Pfaff 1591 Instruction Manual
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Pfaff 1591 Instruction Manual

Pfaff 1591 Instruction Manual

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1591
1593
INSTRUCTION MANUAL
This instruction manual applies to machines from the follow-
ing serial numbers onwards: ??? ??? .
296-12-19 390/002
Instruction manual engl. 04.18

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  • Page 1 1591 1593 INSTRUCTION MANUAL This instruction manual applies to machines from the follow- ing serial numbers onwards: ??? ??? . 296-12-19 390/002 Instruction manual engl. 04.18...
  • Page 2 Internet download, the adjustment manual can also be ordered as a hard copy under order no. 296-12-19 931/002. Reprinting, reproduction and/or translation of PFAFF instruction manuals (including parts thereof) is only permitted with our prior agreement and citation of the source.

  • Page 3: Table Of Contents

    Hand lever to raise the roller presser ................... 18 Swivelling out the roller presser ..................18 Knee switch ......................... 19 Knee lever ..........................19 Edge trimmer -725/04 for PFAFF 1591 ................20 Control panel ........................21 Set-up and Initial Start-up ....................22 Set-up ..........................22 .01.01...
  • Page 4 Table of Contents Contents ..................Page .02.02 Mounting the fl ange motor on the machine ................ 25 .02.03 Mounting the machine cover ....................25 .02.04 Connecting the plug-in connections and ground cable ............26 .02.05 Machine drive home position / fi tting the toothed belt ............27 .02.06 Mounting the fl...
  • Page 5 Table of Contents Contents ..................Page Error messages and description ..................71 Sewing motor errors ......................72 Maintenance and Care ....................... 73 Maintenance intervals ......................73 Cleaning the machine ......................73 Oiling the hook ........................74 Checking the oil level of the hook and front parts ..............74 Lubricating the bevel gears ....................

  • Page 6: Safety

    Fitting or using these products may therefore have negative effects on features which depend on the machine design. We are not liable for any dam- age caused by the use of non-Pfaff parts.

  • Page 7: Safety Symbols

    Safety Safety symbols Hazard point! Special points of attention. Risk of injury to operating personnel or technical staff! Electric voltage! Danger to operating personnel or technical staff Danger of hands being crushed! Danger to operating personnel or technical staff Attention! Do not operate without the fi...

  • Page 8: Operating Personnel And Technical Staff

    Safety Operating personnel and technical staff Operating personnel .05.01 Operating personnel are persons responsible for equipping, operating and cleaning the ma- chine and for fault clearance in the sewing area. The operating personnel are obligated to comply with the following points: ...

  • Page 9: Danger Warnings

    Safety Danger warnings A work area of 1 m must be kept free in front of and behind the machine to en- sure unobstructed access at all times. Do not reach into the needle range during the sewing operation! Risk of injury from the needle! Do not allow any objects to be placed on the table during the adjustment work! The objects could become jammed or be slung away! Risk of injury from parts...

  • Page 10: Proper Use

    The PFAFF 1593 is a single needle post-bed high-speed seamer (post is positioned to the right of the needle) with forwards- and backwards-moving feed wheel and roller presser.

  • Page 11: Technical Data

    Technical Data Technical Data PFAFF 1591 Stitch type: ......................301 (lockstitch) Needle system: ........................134 Model BN7: ............for the machining of medium-weight materials Model CN7: ............for the machining of medium-heavy materials Needle size in 1/100 mm: Model BN7: ........................90 -110 Model CN7: .........................

  • Page 12: Pfaff 1593

    Technical Data PFAFF 1593 Stitch type: ......................301 (lockstitch) Needle system: ........................134 Model BN5: ............for the machining of medium-weight materials Needle size in 1/100 mm: Model BN5: ........................90 -110 Stitch length max ......................5.0 mm Speed max.: Model BN5 ....................3500 stitches/min ...

  • Page 13: Disposal Of The Machine

    Disposal of the Machine Disposal of the Machine  It is up to the customer to dispose of the machine properly.  The materials used for the machine include steel, aluminium, brass and various plastics. The electrical equipment consists of plastics and copper. ...

  • Page 14: Transportation, Packaging And Storage

    Transportation, Packaging and Storage Transportation, Packaging and Storage Transport to the customer’s premises All machines are completely packed for delivery. Transport within the customer’s premises The manufacturer assumes no liability for transport within the customer’s premises or to the individual usage sites. Please ensure that the machines are only transported in a vertical po- sition.

  • Page 15: Work Symbols

    Work Symbols Work Symbols Activities to be performed or important information in this instruction manual are emphasised by symbols. The symbols used have the following meaning: Note, information Cleaning, care Lubrication Maintenance, repairs, adjustment, service work (only to be carried out by technical staff)

  • Page 16: Operating Controls

    Operating Controls Operating Controls Main switch Before switching on the machine, raise the take-up lever as far as possible.  Turning the main switch 1 switches the machine on and off. Fig. 7 - 01 Keys on the machine head ...

  • Page 17: Bobbin Thread Monitoring Using Stitch Counting

    Operating Controls Bobbin thread monitoring using stitch counting  The diode 1 fl ashes on reaching the pre- defi ned stitch count.  The stitch counting re-starts after trim- ming the thread and changing the bob- bin. For presetting the stitch count please refer to chapter 9.09 Switching on / setting the bobbin thread monitoring us-...

  • Page 18: Hand Lever To Raise The Roller Presser

    Operating Controls Hand lever to raise the roller presser  Turning the hand lever 1 raises the roll- er presser. Fig. 7 - 05 Swivelling out the roller presser  The roller presser 1 can be swivelled out by gently pulling downwards when the roller presser is in the raised position.

  • Page 19: Knee Switch

    Operating Controls Knee switch  It is possible to choose between 2 pre- defi ned fullnesses or 2 stitch lengths in manual sewing by pressing the knee switch 1.  It is possible to move to the next seam zones in programmed sewing by using the knee switch 1.

  • Page 20: Edge Trimmer -725/04 For Pfaff 1591

    Operating Controls Edge trimmer -725/04 for PFAFF 1591 Fig. 7 - 09 Do not reach into the knife during operation! Risk of injury! Switching on the knife drive:  Swivel the lever 1 backwards; the knife moves to the operating position.

  • Page 21: Control Panel

    Operating Controls Control panel 2 GB max. Fig. 7 - 10 The current operating statuses are indicated on the control panel 1. The machine is operat- ed with constant dialogue between the control and the operator; different pictograms and / or texts are displayed for this purpose according to the operating status of the machine.

  • Page 22: Set-Up And Initial Start-Up

    Set-up and Initial Start-up Set-up and Initial Start-up The machine may only be set up and started up by qualifi ed personnel! All of the relevant safety regulations must always be complied with in this process! If the machine was delivered without a table, then the stand and the table top provided must safely support the weight of the machine and its motor.

  • Page 23: Inserting The Sewing Machine Into The Stand

    Set-up and Initial Start-up Inserting the sewing machine into the stand .01.02 Fig. 8 - 02  The hinges 1 are screwed to the sewing head base plate.  Insert the sewing machine into the table top.  Insert the sewing head support 2 into the table top hole. Do not operate the machine without the support 2! Risk of damage due to the top-heavy sewing head! Machine can tip over backwards when moving it!

  • Page 24: Assembling The Anti-Tipping Device

    Set-up and Initial Start-up Assembling the anti-tipping device .01.03 Switch off the machine! Risk of injury due to accidental machine start-up!  Screw on the anti-tipping device 1 includ- ed in the accessories with the screw 2.  Do not operate the machine without the anti-tipping device 1! Risk of injury from crushing be- tween the sewing head and the...

  • Page 25: Mounting The Fl Ange Motor On The Machine

    Set-up and Initial Start-up Mounting the fl ange motor on the machine .02.02  Use the screws 3 and 4 to fi x the bear- ing plate 1 of the motor 2 to the ma- chine housing (tighten the screws 3 and 4 slightly).

  • Page 26: Connecting The Plug-In Connections And Ground Cable

    Set-up and Initial Start-up Connecting the plug-in connections and ground cable .02.04 Fig. 8 - 07  Insert all plugs on the control 2 in accordance with their designation. Attention Plugging in connectors incorrectly can damage the control!  Attach the following ground cables in order to discharge static electricity ...

  • Page 27: Machine Drive Home Position / Fi Tting The Toothed Belt

    Set-up and Initial Start-up Machine drive home position / fi tting the toothed belt .02.05  Switch the machine on.  Call up input mode.  Call up the service menu.  Enter the code number, see chapter 9.10 Entering / changing the code number. ...

  • Page 28: Mounting The Fl Ange Motor Belt Guard

    Set-up and Initial Start-up Fig. 8 - 08  Pivot the motor bearing plate 6 so that the toothed belt 5 is taut.  Tighten the screws 7 in this position.  Turn the handwheel in the direction of rotation until the needle point (approaching from above) is on the upper edge of the needle plate and check the value again.

  • Page 29: Connecting The Safety Switch

    Set-up and Initial Start-up Connecting the safety switch .02.07  Connect the plug 1 of the safety switch 2 as shown in Fig. 8 - 10. If the sewing head is tilted back, the safety switch acti- vates the start inhibitor, pre- venting the machine starting up if the main switch is turned on.

  • Page 30: Assembling The Reel Stand

    Set-up and Initial Start-up Assembling the reel stand  Assemble the reel stand as shown in the adjacent fi gure. Fig. 8 - 11 Initial start-up  Inspect the machine, particularly the electric cable, for any damage.  Clean the machine thoroughly and then oil it, see also chapter 12 Maintenance and Care.

  • Page 31: Set-Up

    Set-up Set-up Observe and comply with all regulations and information in this instruction manual. Pay particular attention to all safety regulations! All set-up work may only be carried out by appropriately instructed personnel. Disconnect the machine from the electricity mains for all set-up work by operat- ing the main switch or by removing the mains plug! Inserting the needle Fig.

  • Page 32: Winding The Bobbin Thread, Adjusting The Thread Tension

    Set-up Fig. 9 -02 Winding the bobbin thread, adjusting the thread tension  Fit the empty bobbin 1 onto the bobbin winder spindle 2 with the rest thread chamber on the outside.  Thread in the thread as shown in Fig. 9 - 02 and wind it round the bobbin 1 a few times in an anti-clockwise direction.

  • Page 33: Removing / Inserting The Bobbin Case

    Set-up Removing / inserting the bobbin case Switch off the machine! Risk of injury due to accidental machine start-up! Removing the bobbin case:  Move the take-up lever to its top position  Open the post cover, raise the lever 1 and remove the bobbin case 2.

  • Page 34: Threading The Needle Thread / Adjusting The Needle Thread Tension

    Set-up Threading the needle thread / adjusting the needle thread tension Fig. 9 - 05 Switch off the machine! Risk of injury due to accidental machine start-up!  Thread the needle thread as shown in Fig. 9 - 05. Please ensure that the needle is thread- ed from left to right.

  • Page 35: Selecting A Program Number

    Set-up Selecting a program number  Switch the machine on.  Call up the menu to input the program number.  Select the desired program number or enter it via the keypad  Confi rm the selection and leave the selection menu. The selection of the program number determines the type of sewing, see chapter 10 Sewing.

  • Page 36: Setting Stitch Lengths

    Set-up Setting stitch lengths The feed motion of the roller presser and feed wheel can be changed directly in manual sewing and in the fi xed programs 1 and 2.  Switch the machine on.  Call up the stitch length input menu. ...

  • Page 37: Entering Start And End Backtacks

    Set-up Entering start and end backtacks The selection of the start and end backtacks and the input of the associated values are made directly in manual sewing and in the fi xed programs 1 and 2. A placed stitch can also be defi...
  • Page 38 Set-up  If necessary, activate the placed stitch and enter the value for the placed stitch position.  Conclude the start backtack input.  Call up the menu for inputting the end backtack. The values for the end backtack are entered in the same way as for entering the values for the start backtack.

  • Page 39: Switching On / Setting The Bobbin Thread Monitoring Using Stitch Counting

    Set-up Switching on / setting the bobbin thread monitoring using stitch counting  Switch the machine on.  Call up input mode.  Call up parameter ’104’.  Switch on bobbin thread monitoring via stitch counting (value “1”).  Call up parameter “105” .
  • Page 40 Set-up  Enter the number of stitches that can be sewn with a bobbin.  Conclude the input.  The diode fl ashes on the keypad on the machine head on reaching the stitch count en- tered. The “CHANGE BOBBIN” message appears on the display after thread trimming, see also chapter 11.05 Error messages and description.

  • Page 41: Entering / Changing The Code Number

    Set-up Entering / changing the code number  Switch the machine on.  Call up input mode.  Call up parameter ’810’.  Call up the code number input menu.  Enter the code number using the numeric keypad (code set at the factory is “1500”).
  • Page 42  Call up the code number input menu and enter the desired code number.  Adopt the new code number.  Conclude the input. Remember the code! Protected functions cannot be called up without the corresponding code! In this case, request support from the PFAFF service centre.

  • Page 43: Setting The Control Panel

    Set-up Setting the control panel  Switch the machine on.  Call up input mode.  Call up the service menu.  Call up the control panel functions.  It is not possible to change the display contrast on the BDF P1. ...

  • Page 44: Inserting And Removing The Sd Memory Card

    Set-up Inserting and removing the SD memory card Insert the SD card  Open the cover  Insert the SD card 2 into the card slot with the label facing forwards.  Close the cover 1 again. 2 GB max. Only use FAT 16 format memo- ry cards.

  • Page 45: Sewing

    Sewing Sewing In sewing mode, all settings relevant to the sewing operation are shown on the display and can be altered there directly using the corresponding function. In the sewing mode a differ- ence must be made between manual sewing, sewing with fi xed programs and programmed sewing.
  • Page 46 Sewing Start backtack Opens the menu for entering the seam start, see chapter 9.08 Entering start and end backtacks. End backtack Opens the menu for entering the seam end, see chapter 9.08 Entering start and end back- tacks. Needle raised Positions the needle in the top position (thread lever t.d.c.) Backtack suppression When pressed once, the next bartack is suppressed.

  • Page 47: Sewing With Fi Xed Programs

    Sewing Sewing with fi xed programs Fixed programs are set under program numbers 1 and 2. The fi xed programs are used for the quick and easy sewing of seams with a different number of stitches or fullness. When sewing with fi xed programs, 2 or 3 seam zones are processed one after the other. Press- ing the knee switch moves the machine to the next seam zone.
  • Page 48 Sewing Needle raised Positions the needle in the top position (thread lever t.d.c.) Backtack suppression When pressed once, the next bartack is suppressed. When pressed twice, the next two bartacks are suppressed. Needle position raised If this function is on, the needle moves to the top position when sewing stops (thread lever t.d.c.) Thread trimming When the function is activated, thread trimming with the pedal function is possible.

  • Page 49: Programmed Sewing

    Sewing Programmed sewing Pre-programmed seams can be called up via program numbers 3 - 49. All seam zones for sewing in a sleeve are set in a seam program in programmed sewing mode. The informa- tion on the seam program, such as the program number, the number of programmed seam zones, the programmed comment and the ready-made size are displayed.
  • Page 50 Sewing Program interrupt Interrupts the seam program sequence, see chapter 10.03.03 Program interruption. Roller presser up When this function is activated, the roller presser is raised after sewing stops. Roller presser down after thread trimming When this function is activated, the roller presser is not raised after thread trimming. ...

  • Page 51: Program Interruption

    Sewing Program interruption .03.01 The “program interruption” function is used to interrupt the programmed seam sequence (e.g., in the case of a thread break).  Interrupt the program sequence  Or sequence the program forwards and backwards.  Or change the seam locking and thread tension and perform the other functions as in manual sewing, see chapter 10.01 Manual sewing.

  • Page 52: Input

    Input Input The Parameter input, Info, Create/correct sewing program, Teach-in, Program management and Service functions are available in input mode.  Switch the machine on.  Call up input mode. Description of the functions Sewing mode Quit input mode and call up sewing mode. Parameter selection Select the hundred and unit fi...

  • Page 53: Entering Seam Programs

    Input Entering seam programs Seam programs can be created by inputting parameters in the “Create / correct seam pro- grams” function or by stitching a seam sample with the “Teach-in” function. Irrespective of which function is changed, the program number and basic settings of the sewing program to be processed must fi...
  • Page 54 Input  Defi ne the feed motion for the feed wheel as a basic stitch length.  Or input or change a comment.  Pressing the symbol opens a menu to save the program under a new program number.  End the input of the basic settings and change to the input of the seam zones, see chapter 11.01.02 Seam zone input via the “Create/correct program”...

  • Page 55: Seam Program Input Via The "Create/Correct Program" Function

    Input Seam program input via the “Create/correct program” function .01.02 This function is used to enter the seam program by entering or changing the corresponding values on the control panel. This type of seam program input is particularly suitable for cor- recting already existing seam programs.
  • Page 56 Input  Defi ne the feed motion for the feed wheel This is used to display and change the current values for the feed motion of the feed wheel.  Defi ne the feed motion for the roller presser The difference with respect to the feed motion of the feed wheel (basic stitch length) de- termines the fullness.

  • Page 57: Seam Program Input Via The "Teach-In" Function

    Input Seam program input via the “Teach-in” function .01.03 This function is used to create the seam program by stitching a sewing pattern. A new crea- tion is always made, meaning that when selecting an already existing program it is overwrit- ten.
  • Page 58 Input  Defi ne the feed motion for the top feed (roller presser). The difference with respect to the feed motion of the feed wheel (basic stitch length) de- termines the fullness.  Enter the front backtack (functions at seam start), see chapter 9.08 Entering start and end backtacks.

  • Page 59: Examples For Setting Seam Programs

    Input Examples for setting seam programs Examples of seam program input using the “Create/correct program” .02.01 function The seam program to be created should - contain 2 seam zones, - have a basic stitch length of 2.5 mm and - be saved under program number “10” With the commend “Seam 1” . ...
  • Page 60 Input In the fi rst seam zone - the number of stitches should be 10 stitches - the roller presser should work with a feed motion (stitch length) of 2.6 mm.  Select the value 2.6 for the feed motion (stitch length) of the roller presser. ...

  • Page 61: Example For Seam Program Input Via The "Teach-In" Function

    Input Example for seam program input via the “Teach-in” function .02.02 The seam program to be created should - contain 2 seam zones, - have a basic stitch length of 2.4 mm and saved under program number 5 with the comment “LEARN” . ...
  • Page 62 Input  Select the desired type of end backtack, the selected (active) function is displayed in- versely:  No end backtack  Simple end backtack  Double end backtack Thread trimming When the function is activated, thread trimming with the pedal function is possible. Roller presser up When this function is activated, the roller presser is raised after sewing stops.

  • Page 63: Managing Seam Programs

    Input Managing seam programs The program management displays the contents of the machine memory in the left-hand half of the screen and the SD card in the right-hand half of the screen, and is used to erase and copy programs. The selected programs are displayed in red. The machine data can be saved on the SD card or loaded from the SD card if the MDAT function is activated.
  • Page 64 \P1591 for the 1591 exists. If the directory \P1591 for the 1591 does not exist, only the directory is created. This is to ensure that programs from other machines and other fi les are not lost.

  • Page 65: Parameter Settings

    Input Parameter settings Overview of parameter functions .04.01 After switching the machine on, the input mode is called, in which the individual parameters can be directly called by pressing the desired function. All parameter groups or also individual ones can be protected by a code against unauthorised access. Select parameter User level Mechanic level...

  • Page 66: Example Of A Parameter Entry

    Input Example of a parameter entry .04.02  Switch the machine on.  Call up input mode.  For example, call up parameter “107” (maximum feed motion of the roller presser via the fullness pedal)  For example, set value 4.0. ...

  • Page 67: List Of Parameters For Control P320 And 321

    Input List of parameters for control P320 and 321 .04.03 The parameter “100” is accessible to the operator. Changing of the parameters “200” - “800” can only be carried out after enter- ing the code number and may only be performed by authorised and qualifi ed personnel.
  • Page 68 Open thread tension on stop and roller presser lift ON - OFF Open thread tension after trimming ON - OFF Take-up lever at t.d.c. position 1591 0 - 127 1593 0 - 127 Position of needle at bottom position 1591...
  • Page 69 D= single stitch key on the machine head (E3) E= half stitch key on the machine head (E2) E= reversing key on the machine head (E1) Machine drive home position 8 ± 2 1591 11 ± 2 1593 Run cold start Stitch formation with stepping motors by handwheel...
  • Page 70 1 - 35 Positioning speed 3 - 25 Acceleration ramp 1 - 50 Braking ramp 1 - 50 Reference position 1591 0 - 127 1593 0 - 127 Dead man time 0 - 255 Motor starting current 3 - 10 Anti-vibration fi...

  • Page 71: Error Messages And Description

    Input Error messages and description Error Description E 001 System error E 002 Sewing motor E002/BB/xxx BB = 20: Dead man 02: Position forwards 03: Position in reverse 05: Position by shortest route 09: Write parameters 10: Speed 0A: Reset stitch counter 0B: Stop after xxx stitches 30: Timeout for increasing speed 31: Timeout from uncertain positioning...

  • Page 72: Sewing Motor Errors

    Input Sewing motor errors Error Description Invalid parameter value Brake path too short Communication error Init. not ready Command overrun Mains off during initialisation Excess current directly after mains on Short circuit Excess current during operation No increments Motor blocked No incremental plug Faulty motor operation Incremental encoder missing for transmission/reduction...

  • Page 73: Maintenance And Care

    Maintenance and Care Maintenance and Care Maintenance intervals Cleaning ............daily, several times if in continuous operation Clean the hook area ........daily, several times if in continuous operation General oiling ..................daily, before start-up Oil the hook ..................daily, before start-up Oil level (thread lubrication / hook lubrication) ..........

  • Page 74: Oiling The Hook

    Fig. 12 - 03 Only use oil with a centre viscosity of 22.0 mm²/s at 40 °C and a density of 0.865 g/cm³ at 15 °C! We recommend PFAFF sewing machine oil, order no. 280-1-120 144.

  • Page 75: Lubricating The Bevel Gears

    Risk of injury from crushing be- tween the machine sewing head and the table top! We recommend PFAFF sodium soap grease with a dripping point of approx. 150°C. Order no.: 280-1-120 243. Topping up the thread lubrication oil reservoir Check the oil level before eve- ry start-up.

  • Page 76: Lubricating The Roller Presser Drive Gear Mechanism (Only For A Diameter Of 25 Mm And 35 Mm)

     Fit the cover 2 again.  Tighten the screws 1. Only use grease with a dripping point of approx. 150 °C! We recommend PFAFF sodi- um soap grease with a dripping point of approx. 150 °C. Fig. 12 - 06 Order no.

  • Page 77: Tilt Base

    Tilt base Table Top Tilt base...

  • Page 78: Table Top Cutout

    Table top cutout Table top cutout Anchor nut DIN 7965 (2x) Einschraubmutter DIN 7965 (2x) Order no. 12-177 106-05 Best.--Nr. 12-177 106-05 Stand position Ständerposition Part no. 906-3750-000 Teile-Nr. 906-3750-000...

  • Page 79: Wear And Tear Parts

    This list shows the most important wear and tear parts. A detailed parts list for the complete machine can be downloaded at www.pfaff-industrial.de/de/service-support/downloads/technical. As an al- ternative to the Internet download, the parts list can also be requested as a hard copy under order no.
  • Page 80 12-315 080-15 (2x) 95-774 853-05 95-774 855-05 11-108 846-15 (2x) 11-108 852-15 95-774 856-05 91-263 139-05 91-263 348-05 99-137 151-45 91-171 049-05 91-171 042-05 95-774 464-25 91-700 996-15 1591-725/.. 11-130 167-15 91-011 165-04/001* * See parts list for other knives...
  • Page 81 Notes...
  • Page 82 PFAFF Industriesysteme und Maschinen GmbH Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Tel.: +49 - 6301 3205 - 0 Fax: +49 - 6301 3205 - 1386 E-mail: info@pfaff-industrial.com Gedruckt in der BRD / Printed in Germany / Imprimé en la R.F .A. / Impreso en la R.F .A...

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1593

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