Pfaff Powerline 2545 Adjustment Manual
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Pfaff Powerline 2545 Adjustment Manual

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2545
2546
ADJUSTMENT MANUAL
This Adjustment Manual is valid for machines
from the following serial numbers onwards:
# 2 798 767
296-12-19 220/002
Justieranleitung engl. 06.13

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Summary of Contents for Pfaff Powerline 2545

  • Page 1 2545 2546 ADJUSTMENT MANUAL This Adjustment Manual is valid for machines from the following serial numbers onwards: # 2 798 767 296-12-19 220/002 Justieranleitung engl. 06.13...
  • Page 2 The reprinting, copying or translation of PFAFF Service Manuals, whether in whole or in part, is only permitted with our previous authorization and with written reference to the source. PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern...

  • Page 3: Table Of Contents

    Index Contents ................Page Adjustment ........................... 4 Notes on adjustment ......................4 Tools, gauges and other accessories for adjusting ............... 4 Abbreviations ......................... 4 Explanation of the symbols ....................4 Adjusting the basic machine ....................5 .05.01 Basic position of the balance wheel (adjustment aid) ............5 .05.02 Balance weight ........................
  • Page 4 Index Contents ................Page Adjusting the thread trimmer device -900/82 ..............35 .07 .01 Preliminary testing ....................... 35 .07 .02 Assrémbly of the thread clamp carrier and thread catcher ..........35 .07 .03 Check settings according to the following chapter: ............35 .07 .04 Needle position in sewing direction ..................

  • Page 5: Adjustment

    Adjustment Adjustment Please observe all notes from Chapter 1 Safety of the instruction manual! In particular care must be taken to see that all protective devices are refi tted properly after adjustment, see Chapter 1.06 Danger warnings of the instruc- tion manual! If not otherwise stated, the machine must be disconnected from the electrical power supply.

  • Page 6: Adjusting The Basic Machine

    Adjustment Adjusting the basic machine Basic position of the balance wheel .05.01 (adjustment aid) Requirement When the needle bar is positioned at t.d.c., the marking "0" on the scale should be level with the top edge of the belt guard (see arrow). 127-01 Fig.

  • Page 7: Balance Weight

    Adjustment Balance weight .05.02 Requirement When the needle bar is positioned at b.d.c. (balance wheel position 180°) the largest ec- centricity of the balance weight 1 should be at the top. Fig. 1 - 02 ● Adjust balance weight 1 (screw 2) in accordance with the requirement.

  • Page 8: Zero Position Of The Unison Feed

    Adjustment Zero position of the unison feed .05.03 Requirement When the stitch length is set at "0", the top and bottom feed dogs and the needle bar should not make any feeding motion when the balance wheel is turned. Fig. 1 - 03 ●...

  • Page 9: Feeding Motion Of The Unison Feed

    Adjustment Feeding motion of the unison feed .05.04 Requirement When the needle bar is positioned at b.d.c. (balance wheel position 180°), and the ma- ximum stitch length is set, the top and bottom feed dogs and the needle bar should not make any feeding motion when the reverse-feed lever is pressed.

  • Page 10: Lifting Motion Of The Bottom Feed Dog

    Adjustment Lifting motion of the bottom feed dog .05.05 Requirement When the balance wheel is positioned at 180°, the feed dog should be at t.d.c. Fig. 1 - 05 ● Adjust eccentric 1 (screws 2) in accordance with the requirement. Use the kit with the Order No.
  • Page 11 Adjustment Fig. 1 - 05a Activate lifting movement ● Lifting movement is activated if connection part 8 is swiveled in as shon in fi gures 1 - 05a, and screws 9 (M6 x 16) and 10 (M5 x 16) have been attached. Deactivate lifting movement ●...

  • Page 12: Height Of The Bottom Feed Dog

    Adjustment Height of the bottom feed dog .05.06 Requirement 1. When the needle bar is positioned at b.d.c. (balance wheel position 180°), the bottom feed dog should be positioned 0.5 mm horizontally above the top edge of the needle plate, when crank 5 is in the centre of the slot.

  • Page 13: Feeding Stroke Difference

    Adjustment Feeding stroke difference .05.07 Requirement With the maximum stitch length set, when the balance wheel is turned the feeding stro- kes of the needle and the bottom feed dog should be the same. Fig. 1 - 07 ● With connecting rod 1 (nut 2) increase ("+") or reduce (-) the needle feed stroke in accordance with the requirement.

  • Page 14: Preliminary Adjustment Of The Needle Height

    Adjustment Preliminary adjustment of the needle height .05.08 Requirement When the needle bar is positioned at t.d.c. (balance wheel position 0°), the clearance between the needle point and the needle plate should be 22 mm. Fig. 1 - 08 ● Without turning it, re-position needle bar 1 (screw 2) in accordance with the requirement.

  • Page 15: Needle Rise, Hook Clearance, Needle Height And Needle Guard

    Adjustment Needle rise, hook clearance, needle height and needle guard .05.09 Requirement With the stitch length set at "4.5" and in the needle rise position (see table) 1. The hook point 6 should be positioned at "needle centre" with a hook-to-needle clea- rance of 0.05 –...
  • Page 16 Adjustment ● Adjust needle guard 7 (screw 8) in accordance with requirement 3. If the needle size is changed, a quick adjustment of hook bearing 3 is possible, after loosening screws 4 and 5.

  • Page 17: Top Feed Stroke

    Adjustment Top feed stroke .05.10 Requirement With adjustment wheel 1 set at "5", the top feed dog 7 and presser foot 4 should each rise by 5.0 mm. Fig. 1 - 10 ● Remove the bottom feed dog and set adjustment wheel 1 at "5". ●...

  • Page 18: Top-Feed Lifting Motion

    Adjustment Top-feed lifting motion .05.11 Requirement The top feed dog should just have reached the needle plate when the presser foot lift is set at 5 mm and the needle descending from above is 2 mm above the needle plate. Fig.

  • Page 19: Adjusting The Potentiometer For Speed Reduction

    Adjustment Adjusting the potentiometer for speed reduction .05.12 Machines with P74 ED-L .05.12 .01 ● Switch on the machine ● Set the smallest stroke "0". ● Using the stroke adjustment function, call up the smallest stroke (LED off), see the Cont- rol Panel Instruction Manual.

  • Page 20: Bobbin Case Opener Stroke

    Adjustment Bobbin case opener stroke .05.13 Requirement When the balance wheel is turned 1. The beak 4, when it is at the right point of reversal of the bobbin case opener 1, should rise from the needle plate 5 by the thickness of the thread. 2.

  • Page 21: Adjusting The Shortened Trim Stitch

    Adjustment Adjusting the shortened trim stitch .05.14 Requirement For the trim stitch the machine should carry out a stitch length of 0.5 – 1.0 mm. Fig. 1 - 14 ● Adjust lever 1 (screws 2) in accordance with the requirement.

  • Page 22: Bobbin Winder

    Adjustment Bobbin winder .05.15 Requirement 1. When the bobbin winder is engaged, the winding spindle must be driven reliably. When it is disengaged, friction wheel 3 should not be touching drive wheel 1. 2. When it is switched off, the bobbin winder must click securely into its end position (knife raised).

  • Page 23: Thread Check Spring And Thread Regulator

    Adjustment Thread check spring and thread regulator .05.16 Requirement 1. The movement of thread regulator 3 must be completed when the needle point enters the material. 2. When the thread loop is at its largest while being passed around the hook, the check thread spring 3 should rise slightly from the rest 1.

  • Page 24: Sewing Foot Pressure

    Adjustment Sewing foot pressure .05.17 Requirement The material should be fed properly even at maximum speed and with the smallest stroke. Fig. 1 - 17 ● Turn adjustment wheel 1 in accordance with the requirement.

  • Page 25: Lubrication

    Adjustment Lubrication .05.18 Requirement After a running time of 10 seconds a thin fi lm of oil should be visible on paper strip 1 when this is held over the hook. Fig. 1 - 18 ● Check that the machine is fi lled with oil and that the oil lines are free of air. ●...

  • Page 26: Limiting The Stitch Length

    Adjustment Limiting the stitch length .05.19 When exch ing the parts kit with stitch lengths differing from the as-deliv- ered state of the machine, limit the max. stitch length using stitch adjuster 4. Fig. 1 - 19 ● Set the desired max. stitch length at control button 1 (on model CN9 = 9.0 mm, on model DN12 = 12 mm) ●...

  • Page 27: Speed Reduction

    Adjustment Speed reduction .05.20 Requirement If a stitch length longer than 9 mm is set, the speed reduction switch 3 must be pressed. 128-081 Fig. 1 - 20 ● Adjust retaining plate 1 (screws 2) in accordance with the requirement.

  • Page 28: Re-Engaging The Slip-Clutch

    Adjustment Re-engaging the slip-clutch .05.21 Clutch 1 is adjusted at the works. In the case of a thread jamming, clutch 1 will disengage, in order to avoid damage to the hooks. The following describes how to re-engage clutch 1. Fig. 1 - 21 ●...

  • Page 29: Adjusting The Thread Trimmer -900/81

    Adjustment Adjusting the thread trimmer -900/81 Resting position of roller lever/radial position of control cam .06.01 Requirement 1. When the take-up lever is at t.d.c. (balance wheel position 60 °), control cam 1 should just have moved roller lever 5 into its basic position. 2.

  • Page 30: Position And Height Of The Thread Catcher

    Adjustment Position and height of the thread catcher .06.02 Requirement When the needle bar is positioned at b.d.c. (balance wheel position 180°) the edges of thread catcher 3 and knife 5 should be fl ush (see arrow). 127-096 Fig. 1 - 23 ●...

  • Page 31: Knife Pressure

    Adjustment Knife pressure .06.03 Requirement When the front edge of thread catcher 3 is 5 – 6 mm in front of the knife blade, the knife 4 should be touching the catcher edge with slight pressure. Fig. 1 - 24 ●...

  • Page 32: Bobbin Thread Clamp Spring

    Adjustment Bobbin thread clamp spring .06.04 Requirement When the thread trimmer is in its cutting position, the clamp spring should slightly touch the thread catcher and hold the thread reliably. Fig. 1 - 25 ● Adjust clamp spring 1 (screw 2) in accordance with the requirement. ●...

  • Page 33: Manual Cutting Test

    Adjustment Manual cutting test .06.05 Requirement 1. 1. When moving forward, thread catcher 1 must not move bobbin thread 3 2. When thread catcher 1 is at its front point of reversal, bobbin thread 3 should be in the centre of the marked area (see arrow). 3.
  • Page 34 Adjustment Consult the instruction manual for the drive for a description of the parameter settings and a list of the parameters.

  • Page 35: Adjusting The Thread Trimmer Device -900/82

    Adjusting Adjusting the thread trimmer device -900/82 Preliminary testing .07 .01 Assembly of the thread clamp carrier and thread catcher .07 .02 Fig. 1 - 27a Fig. 1 - 27 ● Assemble thread clamp carrier 1 and thread catcher 2 depending on the hock size: Large hock assembly (bobbin diameter 26 mm) is shown in Fig.

  • Page 36: Needle Position In Sewing Direction

    Adjusting Needle postition in sewing direction .07 .04 Rule At stitch length setting "0", the needle in sewing direction should pierce the middle of the setting gauge hole 1. Fig. 1 - 28 ● Unscrew the needle plate and bottom transporter.. ●...

  • Page 37: Bottom Transporter In Sewing Direction

    Adjusting Bottom transporter in sewing direction .07 .05 Rule At stitch length setting "0", the needle in sewing direction should pierce the middle of the stitch hole in the bottom feed 1. Fig. 1 - 29 ● Adjust bottom feed 1 (screw 2) in accordance with the rule. ●...

  • Page 38: Blade Position

    Adjusting Blade position .07 .06 Rule If the knife is max. to the front and thestitch-length setting "0" the edge 5 of the knife 4 should be 0.2 mm a way from the feed dog 6 0,2 mm Fig. 1 - 30 ●...

  • Page 39: Thread Catcher Height

    Adjusting Thread catcher height .07 .07 Rule When positioning the thread catcher 2 under the setting gauge 1, the thread catcher 2 should directly touch the setting gauge 1 without turning it. Fig. 1 - 31 ● Place the setting gauge 1 (Order No. 61-111 689-07) in the needle plate recess, so that it stands above the thread catcher 2 (see magnifi...

  • Page 40: Thread Catcher Position In Sewing Direction

    Adjusting Thread catcher postition in sewing direction .07 .08 Rule At stitch length setting "0" and the thread catcher 4 in the front turning point position, a gap of 20 mm should exisit between the thread catcher point and the middle stitch hole. 20 mm Fig.

  • Page 41: Thread Catcher Position Crossways To Sewing Direction

    Adjusting Thread catcher postion crossways to sewing direction .07 .09 Rule In the max. forwards position of the catcher 1, the right edge of the catcher and the right edge of the feed dog 3 be lined up. Fig. 1 - 33 ●...

  • Page 42: Position Of The Control Curve

    Adjusting Position of the control curve .07 .10 Regel 1. In the hand wheel position 305°, the catcher should just start with its movment. 2. When the thread trimmer attachment is in its idle state, a gap of 0.1 mm should exist between the roller lever 5 and the control curve 1.

  • Page 43: Thread Clamp

    Adjusting Thread clamp .07 .11 Rule 1. The right edge of the ripper 1 should be fl ush with the right edge of the catcher 5 in it´s rest position. 2. The ripper 1 should sllightly touch the catcher and the top thread gets easy pulled out of the ripper.

  • Page 44: Parameter Values

    Adjusting Parameter values .07 .12 The following parameters has to be set diffrent to the regulare P74 ED instruction manual. Position short trimmer on B, C 0 - 255 Functions A16 0 = no function B, C 0 - 2 1 = midle guide 2 = short trimmer Selection of midle guide...

  • Page 45: Circuit Diagrams

    Block diagram Version 28.03.07 Circuit diagrams Block diagram PFAFF 2545 and 2546 BASIC with control pack P45 PD-L Synchronizer PD 6 2545 BASIC 2546 BASIC BDF - PICO TOP power supply Netzteil unit Ministop drive unit (long) with incremental transducer...
  • Page 46 Circuit diagrams Circuit diagrams PFAFF 2545 and 2546 BASIC Reference list for the Circuit diagrams 91-191 523-95 Controller P45 PD-L Control panel (PicoTop) Sewing lamp Sewing motor Main switch Pedal speed control unit Sewing motor Incremental transmitter Synchronizer PD 6...
  • Page 47 Circuit diagrams 91-191 523-95 Version 27 .07 .07 Part 1...
  • Page 48 91-191 523-95 Circuit diagrams Part 2 Version 27 .07 .07...
  • Page 49 Block diagram Version 10.08.10 Block diagram PFAFF 2545 2546 PLUS with control pack P74 ED-L Synchronizer PD 6 2545 PLUS Y3, Y4, Y5, Y6, Y9 2546 PLUS Y8, Y14, Y1X, R1 BDF - PICO TOP Optional Light barrier A 20...
  • Page 50 Circuit diagrams Circuit diagrams PFAFF 2545 and 2546 PLUS Reference list for the Circuit diagrams 91-191 519-95 Steuergerät P74 ED-L Speed control unit Controller P74 ED-L PicoTop control panel Control panel (PicoTop) Input/output plug Sewing head recognition (OTE) Light barrier plug & bobbin thread...
  • Page 51 Circuit diagrams 91-191 519-95 Version 10.08.10 Part 1...
  • Page 52 91-191 519-95 Circuit diagrams Part 2 Version 20.04.12...
  • Page 53 Circuit diagrams 91-191 519-95 Version 20.04.12 Part 3...
  • Page 54 91-191 519-95 Circuit diagrams Part 4 Version 20.04.12...
  • Page 55 Block diagram Block diagram PFAFF 2545/46 PLUS with PF 321 PD 6 2545 / 46 Y3, Y4, Y5, Y6, Y8, Y14, Y1X, R1 (Option) (Option) Adapter 1113229 B 41 B 80 ST 2 B 18 B 776 for Software download...
  • Page 56 PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Telefon: +49 - 6301 3205 - 0 Telefax: +49 - 6301 3205 - 1386 E-mail: info@pfaff-industrial.com Gedruckt in der BRD / Printed in Germany / Imprimé en la R.F.A. / Impreso en la R.F.A...

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