Pfaff 545 industrial sewing machine overview and video

[gavingear]

Hello all, I just completed a Consew servo motor install on my Pfaff 545 walking foot industrial sewing machine, so I thought I'd take a few minutes to explain how this machine works including a description of the speed reducer, and the servo motor.

Pfaff 545 sewing machine overview:

- Made in Germany (top quality)

- Walking foot with needle feed (feet are clamped on material and needle pierced when feed takes place)

- High lift feet (about 9/16")

- Large capacity top loader bobbin

- Reverse and stitch length adjustment

- All metal lower shaft/gear drive (newer pfaff 1245 has rubber belt that can require replacement)

A couple key additions on this machine:

- Speed reducer (about 3:1) - 3x the effective motor torque, and 1/3 the top speed

- Electronic servo motor (Consew CSM 550) - Spins only when you are sewing, silent otherwise, brake, adjustable top speed, precise speed control and start/stop

Some photos:

Overall machine:

Walking feet:

Speed reducer:

Servo motor:

Overview and operation video:

[Bree]

You won't go wrong with that bad boy! Wonderful machine and the servo definitely kicks it up a notch!! I was sewing a suede patch on the elbow of a 40 year old fringe coat tonight on my 29K60. I was sewing it a stitch at a time using the flywheel because of the nature of the coat and patch. I kept saying to myself when the heck are you gonna pop for $150 and put a servo on this treadle machine??? It sure would have come in handy tonight and made the job a lot easier.

[JoysShop]

I have a 545 pfaff machine also. A few years ago the knee lift, attached to the underside of the table, broke and the parts were lost in a move of my upholstery shop

I can't fix it because I don't know what the missing parts looked like.

After watching your video on youtube, it appears you have the same type of knee lift

Would be able to post some pictures of the lift so that I can have someone make them for me?

I would rather buy a new knee lift, but can't find one

I have two brackets (that a horizontal bar runs through) that attach to the underside of the table. There is a lever with a wheel on it that makes contact with the lever on the underside of the sewing machine

What is missing is maybe another bracket between the lever w/wheel and the front bracket

Thank you for any help

[Kustom]

Good video. I got a lot out of it. Thanks.

[kjelgaard]

I'm thinking of getting a CSM 550 for my Pfaff 545 since they can be found for about 130 shipped in some places. Is it hard to install a reduction drive for these? Where can I find one?

[shoepatcher]

JoysShop,

I have a Pfaff 1245 which replaced the 545. I believe pfaff upgraded the knee lift for the type you have just like Adler did on their 267-373. I do not have a parts list for the 545 but I know someone does. That said, you could then find out what parts you need for the foot lift. I will check and see if I can get you a parts breakdown on that set up.

glenn miller

I have a 545 pfaff machine also. A few years ago the knee lift, attached to the underside of the table, broke and the parts were lost in a move of my upholstery shop

I can't fix it because I don't know what the missing parts looked like.

After watching your video on youtube, it appears you have the same type of knee lift

Would be able to post some pictures of the lift so that I can have someone make them for me?

I would rather buy a new knee lift, but can't find one

I have two brackets (that a horizontal bar runs through) that attach to the underside of the table. There is a lever with a wheel on it that makes contact with the lever on the underside of the sewing machine

What is missing is maybe another bracket between the lever w/wheel and the front bracket

Thank you for any help

[Cobra Steve]

Hi gavingear, nice set up and video. You should put a smaller belt from the motor to the speed reducer so you can utilize your belt tightening capabilities. Steve

[neelsaddlery]

Looks really nice. Godd setup. Good machine!!!!

[shoepatcher]

Joyshop,

I have searched for and finally found a parts manual for the 545 pfaff. It shows the complete illustration for the knee lift assembly on page 96. I can fax it to you so you can determine which parts you are missing since this shows all the pfaff part numbers. It took me some time to find it and I hope it will help you. The parts manual is 117 pages long!!!

glenn miller

[CowboyBob]

Just thought I'd mention that I have what people have been asking for.A DC motor with

a built-in reducer,which mounts like all the other motors but eliminates the lining up & drilling holes required when mounting a reducer & motor separately and for less $$ too.

[Jimbob]

Just thought I'd mention that I have what people have been asking for.A DC motor with

a built-in reducer,which mounts like all the other motors but eliminates the lining up & drilling holes required when mounting a reducer & motor separately and for less $$ too.

Believe the man, he has the cure...these motors work great and I can sew so slow now on my Adler 105-64 that I am able to fall a sleep and and still dont have more then one stitch at the time when I wake up...LOL...!! And you are talking added penetration power!

Well spend money in my book!!

tnx Bob!!

[steadybrook]

Where did you purchase the motor?

[suzelle]

On 8/18/2009 at 10:57 AM, CowboyBob said:

Just thought I'd mention that I have what people have been asking for.A DC motor with

a built-in reducer,which mounts like all the other motors but eliminates the lining up & drilling holes required when mounting a reducer & motor separately and for less $$ too.

Cowboy Bob,

I know this is an older thread, but I have the same machine as gavingear and am about to replace the original motor. Nothing wrong with the motor, I just want one that I can run slower, when desired. I run it fast sewing long seams, but would love to be able to do more intricate work and therefore need a more appropriate motor, a more modern one. When the servo motors first came out, I bought one for another machine I had at the time. But it died on me after only months of using it. I know the servo motors have evolved since then and they seem more affordable, depending on what you get of course. What would you suggest for my Pfaff 545 High lift? Thanks ahead!

[CowboyBob]

Yes,we had problem with the digital readout ones blowing a chip in them.We don't sell them unless someone wants one.We sell a more simple one that has a knob on the front to set the top speed.They run as slow as 300rpm & since they have brushes in them retain a lot of torque @ low speed.

http://www.tolindsewmach.com/motors.html

[suzelle]

Thanks for that information Bob! Much appreciated. I will be contacting you. 

[suzelle]

On 4/8/2017 at 3:48 AM, CowboyBob said:

Yes,we had problem with the digital readout ones blowing a chip in them.We don't sell them unless someone wants one.We sell a more simple one that has a knob on the front to set the top speed.They run as slow as 300rpm & since they have brushes in them retain a lot of torque @ low speed.

http://www.tolindsewmach.com/motors.html

Bob, I'm ready for that motor now! I will be giving you a call!

[CowboyBob]

Ok,I just got back from Weavers & bought 32 machines!But I'll be in tomorrow.

[Trox]

Wow Bob, from Weaver leather? what kind of machines did you buy. I hope you got better prices than on their web site. Nearly 5K $ for a Adler 205-370 clone (with 16 "arm). "But as close to an original Adler as we come" still is not a Duerkopp Adler machine. You know the story behind these, Thanks, Tor 

[MaryLee]

To begin - a big thank you to all the knowledgeable people who share their expertise and excellent sense of humor on this website! Can't imagine attempting anything related to these big machines without you!

So...I'm hoping someone knows the answer to my question. I recently acquired a Pfaff 545 H3 - 6/01 CLMN (whatever that all means). I bought it with the intent to sell. It came with the entire table set up as well as three huge bobbins. It was covered in dust but no rust and the underside looked good (meaning clean, no rust and no oil build-up). It sews - very well, I might add. It's freaking amazing is what is it. Huge, powerful, and I'm finding it relatively easy to work on in terms of cleaning and understanding the functions of all the parts.

I took off the tension assembly in the front - all the pieces came off. I took photos so that I could remember where everything went. When I removed the metal plate that held the two tensioners in place (part #91-000 412-25 on the diagram), there was another piece of black metal screwed to the back of it (#91-010 186-15) . Then when I unscrewed that piece to take it off to clean it, I heard that dreaded sound of metal hitting the floor. A teensy tiny metal rod (#91-010 185-05  ) had fallen out and I haven't a clue as to where it goes or what it does on the machine. It's circled in red on the parts diagram, but there is no indication of where it goes or how it attaches.        

Is there someone out there who can help? Thanks in advance!

Edited January 21, 2019 by MaryLee

[Wizcrafts]

That is the tension release rod. Feed it inside the hollow threaded post that holds the tension disks and release plate, spring and thumbscrew. If that little stud is perfectly straight, it can go in from the back before you reinstall the tension release bracket. If it has a bigger end on one side, or if the release bracket is already screwed down, feed it in from the front through the hollowed post. Then install the two disks, the metal plate that the little sud pushes against, the beehive spring and the nut.

Some things are better left alone, if you know what I mean.

[MaryLee]

Thanks a million - I never would have figured that out on my own! Cheers!