Pfaff Powerline 2545, Adjustment Manual

Page 1: ...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 ADJUSTMENT MANUAL 2545 2546 ...

Page 2: ...on 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: ...d needle guard 14 1 05 10 Top feed stroke 16 1 05 11 Top feed lifting motion 17 1 05 12 Adjusting the potentiometer for speed reduction 18 1 05 12 01 On machines with drive P74 ED L 19 1 05 12 02 On machines with drive PF 321 19 1 05 13 Bobbin case opener stroke 19 1 05 14 Adjusting the shortened trim stitch 20 1 05 15 Bobbin winder 21 1 05 16 Thread check spring and thread regulator 22 1 05 17 Se...

Page 4: ...following chapter 35 1 07 04 Needle position in sewing direction 36 1 07 05 Bottom transporter in sewing direction 37 1 07 06 Blade position 38 1 07 07 Thread catcher height 39 1 07 08 Thread catcher position in sewing direction 40 1 07 09 Thread catcher position crossways to sewing direction 41 1 07 10 Position of the control curve 42 1 07 11 Thread clamp 43 1 07 12 Parameter values 44 2 Circuit ...

Page 5: ... which have to be completely adjusted If only specific individual work steps are carried out both the preceding and following chapters must be observed Screws nuts indicated in brackets are fastenings for machine parts which must be loosened before adjustment and tightened again afterwards 1 02 Tools gauges and other accessories for adjusting Screwdrivers with blade width from 2 to 10 mm Spanners ...

Page 6: ... wheel 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 Fig 1 01 1 2 2 127 01 Adjust the scale dial 1 depending on model screws 2 or 3 in accordance with the re quirement 3 3 ...

Page 7: ... 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 Adjust balance weight 1 screw 2 in accordance with the requirement 1 2 1 2 Fig 1 02 ...

Page 8: ...ent 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 Remove spring 1 Adjust crank 2 screw 3 in accordance with the requirement Replace the spring 1 Fig 1 03 1 3 2 ...

Page 9: ... 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 Adjust eccentric 1 screws 2 in accordance with the requirement Make sure that the cut out see arrow is visible Fig 1 04 1 2 ...

Page 10: ...crews 2 in accordance with the requirement Use the kit with the Order No 91 501 399 90 to deactivate the transporter lif ting movement Install assembly and adjust Remove collar 3 screws 4 and crank 5 screw 6 nut 7 Mount the preassembled parts of the kit as shown in figures 1 05a Adjust bottom transporter height and stroke movement where required Fig 1 05 1 2 3 4 6 5 7 ...

Page 11: ...d swivel connection part 8 screw 11 towards the right Replace screw 9 with a screw M6 x 25 Replace screw 10 with a threaded pin M5 x 25 and tighten to stop Adjust transporter height with deactivated stroke movement so that the upper edge of the transporte is at the height of the upper edge of the needle plate Adjust the transporter height once again with the stroke movement activated as described ...

Page 12: ...5 is in the centre of the slot 2 In the direction of sewing the bottom feed dog should be positioned in the centre of the needle plate slot Turn lifting crank 1 screws 2 and eccentric sleeve 3 screws 4 according to Require ment 1 and set feed dog in centre of needle plate slot as shown in Requirement 2 The height of the bottom feed dog can also be increased or reduced as required by moving crank 5...

Page 13: ...ith 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 With connecting rod 1 nut 2 increase or reduce the needle feed stroke in accordance with the requirement 1 2 Fig 1 07 ...

Page 14: ...uirement Make sure that needle bar 1 and foot 3 do not collide 1 2 Fig 1 08 22 mm 1 3 1 05 08 Preliminary adjustment of the needle height 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 ...

Page 15: ...oned 0 8 mm below hook point 6 and 3 and needle guard 7 must touch the needle just lightly Loosen both screws of the gear drive of hook 1 under cover 2 Adjust hook 1 and hook bearing 3 screws 4 and 5 in accordance with requirement 1 Without turning it re position the needle bar in accordance with the requirement 2 also see Chapter 1 05 08 Preliminary adjustment of the needle bar Needle rise positi...

Page 16: ...Adjustment 16 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: ...the metal gauge over the opening of the needle plate slot so that both sewing feet can be lowered onto the metal gauge For the preliminary adjustment adjust crank 2 screw 3 so that there is a clearance of 5 mm between presser foot 4 and the needle plate Adjust crank 5 screw 6 so that top feed dog 7 and presser foot 4 have the same stroke Check the adjustment in accordance with the requirement and ...

Page 18: ...fting motion 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 Turn eccentric 1 screw 2 in accordance with the requirement ...

Page 19: ...ntrol panel while simultaneously switching the machine on Enter the code 3112 via the numbered keys and confirm by pressing E Select parameter 501 via the numbered keys and confirm by pressing E Set the smallest stroke 0 Using the stroke adjustment function call up the small stroke LED off see instruction manual Take over the value displayed under parameter 501 by pressing Select parameter 502 via...

Page 20: ...e 5 by the thickness of the thread 2 The bobbin case opener 1 should be at its left point of reversal when the balance wheel is positioned at 10 Adjust bobbin case opener 1 screw under cover 2 in accordance with requirement 1 Adjust the eccentric screw under cover 3 in accordance with requirement 2 The thread must be able to pass unhindered between bobbin case opener 1 and bobbin case 6 Fig 1 13 4...

Page 21: ... 21 1 05 14 Adjusting the shortened trim stitch Requirement For the trim stitch the machine should carry out a stitch length of 0 5 1 0 mm Adjust lever 1 screws 2 in accordance with the requirement Fig 1 14 1 2 2 ...

Page 22: ... 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 Adjust drive wheel 1 screw 2 in accordance with the requirement ...

Page 23: ...ssed around the hook the check thread spring 3 should rise slightly from the rest 1 Position rest 1 screw 2 in accordance with requirement 1 Turn sleeve 4 screw 2 to adjust the tension of thread check spring 3 Position thread regulator 5 screw 6 in accordance with requirement 2 For technical reasons it may be necessary to deviate from the indicated spring stroke or spring tension Move thread regul...

Page 24: ...tment 24 Fig 1 17 1 1 05 17 Sewing foot pressure Requirement The material should be fed properly even at maximum speed and with the smallest stroke Turn adjustment wheel 1 in accordance with the requirement ...

Page 25: ...k Check that the machine is filled with oil and that the oil lines are free of air Run the machine for 2 3 min Do not put your hands into the needle area when the machine is running Danger of injury from moving parts With the machine running hold paper strip 1 against the hook and check the require ment If necessary regulate amount of oil with screw 2 Fig 1 18 1 2 ...

Page 26: ...stitch length using stitch adjuster 4 Set the desired max stitch length at control button 1 on model CN9 9 0 mm on model DN12 12 mm Remove adjustment knob 1 screws 2 and scale dial 3 Remove adjustment unit 4 screws 5 Bring lineal 6 screw 7 to the unit using stitch adjuster 4 see arrow Replace adjustment unit 4 scale dial 3 and adjustment knob 1 Fig 1 19 1 2 3 5 4 6 7 ...

Page 27: ...05 20 Speed reduction Requirement If a stitch length longer than 9 mm is set the speed reduction switch 3 must be pressed Adjust retaining plate 1 screws 2 in accordance with the requirement Fig 1 20 1 2 2 128 081 1 3 ...

Page 28: ...rks 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 Remedy jammed thread fault Hold clutch 1 firmly as shown in Fig 13 22 and turn the balance wheel until clutch 1 re engages Fig 1 21 1 ...

Page 29: ... balance wheel position 60 control cam 1 should just have moved roller lever 5 into its basic position 2 When the thread trimmer is in its resting position there should be a clearance of 0 1 mm between roller lever 5 and control cam 1 Adjust control cam 1 screws 2 in accordance with requirement 1 Adjust screw 3 nut 4 in accordance with requirement 2 Fig 1 22 1 2 4 5 0 1 mm 3 ...

Page 30: ...f thread catcher 3 and knife 5 should be flush see arrow Press roller lever 1 against control cam 2 Adjust thread catcher 3 screw 4 in accordance with the requirement The height of thread catcher 3 is pre set by the manufacturer and if necessary it can be adjusted with washers under thread catcher 3 on the base of the hook bearing Fig 1 23 2 4 1 127 096 3 5 ...

Page 31: ...er to its b d c and press roller lever 1 into the control cam 2 Turn the balance wheel until the front edge of catcher 3 is at a distance of 5 6 mm from the blade of knife 4 Swing knife bearing 5 screw 6 in accordance with the requirement After completing the adjustment recheck the position of the thread catcher in accordance with Chapter 1 06 02 Position and height of the thread catcher Fig 1 24 ...

Page 32: ...immer is in its cutting position the clamp spring should slightly touch the thread catcher and hold the thread reliably Adjust clamp spring 1 screw 2 in accordance with the requirement Carry out the cutting operation by hand and check the setting Readjust if necessary Fig 1 25 1 2 ...

Page 33: ...ion has been completed needle and bobbin thread should be cut neatly and bobbin thread 3 held Sew a few stitches Switch off the main switch and the compressed air Carry out a manual cutting test Check requirement 1 If necessary readjust thread catcher 1 in accordance with Chapter 1 06 02 Position and height of the thread catcher Check requirement 3 If necessary readjust bobbin thread clamp spring ...

Page 34: ...Adjustment 34 Consult the instruction manual for the drive for a description of the parameter settings and a list of the parameters ...

Page 35: ... 1 and thread catcher 2 depending on the hock size Large hock assembly bobbin diameter 26 mm is shown in Fig 1 27 Extra large hock assembly bobbin diameter 32 mm is shown in Fig 1 27a 1 07 03 Check settings according to the following chapter Check the home position of the handwheel Check lower upper and needle feed sliding movement Check bottom transporter lifting movement Fig 1 27a 1 2 1 2 ...

Page 36: ...g direction should pierce the middle of the setting gauge hole 1 Unscrew the needle plate and bottom transporter Insert a 100 100 mm thick needle Unscrew setting gauge 1 Order No 61 111 689 07 Adjust needle bar 2 screw 3 in accordance with the rule Unscrew the setting gauge again Reassemble the bottom transporter 3 2 1 ...

Page 37: ...etting 0 the needle in sewing direction should pierce the middle of the stitch hole in the bottom feed 1 Adjust bottom feed 1 screw 2 in accordance with the rule Mounting the needle plate Of you mounte the needle plate make sure that the ball joint 3 of the knife 4 is in the cut out 2 1 3 4 5 ...

Page 38: ...1 to its stop to the front Move support 2 screw 3 acocording to the setting 1 07 06 Blade position 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 1 2 3 4 4 5 6 ...

Page 39: ...etting gauge 1 without turning it 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 magnification The height setting is factory preset Any possible correction required can be carried out by placing a 0 2 mm thick spacing washer underneath Order No 12 360 061 05 between part 3 and part 4 1 2 4 3 ...

Page 40: ...in the front turning point position a gap of 20 mm should exisit between the thread catcher point and the middle stitch hole Bring the roller lever 1 screw 2 to the lowest trim curve position 3 Turn thread catcher 4 in accordance with the rule Make sure that the catcher 5 has no axial player when tighten the screw 2 2 1 3 4 20 mm 5 ...

Page 41: ...atcher postion crossways to sewing direction 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 Move thread catcher 1 screws 2 in accordance with the rule 1 2 3 ...

Page 42: ...e 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 Turn control curve 1 screws 2 in accordance with rule 1 Adjust screw 3 nut 4 in accordance with rule 2 1 2 4 5 0 1 mm 3 ...

Page 43: ... 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 To see better remove the throat plate and the feed dog Move the thread ripper 1 screw 2 according to the setting Move support 3 screw 4 according to the setting Fix the Throad plate and the feed dog 1 5 2 3 4 ...

Page 44: ...ewing start B C 0 2 0 315 Funkctions A15 0 no function 1 Faclean thread monitor 2 Thread pulling at sewing start B C 0 2 0 316 Position to pull thread at seam start B C 0 255 235 317 Time to pull the thread at sewing start B C 10 1000 100 6 657 Stitch protection knotting B C ON OFF ON 7 702 1 Needle position down B C 0 255 20 703 Thread lever position up B C 0 255 235 705 End trim signal1 B C 0 25...

Page 45: ...2546 BASIC with control pack P45 PD L Block diagram Version 28 03 07 Synchronizer PD 6 Ministop drive unit long with incremental transducer for software download Q1 Power switch Mains plug BDF PICO TOP Control unit QA40 PD A1 LED Netzteil H1 2545 BASIC 2546 BASIC LED power supply unit ...

Page 46: ...ller P45 PD L A2 Control panel PicoTop H1 Sewing lamp M1 Sewing motor Q1 Main switch S1 Pedal speed control unit X1 Sewing motor X2 Incremental transmitter X7 Synchronizer PD 6 X3 Speed control unit X4 PicoTop control panel or RS 232 interface PC X5 Input output plug X8 Light barrier plug optional Circuit diagrams ...

Page 47: ...47 Circuit diagrams Version 27 07 07 91 191 523 95 Part 1 ...

Page 48: ...48 91 191 523 95 Part 2 Version 27 07 07 Circuit diagrams ...

Page 49: ...th control pack P74 ED L Synchronizer PD 6 Ministop drive unit long with incremental transducer for software download Q1 Power switch Mains plug Control unit P74 ED A1 Optional Block diagram Version 10 08 10 BDF PICO TOP A 20 2545 PLUS 2546 PLUS Y3 Y4 Y5 Y6 Y9 Y8 Y14 Y1X R1 Optional Light barrier LED power supply unit Adapter ...

Page 50: ...g motor X2 Incremental transmitter X2 1 Incremental transmitter X2 2 Synchronizer PD 6 Circuit diagrams X3 Speed control unit X4 PicoTop control panel X5 Input output plug X7 Light barrier plug bobbin thread monitor optional XA14 A14 Sewing head recognition OTE XA15 1 A15 Oil sensor 2C Bus XA15 2 A15 Oil sensor 2C Bus A16 Keyboard 2C Bus XA20 A20 Bobbin thread monitor optional XR1 R1 Potentiometer...

Page 51: ...51 Circuit diagrams Version 10 08 10 91 191 519 95 Part 1 ...

Page 52: ...52 91 191 519 95 Part 2 Version 20 04 12 Circuit diagrams ...

Page 53: ...53 Circuit diagrams Version 20 04 12 91 191 519 95 Part 3 ...

Page 54: ...54 91 191 519 95 Part 4 Version 20 04 12 Circuit diagrams ...

Page 55: ... Adapter 1113229 USB X 5 KS SWG UFW Option Y3 Y4 Y5 Y6 Y8 Y14 Y1X R1 2 05 Block diagram PFAFF 2545 46 PLUS with PF 321 Mains plug BDF Control panel UWF Lower thraed monitor SWG Speedcontrolunit KS Knee switch for Software download 2545 46 Block diagram ...

Page 56: ...e und Maschinen AG is an authorized licensee of the PFAFF trademark 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 ...