Pfaff Select 1520 Service Manual
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Pfaff Select 1520 Service Manual

Pfaff sewing machine service manual
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Service Manual
1st Release August 2001

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Summary of Contents for Pfaff Select 1520

  • Page 1 Service Manual 1st Release August 2001...

  • Page 3: Table Of Contents

    22. Adjustment 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.
  • Page 4 Stitching off 34. Adjustment of needle threader 35. Adjustment of bobbin winder stop 36. Adjustment of bobbin thread tension 37. Adjustment of needle thread tension 38. Adjustment of thread check spring stroke 39. Adjustment of equal stitch length for left and right buttonhole seams 40.

  • Page 5: Foreword

    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.
  • Page 6 For the proper adjustment of the machine, the following gauges and tools are required: Needle rise gauge: ........00-870136-01 Needle rise clamp: .

  • Page 7: Notes On The Sewing Machine In Relation To Environment, Handling, Cleaning And Safety

    6. To avoid the risk of electric 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.

  • Page 8: Specifications Off Pfaff Machines

    Detailed specifications of the machines Electronic free-arm utility stitch machine Directly controlled automatic utility-stitch unit, step-down ratio 6:1 (1540) Program selection by means of a program dial (1520/1530) Utility stitch width 5.5 mm Stitch length from 0 to 6 mm...
  • Page 9 Small ball point Medium ball point Large ball point Very pointed round point Leather point right hand 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.

  • Page 10: Removing The Housing Covers

    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.
  • Page 11 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 spots marked with arrows on the inner surface of the arm (fig. 5). Remove the rear housing shell.
  • Page 12 Loosen the fastening screws 8, 9, and 10 of the front housing shell (fig. 5 and 6). Remove fastening screws 10 and 11.
  • Page 13 Remove fastening screw 12 (fig. 7). Switch on the top key row of the utility stitch unit. Carefully remove the front housing shell by lifting it off. The assembly must be carried out in reverse order.
  • Page 14 Notes:...

  • Page 15: Feeding System

    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: Loosen screw 1 (fig.

  • Page 16: Adjustment Of Feed Dog In Sideways Direction On Pfaff 1520

    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.

  • Page 18: Adjustment Of Feed Dog In Sideways Direction On Pfaff 1530-1540

    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.

  • Page 20: Adjustment Of Feed Dog Height

    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. Set the maximum stitch length.

  • Page 21: Adjustment Of Presser Bar Height On Pfaff 1520

    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.

  • Page 22: Adjustment Of Presser Bar Height On Pfaff 1530-1540

    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: Raise the presser bar lifter.

  • Page 24: Adjustment Of Top Feed Foot In Sewing Direction

    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 &...

  • Page 26: Adjustment Of Top Feed Foot Height

    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: Raise the presser bar lifter.
  • Page 27 Set guide piece 31 at a clearance of 0.2 mm from cross head 32 (fig. 14). Tighten screw 25. Cross-check: Turn the handwheel and check for clearance of 0.2 mm.

  • Page 28: Adjustment Of Feed Regulator Cranks On Pfaff 1520 / 1530

    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.

  • Page 29: Adjustment Of Feed Regulator Cranks On Pfaff 1540

    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: Loosen the two screws 5 and 36.

  • Page 30: Zero Point Adjustment Of Stitch Length Regulator

    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: Set the stitch length graduated dial to "0". Place a piece of fabric under the presser foot. Lower the presser foot.
  • Page 31 Notes:...

  • Page 32: Timing Of Feed Motion

    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).
  • Page 33 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.

  • Page 34: Automatic Utility-Stitch Unit

    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.

  • Page 36: Adjustment Of The Locking Disk

    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.

  • Page 37: Replacing The Zigzag-Stitch Unit On Pfaff 1520 - 1530

    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.

  • Page 38: Basic Position Of Setting Eccentric For The Sideways Needle Position

    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: Set stitch width adjustment dial 70 to "0" (fig. 27). Set needle position adjustment dial 79 to "center". Switch the automatic unit to position "E".

  • Page 39: Adjustment Of Needle Penetration In Needle Plate Slot

    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: Remove presser foot. Insert a new needle. Set stitch width adjustment dial 70 to "0"...

  • Page 40: Adjustment Of The Sideways Movement Of The Needle Bar

    18. Adjustment of the sideways movement of the needle bar Requirement: During zigzag sewing operation the sideways movement of the needle should stop above the highest possible fabric thickness. The sideways movement of the needle must start when the needle point is leaving the needle plate. It must be completed before the needle enters the fabric again, approx.
  • Page 41 Cross-check: As described under "Check".

  • Page 42: Adjustment Of The Stop For The Left Needle Position

    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: Set stitch width adjustment dial to "5". Set needle position adjustment dial to "center". Set the adjustment dial on the automatic unit to "E". Rotate the handwheel until the needle moves downward on the left side and is at a position of roughly 1 mm above the needle plate.
  • Page 43 Notes:...

  • Page 44: Adjustment Of The Feed Reversing Bar

    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: Set the adjustment dial for the automatic unit to "E". Move the stitch length adjustment dial to the stretch symbol, up to the stop.

  • Page 46: Replacing The Utility-Stitch Unit On Pfaff 1540

    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.

  • Page 48: Adjustment Of The Gears In Relation To Each Other

    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: 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.

  • Page 49: Replacing The Zigzag-Stitch Unit On Pfaff 1540

    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 "0" (fig. 44). Remove circlip 71 from connecting rod 72.

  • Page 50: Basic Position Of Setting Eccentric For The Sideways Needle Position On Pfaff 1540

    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: Set stitch width adjustment dial 70 to "0" (fig. 47).

  • Page 51: Adjustment Of Needle Penetration In Needle Plate Slot On Pfaff 1540

    25. Adjustment of needle penetration in needle plate slot on Pfaff 1540 Requirement: At straight stitch setting with needle position "center" the needle must be exactly in the center of the needle plate slot (fig. 30). Check: Remove presser foot.

  • Page 52: Adjustment Of The Sideways Movement Of The Needle Bar On Pfaff 1540

    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.

  • Page 54: Adjustment Of Zigzag Stitch Penetration In Needle Plate Slot On Pfaff 1540

    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.

  • Page 55: Adjustment Of The Stop For The Left Needle Position On Pfaff 1540

    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.

  • Page 56: Stitch Forming Parts (Sewing Hook)

    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 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.

  • Page 58: Adjustment Of Needle Clearance In Needle Slot In Sewing Direction

    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.
  • Page 59 Cross-check Carry out a visual check at straight and zigzag stitch settings.

  • Page 60: Adjustment Of Hook-To-Needle Clearance

    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.

  • Page 61: 30A. Adjustment Of Bevel Gears

    30a. Adjustment of bevel gears Requirement: The bevel gears must move easily and without play. Adjustment: Push bevel gear with lifting eccentric to the left until it rests on bevel gear 38 without play. Tighten screw 37 on the surface of the drive shaft. Check: As described under "Requirement".

  • Page 62: Sewing Hook Timing

    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.

  • Page 64: Adjustment Of Needle Bar Height

    32. Adjustment of needle bar height This machine has a transverse double-rotating hook. At the right zigzag penetration, the sewing hook reaches the needle a little earlier and at the left 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.

  • Page 65: Adjustment Of Bobbin Case Position Finger

    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 ease but without play between the position finger and the bottom of the groove in the bobbin case base (fig.

  • Page 66: Stitching Off

    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.

  • Page 68: Adjustment Of Bobbin Winder Stop

    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.

  • Page 69: Adjustment Of Bobbin Thread Tension

    36. Adjustment of bobbin thread tension Requirement: The force required for pulling cotton thread 50/2 or synthetic fiber thread 100/3 off the bobbin must be approximately 20-25 g. Check: 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.

  • Page 70: Adjustment Of Needle Thread Tension

    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: Set needle thread tension to "5".

  • Page 72: Adjustment Of Thread Check Spring Stroke

    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.

  • Page 74: Adjustment Of Equal Stitch Length For Left And Right Buttonhole Seams

    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).

  • Page 75: Adjustment Of Equal Forward And Reverse Stitch Length

    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 "F"). Place two layers of linen fabric under the presser foot and sew the honeycomb stitch.

  • Page 76: Making Up A Sewing Sample

    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 1 Straight stitch...

  • Page 77: Repair Instructions

    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 guide 134. Remove guide 134.

  • Page 78: Changing The Pressure Spring In The Handwheel Release

    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. Pull out handwheel release disk 143 and take 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.

  • Page 80: Removing And Fitting The Sewing Hook

    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.

  • Page 82: Changing The Toothed Belt

    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.

  • Page 84: Adjusting The Arm Shaft Crank

    To this end, reposition the needle-rise clamp and check. Refit the needle plate. 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.

  • Page 86: Changing The Bevel Gears

    48. Changing the bevel gears Note: Always change bevel gears in pairs. Removal: 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.
  • Page 88 Refitting: Set the new bevel gear with the lifting eccentric onto the sewing hook bearing. 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.

  • Page 90: Changing The Motor

    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.

  • Page 92: Changing The Motor Circuit Board On Motor Types Uus 390 And Uus

    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. Slightly raise the two locking tabs 163 and remove cover 162 (fig. 114). Unsolder the two cables at points 168.

  • Page 93: Changing The Carbon Brushes On Motor Types Uus 390 And Uus

    51. Changing the carbon brushes on motor types UUS 390 and UUS 393 Removal: Remove the motor in accordance with point 49of this manual. Slightly raise the two locking tabs 163 and remove cover 162 (fig. 115). Unscrew the two groove nuts 170. Pull the motor apart and remove end shield 171.

  • Page 94: Changing The Motor Pinion

    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. Insert two screwdrivers of the same width between pinion 58 and the motor bearing (fig. 116). Rotate the two screwdrivers in opposite directions, thus prizing pinion 58 off the shaft.

  • Page 95: Changing The Motor Toothed Belt

    53. Changing the motor toothed belt Removal: Disconnect the machine lead cord Remove the housing covers as described in this manual. Remove the two screws 56 and 57 of the motor (fig. 117). Disengage the handwheel. Remove plastic cap 141. Remove handwheel screw 142 (fig.

  • Page 96: Changing The Circuit Board In Foot Control Ae

    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.

  • Page 97: Changing The Mains Connections In Foot Control Ae

    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: Turn the foot control so that it is resting on pedal 175.

  • Page 98: Safety Test

    Signal lamp "PE", just above the contact field, will light up if the ground lead is out of order. Insert plug of sewing machine into the main power connection of ABB Metrawatt M 5013. Operate the machine.
  • Page 99 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). Meter reading: 0.50 mA maximum.

  • Page 101: Simulated Leakage Current Measurements Of Complete Motors With Abb Metrawatt M 5013

    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"...
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  • Page 106 PFAFF GmbH Amalienbadstraße 36 D-76227 Karlsruhe Phone +49 (0)721/4001-0 Telefax +49 (0)721/4001-513 E-Mail: info@pfaff.com http://www.pfaff.de Druckerei Gablenz GmbH Stettiner Straße 17 76356 Weingarten © 2003 copyright VSM-Group AB All rights reserved. Printed in Germany Technische Änderungen vorbehalten Subject to alterations in design Sous toute réserve de modifications...

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