Pfaff 1520, 1540 User Manual

Service Manual

1st Release August 2001

Contents 1 Foreword 3 Notes on the sewing machine in relation to environment, handling, cleaning and safety 5 Specifications off PFAFF machines 6 Removing the housing covers 8

Adjustment instructions

Feeding system

1. Adjustment of toothed belt tension 13

2. Adjustment of feed dog in sideways direction on Pfaff 1520 14

3. Adjustment of feed dog in sideways direction on Pfaff 1530-1540 16

4. Adjustment of feed dog height 18

5. Adjustment of presser bar height on Pfaff 1520 19

6. Adjustment of presser bar height on Pfaff 1530-1540 20

7. Adjustment of top feed foot in sewing direction 22

8. Adjustment of top feed foot height 24

9. Adjustment of feed regulator cranks on Pfaff 1520 / 1530 26

10. Adjustment of feed regulator cranks on Pfaff 1540 27

11. Zero point adjustment of stitch length regulator 28

12. Timing of feed motion 30

Automatic utility-stitch unit

13. Replacing the automatic module on Pfaff 1520 - 1530 32

14. Adjustment of the locking disk 34

15. Replacing the zigzag-stitch unit on Pfaff 1520 - 1530 35

16. Basic position of setting eccentric for the sideways needle position 36

17. Adjustment of needle penetration in needle plate slot 37

18. Adjustment of the sideways movement of the needle bar 38

19. Adjustment of the stop for the left needle position 40

20. Adjustment of the feed reversing bar 42

21. Replacing the utility-stitch unit on Pfaff 1540 44

22. Adjustment of the gears in relation to each other 46

23. Replacing the zigzag-stitch unit on Pfaff 1540 47

24. Basic position of setting eccentric for the sideways needle position on Pfaff 1540 48

25. Adjustment of needle penetration in needle plate slot on Pfaff 1540 49

26. Adjustment of the sideways movement of the needle bar on Pfaff 1540 50

27. Adjustment of zigzag stitch penetration in needle plate slot on Pfaff 1540 52

28. Adjustment of the stop for the left needle position on Pfaff 1540 53

Stitch forming parts (sewing hook)

29. Adjustment of needle clearance in needle slot in sewing direction 56

30. Adjustment of hook-to-needle clearance 58 30a. Adjustment of bevel gears 59

31. Sewing hook timing 60

32. Adjustment of needle bar height 62

33. Adjustment of bobbin case position finger 63

Page

Stitching off

34. Adjustment of needle threader 64

35. Adjustment of bobbin winder stop 66

36. Adjustment of bobbin thread tension 67

37. Adjustment of needle thread tension 68

38. Adjustment of thread check spring stroke 70

39. Adjustment of equal stitch length for left and right buttonhole seams 72

40. Adjustment of equal forward and reverse stitch length 73 (for forward and reverse controlled utility stitches)

41. Making up a sewing sample 74

Repair Instructions

42. Removing and fitting the needle thread tension 75

43. Changing the pressure spring in the handwheel release 76

44. Removing and fitting the sewing hook 78

45. Cleaning and oiling the machine 78

46. Changing the toothed belt 80

47. Adjusting the arm shaft crank 82

48. Changing the bevel gears 84

49. Changing the motor 88

50. Changing the motor circuit board on motor types UUS 390 and UUS 393 90

51. Changing the carbon brushes on motor types UUS 390 and UUS 393 91

52. Changing the motor pinion 92

53. Changing the motor toothed belt 93

54. Changing the circuit board in foot control AE 010 94

55. Changing the mains connections in foot control AE 010 95

Safety test

56. Electrical safety test 96

57. Electrical safety test with ABB Metrawatt M 5013 96

58. Simulated leakage current measurements of complete motors with ABB Metrawatt M 5013 99

59. 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 indicated by a circle or a square.

The indications "left", "right", "top", "bottom", "front" and "back" always refer to the upright machine with the controls facing the operator.

When assembling dismantled machines, adjust the machine to approximately the right settings.This facilitates 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 directives, 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:

z Needle r ise gauge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-870136-01

z Needle r ise clamp: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-870137-01

z Spacer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63-102600-18

z Adjustment gauge for the bobbin case holder: . . . . . . . . . . . . . . . . . . .00-880133-01

z Presser foot gauge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63-114690-39

z Ring-shaped open-end spanner 5.5 mm . . . . . . . . . . . . . . . . . . . . . . .43-111010-04

z Torx screwdriver TX 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-434008-40

z Torx screwdriver TX 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-434008-44

z Torx screwdriver TX 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-434008-45

z Torx screwdriver TX 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-434008-46

z Torx screwdriver TX 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-434008-47

z Torx offset screwdriver TX 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-434008-74

z Circlip fitting tool 2.3 short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-437003-20

z Circlip fitting tool 3.2 short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-437003-30

z Circlip fitting tool 4.0 short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-437003-40

z Circlip fitting tool 5.0 short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-437003-50

z Circlip fitting tool 6.0 short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-437003-60

z Circlip fitting tool 10.0 short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-437003-86

z Spr ing hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-437006-00

Subject to design and dimensional modifications.

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. Make sure that it is not subjected to: dust, severe dampness, direct sunlight, static electricity, heat-producing 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 dir t, 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 electric shock, do not open the machine.There are no par ts inside the machine which the user can repair.This is solely the responsibility of our qualified service staff.

7. Be sure to use only or iginal 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

Detailed specifications of the machines

z Electronic free-ar m utility stitch machine z Directly controlled automatic utility-stitch unit, step-down ratio 6:1 (1540) z Program selection by means of a program dial (1520/1530) z Utility stitch width 5.5 mm z Stitch length from 0 to 6 mm z Reverse stitch length from 0 to 3 mm z High-ohm foot control (cold) z FM radio and TV screened, approval marking, suppression degree B z Safety class II with GS test marking z Master switch for motor. z Glare-free built-in sewing lamp 230V or 120V 15 W z Pendulum-type needle bar frame z Transmission of drive from arm shaft to lower shaft by toothed belt, transmission ratio 1:1 z Power input rating: 90 W when sewing at 950 r.p.m.; 40W when stationary

z Maintenance-free PFAFF transverse double-rotating hook z Link take-up lever z Linkage-type feed regulator z Dual fabric feed z Disengageable feed dog z Needle threader z Dr ive from motor to handwheel by flat-toothed belt z 60-1000 stitches per minute z Sintered metal bear ings z Oil for sintered metal bearings: BP Energol HLP 46 or HLP 80 No.28-036550-09 z Oil for sewing hook No. 91-129452-91 z Clear wor kspace: 175, 114, 205 mm z Machine height: 280 mm z Baseplate dimensions: 390, 155 mm z Free arm dimensions: 80, 49, 200 mm z Housing mater ial: lightweight metal z Weight of sewing head: approx. 8 kg z 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 Suffix = 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 390 220-240V 50/60Hz 4500 r.p.m.

No.902-1039-001 27W Radioscreened according to EN 55014 Safety class II

Type UUS 393 110-120V 50/60Hz 4500 r.p.m.

No.902-1039-003 27W Radioscreened according to EN 55014 Safety class II

Removing the housing covers

Note: Before adjusting or repairing the machine, make sure to remove the housing covers as described in this manual.

z Disconnect the machine's main plug. z Remove needle and presser foot. z Remove detachable work support. z Remove top cover. z Switch on bobbin winder. z Remove the two Torx screws of the housing insert.. z Remove housing insert. z Lay the machine on its back and remove the four fastening screws of the baseplate. z Remove baseplate. z Remove the two fastening screws 1 of free-arm cover (fig.1). z Pull the left-hand side of the free-ar m cover a little bit downwards and remove it towards the left. z Remove needle plate. z Remove the two fastening screws 2 of the upper free-arm cover (fig.2). z Loosen fastening screw 3 of free-arm cover. z Remove free-arm cover.

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:

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).

The toothed belt should move forward by some 1 to 3 mm.

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 Loosen the two screws 3 and 4 (fig. 2a). z Loosen screw 5. z Detach spr ing 6. z 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.

z Fir mly tighten the two screws 3 and 4. z Push bolt 11 against connecting bar 10. z Fir mly tighten screw 5. z Re-attach spr ing 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:

z Lay the machine on its back. z Loosen screw 12 (fig. 4). z Remove bolt 13 to the right. z Loosen screw 5. z Remove circlip 14. z Remove bolt 11. z Loosen both screws 3 and 4. z 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.

z Fir mly tighten the two screws 3 and 4. z Detach spr ing 6. z Remove the needle plate. z Pull the feed dog forward with one finger and release. z The complete feed-dog driving shaft 7 must slide lightly back. z Loosen screw 15 (fig. 5). z Move the top feed lever forwards and backwards. z The top feed should move freely without any difficulty (if necessary, remove cause of binding). z Fit bolt 13 with the washer located to the left of pull-rod 18, and ensure that it is free from play (fig. 4). z Move the complete top feed lever forwards and backwards. z Make sure that both top and bottom feed move smoothly and without any difficulty. z Tighten screw 12 and check once again for ease of operation. z Move crank pin 16 with pull-rod 17 to the side in such a way that both top and bottom feed can move

easily.

z Tighten screw 15 and check once again for ease of operation. z Fit bolt 11. z Insert circlip 14. z Push bolt 11 against connecting bar 10. z Tighten screw 5. z Re-attach spr ing 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.

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 Remove the needle. z Remove the presser foot. z Set the maximum stitch length. z Place br idge gauge (63-112120-08) over the feed dog onto the needle plate. z Turn the handwheel until the feed dog has reached its highest working position. z Carry out a visual check. z The feed dog must not touch the gauge, but must clear it by 0.1 mm.

Adjustment:

z Loosen screw 19 by just 1/8 of a turn (fig 7). z Turn eccentric stud 20 until the eccentric is facing the rear part of the housing (basic position) z Turn the eccentric stud to the left until the feed dog height is properly set. z Tighten screw 19.

Cross-check

z Turn the handwheel and check the feed dog height at its highest working position. z Make sure that the feed-dog lowering mechanism neither binds nor hits against anything when the

handwheel is turned.

z Lower feed dog and check the function.

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 Raise the presser bar lifter. z Fit the zigzag foot. z Lower the feed dog. z Fully raise the presser bar lifter and hold it there fir mly. z At the same time, inser t presser foot gauge No. 63-114690-39 from the rear under the zigzag foot and

into the cutouts of the needle plate (fig. 8).

z 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:

z Loosen screw 21 (fig. 9) z With the presser bar lifter raised tur n the zigzag foot until it is parallel to the sides of the presser foot

gauge.

z Use a screwdriver to press presser bar guide 22 firmly downward. z At the same time, fir mly tighten screw 21.

Cross-check:

z 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 must be without play.The presser bar lifter must be in raised.

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:

into the cutouts of the needle plate (fig. 9).

z Lower the presser bar lifter to its normal position again.

Adjustment:

z Loosen the three screws 21, 24 and 25. z With the presser bar lifter raised tur n the zigzag foot until it is parallel to the sides of the presser foot

gauge.

z Use a screwdriver to press presser bar guide 22 firmly downward. z At the same time, fir mly tighten screw 21.

Cross-check:

z 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 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.

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 Raise the presser bar lifter. z Remove presser foot & presser foot holder. z Set the maximum stitch length. z Engage the top feed foot. z Turn the handwheel until the rising feed dog is flush with the needle plate surface. z Lower the presser bar lifter. z Carry out a visual check.

Adjustment:

z Loosen screw 26 (fig. 12). z Raise the presser bar lifter until the top feed foot is just resting on top of the feed dog. z 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.

z Lower the presser bar lifter. z Tighten screw 26, making sure that driving shaft 27 has no play.

Cross-check:

z Check as described under "Check".

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 Raise the presser bar lifter. z Fit the zigzag foot. z Engage the top feed. z Turn the handwheel until the needle bar is at its lowest position.

Caution: The handwheel must now no longer be turned!

z Lower the feed dog. z Fully raise the presser bar lifter and hold it in this position. z At the same time, inser t presser foot gauge No. 63-114690-35 from the rear under the zigzag foot and

into the cutouts of the needle plate.

z Lower the presser bar lifter to its raised position again. z Press the top feed foot 28 about 2 mm upward against the pressure of the spring and release it. z Check that the top feed foot rests only lightly on the presser foot gauge and has no play.

Adjustment:

z Loosen screws 24 and 25. z Push counter bear ing 29 lightly downward until the top feed foot 28 rests lightly on the presser foot

gauge.

z Tighten screw 24 in this position.

Cross-check:

z 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:

z Fully raise the presser bar lifter and hold it in this position. z Remove the presser foot gauge. z Lower the presser bar lifter to its raised position again. z Turn the handwheel until needle bar 30 is in its top position.

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 Loosen the two screws 5. z Push feeding eccentric 33 to the right against the bear ing. z Push bolt 11 to the r ight until connecting bar 10 is in contact with edge 34 of feeding eccentric 33. z Tighten the screws 5.

Cross-check:

z Set the stitch length graduated dial to "6". z Detach spr ing 35. z Check the joints for easy movement and lack of play. z Re-attach spr ing 35.

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 Loosen the two screws 5 and 36. z Push feeding eccentric 33 to the right against the bear ing. z Push bolt 11 to the r ight until connecting bar 10 is in contact with edge 34 of feeding eccentric 33. z 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.

z Tighten screws 5 and 36.

Cross-check:

z Set the stitch length graduated dial to "6". z Detach spr ing 35. z Check the joints for easy movement and lack of play. z Re-attach spr ing 35.

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 Set the stitch length graduated dial to "0". z Place a piece of fabric under the presser foot. z Lower the presser foot. z 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:

z Loosen screw 41 with a 5.5 mm spanner. z 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).

z Tighten screw 41.

Cross-check:

z As descr ibed under "Check".

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