Pfaff Tiptronic 2010-2040 Service Manual

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Page
Contents 1
Foreword 3
Notes on the sewing machine 4
Specifications 5
Dismantling the housing 9
Servi ce Manual
Feeding System
1. Adjustment of the flat-toothed belt tension 17
2. Adjustment of feed dog in sideways direction for Pfaff 2010 18
2a . Adjustment of feed dog in sideways direction for Pfaff 2020 - 2040 20
3. Timing of feed motion 22
4. Adjustment of feed dog height 24
5. Adjustment of synchronizer 26
6. Adjustment of presser foot height 28
7. Adjustment of top feed fool in sewing direction 29
8. Adjustment of top feed height 30
Zigzag mechanism
9. Adjustment of needle in needle hole 32
Stitch forming parts

10. Position of needle in needle hole in sewing direction 35
11. Adjustment of hook-to-needle clearance 38
11a . Adjustment of bevel gears 39
12. Sewing hook timing 40
13. Adjustment of needle bar height 42
14. Adjustment Ihe bobbin case position finger 43
Stitching off
15. Adjustment of needle threader 44
16. Adjustment of bobbin winder stop 45
17. Adjustment of bobbin thread lension 46
18. Adjustment of needle thread tension 46
19. Adjustment of equal forward and reverse stitch length for Pfaff 2010/2020 48
20. Adjustment of equal forward and reverse stitch length for Pfaff 2030/2040 50
21 . Making up a sewing sample 52
Repair instruction s
22 . Dismantling and assembling the needle thread tension 53
23. Changing the torsion spring in handwheel 54
24 . Dismantling and assembling sewing hook 56
25. Cleaning and oiling the machine 56
26. Changing the flat-toothed belt 58
27 . Changing the bevel gears 64
28. Changing the base circuit board 68
29. Changing the upper circuit board on front housing panel 70
30. Changing the control board with keys 72
31 . Changing the key-pair panel 74
32 . Changing the synchronizer circuit board 76
33. Changing the motor 78
34. Changing the cable in the foot control 80
1
35 . Changing the top stepping motor 82
36 . Changing the lower stepping motor 84
37 . Changing the buttonhole sensor 86
38. Changing the thread monitor with free-arm cover 88
39 . Changing the needle threader 90
40. Self-test, foreword 91
41 . Self-test model 2010 and 2020 92
42. Self-test model 2030 95
43. Self-test model 2040 98
44 . Fau lt table for electrical parts 2040 101
45. Electrical safety test 103
46 . Electrical safety test with ABB Metrawatt M5013 103
47. Measures required in case of inadmissible test readings 106
2
Foreword
This service and repair manual is inte nded to assist you in carrying out all repa irs to the machines quickly
and correctly.
Adjustments should only be carried oul if you find the actual settings deviating from the requirements
described here.
When checking or adjusting a machine , please always proceed in the sequence specified . For easier
refere nce every workstep is marked with a dot.
Differing worksteps are marked with a circle or square.
The indications Hright", "Iafr , "topH, "bottom", "frontft or "rear" always refer to the upright machine with its
controls facing the operator.
When assembling dismantled machines , make approximate adjustments right in the course of worle This
facilitates subsequent precise adjustments .
If not specified otherwise, the handwheel must always be turned to the front.
Always pull out the ma ins plug before making repairs to live parts or in their vicin ity. An electrical safety
test must be carried out after every repair, including mechanical ones.
According to the German law on safe machine operation of June 24 , 1958, VDE regulations apply as
official rules in electrical engineering and as such are basic to electrical safety tests of technical devices.
The required electrical tests for appliances are set forth in Para. 4 of the Regulations for Repair.
Modification and Testing of Used Electrical Devices (VDE 0701 , edition 05 .93). After every repair of elec·
trical devices we manufacture , a test in accordance w ith VDE 070 1 is obligatory.
Outside Germany, there are similar regulations in force , which are largely identical with the requirements
of VDE 0701. For repairs of electrical devices , it is therefore by all means necessary to consult an expert.
For correct adjustment of the machines , the following gauges and tools are required :
Needle rise gauge . . .. . .... . ................ . ....... . .. . .......... . ...... 00·870 136·01
Needle rise clamp . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . . . . . . . . .. . . .. . .. . . .. . . .. .61 · 111600·35
Spacer .. . ... . . . . . .. . . ... . . . . .. . . ... . . . . .. . ... . . . • . .. . ... . . . • ... . ... .. .63·102600·18
Adjustment gauge for bobbin case position finger . . . .. . . . . . . . • ... . . .. . . . • ...... . .61·111621-15
Presser fo ot gauge . . . . . . . .. . .. . . . .. . . . . .. ... . . ••. . ••. .... . •. . •• .. . .... . .. 63-11 4690·39
Pointer gauge .... . .. . . . .. . .. . .... . ..... . .... . •.... . .... . • . . ............. 63-1 14690-23
Pin gauge .. . .. . .. . . . .. . .. . .. . . . . . . .. . . .. . . . .. • . . . . .. . . .. .. . . . . .. .. . . .. .63-1 14690·09
Allen key 1.5 mm .. . .. . .... . .. . .. . .... . . •. . ••.. .... . .. • . . . ... ... .• .. ... . .07-433005-28
Combination spanner (wrench) 6.0 mm . .. .. . •. . . .. ... ..•• . . . . ... ..••. . . . .. . .. .07-433007-50
Torx screwdri ver TX 10 . . . .. . . . .. . . . . .. .. .•. . ••• • . .. . . . . ••. . . . . . • . . • . . . . ... 07-434008-44
Torx screwdriver TX 15 . . . .. . . . .. . . . . . . . . . . . . ••• • . . . . . . . ••• • . . . . • . . • . . . . ... 07-434008-45
Torx screwdriver TX 20 .. . . . . .•.. . .. . . .. • •. . . .. . . .. • • .. . .. . . .. • .. . . .. . . .. . .07-434008-46
Torx screwdriver TX 25 . . ... . . . •.. • •. . .... •..• • .. .... • . .• • . . .... .. .• • . ..... 07-434008-47
Circl ip fitting tool 2.3 kz . . . . . . .. • . . .. . . . . .. •. . .. . . . . .. •. . .... . .. . •. . .... . .. .07-437003-20
Circl ip fitting tool 3.2 kz . . .... . ..... . ..... . .......... • •... . ..... • • ... . ...... 07-437003-30
Circl ip fitting tool 4 .0 kz . . ... . . . • . . . • • •. . . . • . . •• . .... . • . . • • . .... . • . . • • ... .. .07-437003-40
Circlip fitting tool 5.0 kz . . . .. . .. • . . . . .. .. .. . .. . . .... . . • . . . . ... . . ••. .. . ... ... 07-437003·50
Circl ip fitting tool 6.0 kz . . . .. . .. • . . .. . ... .. . . . .. . . . . . . • . .. . . . . .. . • . . . . . . . .. .07-437003·60
Circl ip pliers A1 . .... . .. . . . . . . • . . • • • _ . ... • . . • • • _ . ... • . . • • • _ . ... • . . • • ... .. .07-438000·50
Spring hook ... . .. . .. . .... . .. . .. . .... . .. . .. . ..... . • . .. . .... . . • . .. . ...... 07-437006-00
Subject to alterations in design and dimensions.
3
Notes on the sewing machine with regard to ambient conditions,
treatment, cleaning and safety
Ambient conditions:
The recommended ranges are:
Ambient temperature _10" to 40"C (50" to 104"F)

Air humidity 20 % t080 %
This machine is a high-quality electro-mechan ical device. It is designed for household purposes and
should always be supervised when in use.
Make sure that it is not subjected to :
dust, severe dampness, direct sunlight. static electricity, heat-producing objects, corrosive chemicals or
liquids.
The machine must be used on a free surface, for ventitation purposes, which is both firm and even.
Treatment:
Always protect the machine against damage by hitting or dropping.
Cleaning:
Housing:
To clean the housing , use a dry, clean and soft cloth which is free of fluff. To remove any stubborn dirt,
use a soft cloth with a neutral cleansing agent for plastic materials.
Please note!
Do not use any insecticides or chemical products such as petrol (gas) or thin chemicals for cleaning the
housing .
Display :
If necessary, clean display with a soft cloth moistened w ith a little water.
Safety :
1. The machine must be put into opera tion according to the indications on the specification plate.
2. Do not place any objects in openings on the mach ine .
3. Do not use the sewing machine if:
- there is visible damage ,
- its function is disturbed ,
- it is wet, e.g . with condensation.
4. Do not pull the mains plug out of the socket by its cord.
5. If this appliance is used for another purpose than that intended or if it is wrongly operated , we will not
accept any liability for any damage caused .
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 responsibil ity of our qual ified service staff.
7. Be sure to use only original PFAFF parts.
4
Specifications of the PFAFF tiptron ic 2010 - 2020
• Electronic free- arm , utility and fancy stitch sewing machine

• 8 bit processor with 1 Kbyte RAM and 32 Kbyte ROM
• Bobbin thread stitch width = a - 6 mm with 30 full sleps
• a a
Stitch length = to 6 mm forwards and to 6 mm reverse with a total of 30 full steps or 60 half steps
in each direction
• A full step is 0.2 mm and a half step 0.1 mm
• Keys for stitch width, stitch length, pattern length and balance
• 13 different need le positions
• Mirroring key
• One 7.5 e stepping motor for needle zigzag motion 30 V
(contact current switching controller)
• One 7.5 0 stepping motor for fe ed control 30 V
• 2-track synchronizer
• Electronically controlled needle - up~ positioning
• Key for re verse sewing or for finishing a manual buttonhole
• Digital motor control with 950 r.p.m. max. speed
• Approx. 100 - 950 stitches per minute
• Several stitch-length-dependent reduced speeds in add ition
• Numerical LCD
• Built-in test program
• When machine is blocked, the motor is switched off automatically after 1 - 2 sees. (Followed by
approx . 4 secs . interruption before sewing process can be continued .)
• Machine: voltage change-over 11 5/230 V, 50 - 60 Hz
• Low-voltage motor
• High-ohm foot control (cold )
• FM radio and TV screened, approval marking ; safety class II with CE , VL, CSA test markings
• Master switch for motor, electronics and sewing lamp
• Built-in sewing lamp 12 V/5 W
• Needle threader
• Pendulum-type needle bar frame .
• Transmission of drive from arm shaft to lower shaft by flat-toothed belt, transmission ratio 1:1
• Power input rati ng: 75 W when sewing at 950 r.p.m.
27 W when stationary
• Lockstitch of types 30 1, 302, 303, 304, 305 , 308 and all other variants obta inable by sideways needle
moveme nt or forwards and reverse control of the machine feed
• PFAFF horizontal double-rotating hook
• Link take-up
• Slide lever feed regulator for forwards and reverse stitch lengths
• Dua l fabric feed on tiptronic 2020
• Disengageable feed dog
• Drive from motor to handwheel by flat-toothed belt.
• Calotte metal bearings
• Oil for calotte metal bearings: BP Energol HLP 46 or HLP 80 No. 28-036550-09
• Oil for sewing hook: No. 91-129452-91
5
• Clear workspace : 175, 110, 204 mm
• Machine height: 290 mm
• Baseplate dimensions: 402 x 175 mm I machine length 408 mm
I machine length 187 mm
• Free-arm dimensions: 80, 49, 200 mm
• Housing and ba seplate material: die-cast aluminium
• Machine weight without carrying case: 8.3 kg
• Needle system 1301705 H
• Additional needle system classifications :
Twin needle Suffix = Zwi

Wing needle Suffix = Wing
Twin hem stitching needle Suffix = Zwi·Ho
Long needle eye Suffix =N
Stretch needle Suffix = PS
Denim needle Suffix =J
• Possible needle points :
Small ball point Suffix = SES

Mediu m ball point Suffix = SUK
Large ball point Suffix = SKF
Pointed cloth point Suffix = J
Leather point right hand Suffix = LR
Specifications of drive motor for the PFAFF tiptronic 2010 - 2020
No. 92-329945-91 24 V = 27W 5700 r.p.m .
6
Specifications of the PFAFF tiptronic 2030 - 2040
• Fully-electronic free-arm, utility and fancy stitch sewing machine
. 16 bit processor with 3 Kbyte RAM and 96 Kbyte ROM , 512 Byte EPROM
• Bobbin thread stitch width = 0 - 6 m with 30 full steps or 60 half steps
• Stitch length = 0 - 6 mm forwards and 0 - 6 mm backwards with a total of 30 full steps or 60 half steps
in each direction
• A full step is 0.2 mm and a half step 0.1 mm
• Keys for stitch width, stitch length, pattern length and balance
• 13 different needle positions
• Mirroring key
• Info key
• One 7.5 0 stepping motor for needle zigzag motion 30 V
• One 7.5 0 stepping motor for fe ed control 30 V
• 3-track synchronizer
• Electronically controlled take-up lever "up·
(needle "up" positioning) of needle "down" position
with display
• Key with indicator fOf half speed (540 r.p.m)
• Key with indicator for tying off stitch patterns
• Key for reverse sewing or for fin ishing a manual buttonhole
• Digital motor control with 950 r.p.m max. speed
• Approx. 100 - 950 stitches per minute
• Several pattern-dependent reduced speeds in addition
• Numerical LCD, with graphics and a white background
• Built-in test program
• When machine is blocked , the motor is switched off automatically after 1 - 2 secs. (Followed by
approx. 4 secs. interruption before sewing process can be continued. )
• Machine: voltage change-over 115/230 V, 50 - 60 Hz
• Low-voltage motor
• High-ohm foot control (cold)
• FM radio and TV screened, approval marking; safety class II with CE, VL, CSA test markings
• Master switch for motor, electronics and sewing larnp
• Glare-free built-in sewing lamp 12 V 1 5 W
• Needle threader
• Bobbin thread monitor w ith LED on tiptronic 2040
• Buttonhole guide
• Pendulum-type needle bar frame
• Transmission of drive from arm shaft to lower shaft by flat toothed belt. transmission ratio 1:1
• Power input rating : 75 W when sewing at 950 r.p.m.
27 W when stationa ry
• Lockstitch of types 30 1, 302 , 303. 304, 305, 308 and all other variants obta inable by sideways needle
movement or forwards and re verse control of the machine feed
• PFAFF horizontal double-rotating hook (9 mm hook on model 2040)
• Link take-up
• Bobbin thread monitoring on model 2040
7
• Slide lever feed regulator for forwards and reverse stitch lengths
• Dual fabric feed
• Externally disengageable feed dog
• Drive from motor to handwheel by flat toothed belt
• Calotte metal bearings
• Oil for calotte metal bearings: BP Energol HLP 46 or HLP 80 No. 28-036550-09
• Oil for sewing hook : No. 91-129452-91
• Clear workspace: 175. 110. 204 mm
• Machine height: 290 mm
• Baseplate dimensions: 402 x 175 mm 1 machine length 408 mm
1 machine width 187 mm
• Free-arm dimensions: 80 , 49 , 200 mm
• Housing and baseplate material: die-cast aluminium
• Machine weight without carrying case: 8.3 kg
• Needle system 130/705 H
• Additional needle system classifications:
Twin needle Suffix:;. Zwi

Wing needle Suffix:;. Wing
Twin hem stitching needle Suffix = Zwi-Ho
Long needle eye Suffix:;. N
Stretch needle Suffix = PS
Denim needle Suffix::; J
• Possible needle points:
Sma ll ball point Suffix::; SES

Medium ball point Suffix:;. SUK
Large ball point Suffix::; SKF
Pointed cloth point Suffix:;: J
Leather point right hand Suffix::; LR
Spec ifications of drive motor for the PFAFF tiptronic 2030 - 2040
No. 92-329945-91 24 V: 27W 5700 r.p.m.
8
Dismantling the housing cover
Note: Before adjusting or repairing the machine, make sure to dismantle

the housing covers according to the adjustment and repair instructions.
• Pull out the ma ins plug and the socket on the machine .
• Remove the needle and the presser foot shoe.
• Remove the detachable work support.
• Remove the top cover.
• Unscrew and remove the two torx screws of the housing insert.
• Remove the housing insert.
• Slightly raise both lugs 1 and remove the facing panel of the front housing panel by swiveling
it downwards (fig. 1).
• Remove connection plug 2 (fig . 2) from the circuit board .
Fig. 1 1
80
80
8 0
0000 )
Fig.2
9
• Loosen the torx screw on the face plate .
• Remove the complete face plate together with the sewing lamp and cable (fig . 3).
• Remove the carrying handle.
• Unscrew and remove the three fastening screws on the baseplate .
• Tilt the baseplate toward the front.
• Remove 12·wire flat cable 3 and molar cable 4 from the circuit board (fig. 4).
Fig. 3
e ~
~
~
~=
-
3
Fig. 4
10
• Unscrew and remove both fastening screws 5 on the free-arm cover (fig . 5).
• Put the feed drop mechanism in its normal working position .
• Using a small screwdriver, disengage both feed regulators 6.
• Open the cable Clip.
• Remove connection plug 7 from the circuit board (fig. 6).
• Remove the free-arm lid carefully from the housing, to the left.
c
c
, .
Fig.5
5
Fig. 6
11
• Remove the needle plate.
• Unscrew and remove both fastening screws 8 (fig . 7).
• Remove the free-arm cover.
Fig.7
• Loosen screw 9 on the stand cover (fig . 8).

• Remove the stand cover.
000
000
o
Fig. 8
12
• Remove fastening screws 10 and 11 on the rear housing shell (fig . 9 and 10).
• Open the catch connections on the inside of the arm by pressing with your thumb against the points
indicated by the arrows (fig . 11).
• Remove the rear housing shell.
11
10
Fig. 9 Fig. 10
1 \
Fig. 11
13
• Remove the five connection plugs 12, 13, 14, 15 and 16 from the circuit board (fig . 12).
• Loosen fa stening screws 17 and 18 (fig . 13) as well as fastening screw 19 (fig. 14).
• Remove the front housing shell carefully.
- -
12 16 14 15 13 Fig. 12
17 1 Fig. 13
Fig. 14
14
• Remove buttonhole sensor's cable guide 20 (fig . 15).
• Remove the complete buttonhole sensor with the spring.
20
Fig. 15
15
Feeding system
1. Adjustment of the nat-toothed belt tension
Requirement :
The fl at-toothed belt must be so taut that the sewing hook has no play in its rotating direction,
but it must be possible to turn the machine easily.
Adjustment:
• Loosen screw 1 (fig . 1).

• Re-position tensioning roller 2 with a screwdriver accordingly.
• TIghten screw 1.
Check:
• Check adjustment according to " Requirement~.

• Press lightly against middle of flat-toothed belt.
The belt must move 1 to 3 mm forwards .
000
o
Fig. 1
2
17
2. Adjustment of feed d o g in s ideways direc tion f or Pfaff 2010
Requirement:
The distance of the feed dog to the right and left edges of the feed slot must be equal (fig. 2).
Check:
• Carry out a visual check of the feed dog position.
Adjustment:
• Tilt the machine to the rear.

• Unhook spring 3 (fig . 3) .
• Unscrew and remove screw 4 .
• Turn the handwheel until the lobe of drive eccentric 5 is positioned at the rear.
• Fold feed regulator 6 downwards and remove th is and link 7 from the connecting bar rod to the left.
• Remove slide block 8 with spring to the right.
• Unhook spring 9.
• Loosen screws 10 and 11 .
• Re-position the driving shaft together with the two cylindrical pins 12 and 13 sideways without play
until the feed dog is positioned in the middle of the feed slot .
• Tighten screw 10.
• The pressure of the right cylindrical pin must be 1 kg .
• Tighten screw 11 .
• Remove the needle plate .
• Use your finger to pull the feed dog to the front, then release it.
• The complete feed driving shaft 14 must slide slowly to the rear.
• Loosen screw 15.
• Push slide lever shaft 16 complete with stepping motor 15 approx . 1 mm to the right.
• Push slide block 8 with spring onto the pin and install it in slide way 18 in the correct curve radius.
• Tighten screw 15 and check whether the slide block moves easily and without any play.
• Push link 7 complete with feed regulator 6 to the right onto the connecting bar pin.
• Fold feed regulator 6 to the rear and then upward over feed eccentric 5.
• Place screw 4 in clamping plate 21 and tighten it a little.
18
• Move stud 20 sideways until link 7 and connecting rod 19 still have some play and move easily.
• Attach both springs 3 and 9.
• The feed dog must now be positioned in the exact middle of the feed slot.
Fig.2 o
19 7 8 18 3 15 16 17
Fig.3
19
2a . Adjustment of feed dog in sideways direction for Pfaff 2020, 2030 and 2040
Requirement:
The distance of the feed dog to the right and left edges of the feed slot must be equal (fig . 2).
Check :
• Carry out a visual check of the feed dog position .
Adjustment:
• Tilt the machine toward the rear.

• Unhook spring 3 (fig. 5).
• Turn the handwheel until lobe of drive eccentric 5 is positioned at the rear.
• Fold feed regulator 6 downwards and remove th is and link 7 from the connecting bar rod to the left.
• Remove slide block 8 with spring to the right.
• Pull out pin 23 to the right.
• Unhook spring 9.
• Loosen screws 10 and 11 .
• Re-position the driving shaft together with the two cylindrical pins 12 and 13 sideways without play until
the feed dog is positioned in the middle of the feed slot.
• The pressure of the right cylindrical pin must be 1 kg .
• Remove the needle plate .
• Use your finger to pull the feed dog to the front, then release it.
• The complete feed driving shaft 14 must slide slowly to the rear.
• Fit pin 23 without any play and tighten screw 22.
• Move the top feed lever assembly to the front and rear.
The complete top feed lever assembly must move easily and without binding (if necessary remove
cause of binding).
• Re-position crank pin 24 with pull rod 26 sideways until the complete top and bottom feed moves easily
(fig . 6) .
• Tighten screw 25 and check again whether the feed system moves freely.
• Push slide lever shaft 16 complete with stepping motor 15 about 1 mm to the right .
• Push slide block 8 with spring onto the pin and install it in slide way 13 in the correct curve radius.
20
• Check whether the slide block can be moved easily, but without play or binding .
• Push slide lever shaft 16 complete with stepping motor 17 carefully to the left until there is a clearance
of 0.05 mm between slide block 8 and connecting bar 19.
• Tighten screw 15 and check whether the slide block moves easily and without play.
• Push link 7 complete with feed regulator 6 to the right onto the connecting bar pin.
• Push feed regulator 6 to the rear, and then upward over feed eccentric 5.
• Position screw 4 in clamping plate 21 and tighten it a little.
• Move stud 20 sideways a little until link 7 and connecting rod 19 have a slight play and move easily.
• Attach the two springs 3 and 9 .
Cross-ch eck:
• The feed dog must be in the exact center of the feed sial.
Fig. 4
Fig. 2 o 19 7 8 18 3 15 16 17
1 a 4 11 Fig. 5
24 25
Fig. 6 21
3. Timing of feed motion
Operating sequence:
When the rising needle has left 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 (I.d.c).
At a stitch length setting of 6 mm the feed dog now pushes 0.7 mm more to the rear (after-feed move-
ment). After completing the feeding movement, the feed dog moves down under the needle plate surface
and the needle enters the fabric.
Underneath the needle plate the feed dog moves back to its basic position .
Whenever the stepping motor changes the sewing direction from forward to reverse sewing, the feed dog
must be positioned 0.3 - 0.35 mm below the needle plate surface on its way downward .
Requirement:
When the needle bar has moved 2 mm up from its lowest position (b.d.c), it must be possible to insert the
two pins of pin gauge 63-114 690-09 simultaneously in the holes of the feeding eccentric and the stud
(fig . g) .
Check:
• Remove the needle.

• Turn the handwheel to set the needle bar at its lowest position.
• Set the spacer (63-102 600-18) onto the needle bar and push it up against the needle bar frame.
• Push the needle-rise clamp (00-870 137-01) on the needle bar and tighten it lightly.
• Push the 2 mm feeler gauge (00-870136-01) with its cutout on the needle bar above the needle-rise
clamp.
• Loosen the needle-rise clamp and push the 2 mm feeler gauge up against the spacer.
• Tighten the milled screw of the needle-rise clamp (fig. 7).
• Turn the handwheel to and fro a little.
• If there is play at the feeler gauge, repeat this procedure .
• Remove the 2 mm feefer gauge.
• Turn the handwheel in sewing direction until the needle-rise clamp is up against the spacer (fig. 8).
• Tilt the machine over backwards.
• Hold the handwheef in this position while at the same time inserting the pin gauge in the holes of
feeding eccentric 5 and stud 27 (fig . 9).
22
Timing:
• If the adjustment is not correct, remove the needle-rise clamp .

• Loosen the three screws 29 in the lower flat-toothed-belt sprocket.
• Re-fit the needle-rise clamp and repeat the procedure as described in " Check ~ until the needle bar has
moved upwa rds by 2 mm and the clamp is in contact with the spacer (fig . 8).
• Turn the long drive shaft 28 in sewing direction until it is possible to insert the pin gauge in both holes
(fig. 9).
• Insert the pin gauge and tighten one of the screws 29.
Cross-check:
• Remove the pin gauge .

• Tighten all three screws 29 very firmly.
• Check again with the needle-rise gauge and the pin gauge as described under ·Check".
Fig. 7
3 15 Fig. 8
27
Fig. 9 28 5 6 108 20 4 29
23
4. Feed dog height
Requirement:
In the highest position of the feed dog , the points of its teeth must protrude above the needle plate sur-
face by 0.85 - 0.9 mm .
The tolerance must not remain under or exceed 0.85 to 0.9 mm (fig. 10).
Check :
• Remove the needle .

• Remove the presser foot.
• Switch on the master switch .
• Set stitch pattern "1 " and stitch length "6.0".
• Place adjustment gauge (63-114 690-23) on the needle plate so that feeler lever 30 rests on the
needle plate to the right of the cutout (fig . 11 ).
• Turn the hexagon with a 6 mm spanner (wrench) slightly until pointer 31 is exactly at ~ O ·.
• Move the gauge to the left to set feeler lever 30 on the feed dog (fig. 12).
• Turn the handwheel until pointer 31 has moved up to its highest position. The pointer must now point
exactly at mark 0.9.
Adjustment:
• Leave the adjustment gauge on the needle plate .

• Remove baseplate and bobbin thread monitor, but leave all electrical connections in place.
• Turn the handwheel until the feed dog is in its highest working position.
• Loosen screw 32 by just 1/8 of a turn (fig . 13).
• Turn eccentric stud 33 until the eccentric is facing the rear part of the housing (basic position).
• Turn eccentric stud 33 counter-clockwise until pointer 31 is exactly at mark 0.9 (fig . 12).
• Tighten screw 32 (fig. 13).
Cross-check:
• Turn the handwheel until pointer 31 is in its highest position again.

The pointer must now be at mark 0.9. (fig . 12).
• Lower the feed dog and check the fu nction.
24
Fig. 10
• •
31
0.,_
Fig. 11
31
D-
O> - o <Wo
Fig. 12
32
Fig. 13
25
5. Adjustment of synchronizer
Note:
The following machine positions or functions are controlled by the synchronizer:
1. A change of feeding direction

2. Sideways needle bar movement
3. Take-up lever/needle "up" positioning
4. Needle "down" positioning
This adjustment must only be carried out when compelling reasons exist! It must be performed
with maximum accuracy.
Requirement:
A change of feeding direction or stitch length must take place when the feed dog has moved below the
needle plate surface by 0.3 + 0.02 mm (fig. 14).
Check:

• Switch on the master switch .
• Set stitch pattern "01 ~ and stitch le ngth to approx . 0.5 mm.
• Set adju stment gauge (63-114 690-23) on the needle plate so that feeler lever 30 rests on the needle
plate just right of the feed slots (fig . 15).
• Turn the hexagon with a 6 mm spanner (wrench) until pointer 31 is exactly at ~ O·.
• Turn the handwheel a full rotation forwards, then keep on turning it until the feed dog (needle bar)
is in its top position.
• Change the stitch le ngth .
• Set the adjustment gauge with feeler lever 30 to the left on the feed dog (fig . 32).
• Turn the handwheel very slowly forward s until pointer 30 is at 0.3 (fig. 33). In this position the feed
dog must make a visible and audible (switching) movement.
Fig. 14
,
30
Fig. 15
31
.-
26
Adju stment:
• Leave the adjustment gauge on the need le plate.

• Remove the top cover and the housing insert.
• Slightly loosen the fastening screw on control cam 32 (fig. 18).
• Set the stitch length to MO.5".
• Turn the handwheel a full rotation forwards, then keep on turning it until point 31 is at 0.3 (fig. 17).
• Set the stitch length to HOO".
• Keep on turning control cam 32 until the stepping motor switches.
• TIghten the fastening screw on control cam 32 whilst ensuring that the cams of the control cam are in
the midd le of the circuit board guides (fig . 19).
Cross-chec k:
• Set the stitch length to HO.5".

• Turn the handwheel a full rotation forwards, then keep on turning it until the feed dog (needle bar) is at
its highest position .
• Turn the handwheel very slowly forwards until the pOinter is at 0.3 (fig . 17).
In this position the feed dog must make a visible and audible movement (switching).
, , 31
30
.-
Fig. 17
Fig. 16
Fig. 19
000 0
o 0
Fig. 1B 27
6. Adjustment of presser foot height
Requirement:
With the presser bar lifter raised there must be a clearance of 8 mm between the needle plate and the
sale of the zigzag foot .
Check :
• Ra ise the presser bar lifter.

• Fit the zigzag foot.
• Lower the feed dog .
• Fully ra ise the presser bar lifter and hold it in this position .
• Insert the presser foot gauge (63-114 690-39) from behind under the zigzag foot and into the cutout of
the needle plate (fig. 20).
• Lower the presser bar lifter to its normal position again.
The zigzag foot must rest parallel and without play on the presser foot gauge.
However the presser foot gauge must not lift the zigzag foot.
the needle thread tension must be without play (fig . 21).
Adjustment:
• Loosen the three screws 34, 35 and 37 (fig . 21) .

• Turn the zigzag foot with the presser bar lifter raised until it is parallel with the sides of the presser foot
gauge.
• Use a screwdriver to press presser bar guide 36 firmly down .
• At the same time firmly tighten screw 35.
Cross-check:
• Press the presser bar lifter further upward and release it again.
The zigzag foot must rest parallel and without play on the presser foot gauge.
Needle thread tension release lever 33 must be without play. The presser bar lifter must be in its raised
position .
Note: 33 ___
The two screws 34 and 37 are not tightened until later 34 -
when the top feed height is set.
35-
36
37 _ _
Fig. 20 Fig. 21
28
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 . 22).
Check:
• Raise the presser bar lifter.

• Remove the complete presser foot.
• Set the stitch length to M6~ .
• Engage the top feed foot.
• Turn the handwheel until the rising feed dog is flush w ith the needle plate sunace .
• Lower the presser bar lifter.
• Carry out a visual check.
Adjustment:

• Raise the presser bar lifter until the top feed foot is just resting on top of the feed dog .
• At the same time push the top feed dog to the front or to the rear until its front edge is between the first
and second tooth point of the center tooth row.
• Lower the presser bar lifter.
• Tighten screw 39, making sure that driving shaft 38 has no play.
Cross~check:
• Check as described under "Checkft.
o '------,,!
5 I
Fig. 22
29
eBay seller: luxuryfern Fig. 23
8. Adjustment of top feed height
Requirement:
In its highest working position the top feed foot must be 2 mm higher than the lower edge of the zigzag
foot sole (fig . 25) .
Note:
This adjustment must only be carried out when the height of the presser bar is set correctly.
Check :
• Raise the presser bar lifter.

• Insert the zigzag foot sale.
• Engage the top feed .
• Turn the handwheel until the needle bar is in its lowest position .
Caution: The handwheel must now no longer be turned!
• Lower the feed dog .
• Fully raise the presser bar lifter and hold it in this position .
• At the same time insert the presser foot gauge (63-11 4 690-39) from behind under the zigzag foot
and into the cutouts of the needle plate.
• Lower the presser bar to its normal ra ised position .
• Press the top feed lightly downward .
• Check that the top feed foot rests only lightly on the presser foot gauge and has no play.
Adjustment:
• Loosen screws 34 and 37 (fig. 25).

• Push counter bearing 40 lightly downward until the top feed foot rests lightly on the presser foot gauge .
• Tighten screw 34 in this position .
Cross-check:
• Check for lig hl resting and freedom of play of the top feed fool on the presser fool gauge as described
under "Check".
Adjus ting the guide piec e
• Fully raise the presser bar lifter and hold it in this position .
• Remove the presser foot gauge.
• Lower the presser bar lifter to its raised position .
• Turn the handwheel until needle bar 44 is in its top position .
• Set guide piece 42 at a clearance of 0.2 mm from cross head 41 (fig. 24).
30
Cross~check :
• Turn the handwheel and check for clearance of 0.2 mm .
34
41 40
41
42
42 - _ - - ! J
37 ----tlt-t-
Fig. 24
Fig. 25
31
Zigzag mechanism
9. Adju stment of nee dle in n eedle h ole
Requirement:
At the straight stitch setting, the needle must be in the center of the needle hole (fig. 26).
The widest zigzag stitches must be the same distance from the left and right needle hole edges (fig 27.).
Check :

• Insert a new needle.
• Select stitch pattern "01 " for straight stitch.
• Turn the handwheel until the needle is in the needle hole.
• Carry out a visual check (fig. 26).
• Select stitch program "03" and a zigzag width of 6 mm.
• Turn the handwheel and check the left and right distance (fig . 27).
Adjustment:
• Select stitch pattern "01 " for straight stitch .

• Loosen both screws 45 just a little (fig. 28).
• Push the complete slepping motor 46 to the left or to the right until the needle is centered (fig. 26).
• Tighten both screws 45.
Cro s s-c heck :
• Carry out as described under "Check-.
32
(N I m
I I \
, • 1 • I, .I \
1
o \ \ o \ \
Fig. 26 Fig. 27
45 46 45 Fig. 28
33
Stitch forming parts (Hook)
Foreword :
The sewing hook adjustment consists basically of the three following adjustments:
Needle rise
Needle bar height
Hook-la-need le clearance
Needle rise:
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.
When the machine moves further, the looper point must enter the thread loop, widen it and gu ide it
around the bobbin .
Needle bar height:
The needle bar height must be set in such a way that the sewing hook point can easily enter the thread
loop above the needle eye at straight stitch and zigzag stitch settings.
Hook-la-needle clearance:
The distance of the sewing hook point from the needle must be as small as possible , so that the sewing
hook point does not miss the thread loop.
The sequence of sewing hook

adjustments is as follows :
1. Hook-to-needle clearance
2. Bevel gear setting
3. Needle rise
4. Needle bar height
34
10. Position of needle in needle hole in sewing direction
Requirement:
There must be a clearance of 0.2 mm between the back edge of the needle shank and the back edge of
the needle hole in the needle plate (fig. 29).
Note:
Since system 130/705 H needles increases in size at the needle front side only. the point of an Nm 100
needle is positioned exactly in the middle of the needle hole (as seen in feeding direction), while the point
of an Nm 80 needle is positioned slightly closer to the back edge of the hole .
Check:
• Insert a new needle of system 130/7 05 H in size Nm 100.

• Select stitch pattern M 01 ~ for straight stitch .
• Attach zigzag foot.
• Lower zigzag foot.
• Turn the handwheel until the needle is in its lowes! position .
The needle must now have the same distance to the front and rear edges of the needle hole in the foot
and the needle plate.
•I- 02mm
•I
...--
Fig. 29
35
Adjustment in relation to the presser foot:
• Loosen screw 47 (fig . 31 ).

• Move pin 48 together with collar and needle frame 49 to the front or the rear until the needle is exactly
in the middle of the needle hole on the presser foot.
Check:
• Turn the handwheel and bring the needle to its highest position.
• Place a piece of paper underneath the presser foot and lower the foot.
• Turn the handwheel and bring the needle to its lowest position .
• Its distance from the front and rear edges of the needle hole in the foot must be equal.
• Loosen the torx screw on the face plate.
• Remove the face plate.
• Remove Benzing circiip 51 on the needle bar frame (fig . 30).
• Disengage the connecting rod and the needle bar frame .
• Move the needle bar frame to the left and to the right.
Important:
The need le bar frame must move easily and without binding. If this is not the case, any binding must be
removed .
• Re-engage the needle bar frame with the connecting rod.
• Mount Benzing circiip 51 (fig. 30).
Adjusting the needle plate :
• Turn the handwheel and bring the needle to its highest position.
• Remove the zigzag foot.
• Turn the handwheel and bring the needle to its lowest position.
• Turn adjustment eccentric 50 until the distance from the front and rear edges of the needle hole is
equal (fig . 32).
Crosswc heck:
• Carry out a visual check at straight stitch and zigzag stitch settings.
"
51 _ _
Fig. 30
36
100
Fig. 31
50 NM100
-
=
L _ _ _ _ _ _ _ _ _ __ _ __ _ _...l Fig. 32
37
11 . Adjustment of hook-to-needle clearance
Requirement:
At the straight stitch setting the distance of the sewing hook point from the bottom of the scarf in the nee-
dle must be 0.05 mm (fig . 33). In the widest zigzag stitch, the sewing hook point must almost touch the
needle.
Check :
• Remove the baseplate and the free-arm lid .

• Remove the needle.
• Remove the bobbin case.
• Remove the bobbin case position finger.
• Move the bobbin case base so that the hook point is exposed .
• Insert a new needle system 1301705 H size Nm 80.
• Select straight stitch program " 01 ~.
• Turn the handwheel until the hook point is opposite the center line of the needle.
• Check the distance between hook point and needle scarf.
• Check the axia l play of hook 52 to hook shaft bush 54 (fig . 34 ).
Adjustment:
• If the hook shaft has axial play, loosen the two screws 53.
• Press bevel gear 56 with the shaft to the front and push sewing hook 52 to the rear.
• Tighten the two screws 53.
• Loosen screw 57 in Ihe lifting eccentric by 2 - 3
turns.
• Loosen screw 55 slightly.
• Turn the handwheel and the sewing hook until the
hook point is opposite the middle of the needle
scarf.
• Shift the sewing hook complete with hook shaft
bush 54 until the distance of the sewing hook point
to the bottom of the scarf in the needle is 0.05 mm.
• Tighten screw 55 on the narrow flat of the hook
bush .
CJD
o
Fig. 33
38
Note:
The large flat of the hook shaft bush must face the right.
Cross-check:
• Check for free movement of the hook shaft.

• Check again the distance between the sewing hook point and the bottom of the needle scarf.
11a. Adjustment of bevel gears
Requirement :
The bevel gears must move freely and without play.
Adjustment:
• Push the bevel gear with the lifting eccentric to the left until it is in contact with bevel gear 56 and has
no play.
• Tighten screw 57 on the surface of the drive shaft.
Check:
• As described under "Requirement~.
o
53 - - - -
57
55
56 "--
Fig. 34
39
12. 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 opposite the center line
of the need le (fig. 36).
Check :
• Remove the presser foot and the needle plate .

• Select stitch pattern "0 1" for straight stitch.
• Bring the needle bar to its lowest position by turning the handwheel (fig. 35).
• Set the spacer (63-102 600-18) on top of the needle bar and push it upwards against the needle bar
frame.
• Push the needle-rise clamp (61-11 1 600-35) on the needle bar and tighten it lightly.
• Push the 2.2 mm feeler gauge (00-870 136-01) with its cutout on the needle bar above the needle-rise
clamp.
• Loosen the needle-rise clamp and push the 2.2 mm feeler gauge upwards against the spacer.
• Tighten the milled screw on the needle-rise clamp.
• Turn the handwheel back and forth a little .
• If there is any play on the feeler gauge, repeat this procedure.
• Remove the 2.2 mm feeler gauge .
• Turn the handwheel in sewing direction until the needle-rise clamp is in contact with the spacer
(fig. 36).
By this means the needle has moved upwards to the needle rise position of 2.2 mm .
The hook point must now be exactly behind the center line of the needle.
Adjustment:
• If the setting is not correct, remove the needle-rise clamp.

• Loosen the two screws 53 (fig . 37).
• Re-fit the needle-rise clamp and repeat the operation as described under "Check", until the needle bar
has moved 2.2 mm upwards and the needle-rise clamp is in contact with the spacer.
• Turn the hook until the hook point is exactly behind the center line of the needle .
• Press sewing hook 52 and bevel gear 56 together so that there is no play between them . and tighten
one of screws 53 .
Cross-check:
• Turn the handwheel a little backwards and then forwards until the needle-rise clamp rests on the
spacer (fig. 36) .
• The hook point must be exactly behind the center line of the needle.
• Remove the needle-rise clamp.
• Check that the hook shaft has no axial play.
• Tighten the two screws 53 very firmly.
40
Fig. 35 Fig. 36
52
53 ___
Fig. 37
41
13. Adjustment of needle bar height
This machine has a transverse double-rotating hook.

On the rig ht zigzag penetration, the sewing hook reaches the needle a little earlier and at the left penetra-
tion a little later than at the center penetration . Thus the looper point is positioned slightly higher above
the needle-eye for the right zigzag penetration than for the left zigzag penetration (fig. 38).
Requirement:
The distance between the top edge of the needle eye and the lower edge of the sewing hook point must
be 0.5 mm at the widest left zigzag penetration (fi g. 39).
Check:
• Seled stitch program "03~ and the widest zigzag width of 6 mm .

• Turn the handwheel until the needle rises at the left zigzag stitch and the sewing hook point is exactly
behind the center line of the needle.
The distance between the top edge of the needle eye and the bottom edge of the hook point must
be 0.5 mm.
Adjustment:
• Loosen screw 58 just a little (fig . 40).

• Shift needle bar 59 in height, without twisting it, until the clearance of 0.5 mm is set.
• Tighten screw 58 securely.
Cross-check:
• Check the clearance of 0.5 mm . Fig. 38

The needle holder must face exactly square to the right.
58
E
E
];-'-1'---- 59 '"a
,
Fig. 40
Fig. 39
42
14. 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 (fig . 41 ).
Check :
• It must be possible to insert the clearance gauge (61- 111621-15) with ease but without play between
the position finger and the bottom of the groove in the bobbin case base.
Adjustment:

• Insert the clearance gauge.
• Press position finger bracket 61 against the clearance gauge at an angle of 90 degrees.
Cross-check:
• As described under "Check~.
61
60
61-111 621-15
Fig. 41
43
Stitching off
15. Adjustment of needle threader
Requirement:
With the threader key pushed full y down, prong 62 must pass through in the center between the top and
bottom edge of the needle eye of a needle size Nm 70 (fig . 42).
Check :
• Insert a new needle system 1301705 H. size Nm 70.

• Switch on the machine (stitch program 01).
• Set the machine at top needle position by briefly pressing the foot control.
• Push threader key 63 fully down .
• Carry out a visual and functional test.
Height adjustment:
• Loosen the screw on the face cover and remove face cover.
• Press threader key 63 full y down and hold it in this position (fig. 44 ).
• Loosen allen screw 66 by only a 1/4 of a turn (fig . 43).
• Push the complete threader bar frame 67 either upwards or downwards until prong 62 has the same
clearance to the top and bottom edge of the needle eye (fig . 42).
• Tighten allen screw 66 in this position (fig. 43).
Cross-check 1:
• Using threader key 63 , move the needle threader up and down.

Whilst doing so , carry out a visual check of the prong height.
• When the threader key is pushed down , pin 64 must pass completely through the diagonal gu ide slot
and rest on the upper end.
Lateral adjustment:
• Using threader key 63, place threader prong 62 at the front in the needle eye .
• Loosen screw 65 by only 1/8 of a turn (fig . 44 ).
• Push the threader bar frame either to the left or right until the prong is in ,
the exact middle of the needle eye. :, Nm
• Tighten screw 65 . :, 70
,,
,,
,
,
Cross-check 2: ,-f" ' " ~
• Activate th reader key 63. '-f'"''

,"" ------I
, ,
Whi lst doing so , carry out a visual check of the lateral position
of the prong .
Fig, 42
44
._____ 64
~
+'---%-66
65 - -
!---.. 67
63
~~_ _ 63
Fig. 43
Fig. 44
16. 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 68 (fig. 45),

• Position stop 69 to the left for less thread and to right for more thread .
Cross-check:
• Wind a bobbin and check thai the winder stops as required.
- 68
Fig. 45
45
17. Adjustment of bobbin thread tension
Requirement:
The force required for pulling cotton thread 50/2 or synthetic fiber thread 10013 off the bobbin must be
approximately 25 - 30 g.
Check :
• When a threaded bobbin case hangs on its thread , it must not slide downwards by its own weight.
• With a sharp upward movement of the hand , the thread must run off gradually (fig. 46).
• There must not be any thread waste under the tension spring .
• The tension spring must rest evenly and parallel on the bobbin case.
Adjustment:
Loosen the knurled screw a little and turn it in aga in until a resistance is felt when the thread is pulled off.
Check :
• Carry out as described under "Check~
Note:
• Once the bobbi n thread tension has been set correctly, tension adjustments must be made only to the
needle thread tension .
Fig. 46
18. Adjustment of needle thread tension
Requirement:
Within the adjusting range from 3 to 5, the interlacing of the needle thread and the bobbin thread (cotton
thread 50/2 or synthetic fiber thread 100/3) must take place approximately in the middle of the fabric in
straight and zigzag stitch setting (fig. 47 and fig. 50).
46
Check :
• Set the needle thread tension at ~ 5~.

• Set stitch pattern ~OY for zigzag and the stitch width at 86.0 n .
• Set the stitch length at ~2.0".
• Place a piece of fabric under the zigzag foot and sew.
• Select stitch pattern 801" for straight stitch and set the stitch tength at 8 2 . 5~.
• Sew with straight stitch.
Adjustment:
• First turn milled nut 57 fully to the left (fig. 51).

• Set zigzag stitch M03", stitch width ~6 . 0" , and stitch length -2.0".
• Sew with zigzag stitch.
• At the same time turn the milled nut gradually in clockwise direction , until the knot is fanned in the cen-
ter of the fabric (fig. 47).
Cross-check:
• Sew with straight stitch and

zigzag stitch as described
under ~Check " .
Fig. 47
Fig. 48 Fig. 49 Fig. 50
47
Fig. 51
19. Adjustment of equal forward and reverse stitch length for Pfaff 2010/2020
(for all forward and reverse controlled stitch patterns)
Requirement:
Adjusting program 95 must be sewn as a rectangle (fig. 52) and not be sewn from the machine as a
rhombus (fig . 53 or fig. 54).
Linen buttonhole, stitch pattern "09", must be sewn by the machine symmetrica lly (fig . 55.)
In this case the machine must be at operating temperature. i.e. switch-on time 10 - 15 minutes .
Check:
• Switch off the machine.

• Turn on the machine by pressing key "0" and the master switch .
• The display shows adjusting program "95".
• Place a piece of fabric under fancy stitch fool "2".
• Sew adjusting program "95" (fig . 52).
Preliminary adjustment:
• If a rhombus was sewn as seen in fig . 53, turn the adjusting eccentric just 2 " 4 degrees in
direction ~A" using a screwdriver, as shown in fig . 58.
If a rhombus was sewn as seen in fig . 54 . turn the adjusting eccentric just 2 - 4 degrees in
di rection -8 " using a screwdriver, as shown in fig . 58.
Cross-check:
• Sew adjusting program -95" and check.

• Select adjusting program "09", linen buttonhole. and sew.
• Check the symmetry of the linen buttonhole.
Precise adjustment:
• If the buttonhole bartack does not close exactly on the position where the front buttonhole seam starts
(fig. 55), proceed as follows:
• Ifthe linen buttonhole was sewn as seen in fig . 56 , turn the adjusting eccentric 1 - 2 degrees in
direelion "A" using a screwdriver, as shown in fig . 58.
If the linen buttonhole was sewn as seen in fig. 57. turn the adjusting eccentric 1 " 2 degrees in
direction -8 " using a screwdriver as shown in fig . 56.
Cross-check:
• Seleel stitch program "09" (linen buttonhole).

• Place a piece of fabric under buttonhole foot "5".
• Sew stitch program "09".
The bartack must cover the start of the right buttonhole seam (fig . 55).
48
Note:
If very different sewing threads or difficult fabrics are used , buttonholes, utility stitches or fancy stitches
may be sewn with shifts in the pattern design .
To correct this , the customer can adjust the balance.
On top of that, the length of the reverse buttonhole seam can be programmed .
Prog. 95 Prog.09
..
Fig. 52 Fig. 53 Fig. 54 Fig. 55 Fig. 56 Fig. 57
A
Fig. 58
49
20. Adjustment of equal forward and reverse stitch length for Pfaff tiptronic 2030/2040
(for all forward and reverse controlled stitch patterns)
Requirement:
Letters B, 0, G, H sewn in succession must measure 34 .5 +/- 0.5 mm and must not be distorted (fig. 62).
To this end the machine must be at operating temperature, i.e. switch-on time 10 - 15 minutes.
Check :
• Switch off the machine .

• Turn on the mach ine by pressing key "0" and the master switch simultaneously.
• The display shows adjusting program "9 5~.
• Place a piece of fabric under fancy stitch fool "2".
• Sew adjusting program -95" (fig . 59).
Preliminary adjustment:
• If a rhombus was sewn as seen in fig . 60, turn adjusting eccentric just 2 - 4 degrees in
direction "AHas shown in fig . 64 .
If a rhombus was sewn as seen in fig . 61 , turn adjusting eccentric just 2 - 4 degrees in
direction -B", as shown in fig . 64 .
Cross-check:
• Sew adjusting program -95" and check.

• On model 2030, select adjusting program "96" (BOG H) by pressing the program selection key (fig . 65).
• On model 2040, select adjusting program "96" (BOGH) by turning the program selection key (fi g 66).
• 8y sewing , check the length 34 .5 +/- 0.5 mm .
Precise adjustment:
• If the letters are distorted and longer than 35 mm , turn the adjusting eccentric with a screwdriver only
one degree in direction "8" according to fig 64.
If the letters are distorted and shorter than 34 mm, turn the adjusti ng eccentric with a screwdriver only
one degree in direction "AH according to fig . 64.
Cross-check:
• Select stitch program "09" (linen buttonhole).

• Place a piece of fabric underneath buttonhole foot "5".
• Sew stitch program "09".
The buttonhole bartack must cover the right buttonhole seam (fig . 63).
50
Note:
If very different sewing threads or difficult fabrics are used , buttonholes, utility stitches or fancy stitches
may be sewn with shifts in the pattern design .
To correct this , the customer can adjust the balance.
On top of that, the length of the buttonhole reverse seam can be programmed .
Prog .95 Prog. 09
Prog.96
Fig. 59 Fig. 60 Fig. 61 Fig. 63
Fig. 65 Fig. 66
A
Fig. 64
51
21 . Making up a sewing sample
When all sewing checks are completed and the machine sews perfectly, a sewing sample is to be made.
This sewing sample should contain the most important stitch patterns, which can be sewn on a repaired
machine (fig . 67).
If the customer has special requirements, these should appear on a separate sewing sample.
The following is a sewing sample from the PFAFF 2040
Stitch program No. Stitch width Stitch length Presser foot no .

or pattern length
1 Straight stitch 01 2.5 Zigzag foot ~O~
2 Zigzag stitch 03 6.0 2.0 Zigzag foot ~O"

3 Honeycomb stitch 19 6.0 2.0 Zigzag foot ~O"
4 Linen buttonhole 09 4.5 1 Buttonhole foot ~5~
5 Fancy stitch 56 6.0 0.30 Fancy stitch foot ~ 2 "
1 - - - - -- -- -- - - - - - -- - - -- - - -- -- -- ----
4 II I
1111 1111 111111 111111 111111 111111

5 1111 11111 1111 11111 1111 11111 1111 11111 11111 11111 11111 11111
11111 III I III I 1111 III I 1111 1111
Fig. 67
52
Repair Instructions
22. Dismantling and assembling the needle thread tension
Removal:
• Remove the needle thread tension .

• Press the two plastic noses 70 together and remove tension dial 71 (fig . 66).
• Remove spring disc 72 .
• Turn milled nut 73 out of guide 74.
• Remove guide 74 .
• Remove milled nut 73 and pressure-spring 75.
• Pull out or knock out cemented stud 76 complete with pressure piece 77 and the three tension
discs 78 , 79 and 80 .
Fining :
• Insert tension stud 76 with the three tension discs 78 , 79 and 90 and the pressure piece 77.
• Cement the tension stud into the mounting plate with Onmivit-Rapid.
• Push pressure-spring 75 and milled nut 73 onto tension stud .
• Insert guide 74 with its right side and fully screw in milled nut 73.
• Push on tension dial 71 making sure that the guide nose is in contact with the outer surface of the
curve.
• Install the needle thread tension .
• Set the needle thread tension accord ing to section 18.
80
76
74
73
75
Fig. 66
53
23. Changing the torsi on spring in handwheel
Dismantling the handwheel
• Remove stand cover in accordance with the instructions for dismantling the housing .
• Turn the handwheel until the handwheel cutout is facing upward (fig. 67).
• Push lug 81 to the rear using a screwdriver.
• Pull off the handwheel from the arm shaft to the right.
• Till the machine to the rear.
• Place a rag underneath the arm shaft.
• Punch out tapered notch pin 82 using a punch from the arm shaft.
• Remove spring washer 83.
• Loosen motor-mounting fastening screw 84 (fi g. 68).
• Push the motor mounting up slightly.
• Remove the motor's flat toothed belt 85 .
• Remove sprocket 86, bushing 87 , torsion spring 88 and spring washer 89 (fig . 67).
Fittin g the handwh ee l
• Push spring washer 89 onto the arm shaft.

• Insert torsion spring 88 into bushing 87.
• Attach bushing 87 together with torsion spring 88 onto the arm shaft.
• Press sprocket 86 onto the arm shaft.
• Push lockwasher 83 onto the arm shaft.
• Fit the motor's flat-toothed belt 85.
• Tighten the motor's flat-toothed belt 85 in accordance with section 31 , tighten ing fastening screw 84
very securely at the sa me time (fig. 68).
• Tilt back the machine and place a ra9 underneath the arm shaft.
• Punch tapered notch pin 82 , so that its sides have the same distance to the arm shaft .
• Push the handwheel onto the arm shaft, so that lug 81 locks in place above tapered notch pin 82
(fig. 67).
• Attach the stand cover, the housing insert as well as the top cover.
• Carry out an electrical safety test in accordance with VDE 0701 using testing appliance
Metrawatt 5013 .
54
89 87 88 86 1
-- -- - - - - -
Fig. 67
85
84 _ _ -W-
Fig. 68
55
24. Dismantling and assembling the sewing hook
Removal :

• Unscrew the presser foot.
• Remove the bobbin case.
• Unscrew the bobbin case position finger.
• Take out the three screws with springs from behind (fig . 69 ).
• Remove the bobbin case base with sewing hook gib (fig. 70).
• Turn the sewing hook gib to the left or to the right out of the bobbin case base (fig . 71).
• Clean the sewing hook, bobbin case base and hook gib.
Fitting:
• Turn the handwheel until the opening of the sewing hook faces to the left (fig . 72).
• Turn the sewing hook gib to the left into the bobbin case base (fig . 73.).
• Insert the bobbin case base complete with sewing hook gib into the sewing hook (fig. 74 ).
• Fasten the sewing hook gib from beh ind with three screws with springs (fig . 69) .
• Screw on and adjust the bobbin case position finger.
25. Cleaning and oiling the machine
Note:
The machine is equipped with oil-soaked calolte bearings 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 mechanic should oil the machine with BP Energol HLP 46 or HLP aD and the
sewing hook with normal sewing machine oil.
Calotte bearings or parts must not be cleaned with gasoline , petroleum, kerosene , thinners,
trichlorethylene etc .
Dirty or clogged calotle bearings or parts may only be cleaned mechanically by brushing them off.
They are then to be oiled with BP Energol HLP 46 or HLP aD.
56
o
©
Fig. 69 Fig. 70
o
G~
Fig. 71 Fig. 72
o
©
~
,- o
©
Fig. 73 Fig. 74
57
26. Changing the flat-to othed belt
Removal :
• Remove the housing in accordance with the adjustment and repair instructions.
• Turn the handwheel until the lobe of feed eccentric 5 is positioned at the rear.
• Loosen faste ning screw 1 of tension ing roller 2 (fig . 75).
• Tilt the machine to the rear.
• Unscrew and remove fa stening screw 90 of clamping plate 91 on the lower right calotte bearing
(fig. 76).
• Remove the clamping plate .
• Slip off flat-toothed belt 96 from the upper and lower belt wheels 93 and 94.
• Lift complete hook driving shaft 28 out of the lower right calotte bearing 92 as far as it will go.
• Pull the flat toothed belt between calotte 95 and calotte bearing 92.
• Disconnect tension spring 96 on needle bar frame 44 (fig. 75).
• Remove lockwasher 51 on the needle bar frame.
• Remove circl ip 97 on zigzag stepping motor 46 .
• Dismantle the complete connecting rod 99.
• Loosen screw 100 on needle bar crank 101 (fig. 75) .
• Unscrew and remove both clamping plate screws 102.
• Dismantle both clamping plates 103.
• Lift the needle bar with the crank as far out as possible from calotte bearings 104 and 105.
• Hold the needle bar crank firmly. At the same time move needle bar 106 to the right until both parts
are disengaged.
• Dismantle the complete needle bar.
• Remove the flat -toothed belt from the housing to the top.
58
100 101 103 104 102 93 106 97 46 105
102
51 - - -
Fig. 75
92
90 Fig. 76
59
Fitting:
• Lift complete hook driving shaft 28 out of the lower right calotte bearing 92 as far as it will go (fig . 78).
• Pull the flat toothed belt between calolte 95 and calolte bearing 92.
• Place hook driving shaft 28 together with calotte 95 in the lower right calotte bearing 92 exactly.
• Fit clamping plate 91 and fasten with screw 90.
• Pull flat-toothed belt 98, which is in the inner housing , upwards .
• Feed arm shaft 106 from the right into the housing (fig . 77).
• Place flat-toothed belt 98 over arm shaft 106.
• Feed arm shaft 106 into needle bar crank 101.
• Insert arm shaft 106 into calotte bearings 104 and 105.
• Fit clamping plates 103 and fasten with screws 102.
• Check for free movement of arm shaft, if necessary establish the free movement.
• Place flat-toothed belt 98 onto the upper and lower sprockets 93 and 94.
• Set the flat-toothed belt's tension according to section 1.
• Turn the handwheel until the fastening screw of the synchronizer control cam 32 faces downwards
(fig. 79).
• At the same time pin 107 on the upper sprocket faces upwards.
• Press needle bar crank 101 against the calotte of the left calotte bearing 104. At the same time tighten
screw 100 on needle bar crank 101.
• Check for free movement of the arm shaft, if necessary establish it.
• Attach connecting rod 99 (fig . 77).
• Mount lockwasher 51 onto the needle bar frame .
• Attach pull-spring 96.
• Attach circiip 97 to the zigzag stepping motor.
• Attach connection plugs 7, 12, 13, 14, 15 and 16 to the circuit board on the front housing shell.
• Mount the front housing shell and fasten with torx screws 17, 18 and 19.
• Mount the rear housing shell and fasten with torx screws 10 and 11.
• Mount the stand cover and fasten with torx screws 5.
• Attach the needle plate.
• Attach connection plugs 3 and 4 to the circuit board on the baseplate .
• Locate the baseplate, the freearm lid with bobbin thread monitor and the buttonhole sensor to the right
next to the machine.
107
Fig. 79
60
101 103 104 102 93 106 97 46 05
103
102
44 - --1
51 - ---'
Fig. 77
92
Fig. 78
91 90
61
Adjusting the machine:
• Till the machine towards the rear.

• Disconnect spring 3 (fig . 80).
• Turn the handwheel until the lobe of feed eccentric 5 is at the rear.
• Fold feed regulator 6 downward and remove it with link 7 to the left from feed bar pin.
• Check that the slide block can be moved easily without play or binding into the slotted lever.
If necessary, adjust according to section 2 a.
• Fold feed regulator 6 to the rear and then upward over feed eccentric 5.
• Insert screw 4 into clamping plate 21 and tighten just a little.
• Push pin 20 to the side until lever 7 and driving bar 19 still have a little play and move easily.
• Attach spring 3.
• Loosen the three screws 29 in the lower flat·toothed belt sprocket 94 .
• Bring the needle bar to its lowest position by turning the handwheel.
• Fit spacer (63· 102 600-18) on the needle bar and push up against the needle bar frame .
• Push needle rise clamp (61-111 600-35) on the needle bar.
• Push 2 mm feeler gauge (00· 870 136-01 ) with its cutout on the needle bar above the needle rise
clamp.
• Loosen the needle rise clamp and push the 2 mm feeler gauge upward against the spacer.
• Tighten the milled screw on the needle rise clamp.
• Turn the handwheel back and forth .
If there is any play at the feeler gauge, repeat this procedure.
• Remove the 2 mm feeler gauge.
• Turn the handwheel in the normal direction until the needle rise clamp rests on the spacer.
• Hold the handwheel at this position .
• Turn hook driving shaft 28 in the normal direction until the pin gauge can be inserted in the hole of feed
eccentric 5 and pins 27 (fig . 80).
• Insert the pin gauge and tighten one of the screws 29.
• Remove the pin gauge, needle rise clamp and the spacer and tighten all three screws 29.
Note:
On having tightened the screws 29, there must not be any play between the lower flat-toothed belt
sprocket 92 and calotte 95.
• Check section 4 -Adjustment of the feed dog heighr.

• Carry out section 5 "Adjustment of the synchronizer".
• Carry out section 12 "Sewing hook timing".
• Insert the buttonhole sensor.
• Attach the free-arm cover and fasten with both fasten ing screws 5.
• Bring the feed-dog lowering mechanism to the normal working position .
62
• Fold the baseplate towards the machine.
• Attach the cable clip.
• Fasten the baseplate on the housing with the three fastening screws.
• Attach the face plate .
• Attach connection plug 2 onto the circuit board of the front housing shell.
• Install the sewing lamp cable.
• Mount the facing panel of the front housing panel.
• Insert the housing insert and fasten with the torx screws.
• Attach the top cover.
• The following points must be checked and adjusted:
• Section 17 "Adjustment of bobbin thread tension"
• Section 18 "Adjustment of needle thread tension"
• Section 19 "Adjustment of equal forward and reverse stitch length"
• An electrical safety test must be carried out in accordance with VDE 0701 using the testing appliance
Metrawatt 5013.
21
94
19
27
Fig. 80 28 5 6 108 20 4 29
63
27. Changing the bevel gears
Note:
Always change bevel gears in pairs.
Removal :
• Remove the mains plug of the machine.

• Unscrew and remove the three fastening screws of the baseplate .
• Remove both connection plugs 3 and 4 from the circuit board .
• Unscrew and remove both fa stening screws 5 on the free-arm cover.
• Bring the feed-dog lowering mechanism to the normal working position .
• Using a small screwdriver, disengage both feed regulators 6.
• Remove the free-arm cover carefully from the housing to the left and place it aside the machine.
• Remove the needle plate.
• Remove the buttonhole sensor and place it aside the machine.
• Dismantle feed·dog lowering mechanism 107 (fig . 61 ).
• Disconnect both pull-springs 3 and 9.
• Unscrew and remove screw 60 of the bobbin case position finger 61.
• Remove the bobbin case position finger.
• Turn the handwheel until the lobe of feed eccentric 5 is at the rear.
• Unscrew and remove screw 4 and clamping plate 21 .
• Fold feed regulator 6 downwards and remove it with link 7 to left from the driving bar pin.
• Loosen the three screw 29 on the lower flat-toothed belt sprocket 94 .
• Unscrew and remove screw 106 of feed eccentric 5.
• Unscrew and remove screw 57 of lifting eccentric 109.
• Move hook driving shaft 26 as far as possible to the right.
• Loosen screw 22 and remove pin 23.
• Unscrew and remove screw 10 of clamping plate 110.
• Remove the left cylindrica l pin 12.
• Unscrew and remove both fa stening screws 111 of the hook bearing .
• Pull feeding stroke shaft 14 slightly downwards and dismantle the complete sewing hook together with
lifting eccentric 109.
• Loosen both screw 53 of the sewing hook (fig . 82).
• Pull the small hook driving shaft with bevel gear 56 downwards to remove.
64
60 1 1 1 32 33 6 7 19 8 1 21 4
10 110 12 109 57 9 14 28 5 108 22 23 94 29

Fig. 81
52
109
53 - - - -
57
54 _ -::::::::::::t-.L
55
56 ~
Fig. 82
65
Fitting:
• Insert the new hook driving shaft with bevel gear 56 in the sewi ng hook bearing (fig . 82).
• Mount sewing hook 52 with the plastic disk on the sewing hook bearing and set il.
• Fasten the sewing hook bearing using both screws 111 (fig. 83).
Note that the sewing hook bearing is fastened parallel to the housing .
• Push the hook driving shaft to the left until circlip 112 rests against the lower right calotte bearing 92.
• Place the hole of lifting eccentric 109 above the surface of hook driving shaft 28.
• Swivel in screw 57 of lifting eccentric 109 and fasten sl ightly.
• Press lower flat-toothed belt socket 94 to the right a9ainst calotte bearing 92 .
At the same time tighten one of screws 29.
• Check that the hook driving shaft has zero play and moves free of binding.
• Tighten all three screws 29 of the lower flat·toothed belt sockel.
• Slightly loosen screw 57 . Push the bevel gear and lifting eccentric 109 to the left until it rests on bevel
gear 56 without any play.
• Tighten screw 57 on the surface of hook driving shaft 28 (fig . 83 ).
• Screw in dog-point screw 108 into feed eccentric 5 or the hook driving shaft.
Note:
Dog· point screw 108 must always protrude from feed eccentric 5 on the opposite side of screw 57 in
lifting eccentric 109.
• Insert cylindrical pin 12 and fasten w ith the clamping plate.

• Adjust the feed driving shaft according to section 2a .
• Fit pin 23 with the washer situated to the left of the pull rod without any play.
• Pull the feed dog to the fronl.
Important:
The complete feed driving shaft with top feed must slide slowly to the rear.
• Fit slide block 8 with the spring on the pin and insert into slide was in the correct curve radius.
• Check that the slide block can be moved easily without play or binding in the slide way.
• Push link 7 complete w ith feed regulator 6 to the right onto the connecting bar pin .
• Turn feed regulator 6 to the rear and then over feed eccentric 5 from the top.
• Insert screw 4 with clamping plate 21 and tighten slightly.
• Shift stud 20 laterally until link 7 and connecting bar 19 only have a slight play and are freely movable.
• Fit spring 3.
• Fit the feed dog lowering mechanism .
66
• Attach spring 9.
• Set the base plate against the machine.
• Mount both connection plugs 3 and 4 on the circuit board .
Now the following adju stments are to be carried out:
• Section 3: Timing of the feed motion

• Section 4: Adjustment of feed dog height
• Section 5: Adjustment of synchronizer
• Section 11 : Adjustment of hook-to-needle clearance
• Section 12: Hook timing
• Section 13: Adjustment of needle bar height
• Section 14: Adjustment of bobbin case position finger
• Install cable .
• Insert the buttonhole sensor.
• Attach the free-arm cover and secure with both fastening screws 5.
• Bring the feed dog lowering mechanism to its normal working position.
• Engage both feed regulators 6.
• Secure the base plate with the three fastening screws to the housing .
Now the following adju stments are to be checked or ca rried out:
• Section 17: Adjustment of bobbin thread tension

• Section 18: Adjustment of needle thread tension
• After a running-in time of approx . 10 min . - Section 20 : Adjustment of equal forward and
reverse stitch length.
• Use testing appliance ABB Metrawatt M 5013 to carry out an electrical safety test according to
VDE 0701.
60 111 52 107 32 33 6 7 19 8 18 3 21 4
10 110 12 109 57 9 14 28 5 108 22 23 94 29

Fig. 83
67
28. Changing the base circuit board
Note:
The base circuit boa rd is only exchanged as a complete unit.
Removal :
• Remove the mains lead from the mains socket and from the machine.
• Unscrew and remove the three fastening screws on the base plate .
• Till the base plate 10 the front.
• Remove the connection plug of twelve-wire flat cable 3 as well as the connection plug of motor cable 4
from the circuit board (fig . 84).
Fitting
• Set the new base plate complele against the machine .

• Mount both connection plugs 3 and 4 on the circuit board.
• Fold the base plate against the machine and secure it with the three screws.
• After a running-in time of 10 - 15 min . check the adjustment of equal forward and reverse stitch length
in accordance with section 20 of the service manual.
• Carry out an electrical safety test according to VD E 0701 using testing appliance Metrawatt 5013.
68
_ 3
69
29. Changing the upper circuit board on front hou sing panel
Removal :
• Remove the folding cover.
• Unscrew and remove both torx screws of the housing insert.
• Raise both lugs 1 slightly and remove the facing panel of the front housing panel in the direction
of the arrow (fig . 85).
• Remove connection plugs 2, 7, 12, 13. 14, 15, 16, 112 and 113 from the circuit board (fig . 86).
• Unscrew and remove screws 114, 115 and 116.
• Remove the complete circuit board.
Fig. 85
114
11 5 1 1 13 Fig. 86
70
Fitting :
• Place the circuit board on the front housing panel.

• Secure the circuit board with screws 114, 115 and 116 (fig . 86).
• Mount connection plugs 2, 7, 12, 13, 14, 15, 16, 112 and 113 onto the circuit board .
• Mount the facing panel onto the front housing panel , making sure that both lugs 1 lock into place
(fig . 87).
• Attach the housing insert and secure with both torx screws.
• Atlach the folding cover.
• After a running-in time of 10 - 15 min . check the adjustment of equal forward and re verse stitch length
in accordance with section 20 of the service manual .
• Carry out an electrical safety test in accordance with VD E 0701 using testing appliance
Metrawatt 5013.
Fig. 87 1
71
30. Changing the control board with keys
Removal :
• Raise both lugs 1 slightly and remove the facing panel of the front housing panel in the direction
of the arrow (fig . 88).
• Raise both lugs 116 and 117 up and down slightly (fig. 89).
• Push complete control board 118 slightly to the left until the control board can be removed
from the circuit board.
Fig. 88
117
118 Fig. 89
72
Fitting :
• Mount the control board with keys onto the circu it board whilst making sure that all four lugs 116. 117.
119 and 120 lock in completely behind the circuit board (fig. 90).
• Mount the faci ng panel onto the front housing panel and make sure that both lugs 1 lock fully into place
(fig . 91).
• Attach the folding cover.
• Carry out a functional test for all keys.
accord ing to section 20 of this service manual.
• Carry out an electrical safety test in accordance with VOE 0701 using testing appliance
Metrawatt 5013.
116
120 ___~
119 - - 117
118 Fig. 90
Fig. 91
73
31 . Changing the key-pair panel
Removal :
• Remove the housing according to the service manual.

• Remove connection plug 113 from the circuit board (fig. 92).
• Unscrew and remove the six fastening screws 121 (fig . 93).
• Remove the complete circuit board together with the key-pair panel and the keys from the front
housing panel.
-T--- 113
___ 122
Fig. 92
121 121
121
Fig. 93
74
32. Changing the synchronizer circuit board
Removal :
• Remove the detachable work support .
• Remove connection plug 12 from the circuit board on the front housing panel (fig. 96).
• Unscrew and remove fastening screw 123 on circuit board 124 using the torx offset screwdriver TX 15
(fig . 97) .
• Unscrew and remove screw 17 on the housing (fig. 98).
• Raise the front housing panel slightly and pull the circuit board's power cable through cable tie 125.
• Remove the complete circuit board 124.
Fitting:
• Secure circuit board 124 to the housing with fastening screw 123, using the torx offset screwdriver
TX 15 (fig . 97).
Make sure that the circuit board is positioned as such , so that the cams of control cam 32 are posi-
tioned in the middle of the circuit board guides (fig . 99).
• Pull the power cable of circuit board 124 through cable tie 125.
• Secure the cable with cable tie 125 on the bar of the front housing panel (fig . 98).
• Tighten fastening screw 17.
• Mount connection plug 12 onto the circuit board on the front housing panel (fig. 96).
• Adjust the synchronizer in accordance with section 5.
according to section 20 of this service manual.
Metrawatt 5013 .
76
80
80
80
0000 ( )
Fig. 96
Fig. 97
17
125
Fig. 98
24 23
Fig. 99
77
33 . Changing the motor
Note:
The motor is only exchanged complete.
Removal :
• Remove the main s lead from the ma ins socket and the machine.
• Clap the ca rrying handle up.
• Loosen fastening screw 9 on the stand cover (fig . 100).
• Remove stand cover.
• Unscrew and remove fastening screw 84 (fig. 101).
• Remove flat-toothed belt 85.
• Remove the motor from the housing to the right.
• Remove both of the motor's power cables (fig . 102).
Fining :
• Place flat-toothed belt on the handwheel (fig. 101).

• Attach both power cables, paying attention to the plus signs (fig . 102).
• Insert the motor and place the motor pinion in toothed belt 85 (fig . 101).
• Tighten fastening screw 84 slightly.
• Adjust the toothed-belt tension by moving the motor.
• Tighten fastening screw 84.
• Insert the ma ins lead and trial-run the machine.
• Carry out an electrica l safety test in accordance with VDE 0701 using testing appliance
Melrawatl 5013.
78
9
000
o
Fig. 100
85 - -
84 _ _ +
Fig. 101 Fig. 102
79
34. Changing the cable in the foot control
Removal :
• Lift rubber strip 126 and pull it out with its three feet (fig . 103).
• Pull out the two plugs 127.
• Unscrew and remove the four Philips screws 128.
• Remove housing cover 129.
• Remove the rectangular pedal 130 with guide 131 and take out contact spring 136.
• Disconnect the right pressure spring 132.
• Disconnect the right cable 133 with the contact eyelet (fig . 104).
• Press out or pull out demented resistor track 134 (20·KQ·potentiometer) upwards with a screwdriver
or a pair of pliers.
• Remove cable 135.
Fitting:
• Insert cable 135 in the housing.

• Insert the soldered resistor track 134 fully downwards into the guide and secure it with some adhesive.
• Push the soldered contact eyelet 133 onto the right guide pin .
• Place both cables in the respective guide grooves.
• Place contact spring 136 on the guide pin in the larger right section of pedal 130.
• Push pressure spring 132 onto the same guide pin.
• Turn pedal 130 around and push the right spring 132 on the right guide pin of the housing and the left
spring 137 on the left guide pin in pedal 130.
• First press the pedal a little to the right and then downwards in such a way that contact spring 136 is
on the right-hand side of resistor track 134 and not bent.
• Press the pedal further down , as far as it will go; at the same time insert guide 131 in its two open
bearings.
• Hold pedal 130 in this position ; at the same time replace housing cover 129 and press it firmly on the
housing (fig . 103).
• Insert and tighten the four Philips screws.
• Insert rubber strip 126 and the two plugs 127.
Metrawatt 5013 .
80
',,--- 128
127
129
126
130- - -
131 --~ :;:;:;::;;;;;~;;;;;;

Fig. 103
136
l - _ - 132
...... 133
Fig. 104
81
35. Changing the top stepping m ot or
Note:
The stepping motor for sideways needle bar movement is only exchanged complete.
Removal :
• Remove mains lead .

• Remove detachable work support .
• Remove the housing according to the service manual .
• Remove circlip 97 on zigzag stepping motor 46 (fig. 105).
• Disengage connecting rod 99 and the tooth segment of zigzag stepping motor 46.
• Unscrew and remove both fastening screws 45.
• Lift zigzag stepping motor 46 upwards out of the retainer in the direction of the arm shaft.
• Remove the zigzag stepping motor to the front, out of the housing .
Fitting:
• Install zigzag stepping motor 46 in the housing .

• Pull power cable downward.
• Insert and tighten both fastening screws 45 (fig. 106).
• Insert the pin of connecting rod 99 in the hole of the tooth segment.
• Attach circlip 97.
• Mount the housing according to the service manual.
Note:
Having exchanged the zigzag stepping motor for sideways needle movement, adjustment of the needle
in the needle hole, section 9 must be repeated .
• Carry out a check of aU functions.

• Carry out an electrica l safety test in accordance with VDE 0701 using testing appliance Metrawatt
5013.
82
97
99
_ 45
..!.----
45 - - 46
Fig. 105
99 45 97 46 45 Fig. 106
83
36. Changing the lower stepping motor
Note:
The feed stepping motor is only exchanged complete.
Removal :
• Remove the machine's power plug .

• Remove the housing according to the service manual.
• Remove tension spring 3 (fig . 107).
• Unscrew and remove fastening screw 4.
• Remove clamping plate 21 .
• Turn the handwheel until the lobe of feed eccentric 5 is positioned at the rear.
• Fold feed regulator 6 downwards and remove this and link 7 from the connecting bar rod to the left.
• Remove slide block 8 with the spring to the right.
• Unscrew and remove both screws 15 of the stepping motor.
• Remove the complete stepping motor 17.
Fitting:
• Insert feed stepping motor 17 complete with the bracket (fig . 107).
• Insert and slightty tighten upper fastening screw 15.
• Insert and slightly tighten clamp spring 137 with the lower screw 15.
• Push slide block 8 with spring onto the bolt and set it in the guide slot in the correct curve radius.
Check that the slide block moves freely, but without play or binding , in the guide slot.
• Push guide lever 16 complete with stepping motor 17 carefully to the left, until there is a clearance of
0.05 mm between the slide block 8 and the connecting bar 19.
• Tighten screws 15 and check that the slide block moves freel y, but w ithout play.
• Push link 7 complete with feed regulator 6 to the right onto the connecting bar pin .
• Insert fastening screw 4 in clamping plate 21 and tighten it a little .
• Shift fulcrum stud 20 laterally so that link 7 and connecting bar 19 still have a sl ight play and can
move freely.
• Attach tension spring 3.
• Mount the housing according to the service manual.
• After a runn ing-in time of 10 - 15 min. check the adjustment of equal forward and reverse stitch length
according to section 20 of this service manual.
Metrawatt 5013 .
84
16 17
6 5 21 4 20 Fig. 107
85
37. Changing the buttonhole sensor
Note:
The buttonhole sensor is only exchanged complete.
Removal :
• Remove the machine·s mains lead.

• Remove the needle and presser foot.
• Unscrew and remove both torx screws from the housing insert.
• Raise both lugs 1 slightly and remove the facing panel of the front housing panel.
• Place the machine on its back .
• Unscrew and remove the three screws in the base plate.
• nit the base plate to the front and remove both connecUon plugs 3 and 4 from the circuit board
(fig . 108).
• Unscrew and remove both screws 5 from the free·arrn cover (fig . 109).
• Bring the feed-dog lowering mechanism into its normal working position .
• Disengage both feed regulators 6 using a small screwdriver (fig. 109).
• Remove the cable cl ip.
• Remove connection plug 16 from the circuit board of the front housing pa nel and pull the cable
downward (fig . 110).
• Remove the free·arm cover from the housing to the left.
• Remove connection plug 13 from the circuit board of the front housing panel and pull the cable
downward (fig . 110).
• Remove cable guide 20 (fig . 109).
• Dismantle buttonhole sensor 138 complete with the spring.
Fitting:
• Install buttonhole sensor 138 complete with the spring .

• Insert the cable with cable guide 20 in the housing .
• Turn the machine upside down .
• Place the cable , using a spring hook , between the motor and the housing wall.
• Mount connection plug 13 on the circuit board of the front housing panel (fig . 110).
• Put the machine in its working position .
• Mount the free·arm cover carefully and secure with both fastening screws 5.
• Engage both feed regulators 6 (fig . 109).
• Turn the machine upside down .
• Place the cable, using a spring hook, between the motor and the housing .
• Mount connection plug 16 on the circuit board ofthe front housing panel (fig . 109).
• Attach the cable clip .
• Mount both connection plugs 3 and 4 on the circuit board of the base plate (fig . 108).
86
• Fold the base plate to Ihe machine and secure with the three fastening screws.
• Mount the facing panel onto the fronl housing panel.
• Insert the housing insert and secure with both torx screws.
Metrawatt 5013.
f- 3
Fig. 108
4
5 138 5
3
Fig. 109
Flg.ll0
87
38. Changing the thread monitor with free-arm cover on model 2040
Note:
The thread monitor IS only exchanged complete with the free-arm cover.
Removal :
• Remove the machine's mains lead.

• Remove the needle and presser foot.
• Raise both lugs 1 slightly and remove the facing panel of the front housing panel.
• Place the machine on its back.
• Unscrew and remove the three screws in the base plate.
• Till the bast to the front and remove both connection plugs 3 and 4 (fig . 111).
• Unscrew and remove both fastening screws 5 of the free-arm cover (fig . 112).
• Disengage both feed regulators 6 using a small screwdriver (fig . 112).
• Remove the cable clip.
• Remove connection plug 16 from the circuit board of the front housing panel and pull the cable
downward (fig. 113).
• Remove the free-arm cover with the thread mon itor from the housing to the left.
Fitting:
• Install the new free-arm cover with thread monitor and secure with both fastening screws 5 (fig . 112).
• Bring the feed-dog lowering mechanism into its normal working position.
• Engage both feed regulators 6 (fig . 112).
• Place the cable, using a spring hook, between the motor and the housing .
• Mount connection plug 16 onto the circuit board of the front housing panel (fig. 113).
• Mount both connection plugs 3 and 4 onto the circuit board of the base plate (fig. 111).
• Fold the base plate to the machine and secure with the three fastening screws.
• Mount the facing panel onto the front housing panel .
• Insert the housing insert and secure with both torx screws.
• Attach the mains lead.
• Carry out a test of the thread monitor with an empty and a full bobbin .
Metrawatt 5013.
88
_ 3
Fig.111
20
5 5
3
Fig.112
Fig.113
89
39. Changing the needle threader
Note:
The needle threader is only exchanged complete with the threader bar frame .
Rem oval :
• Remove the machine's mai ns lead .

• Remove the needle and the presser foot.
• Presser threader key 63 down completely and keep it pressed (fig . 114).
• Using a small screwdriver, raise bracket 139 of threader bar frame 140 slightly.
• Remove the complete threader bar frame downward from threader bar 141.
Fitting:
• Push Ihe new Ihreader bar frame together with the needle threader on to the threader bar, until bracket
139 clicks back into place.
Cross-c heck:
• Insert a new needle Nm 70.

• Move the needle threader up and down by pressing threader key 63.
• Carry oul a visual check of Ihe position of Ihe needle-threader prong in the needle eye .
tf necessary, readjust the position according to section 16 of the service manual .
Metrawatt 5013.
141
63
.'----
Fig.114
90
40. Self-test, foreword
The self-test provides the mechanic with a simple and quick means of checking the machine.
Sequential faults are not detected.
Faults are only detected if the machine is mechanically in order.
The self-test is ca rried out sequentially; changing the test sequence is not possible. However,
the program can be stopped any time by switching the machine off.
If a fault occurs, the test is interrupted .
Generally an error in th e corresponding test phase is indicated on the display with -ER". (-EW = Error)
In some test steps an add itional visual check must be carried out.
In some cases the operator has to ca rry out actions at the machine within a certain time span
(see c olumn " Remarks" ), as otherwise the test prog ram will consider a fault.
In this case -EW will appea r on the display.
The test should then be repeated for reasons of safety.
If no fault occurs during the test, the machine will display ·OK". To change back to a sewing program,
the machine must be turned off and then back on again .
91
41 . Self-test model 2010 and 2020
Step Display/Function Visual Check! Nom ina l Remar1<.s

no Sewing machine action at machine machine display
1 Machine without needle

Master switch off
2 Press pattern mirroring TE After releasing both keys,
key and actuate master you have to wait for a
switch at the same time. period of 3 secs . which is
shown on the display.
If no d isplay use fault-
finding chart.
3 Visual check:AII indicator All indicator ele- Visual check negative:

elements must flash 5 ments flash change respective sub-
times assembly.
.If one of the modules
returns an error, -EW will
appear on the display
and the following tests
will be skipped .
4 KY(key test) Actuate the key shown The next key to A time span of approx .
O=sewing on buttons be actuated is 12 secs is planned for
1 =straight stitch shown each key actuation.If the
2=stretch triple- key is not pressed within
straight stitch this time span , the next
3=zigzag stitch key to be actuated is d is-
4=elastic stitch played and the non-actu-
5=blind stitch ahon of the key is regis-
6=elastic blind stitch tered as an error and dis-
7=overlock stitch played at the end of the
8=faggoting stitch program .
9=buttonhole
10=prog . seL key left
11 =prog. sel. key right
12=stitch width -
13=stitch width +
14=stitch length
15=stitch length +
16=correction -
17=correction +
18=reverse key
19=patlern mirror
92
5 SM Visual check: 5 According to the stan·
(stepping motors test) Both stepping motors 4 dard , both stepping
rotale through the stroke 3 motors fotate through the
5 times 2 stroke 5 times alternate-
1 Iy, no error must occur.
6 Fe Press fool control slowly max. 92 [f control is not actuated ,

(foot control test) as far as it will go twice . the width display is
empty.
If control is actuated , the

width display will show
the standardized foot
control reading .
If control is not actuated

during the period of read-
ing , an error will be dis-
played .
7 PT Turn handwheel two Pas. up:

Synchronizer test revolutions evenly to the Pas. up t The width arrow ~up~
front is displayed .
Stop up t. Stop up:

The width arrow -up~
and the decimal point are

displayed
Pos. down .J, Pas. down:

The width arrow ~down ~
is displaed
Intermed iate Intermediate position:

pas , -- The hyphen is displayed
8 MT Actuate the foot control If the control is not actu-

(motor test) aled , the width display is
empty.
If the control is actuated ,
the w idth display shows
the standardized rpm
(actual reading = e.mJ.)
Actual reading:
and the length display
max . 85
shows the standardized
Desired reading:
desired reading.
85
93
ing, or the r.p.m. are too
low, an error will be dis-
played. The program
stops after 12 secs and
the motor stops.
9 OK Test completed OK The program can only be

exited by switching off
machine.
94
42. Table for self-test model 2030
Before you start the self- test, the mains lead and the foot control should be connected , the buttonhole
guide should be fully inserted and the bobbin case should be removed.
When turning the machine on, the - mirroring ~ key must be actuated. The program can only be exited be
turning off the machine.
The machine will display -G.M. PFAFF AG TESr .
Step Display/function Visual Check! Nominal Remarks

no . Sewing mach ine action at machine machine display
1 Machine without needle

Master switch off
2 G.M . PFAFF AG TEST Actuate master switch G.M. PFAFF AG After releasing the key
and mirroring key at the TEST you have to wait for a
same time period of approx. 3 secs,
which is shown on the
display.
If no message appears,
use fault-fi nding chart.
3 DISPLAY Visual check: All indicator Visual check negative :

All indicator elements elements fla sh change respective sub-
must fla sh 4 times. assembly.
4 KEYBOARD Actuate the key shown The next key to A time span of approx.
(Key test) be actuated is 12 secs is planned for
O=sewing on buttons shown . each key actuation .
1=straight stitch If all keys have If the key is not pressed
2=stretch triple-straight been recog- within th is time span, the
stitch nized by the next key to be actuated
3=zigzag stitch machine, the is displayed and the non-
4=etastic stitch message -OK" actuation of the key is
5=blind stitch will appear. registered as an error
6=elastic blind stitch If a key has not and displayed at the end
7=overlock stitch been recog- of the program .
8=faggoting stitch nized , the mes-
9=buttonhole sage -ERROR"
10=pattern sequence will appear
11 =cursor left
12=cursor right
13=block monograms
95
14=store pattern
sequence
15=clear
16=prog . set. key left
17=prog. set. key right
18=stitch width -
19=stitch width +
20=stitch length -
21 =stitch length +
22=correction -
23=correction +
24=info
25=pattern mirroring
26=slow
27=needle lowered
28=sewing off
29=reverse sewing key
5 Stepping motor Visual check: Accord ing to the stan-
(stepping motor test) Both stepping motors 5 dard, both stepping
rotate through the stroke 4 motors rotate through the
5 times 3 stroke 5 times alternate-
2 ty, no error must occur.
1
6 Foot control Press foot control slowly from "0· - "85- If control is not actuated ,
(foot control test) as far as it will go twice. the width display is
empty.
If control is actuated , the

Message : width display will show
-OK" or the standardized foot
"ERROR' control reading .
The display value must

count from 0 - 85 .
If this isn't the case, the

foot control is faulty.
during the period of read ·
ing, an error will be regis-
tered.
7 Pas. Detector Turn the handwheel even- Display appears If all signals are recag-
(Synchronizer test) Iy to the front in field for pat- nized, the message
tern display -OKAY· will appear in the
display.
If a signal has not been
recognized ,
96
"ERROR" will appear in
the display.
8 Buttonhole sensor Remove buttonhole guide from "1 " to "95" Display appears in field
(buttonhole sensor test) for length display.
9 Main motor Actuate foot control If control is not actuated ,

(motor test) the width display field is
empty.
actual reading : If the control is actuated ,

max. 85 the width display shows
desired the standardized rpm
reading : 85 (actual reading = e.mJ.)
If the compari- and the length display
son of the actu - shows the standardized
al to the desired desired reading.
reading is all If control is not actuated
B
right, "OKAY during the period of read-
will appear in ing , or the r. p.m. are too
the display low, a error will be dis-
played .
The program stops after
12 secs and the motor
stops .
10 OKAY Test completed OKAY The program can only be

exited by turning off the
machine .
97
43. Table for self-test model 2040
Before you start the self-test, the mains lead and the foot control should be connected, the buttonhole
guide should be fully inserted and the bobbin case should be removed.
When turn ing the machine on , the "mirroring" key must be actuated . The program can only be exited be
turning off the machine .
The machine will display "G. M. PFAFF AG TEST" .
Step Display/function Visual Check/action Nominal Remarks

no. Sewing machine at machine machine display
1 Machine without
needle Master
2 G.M . PFAFF AG TEST Actuate master switch G.M. PFAFF AG After releasing the key
and mirroring key at the TEST you have to wait for a
same time period of approx . 3 secs,
which is shown on the
display.
If no message appears ,
use fault-finding chart.
3 DISPLAY Visual check: All indicator ele- Visual check negative:

All indicator elements ments flash change respective sub-
must flash 4 times. assembly.
4 KEYBOARD Actuate the key shown The next key to A time span of approx .
(Key test) be actuated is 12 secs is planned for
O=sewing on buttons shown each key actuation .
1=straight stitch If all keys have If the key is not pressed
2=stretch triple-straight been recog- within this time span , the
stitch nized by the next key to be actuated
3=zigzag stitch machine , the is displayed and the non-
4=elastic stitch message -OK- actuation of the key is
5=blind stitch will appear. registered as an error
6=elastic blind stitch If a key has not and displayed at the end
7=overlock stitch been recog - of the program.
8=faggoting stitch nized , the mes-
9=buttonhole sage -ERROW
10=pattern sequence will appear
11 =cursor left
12=cursor right
13=block monograms
98
14=store pattern
sequence
15=clear
16=monograms italics
17=stitch width -
18=stitch width +
19=stitch le ngth -
20=stitch length +
21 =correction -
22=correction +
23=info
24=pattern mirroring
25=slow sewing
26=needle lowered
27=sewing off
28=reverse sewing key
5 DIAL Turn dial to the left and in mono-

~ 50" Counts backwards and
turn left and right (pro- the to the right gram window the forwards.
gram selection key test)
6 Stepping Motor (stepping Visual check:Both step- According to the stan-
motor test) ping motors rotate dard , both stepping
through the stroke 5 times 5 motors rotate through the
4 stroke 5 times alternate-
3 Iy, no error must occur.
2
1
7 Foot control Press foot control slowly from ~O" - ~85" control is not actuated ,
~ If
(foot control test) as far as it will go twice. the width display is

empty.
from ~O H _ W
85"Message:
WOK" or "ERROR" If control is actuated , the
width display will show
the standardized foot
Message : control read ing.
~O K" or Error
The display value must

count from 0 - 85.
If this isn't the case, the
foot control is faulty.

ing, an error will be regis-
tered .
99
8 Pos . Detector Turn the handwheel even- D isplay appears If all signals are raeog-
(Synchronizer test) Iy to the front in field for pat- nized , the message
tern display MOKAY" will appear in the
display.
.If a signal has not been
recognized, MERROW
will appear in the display.
9 Buttonhole sensor (but- Remove buttonhole guide from M1" to M95~ Display appears in field
tcnhole sensor test) for length display.
10 Bobbin sensor open hook open the free -arm cover 3 Main motor runs
cover (bobbin monitor and actuate foot control 2
test) 1
,OKAY"
11 Bobbin sensor Close free-arm cover and

actuate foot control
12 Main motor Actuate foot control If control is not actuated ,

(motor test) the width display field is
empty
.If the control is actuated,
the width display shows
the standardized rpm
(actual reading = e.m .f. )
and the length display
actual reading:
shows the standardized
max. 85
desired reading .
desired reading :
during the period of read·
85
ing, or the r.p.m. are too
low, a error will be dis·
played.
The program stops after
If the compari· 12 secs and the motor
son of the actu· stops.
al to the desired
read ing is all
right, ·O KAY ~
will appear in
the display
10 OKAY Test completed OKAY The program can only be

exited by turning off the
machine.
100
44, Fault table for electrical parts 2040
Fault 1st replacement pt. 2nd replacement pt. 3rd replacement pt. 4th replacement pt. 5th replacement pt.
Machi ne is switched on, bul mains lead Foot control Power pack! Upper circuit boa rd Motor
does not run when foot control (base plate)
is actuated.
Machines runs contin uously on foot control Power pack! Upper circuit board
its own after a brief switch-on (base plate)
time
Figures do not light up or flick- upper circuit board Power pack!

er on display field (base plate)
Zigzag stepping motor runs base circuit board! Zigzag stepping motor Key board Synchronizer
continuously or needle bar upper circuit board
moves continuously to and fro
Feed stepping motor run s con- base ci rcuit board! Feed stepping motor Key board Synchronizer
tinuously or the feed dog upper circuit board
moves continuously to and fro.
Machine sta rts running at top upper circuit board Exchange synchroniz- Power pack
speed , then stops again . er and then adjust
--
o
~
o
~
Fault 1st replacement pt. 2nd replacement pt. 3rd replacement pt. 4th replacement pt. 5th replacement pt.
Feed out of step Slide block jams or Feed stepp ing motor Upper circuil
(straight stitch sewn with long has too much play board/lower ci rcuit
curves) boa rd
Zigzag movement of needle Need le bar frame Zigzag stepping motor Upper circuit
out of step (straight stitch jams or is loose boa rd /lower ci rcuil

sewn) board
Take-up lever lop position and Adjust synchronizer Exchange Upper circuil
needle down position synch ronizer board/lower ci rcuit
boa rd
Speed control Foot control Lower circuit Upper circuit boa rd Ma in motor
(faster or slower) board/power pack
Sewing lamp does not light up Change sewing lamp Power pack Upper circuit boa rd
Safety test
45. Electrical safety test
According to the German law of safe machine operation of 24th June 1986, the VDE-regurations are
regarded as the official ru tes in electronics and are the basis for the regulations for testing electrical
safety of technical devices.
The requ ired electrical tests are established in the regulations for repair, modification and testing of used
electrica l appliances (VOE 0701 issue 10.66) par. 4.
We are obliged to perform a test in accordance with VOE 0701 on every electrical appliance after
repalf.
In European foreign countries, there are similar regulations in force which are largely identical with the
req uirements of the VDE 0701.
48. Electrical safety test with ABS Matrawatt M 501 3
1) Mains voltage test: Volt =V

• For all following tests insert plug of AB8 Metrawatt M 5013 in the grounded mains socket (fig . 115).
• Set knob for measuring range at "250 V" (fig. 115). If there is mains voltage, the LCD shows the
respective value (230 V +/. 10%).
• Touch contact field , which is located a bit to the right jusl below the knob for the measuring range, with
your finger, thus checking the ground lead of the mains. Signal lamp ~ PE ~ just above the contact field
will light up on ly in case the ground lead is out of order.
• Insert plug of sewing machine into the mains socket of A88 Metrawat! M 5013.
• Run the machine.
• Meter reading : 230 V +/. 10%
• Measuring appliance M 5013 can only be used with ma ins voltages from 207 V to 253 V
(230 V +/- 10%) .
II) Appliance current test: Ampere =A

• Plug of sewing machine remains in mains socket.
• Set knob for the measuring range at 16 A (fig. 116).
• Run the machine .
• Meter reading : 0.5 A maximum.
III) Insulation resistance : M Ohm =M

• Insert plug of sewing machine in lester socket .
• Use clamp to attach test lead of testing appliance M 5013 to presser bar.
• Set knob for measuring range at "20 M Ohm" (fig. 117).
• Meter reading : minimum 2 M Ohm
• With meter readings higher than 20 M Ohm, appliance M 5013 displays the figure 11 In these cases,
the remark "Insulation resistance higher than 20 M Ohm" must be recorded in the testing certificate.
103
IV) Stray current: Milliampere = mA
• Sewing machine plug remains in tester socket.
• Use clamp to attach test lead of testing appliance M 5013 to presser bar.
• Set knob for measuring range at ~20 mA~ (fig. 118).
• Meter reading : maximum 0.50 mAo
Fig. 115
Fig.116

Fig. 117
Fig. 118

105
47. Measures required in case of inadmissible test readings
As to I) If one of the 4 test functions is a failure , the ground mains socket is defective.
Inform the landlord.
A s to II) If the current consumption deviates considerably from the indicated value,
although the machine does not bind , the motor is defective and must be exchanged.
As to III) If the insulation resistance drops below the requ ired value , the defective components
must be found by systematic checking and must be repaired or replaced .
As to IV) Here, the components with inadm issably high leakage current must also be found
by systematic checking and must be repa ired .
Karlsruhe-Durlach, 24th February 1999

PHIHTS
106
Notes:
107
108
PFAfF
GritznerstraBe 11
76227 Karlsruhe
Femruf (072 1) 4001 0 TechnisdIe Anderungen v.. behallen
Femschreiber 7825638 Subject 10 alterations in dd]l1
Orahtwort Pfaffwerk Soils loW! , ;' ' MI de modificalioos
Telelax (072 1) 4001513
Salvo rwdilicMion os tecniche
Con riserva di rroodilid .. leo id ..
Nr. BP 10302 ' .. ..., m
tiptronic
2010 2020
20 0 204
Teileliste
List of spare parts
Liste des pieces detacMes
Catalogo pezzi staccati
Lista de piezas de repuesto

1. Ausgabe Marz 1999
Nicht numerierte Teile im Katalog werden
nicht geliefert.
Les pieces qui ne sont pas numerotees

dans la liste de pieces detachees ne
peuvent pas etre livrees.
The parts mentioned without number in

the parts lists are not available.
Bei Bestellung von Ersatzteilen mur.. die Modell-Nummer der Maschine

und die Teilenummer angegeben werden .
Die Verschleir..teile-Nummern sind in der Teileliste unterstrichen .
Piere d'indiquer dans vas commandes de pieces de rechange, Ie

numero de la machine , ainsi que les numeros des pieces
commandees.
Les numeros de pieces d'usure sont imprimes soulignes dans la liste
des pieces.
When ordering spare parts, please state the model number, and the
numbers of the parts called for.
The wear and tear part numbers are underlined in the parts list.

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v
PFAFF TIPTRONIC 2010, 2020, 2030, 2040 5
~ ---------------------------- -- --- -- -- - I
I I
I I
I I
I ~ I
I ~ I
I .93-OJ:i 06HI5 I
. I
I M-694 86Hl1 91Hi94 8.43-00 98~94 &45-00 9J.-0J6.-99G-91 9&-1102 422-00 93-033 063-44-
I I
I H- - - ij
I I
I I
I I
I~ ~ I
I '®J ~ ,'lit)' I
I 93-040 9111-45 93-036 0(3-"4 93-036 049-44 \ \ :

• I
I ! . I
IL _ _ _ _ _ _ _ _ _ _ _ _ _ ~~~ _ _ _ _ _ _ _ _
9J.-l!47 !179-91 99-05j 016-9 1 93-10)1 «7~
~ _____________ I
r----------------- ------ ------ ----- -------- l
••
•
9HJ.306H15
93-694 81 4-00 93-694 818-00 98-{;94 384-00 93-036-990-91 93-03596G-91
•
9J.-Ol5 91G-91 ,
98-801 422-00 9J.-Q.(O 97G-45 93-036 048 44 48-0208().4-31 9l-M7919--91 ~OH'-91
------------ --------------------------------
93-036 001 -91 (2020)
"'~)
(21140)
93-037595-91 (2030)
(2040)
__ '- 93-035 05(1.-44
••
•
93-038 Q95-.43

6 PFAFF TIPTRONIC 2010, 2020, 2030, 2040
92_329 978-115 (2030, 21140)
,,,
,,
92_32'9917_9 5 (2010, 2020)
92-329931 _91
(2010. 2n20) 92-329 4'lS-45 (2030)
92_J2'l4<;11.-!;5 (20""')
92_32'9497-45 (2010)
,
92_329 497-65 (l020)
92_329 31!1-91
93-1133
92_329 a 17-45
!I3-038091_25
_ 92-32'1 914-05 ~10 . 2020)
" " ; 118-55 (5JI)
- - _ · 92-329 9-0-91
(2010, 2020)
92-329955-95
(20 10, 2020)
_ _92-3299-10-91
(2030) ,, 92_329 911-45
- __ ~ . 92_329 9411-91 (2040)

92_329 947-115 (2040)
92_329 95!1-95 . _.
(2040 )

PFAFF TIPTRONIC 2010, 2020, 2030, 2040 7
r--1---11-mIn-~(2x)
1 '
- - - - - ~
I ,
I "
I "
192-322 969-91~ '- '-
I \
I I
I \
I \
I I
I I
- l1-m 223-551002
, -------------------------------- 1
" i l l 175.-25 I
I
I
I
I
I
I
I
'"-- -- - -- --, I
, I
92-322 '""" 1, I
I
1
, I
1, I
1,
I
I
-----r---------- I
I
I
I
I
----------- I
~~':-'~~'~M<~"__ ___ ~~~ I
I
I
92-330 105-75 I
I
- - - - - - - - - - - - - - - -1- - - - - - - - - - - - - - - - -
I
1902-220 7-001 1

Nummernverzeichnis • Numerical index. Index· Elenco dei numeri • Indice numerico
11-039 089-15 2 92-322 462-91 7 93-033 063-44 5

11-190905-15 1 92-322 467-55 7 93-033 064-05 5
11-193 901-05 2 92-324 884-35 7 93-033 113-45 1
11-193902-05 3 92-328 986-91 1 93-033 118-55 1,6
11-315917-05 2 92-328 998-05 1 93-034 126-05 2
11-315 930-50 4 92-329 497-45 6 93-034127-15 2
11-315 933-05 2,3,4 92-329 497-55 6 93-034 128-05 2
11-317223-25 2 92-329 498-45 6 93-034 130-15 2
11-721432-55/ 002 4 92-329 498-55 6 93-034 131-25 2
11-722172-55 1,2,3,4,7 92-329 874-91 7 93-034 133-05 2
11-722 178-55/ 002 4 92-329 875-91 7 93-035 033-15 1
11 -722 223-55/ 002 1,2,4,7 92-329 877-45 6 93-035 050-44 5
11-723 503-55/ 002 4 92-329 879-91 6 93-035 066-15 1
11-725 175-25 7 92-329 914-05 6 93-035 087-15 4
11-726232-25/ 002 2,3 92-329 915-45 6 93-035 088-15 4
12-024 121-25 4 92-329 916-45 6 93-035 128-05 2
12-090901-05 2,4 92-329 917-05 6 93-035 129-91 2
12-369 001-05 3 92-329 921-91 1 93-035 137 -91 2
12-370 002-05 2 92-329 924-91 7 93-035 140-45 2
12-505120-15 4 92-329 929-91 1 93-035141-05 2
12-618120-45 2 92-329 931 -91 6 93-035 151-05 2
12-618140-45 1 92-329 940-91 6 93-035 155-05 2
12-618170-45 3 92-329 947-05 6 93-035 1 85-05 2
12-618190-45 2 92-329 955-95 6 93-035 186-11 2
12-630 150-55 4 92-329 957-95 6 93-035 199-05 2
12-640 090-55 1,2 92-329 959-95 6 93-035 304-91 4
12-640 130-55 2,3,4 92-329 967-91 7 93-035 306-05 3
12-640 150-55 2,4 92-329 968-91 1 93-035314-91 4
12-640 170-55 2 92-329 969-91 7 93-035347-05 4
12-640 190-55 4 92-329 975-05 1 93-035 575-15 2
12-640 210-55 2 92-329 976-91 1 93-035 576-15 2
13-052 986-15 2 92-329 977-95 6 93-035 577-45 2
13-071 034-55 2 92-329 978-85 6 93-035 584-45 2
48-020 804-31 5 92-329 986-91 1 93-035 587-05 2
70-332 772-14 7 92-329 988-45 2 93-035 910-91 5
70-332 773-14 7 92-330 101-91 6 93-035 960-91 5
70-332 774-14 7 92-330 103-91 6 93-036 048-44 5
70-332 775-14 7 92-330 109-91 6 93-036 049-44 5
902-2207-001 7 92-330 112-91 1,6 93-036 109-15 2
91-000 390-05 4 92-330 117-91 1 93-036 115-91 2
91-000 678-15 4 92-330 124-91 1,6 93-036 132-91 2
91-001 382-15 4 92-330 125-91 1,6 93-036 146-91 2
91 -002 134-05 4 92-330 129-91 1,6 93-036 150-91 2
91 -009 026-05 4 92-330 156-91 1 93-036152-15 2
91-100346-15 4 92-330105-75 7 93-036 155-05 2
91-105535-91 4 93-030 174-35 1 93-036 166-05 2
91-105544-91 4 93-032 050-25 1 93-036 195-05 2
91-1 05 546-05 4 93-032 272-05 1 93-036 196-15 2
91-106 528-9j 4 93-032 273-05 1 93-036 198-15 2
91-106 375-05 4 93-032 633-05 4 93-036 204-45 3
91 -106376-05 4 93-033 052-25 1 93-036 205-91 3
91-106 380-91 4 93-033 052-44 1 93-036 206-01 3
91-106 494-05 4 93-033 054-05 1 93-036 209-05 3
92-322 458-05 7 93-033 057-25 1 93-036 212-91 3
Nummernverzeichnis • Numerical index· Index· Elenco dei numeri • Indice numerico
93-036 217-91 3 93-038 057-25 1 93-038 253-44 2

93-036 225-05 3 93-038 065-43 1 93-038 254-44 2
93-036 227-91 3 93-038 066-55 1 93-038 299-91 4
93-036 230-91 3 93-038 067-43 1 93-038 300-91 4
93-036 240-15 3 93-038 068-43 1 93-038 301-91 4
93-036 244-05 3 93-038 069-43 1 93-038 305-05 4
93-036 249-91 3 93-038 070-43 1 93-038 306-91 4
93-036 253-45 3 93-038 075-91 1 93-038 31 1-05 3,4
93-036 257-05 3 93-038 076-43 1 93-038 312-05 4
93-036 258-91 3 93-038 077-43 1 93-038 313-05 4
93-036 285-91 3 93-038 081-43 1 93-038 314-05 3,4
93-036 286-91 3 93-038 084-55 1 93-038 320-91 4
93-036 292-05 3,4 93-038 085-43 1 93-038 324-45 3
93-036 297-91 3 93-038 090-43 6 93-038 325-45 3
93-036 323-05 4 93-038 091-25 6 93-038 330-91 4
93-036 339-45 4 93-038 092-43 1 93-038 332-91 4
93-036 344-91 4 93-038 095-43 5 93-038 335-05 4
93-036 348-45 2,3 93-038 101-05 2 93-038 336-05 4
93-036 354-05 4 93-038 102-91 2 93-038 348-91 4
93-036 356-45 4 93-038 104-05 2 93-038 349-05 4
93-036 358-91 4 93-038 106-91 2 93-038 359-45 4
93-036 360-05 4 93-038 110-91 2 93-038 900-91 5
93-036 361-05 4 93-038 111-45 2 93-038 901 -91 5
93-036 362-91 4 93-038-113-05 2 93-038 909-35 1
93-036 363-15 4 93-038 114-05 2 93-038 91 0-35 1
93-036 364-05 4 93-038 115-91 3 93-038 920-91 5
93-036 381-05 4 93-038 116-91 2 93-040 060-05 1
93-036 382-45 4 93-038 118-05 2 93-040 184-15 2
93-036 562-91 2 93-038 128-05 7 93-040 206-05 2
93-036 582-25 2 93-038 129-44 2 93-040 207-15 2
93-036701-71 2 93-038 130-91 2 93-040 294-91 3
93-036702-71 2 93-038 131-05 2 93-040 654-05 2
93-036 990-91 5 93-038 132-05 2 93-040 970-45 4,5
93-037 118-91 4 93-038 134-05 2 93-101 815-05 2
93-037 338-55 1 93-038 135-05 2 93-105 535-91 4
93-037 543-45 2 93-038 136-05 2 93-847979-91 5
93-037 545-05 2 93-038137-15 3 98-694 814-00 5
93-037 574-05 2 93-038 138-91 2 98-694 816-00 2
93-037581-05 2 93-038 140-05 1 98-694 818-00 5
93-037 583-05 2 93-038 141-44 1 98-694 843-00 5
93-037 595-91 5 93-038 142-05 1 98-694 845-00 5
93-038 002-91 1 93-038 143-45 1 98-694 847-00 2
93-038 029-91 1 93-038147-91 2 98-694 864-01 5
93-038 030-91 1 93-038 149-05 7 98-694 884-00 5
93-038 031-43 1 93-038 165-91 2 98-694 886-00 2
93-038 035-43 1 93-038 166-91 2 98-694 889-00 2
93-038041-70 1 93-038 167-91 2 98-694 890-00 5
93-038 042-55 1 93-038 170-45 2 98-694 897-00 5
93-038 044-43 1 93-038 200-77 1 98-802 422-00 5
93-038 050-91 1 93-038 202-78 1 99-053 016-91 5
93-038 052-25 1 93-038204-79 1
93-038 053-44 1 93-038 206-43 1
93-038 054-05 1 93-038 250-91 2
93-038 055-05 1 93-038 251-43 2
PFAFF
Gmznerslrasse 11
76227 Karlsruhe
So4 jt ::Ito alte<a..... in design.
Femruf (07 21) 4 00 10
Femschreiber 7 825 638 Sous louie reserve de m"diicaliam
Drahtwort Pfalfwerk tl!dnques
Telefax (07 21 ) 4 00 15 13
SaM> rro:>dificri>nes tOCniche_
Druckeroi GabIenz Grr4>H Con riversa di rnodiIiche II!oid ..
Stelti .... Strasse 17
76356 Weingart"" BP 99279 • DG • 3199

Pfaff Tiptronic 2010-2040 Service Manual

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Pfaff Tiptronic 2010-2040 Service Manual

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Stitch forming parts

Subject to alterations in design and dimensions.

The recommended ranges are:

Ambient temperature _10" to 40"C (50" to 104"F)

Always protect the machine against damage by hitting or dropping.

• Electronic free- arm , utility and fancy stitch sewing machine

• Additional needle system classifications :

Twin needle Suffix = Zwi

• Possible needle points :

Small ball point Suffix = SES

Specifications of drive motor for the PFAFF tiptronic 2010 - 2020

No. 92-329945-91 24 V = 27W 5700 r.p.m .

• Additional needle system classifications:

Twin needle Suffix:;. Zwi

• Possible needle points:

Sma ll ball point Suffix::; SES

No. 92-329945-91 24 V: 27W 5700 r.p.m.

Note: Before adjusting or repairing the machine, make sure to dismantle

• Loosen screw 9 on the stand cover (fig . 8).

1. Adjustment of the nat-toothed belt tension

• Loosen screw 1 (fig . 1).

• Check adjustment according to " Requirement~.

• Carry out a visual check of the feed dog position.

• Tilt the machine to the rear.

• Carry out a visual check of the feed dog position .

• Tilt the machine toward the rear.

• Remove the needle.

• If the adjustment is not correct, remove the needle-rise clamp .

• Remove the pin gauge .

• Remove the needle .

• Leave the adjustment gauge on the needle plate .

• Turn the handwheel until pointer 31 is in its highest position again.

The following machine positions or functions are controlled by the synchronizer:

1. A change of feeding direction

• Remove the needle .

• Leave the adjustment gauge on the need le plate.

• Set the stitch length to HO.5".

• Ra ise the presser bar lifter.

• Loosen the three screws 34, 35 and 37 (fig . 21) .

• Raise the presser bar lifter.

• Loosen screw 39 (fig . 23).

• Check as described under "Checkft.

• Raise the presser bar lifter.

• Loosen screws 34 and 37 (fig. 25).

Adjus ting the guide piec e

• Turn the handwheel and check for clearance of 0.2 mm .

9. Adju stment of nee dle in n eedle h ole

• Remove the presser foot.

• Select stitch pattern "01 " for straight stitch .

Cro s s-c heck :

• Carry out as described under "Check-.

Needle bar height:

The sequence of sewing hook

• Insert a new needle of system 130/7 05 H in size Nm 100.

• Loosen screw 47 (fig . 31 ).

Adjusting the needle plate :

• Remove the baseplate and the free-arm lid .

• Check for free movement of the hook shaft.

11a. Adjustment of bevel gears

The bevel gears must move freely and without play.

• As described under "Requirement~.

• Remove the presser foot and the needle plate .

• If the setting is not correct, remove the needle-rise clamp.