Pfaff 1540 User Manual Page 1

Service Manual1st Release August 2001

8Removing the housing coversNote:Before adjusting or repairing the machine, make sure to remove the housing covers as describedin this manual.z Discon

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9958. Simulated leakage current measurements of complete motors with ABB Metrawatt M 5013V Simulated leakage current measurements of complete motorsz

100Notes:

101Notes:

102Notes:

103Notes:

PFAFF GmbHAmalienbadstraße 36D-76227 KarlsruhePhone +49 (0)721/4001-0Telefax +49 (0)721/4001-513E-Mail: [email protected]://www.pfaff.deDruckerei Gab

9z 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

10z Loosen the fastening screws 8, 9, and 10 of the front housing shell (fig. 5 and 6).z Remove fastening screws 10 and 11.

11z 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

12Notes:

13Feeding system1. Adjustment of the toothed belt tensionRequirement:The toothed belt must be so taut that the sewing hook has no play in its directio

142. Adjustment of feed dog in sideways direction on Pfaff 1520Requirement:The left and right clearance of the feed dog in the feed slot must be the s

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163. Adjustment of feed dog in sideways direction on Pfaff 1530-1540Requirement:The left and right clearance of the feed dog in the feed slot must be

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184. Adjustment of feed dog heightRequirement:At the highest working position of the feed dog, the tips of the feed dog teeth must protrude above then

195. Adjustment of presser bar height on Pfaff 1520Requirement:With the presser bar lifter raised, there must be a clearance of 8 mm between the needl

206. Adjustment of presser bar height on Pfaff 1530-1540Requirement:With the presser bar lifter raised, there must be a clearance of 8 mm between the

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227. Adjustment of top feed foot in sewing directionRequirement:The front edge of the top feed foot must be between the first and second tooth point o

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248. Adjustment of top feed foot heightRequirement:At its highest working position the top feed foot must be 2 mm higher than the lower edge of the zi

25z 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 clearan

269. Adjustment of feed regulator cranks on Pfaff 1520 / 1530Requirement:The feed regulator cranks must not have any axial play.Check:Move the feed re

2710. Adjustment of feed regulator cranks on Pfaff 1540Requirement:The feed regulator cranks must not have any axial play.Check:Move the feed regulato

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

2811. Zero point adjustment of stitch length regulatorRequirement:When the stitch length graduated dial is set to "0", the feed dog should o

29Notes:

3012.Timing of feed motionOperating sequence:When the rising needle has cleared the fabric, the feed dog moves up above the needle plate.The risen fee

31z Turn the long drive shaft 45 clockwise until the line marks on edge 34 of feeding eccentric andconnection rod 10 are opposite each other (fig. 19)

32Automatic utility-stitch unit13. Replacing the automatic module on Pfaff 1520 - 1530Removal:z Disconnect the machine's mains plug.z Remove the

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3414. Adjustment of the locking diskNote:Carry out this adjustment only if compelling reasons exist.For this adjustment the automatic module has to be

3515. Replacing the zigzag-stitch unit on Pfaff 1520 - 1530Removal:z Disconnect the machine's mains plug.z Remove the housing covers as described

3616. Basic position of setting eccentric for the sideways needle positionRequirement:In its basic position the setting eccentric must point downwards

3717. Adjustment of needle penetration in needle plate slotRequirement:At straight stitch setting with needle position "center" the needle m

2Stitching off34. Adjustment of needle threader 6435. Adjustment of bobbin winder stop 6636. Adjustment of bobbin thread tension 6737. Adjustment of n

3818. Adjustment of the sideways movement of the needle barRequirement:During zigzag sewing operation the sideways movement of the needle should stop

39Cross-check:z As described under "Check".

4019. Adjustment of the stop for the left needle positionRequirement:At the widest zigzag stitch setting the crank should rest on the stop.Check:z Set

41Notes:

4220. Adjustment of the feed reversing barRequirement:At straight stitch or stretch stitch setting there must be a clearance of 0.2 mm between reversi

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4421. Replacing the utility-stitch unit on Pfaff 1540Removal:z Loosen screw 5 (fig. 42).z Remove circlip 14.z Remove bolt 11.z Remove circlip 92.z Dis

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4622. Adjustment of the gears in relation to each otherRequirement:The two gears must not have any play, must not bind, and must be parallel to each o

4723. Replacing the zigzag-stitch unit on Pfaff 1540Removal:z Disconnect the machine's mains plug.z Remove the housing covers as described in thi

3ForewordThe purpose of this service manual is to assist you in quick and correct repair of the machines.Adjustments should only be made if the settin

4824. Basic position of setting eccentric for the sideways needle position on Pfaff 1540Requirement:In its basic position the setting eccentric must p

4925. Adjustment of needle penetration in needle plate slot on Pfaff 1540Requirement:At straight stitch setting with needle position "center"

5026. Adjustment of the sideways movement of the needle bar on Pfaff 1540Requirement:During zigzag sewing operation the sideways movement of the needl

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5227. Adjustment of zigzag stitch penetration in needle plate slot on Pfaff 1540Requirement:The widest zigzag stitches must have the same distance to

5328. Adjustment of the stop for the left needle position on Pfaff 1540Requirement:When all push buttons are switched off, the needle must be approx.

54Stitch forming parts (sewing hook)Foreword:The sewing hook adjustment consists basically of the three following adjustments:z Needle rise (sewing ho

55Shuttles and sewing hook types in lockstitch sewing machinesOscillating CBhook and beak shuttleHorizontal rotaryhookLarge horizontalrotary hookVerti

5629. Adjustment of needle clearance in needle slot in sewing directionRequirement:There must be a clearance of 0.2 mm between the rear edge of the ne

57Cross-checkz Carry out a visual check at straight and zigzag stitch settings.

4For the proper adjustment of the machine, the following gauges and tools are required:z Needle rise gauge: . . . . . . . . . . . . . . . . . . . . .

5830. Adjustment of hook-to-needle clearanceRequirement:At the straight stitch setting the clearance between the sewing hook point and the bottom of t

5930a. Adjustment of bevel gearsRequirement:The bevel gears must move easily and without play.Adjustment:z Push bevel gear with lifting eccentric to t

6031. Sewing hook timingRequirement:When the needle bar has moved 2.2 mm upwards from its lowest position, with the machine set forstraight stitch and

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6232. Adjustment of needle bar heightThis machine has a transverse double-rotating hook.At the right zigzag penetration, the sewing hook reaches the n

6333. Adjustment of bobbin case position fingerRequirement:The clearance between the position finger and the bottom of the groove in the bobbin case b

64Stitching off34. Adjustment of needle threaderRequirement:With the threader lever pushed fully down, prong 115 must pass through in the center betwe

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6635. Adjustment of bobbin winder stopRequirement:The bobbin winder must stop when the thread has reached a level of 1 mm below the bobbin rim.Check:z

6736. Adjustment of bobbin thread tensionRequirement:The force required for pulling cotton thread 50/2 or synthetic fiber thread 100/3 off the bobbin

5Notes on the sewing machine in relation to environment, handling,cleaning and safetyEnvironment:The recommended operating ranges are as follows:Ambie

6837. Adjustment of needle thread tensionRequirement:Within the adjusting range from 3 to 5, the interlacing of needle thread and bobbin thread (cotto

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7038. Adjustment of thread check spring strokeThe thread check spring prevents the descending needle from piercing the slack needle thread.Theneedle t

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7239. Adjustment of equal stitch length for left and right buttonhole seams Requirement:The stitch lengths of the left buttonhole seam and of the righ

7340. Adjustment of equal forward and reverse stitch length (for forward and reverse controlled utility stitches)Requirement:The needle perforations f

7441. Making up a sewing sampleWhen all sewing checks are completed and the machine sews perfectly, a sewing sample is to be made.This sewing sample s

75Repair Instructions42. Removing and fitting the needle thread tensionRemoval:z Remove the needle thread tension.z Press the two plastic noses 131 to

7643. Changing the pressure spring in the handwheel release Removing the handwheel release z Remove plastic cap 141 using clearance gauge 00-880 133-0

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6Specifications of PFAFF machinesPFAFF 1540Electronic free-arm utility stitch machine with 40 sewing programs (push buttons).A straight stitch program

7844. Removing and fitting the sewing hookRemoval:z Remove the needle.z Unscrew the presser foot.z Remove the bobbin case.z Remove the bobbin case pos

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8046. Changing the toothed beltRemoval:z Disconnect the machine lead cord.z Remove needle and presser foot.z Remove detachable work support.z Remove t

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8247. Adjusting the arm shaft crankz Press the straight stitch button.z Carefully loosen screw 152 on arm shaft crank 153 just enough to allow the arm

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8448. Changing the bevel gearsNote:Always change bevel gears in pairs.Removal:z Remove the housing covers as described in this manual.z Remove the syn

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86Refitting:z Set the new bevel gear with the lifting eccentric onto the sewing hook bearing.z Insert hook shaft bushing 109 and tighten screw 110 lig

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7z Maintenance-free PFAFF transverse double-rotating hookz Link take-up leverz Linkage-type feed regulatorz Dual fabric feedz Disengageable feed dogz

8849. Changing the motorNote:The motor must be replaced as a complete unit.Removal:z Disconnect the machine lead cordz Remove the detachable work supp

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9050. Changing the motor circuit board on motor types UUS 390 and UUS 393Note:Capacitor and master switch must always be replaced with the circuit boa

9151. Changing the carbon brushes on motor types UUS 390 and UUS 393Removal:z Remove the motor in accordance with point 49of this manual.z Slightly ra

9252. Changing the motor pinion Note:The motor pinion must only be removed when a rotor is exchanged.Removal:z Remove the motor in accordance with poi

9353. Changing the motor toothed belt Removal:z Disconnect the machine lead cordz Remove the housing covers as described in this manual.z Remove the t

9454. Changing the circuit board in foot control AE 010Removal:z Turn the foot control so that it is resting on pedal 175.z Insert a screwdriver with

9555. Changing the mains connections in foot control AE 010Note:When changing connections it is compulsory to use original PFAFF connection cables, as

96Safety test56. Electrical safety test According to the German law on safe machine operation of June 24, 1986, VDE regulations are the reco-gnized ru

97IV Simulated leakage current test: Milliampere = mAz Leave sewing machine plug in tester connection.z Use clamp to attach test lead of testing appli