing and remove hook shaft bushing 109 fig 112 Remove the large bevel gear with the lifting eccentric from the hook shaft 1 All TEL Fig 110 45 10 34 33 161 44 101 97 lr m ATC 114 11 TES C M sq 1 1 1 1 1 3 8 112 6 7 Fi
10. Set needle position adjustment dial to center Set the adjustment dial on the automatic unit to E 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 e Crank 90 should now rest on stop 85 Adjustment Set stitch width adjustment dial to 5 0 Set needle position adjustment dial to center Set the adjustment dial on the automatic unit to E Rotate the hand wheel until the needle moves downward on the left side and is at a position of roughly 1 mm above the needle plate Push stop 85 against crank 90 fig 38 Tighten screw 84 Cross check e As described under Check O EI 1 A gt gt q 1 7 Fig 38 al o 90 40 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 0 Set the adjustment dial for the automatic unit to e Move the stitch length adjustment dial to the stretch symbol up to the stop e Rotate the handwheel until adjusting crank 39 is positioned fully to the front fig 40 Move feed reversing bar 54 up and down a little and at the same time check the 0 2 mm clearance between reversing bar 54 and the end of the lever of feeler 91 fig 39 Adjustme
11. Zigzag foot 0 5 Stretch triple straight stitch Zigzag foot 0 6 Stretch triple zigzag stitch Zigzag foot 0 8 Linen buttonhole approx 0 3 Buttonhole foot 5 TT Ts mm mum 11111 1111 1111111 Fig 3 74 Repair Instructions 42 Removing and fitting the needle thread tension Removal 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 quide 134 Remove quide 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 tensi on disks 138 139 and 140 Fitting e Insert tension stud 136 with the three tension disks and fit pressure piece Cement tension stud into the mounting plate with Onmivit Rapid Push pressure spring 135 and knurled nut 125 onto tension stud 136 e Insert guide 134 with its right side and fully screw in knurled nut 125 e Push on adjustment dial 132 making sure that the guide nose is in contact with the outer surface of the curve e Install the needle thread tension e Adjust the needle thread tension according to section 35 75 43 Changing the pressure spring in the handwheel release Removing the handwheel release Remove plastic cap 141 using clearance gauge 00 880 133 01 fig 94 Remove metal screw 142 e Pull out handwheel release disk 143 and ta
12. m mi 11111 1 7 Wi al 0000 0 27 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 e Set the stitch length graduated dial to O Place a piece of fabric under the presser foot e Lower the presser foot e 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 Precondition 2 Eccentric 40 must be in its basic position facing upwards fig 18 Adjustment e Loosen screw 41 with a 5 5 mm spanner e Re position screw 41 until the center lines of the bolts in actuating crank 39 and linkage 42 and rod 43 are level see dot dash line e Tighten screw 41 Cross check e As described under Check O Fig 17 28 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 After completing the feeding movement the feed dog moves down below the needle plate surface and the needle ent
13. 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 Make sure that it is not subjected to dust severe dampness direct sunlight static electricity heat produ cing objects corrosive chemicals or liquids To ensure adequate ventilation the machine should be placed unobstructed on a firm even surface Handling Always protect the machine from damage caused by hitting or dropping Cleaning To clean the housing use a dry clean soft lint free cloth To remove particularly persistent dirt use a soft cloth with a neutral cleansing agent for plastic materials Please note Do not use any insecticides or chemical products such as petrol gas or liquid chemicals to clean the housing Safety 1 The machine must be put into operation according to the indications on the specification plate 2 Do not place any objects in the openings on the machine 3 Do not use the sewing machine if there is visible damage its function is defective it is wet e g with condensation 4 Do not pull the mains plug out of the socket by its cord 5 If this appliance is used for another purpose than that intended or if it is wrongly operated we cannot accept any liability for any damage caused 6 To avoid the risk of ele
14. 3 and 4 fig 2a Loosen screw 5 e Detach spring 6 e 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 Push bolt 11 against connecting bar 10 Firmly tighten screw 5 Re attach spring 6 Cross check The feed dog must be exactly in the center of the feed slot The feed driving shaft must not bind nor have any play 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 O Lay the machine on its back e Loosen screw 12 fig 4 Remove bolt 13 to the right Loosen screw 5 e Remove circlip 14 e Remove bolt 11 e Loosen both screws 3 and 4 e 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 Detach spring 6 Remove the needle plate Pull the feed dog forward with one finger and release The complete feed dog driving shaft 7 must slide lightly back Loosen screw 15 fig 5 Move the top feed lever forwards and backwards The top feed should move freely without any difficulty if necessary remove cause of binding Fit bolt 13 with the washer located to the left of pull
15. Insulation resistance higher than 20 M Ohm must be recorded in the testing certificate 96 IV Simulated leakage current test Milliampere mA 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 e Meter reading 0 50 mA maximum O ABB METRAWATT M 50139 fm O ABB METRAWATT M 50130 97 Fig 124 58 Simulated leakage current measurements of complete motors with ABB Metrawatt M 5013 V Simulated leakage current measurements of complete motors 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 Set testing range switch at 20 mA fig 125 Screw nut No 92 320 068 05 to the motor Connect auxiliary angle plug No 29 924 800 04 to the motor plug Connect the two test leads as in fig 125 e Meter reading 0 75 mA maximum 59 Measures required in case of incorrect readings Re I If one of the four test functions is a failure the grounded electrical outlet is defective Take necessary steps to repair the electrical outlet Re II If the current consumption deviates considerably from the indicated value even though the machine does not bind
16. The old motor pinion gear is no longer usable Refitting e Support the rotor shaft at the opposite end and push on the new motor pinion Measure the simulated leakage current in accordance with section 58 of this manual Fit and glue on outer disk 172 Fit the motor in accordance with section 49 e Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metrawatt M 5013 92 53 Changing the motor toothed belt Removal e 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 e Disengage the handwheel e Remove plastic cap 141 e Remove handwheel screw 142 fig 118 Remove the complete handwheel Remove toothed belt 59 Refitting e Insert the new toothed belt 59 and press it up until there is enough space for the handwheel fig 117 e Insert handwheel and place the toothed belt 59 correctly onto the handwheel pinion Insert handwheel screw 142 and moderately tighten it Fit the toothed belt onto motor pinion 58 e Secure the motor with screws 56 and 57 and at the same time adjust the belt tension e Refit plastic cap 141 e Refit the hosing covers as described in this manual Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metravvatt M 5013
17. above the needle plate fig 50 Check e Set stitch width adjustment dial to the maximum zigzag width 0 Set needle position adjustment dial to center Press zigzag stitch button Remove presser foot e Turn the handwheel in sewing direction until the needle rises on the left hand side and the needle point is positioned exactly on the surface of the needle plate fig 51 e You can check the start of the sideways movement of the needle by simultaneously touching the back side of the needle bar frame and the machine head with the index finger of your left hand while turning the handwheel very slowly with your right hand Adjustment e Loosen the two screws 101 fig 52 Turn the handwheel in sewing direction until the needle rises on the left hand side and the needle point is positioned exactly on the surface of the needle plate fig 51 e Rotate the large gear 98 in the direction of the arrow until feeler finger 102 fig 53 is exactly at the starting point of rising cam 103 e Hold the large gear 98 firmly in this position to prevent it from turning e Disengage the small gear 97 by moving it to the right rotate it until one of the screws 101 is accessible and then move it fully to the left and re engage e Gently tighten screw 101 Cross check e Test the needle bar sideways movement as described under Check Tighten the two screws 101 50 7 0 ommf T 8 mm IDA VL PIII 02222222
18. crank 153 fig 106 Loosen screw 1 on tensioning roller 2 Remove screw 154 on the upper toothed belt sprocket 155 Remove the circlip 156 from the arm shaft Moving arm shaft 157 to the right remove the toothed belt for the machine and the toothed belt for the motor 59 e Loosen the three screws 94 95 and 96 on the automatic utility stitch unit Loosen the two screws 101 and remove small gear 97 to the right Move the automatic utility stitch unit a little to the front and remove toothed belt 158 between the large gear and the shaft end Refitting Insert the new toothed belt 158 for the machine between the large gear and the end of the shaft and mount it on the lower belt sprocket 159 Tighten the three screws 94 95 and 96 on the automatic utility stitch unit e Pull toothed belt 158 upwards Slide arm shaft 157 to the left through toothed belt 158 into the left bearing and arm shaft crank 153 e Refit circlip 156 on the arm shaft Secure the arm shaft and insert screw 152 in the arm shaft crank e Mount toothed belt 158 on the upper belt sprocket 155 e Insert screw 154 in the upper belt sprocket and firmly tighten Adjust tensioning roller in accordance with section 1 e Mount toothed belt 59 for the motor on the handwheel e Refit small gear 97 on the shaft and gently tighten screws 101 e Adjust the gears in accordance with section 22 80 81 47 Adjusting the arm shaft crank O Press
19. e Utility stitch width 5 5 mm e Stitch length from 0 to 6 mm Reverse stitch length from to 3 mm High ohm foot control cold e FM radio and TV screened approval marking suppression degree B Safety class with GS test marking Master switch for motor Glare free built in sewing lamp 230V or Pendulum type needle bar frame Transmission of drive from arm shaft to lower shaft by toothed belt transmission ratio 1 1 e Power input rating 90 when sewing at 950 r p m 40 when stationary e Maintenance free PFAFF transverse double rotating hook Link take up lever e Linkage type feed regulator e Dual fabric feed Disengageable feed dog Needle threader e Drive from motor to handwheel by flat toothed belt e 60 1000 stitches per minute Sintered metal bearings e Oil for sintered metal bearings BP Energol HLP 46 or HLP 80 No 28 036550 09 e Oil for sewing hook No 91 129452 91 e Clear workspace 175 114 205 mm Machine height 280 mm e Baseplate dimensions 390 155 mm Free arm dimensions 80 49 200 mm e Housing material lightweight metal e Weight of sewing head approx 8 kg Needle system 130 705 H Additional needle system classifications Twin needle Suffix Zwi Wing needle Suffix Wing Twin hem stitching needle Suffix Zwi Ho Top stitch needle Suffix N Stretch needle Suffix PS Jeans needle Suffix J Possible needle points Small ball point Suf
20. flush with the left hand side and dot mark 80 is indicated in the position shown in fig 34 e Continue to turn worm 87 slowly until the needle begins to move to the right e Prevent the stack of cams 88 from rotating by holding it from the front fig 37 e Turn the worm backwards until a little binding can be felt thus making sure that worm 87 and worm gear 89 have no play fig 34 e Tighten one of the screws 86 e Check the sideways movement of the needle by rotating the handwheel e Check the needle penetration in the needle plate slot e If necessary loosen the two fastening screws 61 on the automatic unit bracket and move the automatic unit bracket to the left or right until the needle has the same clearance from the left and right edges of the needle plate slot Tighten the two fastening screws 61 on the automatic unit bracket e Check the setting for sideways needle movement once again and if necessary re adjust Tighten the three fastening screws 86 on worm 87 38 Cross check e As described under Check Hla VZ 22222222222 omm T 8 mm DAVE ZA VLD 1 1 1 ESA A gt 7 sje L T co rss el re 86 87 Fig 34 EN 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 0 Set stitch width adjustment dial to 5
21. requirements of the VDE 0701 57 Electrical safety test with ABB Metrawatt M 5013 Mains power voltage test volt V For all following tests insert plug of ABB Metrawatt M 5013 into a grounded electrical outlet Set the testing range switch at 250 V fig 121 If there is mains power voltage the LCD shows the respective value 230 V 10 The contact field is located a bit to the right just below the knob for the measuring range Touch this field with your finger to check the ground lead of the electrical outlet Signal lamp PE just above the contact field will light up if the ground lead is out of order e Insert plug of sewing machine into the main power connection of ABB Metrawatt M 5013 e Operate the machine Meter reading 230 V 10 Measuring appliance M 5013 can only be used with mains power voltages from 207 to 253 10 II Appliance current test Ampere A Leave sewing machine plug in mains socket Set testing range switch at 16 A fig 122 e Operate the machine Meter reading 0 5 A maximum lll Insulation resistance M ohm M e Insert plug of sewing machine in tester connection Use clamp to attach test lead of testing appliance M 5013 to presser bar 0 Set testing range switch at 20 M Ohm fig 123 Meter reading minimum 2 M Ohm With meter readings higher than 20 M Ohm appliance M 5013 displays the figure 1 In these cases the remark
22. 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 34 and when during a left hand zigzag stitch the point of the rising needle is level with the surface of the needle plate fig 35 dot mark 81 on the large gear wheel 82 must be exactly in the center of the small gear wheel 83 fig 36 Check Unscrew the baseplate e Set stitch width adjustment dial to the maximum zigzag width 0 Set needle position adjustment dial to center 0 Set the adjustment dial of the automatic unit to the E position Remove presser foot e Turn the handwheel in sewing direction until hole mark 80 is indicated on the automatic unit bracket the needle rises on the left hand side and the needle point is positioned exactly on the surface of the needle plate e Check the position of the dot mark on the large gear wheel in relation to the small gear wheel e Slowly rotate the handwheel and check the start of the sideways movement of the needle Adjustment e Loosen screw 84 on stop 85 for the left hand needle position e Loosen the three fastening screws 86 on worm 87 e Rotate the handwheel until the point of the rising needle is level with the surface of the needle plate fig 35 The handwheel must not be rotated any further e Turn worm 87 to the front until it is
23. the motor is defective and must be exchanged or repaired Re III If the insulation resistance drops below the required value the defective components must be found by systematic checking and must be repaired or replaced Re IV The components with inadmissibly high leakage current must also be found by systematic checking and must be repaired or replaced ReV Return the motor to the factory 76227 Karlsruhe 21 08 2001 HTS O ABB METRAWATT 77 Fig 125 99 Notes 100 Notes 101 Notes 102 Notes 103 8 amp Th G b ImageDesign e mail info tg imagedesign de www tg imagedesign com PFAFF PFAFF GmbH AmalienbadstraBe 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 Druckerei Gablenz GmbH Stettiner Stra e 17 76356 Weingarten 2003 copyright VSM Group AB All rights reserved Printed in Germany Technische nderungen vorbehalten Subject to alterations in design Sous toute r serve de modifications techniques Salvo modificaciones t cniche Con riserva di modifiche tecniche No BP 00059
24. the straight stitch button e Carefully loosen screw 152 on arm shaft crank 153 just enough to allow the arm shaft crank to be tur ned on its shaft fig 107 e Raise the needle bar and insert the needle e Firmly hold arm shaft crank 153 using the left hand 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 Now firmly hold the handwheel and at the same time turn arm shaft crank 153 until the needle bar rea ches its lowest position Fit spacer 63 102600 18 on the needle bar Place the needle rise clamp 00 870137 01 onto the needle bar and tighten it just a little fig 109 Place the 2 2 mm feeler gauge 00 870136 01 onto the needle bar with its cutout above the needle rise clamp Push the needle rise clamp and the 2 2 mm feeler gauge up against the spacer Tighten the knurled screw on the needle rise clamp If there is play on the feeler gauge repeat the above procedure Remove the 2 2 mm feeler gauge Hold the handwheel and turn arm shaft crank 153 in sewing direction until the needle rise clamp rests on the spacer The sewing hook point must now be exactly opposite the center line of the rear side of the needle e If this is not the case turn simultaneously handwheel and arm shaft crank 153 until the sewing hook is exactly opposite the center line of the rear side of the needle with the clamp resting on the spacer
25. 02600 58 e Adjustment gauge for the bobbin case holder 00 880133 01 O Presser foot gauge 63 114690 39 e Ring shaped open end spanner 5 5 mm 43 111010 04 O Torx screwdriver TX 6 07 434008 40 Torx screwdriver TX 10 07 434008 44 O Torx screwdriver TX 15 07 434008 45 Torx screwdriver TX 20 07 434008 46 Torx screwdriver TX 25 07 434008 47 e Torx offset screwdriver TX 15 07 434008 74 e Circlip fitting tool 2 3 short 07 437003 20 e Circlip fitting tool 3 2 short 07 437003 30 e Circlip fitting tool 4 0 short 07 437003 40 e Circlip fitting tool 5 0 short 07 437003 50 e Circlip fitting tool 6 0 short 07 437003 60 e Circlip fitting tool 10 0 short 07 437003 86 SPNO NOOK med 07 437006 00 Subject to design and dimensional modifications Notes on the sewing machine in relation to environment handling cleaning and safety Environment
26. 222 202 2 22222222222 1 1 1 4 Fig 51 Fig 50 NE SSS i JE we 0 JS TO 97 101 98 Fig 52 02 103 7 Fig 53 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 Remove the presser foot e Insert a new needle e Set zigzag stitch adjustment dial to 5 Set needle position adjustment dial to center e Press zigzag stitch button Turn the handwheel and check the left and the right clearance in the slot Adjustment e Loosen screw 84 fig 38 and move stop 85 to the left Loosen screw 73 fig 55 e Rotate setting eccentric 74 until the two clearances are equal Tighten screw 78 Cross check e Turn the handwheel and check the clearances Fig 55 Fig 54 52 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 e Set stitch width adjustment dial to 5 Set needle position adjustment dial to center Press the zigzag stitch button Rotate the handwheel until the needle moves downward on the left side an
27. PFAFF select 1520 1530 1540 german engineering Service Manual Contents Foreword Notes on the sewing machine in relation to environment handling cleaning and safety Specifications off PFAFF machines Removing the housing covers Adjustment instructions Feeding system Adjustment of toothed belt tension Adjustment of feed dog in sideways direction on Pfaff 1520 Adjustment of feed dog in sideways direction on Pfaff 1530 1540 Adjustment of feed dog height Adjustment of presser bar height on Pfaff 1520 Adjustment of presser bar height on Pfaff 1530 1540 Adjustment of top feed foot in sewing direction Adjustment of top feed foot height 9 Adjustment of feed regulator cranks on Pfaff 1520 1530 10 Adjustment of feed regulator cranks on Pfaff 1540 11 Zero point adjustment of stitch length regulator 12 Timing of feed motion gt Automatic utility stitch unit 13 Replacing the automatic module on Pfaff 1520 1530 14 Adjustment of the locking disk 15 Replacing the zigzag stitch unit on Pfaff 1520 1530 16 Basic position of setting eccentric for the sideways needle position 17 Adjustment of needle penetration in needle plate slot 18 Adjustment of the sideways movement of the needle bar 19 Adjustment of the stop for the left needle position 20 Adjustment of the feed reversing bar 21 Replacing the utility stitch unit on Pfaff 1540 22 Adjustmen
28. ar above the needle rise clamp Loosen the needle rise clamp and push the 2 2 mm feeler gauge upwards against the spacer e Tighten the knurled screw on the needle rise clamp e Slightly turn the handwheel back and forth e If there is any play on the feeler gauge repeat this procedure Remove the 2 2 mm feeler gauge e Turn the handwheel in sewing direction until the needle rise clamp rests on the spacer This means that the needle has moved upwards by 2 2 mm to the needle rise position The hook point must now be exactly behind the center line of the needle fig 62 Adjustment e If the setting is not correct remove the needle rise clamp e Loosen the two screws 108 fig 64 e Refit the needle rise clamp and repeat the operation as described under Check until the needle bar has moved 2 2 mm upwards and the needle rise clamp rests on the spacer Turn the hook until the hook point is exactly behind the center line of the needle e Press sewing hook 107 and bevel gear 111 together so that there is no play between them and tighten one of screws 108 Cross check e Slightly turn the handwheel back and forth until the needle rise clamp rests on the spacer fig 62 The hook point must be exactly behind the center line of the needle e Remove the needle rise clamp e Check that the hook shaft has no axial play e Tighten the two screws 108 very firmly 60 7 ELLE 111 Fig 64 61 32 Adju
29. ase but without play between the position finger and the bottom of the groove in the bobbin case base fig 68 Adjustment Loosen the two screws 114 e Insert clearance gauge e Press bobbin case position finger 113 against the gauge at an angle of 90 degrees e Tighten the two screws 114 Cross check e As described under Check M S 114 00 880 133 01 63 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 Insert a new system 130 705 H size 70 needle e Move the needle bar to its top position by turning the handwheel e Push threader lever 116 fully down and swivel it forwards e Carry out a visual check Height adjustment e Disconnect pull spring 117 from above fig 71 Press threader bracket 118 down and hold it in this position Loosen Phillips screw 119 by just 1 4 of a turn Push threader bracket 123 upward or downward until prong 115 has the same distance from the top and bottom edge of the needle eye fig 69 e Tighten screw 119 in this position Cross check 1 Use the button to move threader prong 115 to the rear and to the front again e At the same time carry out a visual check of the prong height
30. bar has moved upwards by 2 mm and the needle rise clamp rests on the spacer fig 21 30 e 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 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 e Tighten all three screws 44 very firmly EL 45 10 34 33 44 31 Automatic utility stitch unit 13 Replacing the automatic module on Pfaff 1520 1530 Removal 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 Remove screws 56 and 57 and the two washers Remove motor pinion 58 from toothed belt 59 and remove the motor to the front Remove circlip 60 fig 23 Remove the two screws 61 Remove the complete automatic module downwards Fitting 32 Loosen the three screws 62 on worm 63 Push worm 63 to the left Insert the module upwards and at the same time insert pin 64 in the eyelet on connecting bar 65 Position the automatic unit in such a way that the two screws 61 are
31. bbin 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 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 Adjustment Loosen the knurled screw a little and turn it in again until a resistance is felt when the thread is pulled off Cross check e As described under Check Note e Once the bobbin thread tension has been set correctly tension adjustments should be made only on the needle thread tension 67 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 e Set needle thread tension to 5 Press the button for the widest zigzag stitch 0 Set stitch length to 2 0 Place a piece of fabric under the zigzag foot and sew e Press the button for straight stitch 0 Set stitch length to 2 5 e Sew with straight stitch Adjustment e First turn knurled nut 125 fully to the left fig 76 Press the butto
32. be without play The presser bar lifter must be in raised position Note Tighten the two screws 24 and 25 later when the top feed foot height is adjusted 20 a SS 5 E ad 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 Raise the presser bar lifter Remove presser foot amp presser foot holder e Set the maximum stitch length Engage the top feed foot e Turn the handwheel until the rising feed dog is flush with the needle plate surface Lower the presser bar lifter e Carry out a visual check Adjustment e Loosen screw 26 fig 12 e Raise the presser bar lifter until the top feed foot is just resting on top of the feed dog e At the same time push the top feed dog to the front or to the rear until its front edge is between the first and second tooth point of the center tooth row Lower the presser bar lifter e Tighten screw 26 making sure that driving shaft 27 has no play Cross check e Check as described under Check 22 Fig 11 Fig 12 23 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 press
33. ctric shock do not open the machine There are no parts inside the machine which the user can repair This is solely the responsibility of our qualified service staff 7 Be sure to use only original PFAFF parts 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 A straight stitch program with 15 needle positions A zigzag program with 15 needle positions A buttonhole program with adjustable width 12 utility stitches High ohm foot control cold with torque raising Dual fabric feed PFAFF 1520 Electronic free arm utility stitch machine with 15 sewing programs program dial A straight stitch program with 15 needle positions A zigzag program with 15 needle positions A buttonhole program with adjustable width 12 utility stitches High ohm foot control cold with torque raising Detailed specifications of the machines Electronic free arm utility stitch machine e Directly controlled automatic utility stitch unit step down ratio 6 1 1540 e Program selection by means of a program dial 1520 1530
34. d is at a position of roughly 1 mm above the needle plate fig 56 e Press the button for the buttonhole bartack The needle should now move approximately 0 2 mm to the left Adjustment e Set stitch width adjustment dial to 5 e Set needle position adjustment dial to center Press the zigzag stitch button Loosen screw 84 fig 38 Push stop 85 to a position 0 2 mm from the crank 90 e Tighten screw 84 Cross check Press the zigzag stitch button and the button for the buttonhole bartack alternately and check whether the needle moves by approx 0 2 mm without touching the needle plate i x 1 Wa dw A UIA 0 aN 0 2 mm Fig 56 Fig 38 53 Stitch forming parts sewing hook Foreword The sewing hook adjustment consists basically of the three following adjustments Needle rise sewing hook timing Needle bar height e 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 Needle bar height The needle bar height must be set in such a way that the sewing hook point can easily enter the thread loop above the needle eye at straight stitch and zigzag stitch setti
35. ease it again The zigzag foot must rest parallel and without play on the presser foot gauge Needle thread tension release must be without play The presser bar lifter must be in raised 19 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 O Raise the presser bar lifter e Fit the zigzag foot 0 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 Lower the presser bar lifter to its normal position again The zigzag foot must rest parallel and without play on the presser foot gauge However the presser foot gauge must not lift the zigzag foot and the needle thread tension release 23 must be without play fig 10 Adjustment e Loosen the three screws 21 24 and 25 With the presser bar lifter raised turn the zigzag foot until it is parallel to the sides of the presser foot gauge e Use a screwdriver to press presser bar guide 22 firmly downward At the same time firmly tighten screw 21 Cross check Push the presser bar lifter further upward and release it again The zigzag foot must rest parallel and without play on the presser foot gauge Needle thread tension release 23 must
36. ection 58 of this manual e Fit the motor in accordance with section 49 e Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metrawatt M 5013 90 51 Changing the carbon brushes on motor types UUS 390 and UUS 393 Removal Remove the motor in accordance with point 4901 this manual e 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 e Detach the torsion springs and remove carbon brushes 169 e Clean the collector and the motor Refitting Insert the two new carbon brushes and re attach the torsion springs Refit end shield 171 Insert the two groove nuts 170 and firmly tighten Insert cover 162 onto one side and allow it to engage on the other Measure the simulated leakage current in accordance with section 58 of this manual Fit the motor in accordance with section 49 Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metrawatt M 5013 Fig 115 91 52 Changing the motor pinion Note The motor pinion must only be removed when a rotor is exchanged Removal Remove the motor in accordance with point 49 of this manual e Insert two screwdrivers of the same width between pinion 58 and the motor bearing fig 116 e Rotate the two screwdrivers in opposite directions thus prizing pinion 58 off the shaft Note
37. emoving and fitting the needle thread tension Changing the pressure spring in the handwheel release Removing and fitting the sewing hook Cleaning and oiling the machine Changing the toothed belt Adjusting the arm shaft crank Changing the bevel gears Changing the motor Changing the motor circuit board on motor types UUS 390 and UUS 393 Changing the carbon brushes on motor types UUS 390 and UUS 393 Changing the motor pinion Changing the motor toothed belt Changing the circuit board in foot control AE 010 Changing the mains connections in foot control AE 010 Safety test 56 57 58 59 Electrical safety test Electrical safety test with ABB Metrawatt M 5013 64 66 67 68 70 72 73 74 75 76 78 78 80 82 84 88 90 91 92 93 94 95 96 96 Simulated leakage current measurements of complete motors with ABB Metrawatt M 5013 99 Measures required in case of incorrect readings 99 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 indica ted by a circle or a square The indications left right top bottom front and back always refer to the up
38. er bar is set correctly Check Raise the presser bar lifter e 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 Fully raise the presser bar lifter and hold it in this position At the same time insert presser foot gauge No 63 114690 35 from the rear under the zigzag foot and into the cutouts of the needle plate Lower the presser bar lifter to its raised position again e Press the top feed foot 28 about 2 mm upward against the pressure of the spring and release it e Check that the top feed foot rests only lightly on the presser foot gauge and has no play Adjustment e Loosen screws 24 and 25 Push counter bearing 29 lightly downward until the top feed foot 28 rests lightly on the presser foot gauge e Tighten screw 24 in this position Cross check Check for light resting and freedom of play of the top feed foot on the presser foot gauge as described under Check Adjusting the guide piece Fully raise the presser bar lifter and hold it in this position Remove the presser foot gauge e Lower the presser bar lifter to its raised position again Turn the handwheel until needle bar 30 is in its top position 24 Set guide piece 31 at a clearance of 0 2 mm from cross head 32 fig 14 e Tighten screw 25 Cross check Turn the handwheel and check
39. ers the fabric Underneath the needle plate the feed dog moves back to its basic position Requirement When the needle bar has moved 2 mm up from its lowest position b d c the line marks on the edge 34 of feeding eccentric 33 and connection rod 10 must be opposite each other fig 19 Check Remove needle Turn handwheel to set needle bar at its lowest position e Apply spacer 63 102600 18 over the needle bar and push it up against the needle bar frame fig 20 Place the needle rise clamp 00 870 137 01 onto the needle bar 30 and secure it lightly Place the 2 feeler gauge 00 870 136 01 onto the needle bar with its cutout above the needle rise clamp e Loosen the needle rise clamp and push the 2 mm feeler gauge up against the spacer e Tighten the knurled screw of the needle rise clamp e Turn the handwheel back and forth slightly e If there is play on the feeler gauge repeat the above procedure Remove the 2 mm feeler gauge Turn the handwheel in sewing direction until the needle rise clamp rests on the spacer fig 21 Tilt the machine over backwards The line marks on edge 34 of the feeding eccentric 33 and connection rod 10 must now be opposite each other Adjustment e If the adjustment is not correct remove the needle rise clamp e Loosen the three screws 44 in the lower belt gear e Re fit the needle rise clamp and repeat the procedure as described in Check until the needle
40. ether with hook shaft bushing 109 until the clearance between the sewing hook point and the bottom of the scarf in the needle is 0 05 mm e Tighten screw 110 on the narrow flat of hook bushing Note The large flat of the hook bushing must face right Cross check e Check for free movement of the hook shaft e Check the clearance between the hook point and the bottom of the needle scarf once again 58 30a Adjustment of bevel gears Requirement The bevel gears must move easily and without play Adjustment e Push bevel gear with lifting eccentric to the left until it rests on bevel gear 38 without play e Tighten screw 37 on the surface of the drive shaft Check e As described under Requirement Fig 61 59 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 Remove presser foot and needle plate Press the straight stitch button e Bring the needle bar to its lowest position by turning the handwheel Push the spacer 63 102 600 18 onto the top of the needle bar and slide it upwards against the need le bar frame fig 63 Push the needle rise clamp 00 870 137 01 on the needle bar and tighten it lightly e Push the 2 2 mm feeler gauge 00 870 136 01 with its cutout on the needle b
41. fix SES Medium ball point Suffix SUK Large ball point Suffix SKF Very pointed round point Suffix J Leather point right hand Suffix LR Specifications and versions of built in motors in the PFAFF 1520 1540 Type UUS 390 No 902 1039 001 Radioscreened according to EN 55014 Type UUS 393 No 902 1039 003 Radioscreened according to EN 55014 220 240 50 60Hz 27W Safety class Il 110 120V 50 6012 27W Safety class Il 4500 r p m 4500 r p m Removing the housing covers Note Before adjusting or repairing the machine make sure to remove the housing covers as described in this manual 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 Remove the two fastening screws 1 of free arm cover fig 1 Pull the left hand side of the free arm cover a little bit downwards and remove it towards the left Remove needle plate Remove the two fastening screws 2 of the upper free arm cover fig 2 Loosen fastening screw 3 of free arm cover Remove free arm cover Fig 1 e Loosen the fastening screws 4 5 6 and 7 of the rear housing shell fig 3 and 4 Loosen the snap connections by pressing with your thumb on the sp
42. for clearance of 0 2 mm Fig 13 25 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 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 Set the stitch length graduated dial to 6 e Detach spring 35 e Check the joints for easy movement and lack of play Re attach spring 35 Fig 15 26 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 e 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 Push the circlip along with shaft 37 and tooth segment 38 along with actuating crank 39 to the left until no crank or joint has any play anymore Tighten screws 5 and 36 Cross check Set the stitch length graduated dial to 6 Detach spring 35 Check the joints for easy movement and lack of play e Re attach spring 35
43. g 111 10 39 9 4 Fig 112 85 Refitting e Set the new bevel gear with the lifting eccentric onto the sewing hook bearing e Insert hook shaft bushing 109 and tighten screw 110 lightly fig 110 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 Insert set screw 160 and fasten the hook bearing fig 111 e Insert sewing hook 44 and tighten one of screws 108 fig 112 Push the hook driving shaft 45 to the left Insert screw 112 into the large bevel gear and set it onto the surface of the hook driving shaft e Push the plastic washer to the right against the bearing Fit the circlip making sure that the plastic washer is between bearing and circlip e Pull hook driving shaft 45 to the right as far as it will go and use one of screws 44 of the toothed belt sprocket to remove any lengthwise play in the shaft fig 110 e Insert and knock in hollow pin 161 e Push driving eccentric 33 to the right Note Hollow pin 161 must always be visible on driving eccentric 33 on the opposite side of screw 112 in the lif ting eccentric Place connecting bar 10 complete onto actuating crank 39 fig 111 e Insert bolt 11 e Insert washer 14 Adjust feed regulator cranks in accordance with section 7 e Refit the feed dog lowering mechanism e Connect pull spring 6 Push the small gear 97 o
44. he two circlips 99 fig 45 Remove plastic angle lever 100 from the front e Loosen fastening screws 75 fig 45 Carefully remove the zigzag stitch unit from the machine Fitting e Insert bolt 76 of connecting rod 72 into joint piece 77 on the zigzag stitch unit fig 44 Fit the zigzag stitch unit in the machine inserting at the same time connecting rod 72 with sliding block 78 into the crank e Position the zigzag stitch unit parallel to the arm shaft and gently tighten fastening screws 75 Replace circlip 71 e Insert plastic angle lever 100 together with pull rod 93 fig 45 Refit the two circlips 99 Re attach pull rod 93 and refit circlip 92 fig 46 Hm QM EN 7 47 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 e Set stitch width adjustment dial 70 to 0 fig 47 0 Set needle position adjustment wheel 79 to center Press straight stitch and zigzag stitch button e Loosen screw 73 fig 49 Rotate setting eccentric 74 upwards and 45 degrees to the left e Rotate setting eccentric 16 to the left and to the right until the needle is centered in the needle slot fig 48 Tighten screw 73 Fig 50 48 25 Adjustment of needle penetra
45. ke out pawl 144 clutch piece 145 and pressure spring 146 Fitting the handwheel release 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 e Place pressure spring 146 onto the handwheel boss so that its rear side fits into the guide groove fig 96 e First place clutch piece 145 onto the handwheel boss then press it towards the back The pressure spring is thus placed vertical and the clutch piece is positioned as shown in fig 97 e Push the pin of pawl 144 into the hole in such a way that it is positioned as shown in fig 98 e Push handwheel release disk 143 with its square mark 150 facing up into the handwheel fig 99 e In order to be able to lock into the catch handwheel release disk 143 must be turned counter clockwi se by approx 5 mm e Fit metal screw 142 with washer 151 e Hold handvvheel in position and turn release disk 143 in sewing direction until you hear it snap in place e Fit the plastic cap e Check the handwheel release by engaging and disengaging it 76 148 145 Fig 99 77 147 150 44 Removing and fitting the sewing hook Removal Remove the needle Unscrew the presser foot Remove the bobbin case e 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
46. located in the center of the slots and the automatic module after having been moved forwards is parallel to the housing Gently tighten screws 61 Place circlip 60 onto pin 64 Install the motor attaching at the same time the motor pinion 58 to toothed belt 59 fig 22 Insert the two screws 56 and 57 with their washers and tighten them a little Adjust the toothed belt to its correct setting and tighten screws 56 and 57 Insert reverse button 52 complete with bolt 53 connecting rod 54 plastic angle piece 55 and tension spring 47 and tighten by means of fastening screw 48 Refit circlip 51 Re attach connecting lever 50 Refit circlip 49 Re attach tension spring 47 at the top of the push lever Reconnect light plug 46 Fe q m 101 i er miij Fig 23 65 64 60 61 61 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 e Set adjustment dial 67 at the dot mark Move push lever 68 back and forth e 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 Adjustment e Loosen screw 69 Fig 25 Turn adju
47. n for the widest zigzag stitch 0 Set stitch length to 2 0 e Sew with zigzag stitch At the same time turn the knurled nut gradually in clockwise direction until the interlacing is in the cen ter of the fabric fig 75 Cross check Sew with straight stitch and zigzag stitch as described under Check 68 mu SE Fig 74 Fig 75 69 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 ent ers the fabric Check O Press the straight stitch button 0 Set stitch length to 6 0 Place two layers of fabric under the presser foot Sew a few stitches e Turn the handwheel and determine the end of the thread check spring stroke Correct slackening of the needle thread takes place when it enters the needle eye not tautly but in a loose curve Adjustment Loosen screw 128 e Turn thread check spring stop sleeve 127 until thread check spring 126 is in the correct position Tighten screw 128 Cross check O Sew a few stitches and proceed as described under Check 70 126
48. ngs Hook to needle clearance The distance of the sewing hook point from the needle must be as small as possible so that the sewing hook point does not miss the thread loop The sequence of sewing hook adjustments is as follows 1 Hook to needle clearance 2 Bevel gear setting 3 Needle rise sewing hook timing 4 Needle bar height 54 I ulqqoq ulqqoq o ulqqoq e u qqog 81919 105 hinus 89 8980 eses 8 ulqqoq P en6 9 99 pue 6 yooH 9 99 206 yooH 6 pue 2 0 016 yooH aseo 56 poq 9 65 l ldulo 117 2 00 0 60 yooy 6 02110 717 00 28101 211021101 mnys yeaq pue yooy go 0 s uluopul 6 1 16 0 UI s d4 KOOY 6 pue s minus 55 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 Note Since system 130 705 H needles increase in size at the needle front side only the point of a size 100 needle is positioned exactly in the middle of the needle slot as seen from front to back while the point of a size 80 needle is positioned slightly closer to the rear edge of the needle slot Check Insert a new size 100 system 130 705 H needle O Press the straight stitch button e Attach
49. nt e Loosen screw 73 fig 41 e First turn setting eccentric 74 downwards to its basic position e Turn the setting eccentric slightly in a clockwise direction until reversing bar 54 is touching feeler 91 Turn the setting eccentric back again until a clearance of 0 2 mm is set Tighten screw 78 Cross check Move feed reversing bar 54 gently up and down and check the clearance of 0 2 mm e Activate the reverse button at the largest stitch length setting and check the clearance between the feed reversing bar and the feeler 42 21 Replacing the utility stitch unit on Pfaff 1540 Removal 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 Fitting e Install the utility stitch unit in the machine e Insert the two long screws 95 and 96 at the bottom and the shorter screw 94 at the top Tighten them lightly fig 41 Place the feed regulator cranks onto the bolt of actuating crank 10 e Insert bolt 11 Refit circlip 14 Move bolt 11 to the right until the feed regulator cranks ha
50. nto hook shaft 45 Now the following adjustments must be carried out e Adjustment of feed dog height section 4 e Timing of feed motion section 12 e Adjustment of hook to needle clearance section 28 Adjustment of bevel gears section 28a e Sewing hook timing section 29 Adjustment of needle bar height section 30 Adjustment of bobbin case position finger section 31 Adjustment of needle threader section 32 Adjustment of bobbin thread tension section 34 Adjustment of needle thread tension section 35 Adjustment of equal forward and reverse stitch length for utility stitches section 33 Making up a sewing sample section 34 e Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metrawatt M 5013 86 Fig 110 45 10 34 33 161 44 101 97 nes io l e Fig 111 10 39 9 4 mk ur Fig 112 87 49 Changing the motor Note The motor must be replaced as a complete unit Removal 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 Refitting e Befo
51. ots marked with arrows on the inner surface of the arm fig 5 e Remove the rear housing shell Remove motor cover e Loosen the fastening screws 8 9 and 10 of the front housing shell fig 5 and 6 Remove fastening screws 10 and 11 sadel see Fig 5 e Remove fastening screw 12 fig 7 e Switch on the top key row of the utility stitch unit e Carefully remove the front housing shell by lifting it off The assembly must be carried out in reverse order Fig 7 11 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 e Loosen screw 1 fig 1 e Re position tensioning roller 2 with a screwdriver as required e Tighten screw 1 Check e Check adjustment according to the Requirement Press lightly against the middle of the toothed belt 250 g The toothed belt should move forward by some 1 to 3 mm 0 Vi N Q Fig 1 13 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 e Loosen the two screws
52. re refitting the motor simulated leakage current must be measured see section 58 of this manual e Insert the motor and place motor sprocket 58 in toothed belt 59 fig 113 e Install the sewing lamp wire at the motor and attach plug 46 e Insert and slightly tighten top motor retaining screw 56 e Insert and slightly tighten right motor retaining screw 57 Tension toothed belt 59 and firmly tighten the two screws e Refit the housing cover as described in this manual e Reconnect the mains plug and test run the machine e Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metrawatt M 5013 88 Fig 113 89 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 Remove the motor in accordance with section 49 of this manual e 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 e Solder the two cables to points 168 at the top of the new circuit board Insert circuit board 164 e Insert the three screws 165 in contact pins 167 and firmly tighten Push cover 162 onto one side and allow it to engage on the other e Measure the simulated leakage current in accordance with s
53. right machine with the controls facing the operator When assembling dismantled machines adjust the machine to approximately the right settings This facili tates the subsequent fine adjustments Unless otherwise specified the handwheel must always be turned forward When carrying out maintenance work on live parts or in their proximity the machine is to be separated from the power supply by disconnecting the lead cord from the electrical socket An electrical safety test must be carried out after all repair work even if the repair work is of a mechanical nature The required electrical tests for the appliances are laid down in the current EU regulations EEC direc tives and the EMC law Standard EN 60335 1 A 96 ICE 335 1 91 A1 94 mod It is obligatory to perform a safety test in accordance with VDE 0701 1 after repair modification and testing of electrical appliances Outside Germany there are similar regulations in force which are largely identical with the requirements of VDE 0701 It is therefore necessary to consult a specialist when carrying out repairs on electrical appliances For the proper adjustment of the machine the following gauges and tools are required O Needle rise gauge 00 870136 01 Needle rise clamp 00 870137 01 O SPACE dee 63 1
54. rod 18 and ensure that it is free from play fig 4 Move the complete top feed lever forwards and backwards Make sure that both top and bottom feed move smoothly and without any difficulty Tighten screw 12 and check once again for ease of operation Move crank pin 16 with pull rod 17 to the side in such a way that both top and bottom feed can move easily Tighten screw 15 and check once again for ease of operation Fit bolt 11 Insert circlip 14 Push bolt 11 against connecting bar 10 Tighten screw 5 Re attach spring 6 Cross check The feed dog must be exactly in the center of the feed slot Both top and bottom feed must not bind nor have any play Fig 5 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 Remove the needle Remove the presser foot e Set the maximum stitch length Place bridge gauge 63 112120 08 over the feed dog onto the needle plate e Turn the handwheel until the feed dog has reached its highest working position e Carry out a visual check e The feed dog must not touch the gauge but must clear it by 0 1 mm Adjustment e Loosen screw 19 by just 1 8 of a turn fig 7 e Turn eccentric stud 20 until the eccentric is facing the rear part of the housing basic position e Turn the eccentric stud to
55. stment dial 67 until lifting pin 66 is exactly centered in the groove fig 24 Firmly tighten screw 69 fig 25 Cross check Move push lever 68 back and forth and check as described under Check 67 Fig 24 Fig 25 34 15 Replacing the zigzag stitch unit on Pfaff 1520 1530 Removal 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 Insert bolt 76 of connecting rod 72 into joint piece 77 of the zigzag unit fig 26 Fit the zigzag unit in the machine inserting at the same time connecting rod 72 with sliding block 78 into the crank Position the zigzag unit parallel to the arm shaft and gently tighten fastening screws 75 Refit circlip 71 Insert connecting rod 65 Refit circlip 60 gt 1 I 35 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 e Set stitch width adjustment dial 70 to O fig 27 Set needle position adjustment dial 79 to center e Switch the automatic unit to position E e Loosen screw 73 fig 28 Rotate setting eccentric 74 downwards
56. stment 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 penetrati on 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 Requirement The clearance between the top edge of the needle eye and the lower edge of the sewing hook point must be 0 5 mm at the widest left zigzag penetration fig 66 Check e Press the button for the widest zigzag stitch e Turn the handwheel until the needle rises at the left zigzag stitch and the sewing hook point is exactly behind the needle center line The clearance between the top edge of the needle eye and the lower edge of the sewing hook point must be 0 5 mm Adjustment e Loosen screw 112 just a little fig 67 Shift needle bar 30 in height without twisting it until the clearance of 0 5 mm is set e Tighten screw 112 Cross check Check the clearance of 0 5 mm The needle holder must face exactly square to the right 0 5 mm Fig 66 62 A 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 It must be possible to insert clearance gauge 00 880133 01 with e
57. t of the gears in relation to each other 23 Replacing the zigzag stitch unit on Pfaff 1540 24 Basic position of setting eccentric for the sideways needle position on Pfaff 1540 25 Adjustment of needle penetration in needle plate slot on Pfaff 1540 26 Adjustment of the sideways movement of the needle bar on Pfaff 1540 27 Adjustment of zigzag stitch penetration in needle plate slot on Pfaff 1540 28 Adjustment of the stop for the left needle position on Pfaff 1540 Stitch forming parts sewing hook 29 Adjustment of needle clearance in needle slot in sewing direction 30 Adjustment of hook to needle clearance 30a Adjustment of bevel gears 31 Sewing hook timing 32 Adjustment of needle bar height 33 Adjustment of bobbin case position finger Page com 01 Co 13 14 16 18 19 20 22 24 26 27 28 30 32 34 35 36 37 38 40 42 44 46 47 48 49 50 52 53 56 58 59 60 62 63 Stitching off 34 35 36 37 38 39 40 41 Adjustment of needle threader Adjustment of bobbin winder stop Adjustment of bobbin thread tension Adjustment of needle thread tension Adjustment of thread check spring stroke Adjustment of equal stitch length for left and right buttonhole seams Adjustment of equal forward and reverse stitch length for forward and reverse controlled utility stitches Making up a sewing sample Repair Instructions 42 43 44 45 46 47 48 49 50 51 52 53 54 55 R
58. the left until the feed dog height is properly set e Tighten screw 19 Cross check e Turn the handwheel and check the feed dog height at its highest working position Make sure that the feed dog lowering mechanism neither binds nor hits against anything when the handwheel is turned e Lower feed dog and check the function 63 112 120 08 Fig 7 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 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 Lower the presser bar lifter to its normal position again The zigzag foot must rest parallel and without play on the presser foot gauge However the presser foot gauge must not lift the zigzag foot and the needle thread tension release 23 must be without play Adjustment e Loosen screw 21 fig 9 e With the presser bar lifter raised turn the zigzag foot until it is parallel to the sides of the presser foot gauge e Use a screwdriver to press presser bar guide 22 firmly downward At the same time firmly tighten screw 21 Cross check Push the presser bar lifter further upward and rel
59. the zigzag foot e Lower the zigzag foot e Turn the handwheel until the needle is at its lowest position The needle must now have the same distance to the front and rear edges of the needle slot in the presser foot and in the needle plate Adjustment of the needle in the needle slot of the presser foot e Loosen screw 104 fig 58 e Move bolt 105 together with collar and needle bar frame 106 to the front or the rear until the needle is exactly in the middle of the needle slot in the presser foot e Tighten screw 104 Cross check Raise the needle by turning the handwheel O Place a piece of paper under the presser foot and lower the presser foot e Turn the handwheel until the needle has reached its lowest position e The needle must now have the same clearance to the front and rear edges of the needle slot in the presser foot Important The needle bar frame must move must move easily and without binding If this is not the case any binding must be removed Adjustment of the needle plate e Turn the handwheel and raise the needle e Remove the zigzag foot e Turn the handwheel until the needle has reached its lowest position e Turn the setting eccentric until the clearance from the front and rear edge of the needle plate slot is the same fig 59 56 Cross check Carry out a visual check at straight and zigzag stitch settings 009 1 106 0 2mm IZ gt er 5 gt 105
60. tion 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 e Remove presser foot Insert a new needle Set stitch width adjustment dial 70 to fig 32 e Set needle position adjustment dial 79 to center Press straight stitch and zigzag stitch button on the automatic utility stitch unit e Turn the handwheel and check the centered position of the needle Adjustment Loosen the three screws 75 on the zigzag stitch unit by just 1 8 of a turn e Turn the handwheel until the needle point is level with the surface of the needle plate fig 31 e Move the zigzag stitch unit to the left or right until the needle is exactly in the center of the needle plate slot fig 32 Note The zigzag stitch unit should now be parallel to the arm shaft and clear it by 3 0 mm Tighten the three screws 75 Cross check The needle must be exactly in the center of the needle plate slot 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
61. ve no sideways play and move easily Tighten screw 5 e Re attach pull rod 93 e Refit circlip 92 44 7 TE z il il UD um 2 mia i N mr 9 g Fig 43 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 e 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 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 Tighten the three screws Cross check e As described under Check e Firmly tighten screws 94 95 and 96 Note e The feed regulator cranks must now be adjusted according to section 10 of this manual D en all 000 gt gt S 46 23 Replacing the zigzag stitch unit on Pfaff 1540 Removal Disconnect the machine s mains plug Remove the housing covers as described in this manual Set stitch width adjustment dial 70 to O fig 44 e Remove circlip 71 from connecting rod 72 Remove circlip 92 fig 46 e Detach pull rod 93 and remove it from the top e Remove t
62. with a wide blade on the side opposite to the cables fig 120 e Turn the screwdriver while removing pedal 175 upwards e Carefully remove mains connection cables or machine cables 177 from the circuit board fig 120 e Loosen screw 178 or 179 Remove mains lead cleat 180 Remove mains connection cable or machine cable Refitting Insert new cable 177 through the bore Insert mains lead cleat 180 and secure with screw 173 or 174 Connect mains connection cables or machine cables 177 Refit pedal 175 e Use a screwdriver with a wide blade to press the pedal a little aside and insert it downwards Carry out a functional test Carry out an electrical safety test in accordance with VDE 0701 using testing appliance ABB Metrawatt M 5013 175 95 Safety test 56 Electrical safety test According to the German law on safe machine operation of June 24 1986 VDE regulations are the reco gnized 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 We are obliged to perform a test in accordance with VDE 0701 on every electrical appliance after repair In European foreign countries there are similar regulations in force which are largely identical with the

Pfaff 1520 Sewing Machine User Manual

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