Pfaff Industrial POWERline 2542 Guide

This Adjustment Manual is valid for machines
from the following serial numbers onwards:
# 2 782 990
296-12-19 177/002
Justieranleitung engl. 12.12
ADJUSTMENT MANUAL
2542

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

Index
Contents ................................................................................ Page
1Adjustment ........................................................................................................................... 4
1.01 Notes on adjustment ............................................................................................................. 4
1.02 Tools, gauges and other accessories for adjusting ............................................................... 4
1.03 Abbreviations ......................................................................................................................... 4
1.04 Explanation of the symbols.................................................................................................... 4
1.05 Adjusting the basic machine .................................................................................................. 5
1.05.01 Basic position of the balance wheel (adjustment aid)............................................................ 5
1.05.02 Balance weight ...................................................................................................................... 6
1.05.03 Zero position of the bottom and needle feed ........................................................................ 7
1.05.04 Feeding motion of the bottom and needle feed..................................................................... 8
1.05.05 Lifting motion of the bottom feed dog ...................................................................................9
1.05.06 Height of the bottom feed dog ............................................................................................ 10
1.05.07 Feeding stroke difference .................................................................................................... 11
1.05.08 Preliminary adjustment of the needle height....................................................................... 12
1.05.09 Needle rise, hook clearance, needle height and needle guard ............................................ 13
1.05.10 Bobbin case opener stroke .................................................................................................. 14
1.05.11 Adjusting the shortened trim stitch......................................................................................15
1.05.12 Bobbin winder...................................................................................................................... 16
1.05.13 Thread check spring and thread regulator............................................................................ 17
1.05.14 Sewing foot pressure........................................................................................................... 18
1.05.15 Lubrication ........................................................................................................................... 19
1.05.16 Limiting the stitch length ..................................................................................................... 20
1.05.17 Re-engaging the slip-clutch.................................................................................................. 21
1.06 Adjusting the thread trimmer -900/81.................................................................................. 22
1.06.01 Resting position of roller lever/radial position of control cam .............................................. 22
1.06.02 Position and height of the thread catcher ............................................................................ 23
1.06.03 Knife pressure...................................................................................................................... 24
1.06.04 Bobbin thread clamp spring ................................................................................................. 25
1.06.05 Manual cutting test .............................................................................................................. 26
3Circuit diagrams................................................................................................................. 28

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1 Adjustment
Please observe all notes from Chapter 1Safety of the instruction manual!
In particular care must be taken to see that all protective devices are refitted
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. Danger of injury due to unintentional starting of the machine!
1.01 Notes on adjustment
All following adjustments are based on a fully assembled machine and may only be carried
out by expert staff trained for this purpose.
Machine covers, which have to be removed and replaced to carry out checks and adjust-
ments, are not mentioned in the text.
The order of the following chapters corresponds to the most logical work sequence for
machines 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 2to 10 mm
●Spanners (wrenches) with jaw width from 7to 14 mm
●1set Allen keys from 1.5to 6mm
●1feed dog adjustment gauge, Part No. 61-111 689-04
●Metal rule (part No. 08-880 218-00)
●Sewing thread and test materials
1.03 Abbreviations
t.d.c. = top dead centre
b.d.c. = bottom dead centre
1.04 Explanation of the symbols
In this adjustment manual, symbols emphasize operations to be carried out or important in-
formation. The symbols used have the following meaning:
Note, information
Service, repair, adjustment, maintenance
(work to be carried out by qualified staff only)

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Fig. 1 - 01
1
2
2
3
3
1.05 Adjusting the basic machine
1.05.01 Basic position of the balance 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).
●Adjust the scale dial 1( depending on model screws 2or 3) in accordance with the re-
quirement.

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Fig. 1 - 02
12
1
2
1.05.02 Balance weight
Requirement
When the needle bar is positioned at b.d.c. (balance wheel position 180°) the largest ec-
centricity of the balance weight 1should be at the top.
●Adjust balance weight 1(screw 2) in accordance with the requirement.

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Fig. 1 - 03
13
2
1.05.03 Zero position of the bottom and needle feed
Requirement
When the stitch length is set at "0", the 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.

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Fig. 1 - 04
1.05.04 Feeding motion of the bottom and needle feed
Requirement
When the balance wheel is positioned at 180°, the feed dog must not make any feeding
motion when reversefeed lever 3is operated.
●Adjust eccentric 1(screws 2) in accordance with the requirement. Make sure that the
cut-out (see arrow) is visible.
1
2
3

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Fig. 1 - 05
●Adjust eccentric 1(screws 2) in accordance with the requirement.
1
2
1.05.05 Lifting motion of the bottom feed dog
Requirement
When the balance wheel is positioned at 180°, the feed dog should be at t.d.c.

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Fig. 1 - 06
0,5 mm
12
3
4
2
4
127-091
6
5
1.05.06 Height of the bottom feed dog
Requirement
1. When the needle bar is positioned at b.d.c. (balance wheel position 180°), the bottom feed
dog should be positioned 0.5mm horizontally above the top edge of the needle plate,
when crank 5is 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(nut 6) up or down.

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Fig. 1 - 07
12
1.05.07 Feeding stroke difference
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.
●With connecting rod 1(nut 2) increase ("+") or reduce (-) the needle feed stroke in
accordance with the requirement.

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Fig. 1 - 08
●Without turning it, re-position needle bar 1(screw 2) in accordance with the
requirement.
1
2
22 mm
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.

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1.05.09 Needle rise, hook clearance, needle height and needle guard
Requirement
With the stitch length set at "4.5" and in the needle rise position (see table)
1. The hook point 6should be positioned at "needle centre" with a hook-to-needle clea-
rance of 0.05 – 0.10 mm.
2. The top of the needle eye should be positioned 0.8mm below hook point 6. and
3. and needle guard 7must touch the needle just lightly.
●Loosen both screws of the gear drive of hook 1(under cover 2).
●Adjust hook 1and hook bearing 3(screws 4and 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.
●Adjust needle guard 7(screw 8) in accordance with requirement 3.
If the needle size is changed, a quick adjustment of hook bearing 3is possible,
after loosening screws 4and 5.
Fig. 1 - 09
0,8 mm
6
5
5
4
2
3
7
8
1
Needle rise position
Model A: Balance wheel position approx. 197° / 1.8 mm
Model B;C: Balance wheel position approx. 202° / 2.0 mm

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1.05.10 Bobbin case opener stroke
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 5by the thickness of the thread.
2. The bobbin case opener 1should 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 - 10
4
5
1
6
3
2

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Fig. 1 - 11
1
22
1.05.11 Adjusting the shortened trim stitch
Requirement
For the trim stitch the machine should carry out a stitch length of 0.5– 1.0mm.
●Adjust lever 1(screws 2) in accordance with the requirement.

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Fig. 1 - 12
2
1
3
1.05.12 Bobbin winder
Requirement
1. When the bobbin winder is engaged, the winding spindle must be driven reliably.
When it is disengaged, friction wheel 3should 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.

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Fig. 1 - 13
2
4
5
6
3
7 mm
1
1.05.13 Thread check spring and thread regulator
Requirement
1. The movement of thread regulator 3must be completed when the needle point enters
the material (spring stroke approx. 7 mm).
2. When the thread loop is at its largest while being passed around the hook, the check
thread spring 3should 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 regulator 5(screw 6) towards ("+") (= more thread) or ("-") (= less
thread).

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Fig. 1 - 14
1
1.05.14 Sewing foot pressure
Requirement
The material should be fed properly even at maximum speed and with the smallest stroke.
●Turn adjustment wheel 1in accordance with the requirement.

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Fig. 1 - 15
1
2
1.05.15 Lubrication
Requirement
After a running time of 10 seconds a thin film of oil should be visible on paper strip 1
when this is held over the hook.
●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 1against the hook and check the require-
ment.
●If necessary, regulate amount of oil with screw 2.

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Fig. 1 - 16
1
2
3
5
4
6
7
1.05.16 Limiting the stitch length
When exchanging 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.
●Set the desired max. stitch length at control button 1
(on model A, B and C = 4.5mm, on model AN, BN and CN = 6.0mm)
●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 3and adjustment knob 1.