Pfaff Passport 2.0 Service Manual

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Owner's manual (32 pages)

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Passport 2.0

Passport 3.0

Service Manual

104 73 31-26

19 Oct 2015

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Summary of Contents for Pfaff Passport 2.0

Page 1 Passport 2.0 Passport 3.0 Service Manual 104 73 31-26 19 Oct 2015...
Page 2 Contents IMPORTANT SAFETY INSTRUCTIONS ....................5 Directions for use ..........................6 ESD 6 Service tools ........................... 7 Settings - Quick reference ......................... 8 Belt tension - drive belt ......................11 Motor Belt tension ........................12 Upper shaft axial play ......................13 Take up lever ........................
Page 3 Names of principal parts ....................... 45 Main Circuit board - Circuit diagram Passport 2.0 ................47 Main Circuit board - Circuit diagram Passport 3.0 ................48 Fault ﬁ nding ..........................49 No operation sewing machine ......................49 LED no display ..........................49 No operation/function of the pushbutton ..................
Page 4 104 73 31-26...
Page 5 This household sewing machine is designed to comply with IEC/EN 60335-2-28 and UL1594 IMPORTANT SAFETY INSTRUCTIONS When using an electrical appliance, basic safety precautions should always be followed, including the following: Read all instructions before using this household Sewing machine. DANGER –...
Page 6 Directions for use These service instructions are intended to be used by service workshop personnel, or by salesmen who carry out servicing in their own districts. They assume a thorough knowledge of the handling of precision appliances and accessibility to service tools. The manual is divided into four sections and covers all service operations and checks which should be carried out when making a complete overhaul of a sewing machine.
Page 7 Service tools A reasonable requirement in a domestic sewing machine is that it should able to sew all types of fabrics used in the home. The settings made when assembling and sewing-in the machines are those most suited to give the best results in the majority of fabrics and fabric combinations. In doing so, consideration has been given to the requirements of different markets.
Page 8 Settings - Quick reference Settings - Quick reference Belt tension, drive belt The belt tension shall be adjusted by re-position tensioning roller by push 3~4m/m it up or down until it is a ﬁ rm belt tension. Belt tension, motor belt Move the motor unit (b) util a correct belt tension is obtained.
Page 9 Settings - Quick reference 12. Setting the bobbin stop to the bobbin. 13. Setting the feed dog in relation to the needle plate Sideways the feed dog should be symmetrically set in relation to the needle plate slot. 14. Feed dog height 0.9~1.05mm When Feed dog teeth are in its highest position they should be 0.9-1.05 mm above the needle plate.
Page 10 Settings - Quick reference 23. Lower thread tension (thread tension of the bobbin case) The thread tension spring of the bobbin case shall give a resistance of 19-22 g when pulling the thread slowly, using normal polyester thread. 24. Upper thread tension When the thread tension dial is set at 5, a correct take-up should be obtained at straight stitching and zig-zag using normal cotton fabrics and polyester thread.
Page 11 Settings 1. Belt tension - drive belt Check The ﬂ at-toothed belt must be set so that the sewing hook has no play in its rotating direction, but it must be possible to turn the machine easily. The belt should have approx. 3-4 mm slack when a pressure of 200 grams is applied to the middle of the belt.
Page 12 Settings 2. Motor Belt tension Too tight or too loose motor belt tension can cause belt noise. Too tight motor belt tension can make the machine to run slow and overload the motor. Too loose motor belt tension may cause jumping of the belt teeth on the motor pulley. Check When pushing the motor belt with 200 grams load the deﬂ...
Page 13 Settings 3. Upper shaft axial play Check The axial play of the arm shaft should not be larger than 0.05 mm. Adjustment Remove all the covers. Loosen 2 screws (A, B) on main shaft collar (C). Pull hand wheel to the right. Push main shaft collar (C) to the left against main shaft bushing (D), and tighten screws (A, B).
Page 14 Settings 4. Take up lever Check When turning the hand wheel no noise should appear in the thread take up lever. If is too tight, it will be difﬁ cult to turn the hand wheel. If is too loose, it will make noise while turning the hand wheel. Adjustment 1.
Page 15 Settings 5. Timing of the Feeding in relation to the needle Check Remove all covers. Turn the hand wheel so the needle comes to its lowest point. The feed lifting rock cam (A) and the screw (B) of feed rock cam (C) should now be parallel. Adjustment Turn the hand wheel to make the needle comes to its lowest point.
Page 16 Settings 6. Setting the needle in centre position Check Insert a new needle size 90 universal in the machine. The needle should always go its to the centre position, when the machine is turned on repeatedly. Adjustment 1. Remove the face cover. 2.
Page 17 Settings 7. Zig-zag movement of the needle adjustment Check Choose the pattern #03. Set needle bar at its lowest point when it swings to left. Turn the hand wheel to move the needle bar upward. The vertical distance in which the needle point goes up until it swings over to the right side should be 6.0~6.2 mm.
Page 18 Settings 8. The timing of the hook in relation to the needle Check Set a new needle size 90 universal into the machine. Choose the pattern #01. Set machine on straight stitching. Remove the needle plate, bobbin case holder and the bobbin case. Set the needle bar at its lowest point.
Page 19 Settings 9. Play between Hook gear and lower shaft gear It is impossible to obtain an equally large play in one rotation of the cog wheel, but it should be as small as possible at the tightest spot during the revolution. Check Move the cog wheel with the hand wheel and check play of the gears at 4 positions –...
Page 20 Settings 10. The gap between the needle and the hook Check Choose the straight stitch pattern. Insert a new needle size 90 universal in the machine. Remove the bobbin case. Rotate hand wheel until the tip of the hook arrives behind the needle. Check the gap by pressing a small screw driver against the needle.
Page 21 Settings 11. Setting the needle plate in relation to the needle in the feeding direction Check Insert a new needle size 90 universal in the machine. Set the needle so the needle eye is just above the needle plate. In the feeding direction the needle should descend right into the middle of the needle hole of the needle plate.
Page 22 Settings 12. Setting the bobbin stop to the bobbin Remove the needle plate. Back bobbin stop Check Turn the hand wheel counter-clockwise, the shuttle hook (A) will move towards rotary hook plate (B), and generate a distance between the shuttle hook (A) and the rotary hook plate (C). Using the distance gauge to test the play, the distance should be 0.3-0.5 mm.
Page 23 Settings 13. Setting the feed dog in relation to the needle plate Check Sideways the feed dog should be symmetrically set in relation to the needle plate slot. Adjustment Loosen the screws (A, B). Adjust feed dog to center position by moving feed crank shaft (C) left/right. Tighten screw (A) to ﬁ...
Page 24 Settings 14. Feed dog height Check Bring the feed dog to its highest position. The top of the feed dog should be 0.9-1.05 mm above the needle plate. Check with setting gauge 63-112 120 08/000. Adjustment Bring the feed dog to its highest position. Remove the lower free arm cover.
Page 25 Settings 15. The needle bar height Check Remove face plate, needle plate and bobbin case. Put in the setting needle (412 35 29 - 03). Choose the pattern #01, the needle shall be in its centre position, straight stitching. Remove the screws of rotary hook plate (A, B) and rotary hook plate. Remove the bobbin case (C).
Page 26 Settings 16. Threading device Check Insert a new # 70 needle. Bring the needle bar to its highest turning position. The threader hook (C) shall go smoothly into the needle eye. Adjustment height - stop Remove the face plate. Turn on machine and press the Needle up/down button to set the needle bar at its lowest position. Loosen screw (A) of the threader stopper (B).
Page 27 Settings 17. Presser foot height and parallelism to the needle plate Check When the presser foot is in its highest lifting position it shall be approx. 7~7.2 mm above the needle plate and in its down position the presser foot should be parallel to the feed dog. Adjustment Put on a presser foot.
Page 28 Settings 18. Height of presser bar’s guide piece Check Raise the presser foot to second position. Set the needle at the highest position. The gap between presser bar and press bar ring should be around 0.5 mm. Adjustment Loosen up the screw (A). Set the Guide piece so its 0.5 mm between presser bar ring and guide peice.
Page 29 Settings 19. Setting the IDT excenter Check Remove face plate and top cover. Bring the needle bar to its lowest position. Check position of feed cam marking (A) with marking (B) on arm shaft. Adjustment Remove face plate and top cover. Bring the needle bar to its lowest position.
Page 30 Settings 20. Adjustment of the IDT foot - height Check Put on the presser foot #0A. Engage the IDT. Turn on the machine and set it to stitch length 4.5 mm. Press the needle up/down button to make sure the needle is fully down. Lower the presser bar with the functions button presserfoot down.
Page 31 Settings 21. Adjustment of the IDT foot - feeding position Check Turn on the machine and set it to Straight stitch and lengths 4.5 mm. Press the needle up/down button to make sure the needle is fully raised. Turn the handwheel in sewing direction until the rising feed dog teeth is ﬂ ush with the needle plate surface.
Page 32 Settings 22. Setting IDT foot sideways Check The front edge of the IDT foot must be in the middle of the center feed dog. Adjustment Raise the presser foot lever and engage IDT. Remove the presser foot and face plate. Set the feed dog ﬂ...
Page 33 Settings 23. Lower thread tension (thread tension of the bobbin case) Check Insert a full bobbin into the bobbin case. The thread tension spring of the bobbin case shall give a resistance of 19-22 g when pulling the thread slowly, using normal polyester thread. Adjustment Turn screw (A) until the correct thread tension is obtained.
Page 34 Settings 24.Upper thread tension Check A correct interlacing of the upper thread and the bobbin thread (cotton thread 50/2 or synthetic ﬁ ber thread 100/35) must take place approximately in the middle of the fabric at straight and zig-zag stitch setting with the tension dial at ”4”.
Page 35 Settings 25. Darning stitch position adjustment Check Choose the pattern No 20 on Passport 2.0 , the pattern No 21 on Passport 3.0. Test the darning stitch with #2A-presser foot. Fancy stitch foot 2A : When sewing decorative stitches or short zig-zag stitches and other utility stitches with less than 1.0 mm stitch length, use this foot.
Page 36 Settings 26. Stretch stitch balance Check Choose the pattern No 07 on Passport 2.0 , the pattern No 06 on Passport 3.0. Test the Decorative stitch with #1A-presser foot. Fancy stitch foot 1A with IDT : This foot is used for decorative stitches. The groove on the underside of the foot is designed to ﬂ ow smoothly over the stitches.
Page 37 Settings 27. BH photo sensor position adjustment NOTE! Check and adjustment is done without the buttonhole foot on the machine. Check Remove the face plate and back cover. Pull the BH lever (A) down. The BH lever crank (B) and the photo sensor’s (C) blocking movement should be set in the middle. Adjustment Loosen screw (D) of BH movement crank (E).
Page 38 Settings 28. Adjustment of bobbin winding Check When winding up the lower thread onto the bobbin the machine should wind even. Adjustment Place empty bobbin on spindle. While winding, observe the shape of bobbin winding: - When the lower part of bobbin winding is thicker, turn the screw (A) of threader guide counterclockwise.
Page 39 Settings 29. Adjustment of bobbin winder stop Check When winding up the lower thread onto the bobbin the machine should stop when there is a min. of 1 mm between the edge of the bobbin and the thread. Adjustment If bobbin winding before ist 1 mm between the edge of the bobbin and the thread, adjust by turning the screw (A) of bobbin winder bracket shaft clockwise.
Page 40 Settings 30. Adjustment of thread cutter - Passport 3.0 Check When use the thread cutter the move plate should stop with the gap between 0.8~1.2. 0.8~1.2 Adjustment If the move plate stop with the gap is smaller than 0.8 after cut the thread , adjust by loosen the screw (A) to move the move plate (B) to right.
Page 41 Covers Removing the covers NOTE! Before adjusting or repairing the machine, make sure to: - Disconnect the machine’s main plug. - Remove needle and presser foot. - Remove detachable work support. Accessory box Keep the snap-in accessory box horizontal, and pull it in the direction of the arrow. Base cover 1.
Page 42 Covers Free arm cover 1. Remove the screw (i). 2. Remove the free arm cover. Face plate 1. Stand up the machine. 2. From the left side of the machine remove the screw (j). 3. Remove the face plate. Front cover 1.
Page 43 Covers 3. Remove screw cap (m). 4. To locate the screw (m) use an electric torch (ﬂ ash light) since its positioned inside the machine. 5. Loosen the screw (n). 6. Turn the machine and Remove 2 screws (o, p). 7.
Page 44 Covers Turn the machine and remove 2 screws (u, v). Turn the machine and Remove the screw (w). Remove the back cover. 104 73 31-26...
Page 45 Names of principal parts Front side 1. Threading slots 11. Needle screw 2. Thread cutter 12. Needle thread guide 3. LED lights 13. Presser foot bar and presser foot holder 4. Built-in needle threader 14. Presser foot 5. Buttonhole lever 15.
Page 46 Top parts 20. Presser foot pressure dial 21. Thread guides 22. Spool caps 23. Hole for auxiliary spool pin 24. Bobbin winder lever and bobbin spindle 25. Take-up lever 26. Thread tension discs 27. Thread tension dial 28. Bobbin winder tension disc Rear side 29.
Page 47 Dismantling and mounting Main Circuit board - Circuit diagram Passport 2.0 FOR SAFTEY REASONS ALWAYS DISCONNECT THE POWER CORD FROM THE MACHINE BEFORE REMOVING THE CIRCUIT BOARD AND MAKE SURE TO USE WRIST BAND AND ESD MAT. ATTENTION! It is of the utmost importance that precautions are being taken in order to avoid damage of the electronics by electro static discharges (ESD).
Page 48 Main Circuit board - Circuit diagram Passport 3.0 FOR SAFTEY REASONS ALWAYS DISCONNECT THE POWER CORD FROM THE MACHINE BEFORE REMOVING THE CIRCUIT BOARD AND MAKE SURE TO USE WRIST BAND AND ESD MAT. ATTENTION! It is of the utmost importance that precautions are being taken in order to avoid damage of the electronics by electro static discharges (ESD).
Page 49 Fault ﬁ nding Fault ﬁ nding No operation sewing machine Check if HF transformer complete plug J7 in main board is properly connected. Replace motor. Replace main board. LED no display 1. Check if LED control board P2 and the main board P1 cable are properly connected. 2.
Page 50 Fault ﬁ nding No operation Start/Stop, Reverse button Check if the cable from start/stop, reverse is properly connected to the LED control board J30. Replace the start/stop board. Replace the LED control board. Replace the main board. Speed adjustment no operation Check if the connector from the speed adjustment is properly connected to the LED control board J29.
Page 51 Fault ﬁ nding The bobbin winder spindle is in ”off” position Check if the connector J11 is properly connected to the main board. Check if the bobbin winder spindle and microswitch are making proper contact. Adjustment Loosen the screw that holds the microswitch in place, reposition the micro-switch until it is positioned in such a way that the bobbin spindle is pressing fully against the switch, tighten the screw.

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