Pfaff POWERline 2591 ME, Service Manual

Page 1: ...This service manual applies to machines from software version 0389 001 and serial number 2 766 760 onwards 296 12 19 129 002 Justieranleitung engl 09 10 SERVICE MANUAL 2591ME 2591PREMIUM ...

Page 2: ...on of PFAFF Service Manuals whether in whole or in part is only permitted with our previous authorization and with written reference to the source PFAFF Industriesysteme und Maschinen AG Hans Geiger Str 12 IG Nord D 67661 Kaiserslautern ...

Page 3: ...eight and stroke of the bobbin case opener 15 1 05 09 Height of the feed wheel 16 1 05 10 Roller presser 17 1 05 11 Clearance between roller presser and feed wheel 18 1 05 12 Knee lever 19 1 05 13 Tension release 20 1 05 14 Thread check spring and thread regulator 21 1 05 15 Bobbin winder 22 1 05 16 Sewing foot pressure 23 1 05 18 Lubrication 24 1 05 19 Re engaging the slip clutch 25 1 06 Adjustin...

Page 4: ... for control P321 33 1 08 Error Messages and Description 38 1 09 Motor Errors 39 1 10 Internet Update der Maschinen Software 40 1 10 01 Updating 2591 ME with null modem cable 40 1 10 02 Updating 2591 PREMIUM with SD card 41 2 Circuit diagrams 43 ...

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

Page 6: ...5 01 Basic position of the balance wheel adjustment aid Requirement When the needle bar is positioned at t d c the marking 0 on the scale should be level with the top edge of the belt guard see arrow Adjust the scale dial 1 four screws 2 in accordance with the requirement ...

Page 7: ...02 Balance weight Requirement When the needle bar is positioned at b d c balance wheel position 180 the largest ec centricity of the balance weight 1 should be at the top Adjust balance weight 1 screw 2 in accordance with the requirement ...

Page 8: ... machine off and on synchronise needle bar to stitch length Sew a stitch and check the rear position of the needle according to the requirement Press the stitch control key sew a stitch and check the forward position of the needle ac cording to the requirement and where necessary make the following adjustments Turn off machine and loosen screws 1 and 2 Push the adjusting pin s angled part Order No...

Page 9: ...Adjustment 9 Move the needle bar frame 5 according to the requirement and tighten screw 1 Check according to the requirement Screws 2 remain loosened for the subsequent adjustment ...

Page 10: ...at 5 when the needle is in its front and rear point of reversal screw 3 should be the same distance from the inside edge of its hole Set stitch length to 5 Select parameter 605 Turn the handwheel in the direction of rotation and check the requirement If necessary move regulating bow 1 screw 2 3 2 1 3 ...

Page 11: ...ht Requirement When the needle bar is positioned at t d c handwheel position 0 there should be a gap between upper edge needle bar and upper edge needle pendulum of about 54 mm Without turning it re position needle bar 1 screw 2 in accordance with the requirement 2 1 54 mm ...

Page 12: ...edle lightly Set stitch length at 0 8 Loosen screws 1 2 3 and 4 as well as screw 5 on both sides of the post Select parameter 605 Unscrew the needle plate Turn the handwheel four times in the direction of rotation Bring the handwheel into position 202 needle bar position 2 0mm after b d c Set the hook point on the middle of the needle Take care that the needle is not squeezed by needle guard 6 Adj...

Page 13: ... movement Move collar 7 up against bevel gear wheel 8 and tighten screws 1 Screws 5 remain loosened for further adjustments Adjust needle guard 6 screw 9 according to requirement 3 When changing a clamp take care that the markings 10 and 11 are on one side 10 11 ...

Page 14: ...sition crosswise to sewing direction Requirement As seen crosswise to the sewing direction the needle must penetrate in the centre of the needle hole Adjust feed wheel post 1 screws 2 3 and 4 according to the requirement 1 2 63 019 4 4 4 4 3 ...

Page 15: ... has deflected the bobbin case to its furthest point the catch of the bobbin case should be 0 3 0 5 mm from the back edge of the needle plate recess Adjust bobbin case opener 1 screw 2 in accordance with requirement 1 Turn the balance wheel until the bobbin case opener has deflected the bobbin case to its furthest point Adjust bobbin case opener 1 screw 2 in accordance with requirement 2 0 3 0 5 m...

Page 16: ...eel Requirement The feed wheel should protrude from the needle plate by tooth height approx 0 8 mm Swing out the roller presser Loosen screws 1 Adjust eccentric 3 fastening screw accessible through hole 2 according to the requirement 3 2 1 61 039 0 8 mm ...

Page 17: ...viewed in transverse direction of sewing 3 Raise the roller presser 1 Place roller presser bracket 2 screws 3 flush to the bottom edge of presser bar 4 Always observe requirement 1 when carrying out the following adjustments Move the roller presser 1 screw 5 in accordance with requirement 2 Allow the roller presser 1 to come to rest on the feed wheel 6 Move bracket 7 screw 8 according to requireme...

Page 18: ...should 2 be 8mm Set the roller presser down on the needle plate Decrease roller presser pressure Adjust lift piece 1 screws 2 according to the requirement 1 Push magnet bracket 3 screws 4 downwards as far as it will go Raise the roller presser and place an 8mm gauge under the roller presser With magnet plunger 5 extended move lever 6 up against lift piece 1a and mount lever 7 screws 8 on to magnet...

Page 19: ...knee lever is pressed the roller presser should raise up 1 7mm Before the roller presser raises up the knee lever should have a little bit of clearance 2 Turn screw 1 nut 2 according to requirement 1 Turn screw 3 nut 4 according to requirement 2 4 1 2 3 61 040 7 mm ...

Page 20: ... 05 13 Tension release Requirement With the roller presser raised the tension shims 3 should be about 0 5mm loosened from each other Raise roller presser and calibrate lever 1 screw 2 according to the requirement 1 2 0 5 mm 3 ...

Page 21: ...ed around the hook the check 2 thread spring 3 should rise slightly from the rest 1 Position rest 1 screw 2 in accordance with requirement 1 Turn sleeve 4 screw 2 to adjust the tension of thread check spring 3 Position thread regulator 5 screw 6 in accordance with requirement 2 For technical reasons it may be necessary to deviate from the indicated spring stroke or spring tension Move thread regul...

Page 22: ...ngaged the winding spindle must be driven reliably 1 When it is disengaged friction wheel 3 should not be touching drive wheel 1 When it is switched off the bobbin winder must click securely into its end position 2 knife raised Adjust drive wheel 1 screw 2 in accordance with the requirement ...

Page 23: ...ment 23 Fig 1 16 Requirement The material must be fed smoothly 1 No pressure marks should be visible on the material 2 Turn adjustment screw 1 in accordance with the requirement 1 1 05 16 Sewing foot pressure ...

Page 24: ...ook Check whether oil has been filled in and that there is no air in the oil lines Let the machine run for 2 3 min While the machine is running do not place hands in the needle or hook area Danger of injury from moving parts With the machine running hold a strip of paper 1 on the hook and check the require ment If necessary adjust the oil flow on screw 2 2 1 ...

Page 25: ...orks In the case of a thread jamming clutch 1 will disengage in order to avoid damage to the hooks The following describes how to re engage clutch 1 Remedy jammed thread fault Hold clutch 1 firmly as shown in Fig 1 19 and turn the balance wheel until clutch 1 re engages Fig 1 19 1 ...

Page 26: ...When thread lever at t d c handwheel position 2 53 the control cam 1 should have just bought roller lever 4 to rest Create a distance of 50 mm between the highest point of control cam 1 screws 2 and collar 3 Turn the handwheel in the direction of rotation until the highest point of control cam 1 is opposite roller 4 Ensure that plunger 5 is at the leftmost position move magnet 6 two screws accordi...

Page 27: ...th in the neutral position and the foremost position of the catcher the distance between the toothed segment 4 and the outer edge of the thread catcher holder 1 should be the same see arrow Adjust the thread catcher holder 1 screws 2 according to the requirements If requirement 2 cannot be fulfilled loosen screw 2 and move the toothed segment 4 by one tooth 1 4 3 4 1 2 4 1 2 ...

Page 28: ... plate Requirement During its swivel movement thread catcher 1 should not pass the edge of the needle plate see arrow in magnification Move thread catcher 1 screws 2 two screws parallel to the thread catcher holder in accordance with the requirement Fig 1 22 1 2 2 1 ...

Page 29: ...thread trimmer is in its neutral position the rear edge of thread catcher 2 should be positioned approx 2 5 3 mm behind the edge of the knife Move thread catcher 1 screws 2 two screws in accordance with requirement 1 Turn thread catcher 1 screw 3 in accordance with requirement 2 Thread catcher 1 must be parallel to the surface of the thread catcher holder 4 86 022 5 5 3 4 1 0 1 mm 2 5 3 mm 2 Fig 1...

Page 30: ...ent The knife 1 1 should be touching the needle plate The knife pressure should be set as low as possible but the cutting operation should 2 still be carried out reliably Move knife 1 screws 2 in accordance with requirement 1 or swivel it in accordance with requirement 2 1 2 ...

Page 31: ...in accordance with requirement 1 Adjust the tension in accordance with requirement 2 by bending side 4 of the bobbin thread clamp spring 1 Control requirement 1 Switch off the machine and bring the take up lever to its b d c Engage and disengage the thread catcher 3 by hand and check requirement 1 Adjust if necessary Control requirement 2 After the thread has been cut sew a few stitches by turning...

Page 32: ...he needle thread and the bobbin thread must be 3 perfectly cut and bobbin thread 3 retained Sew a few stitches Turn off the on off switch Carry out the cutting operation manually Check requirement 1 and 2 and if necessary readjust thread catcher 1 in accordance with Chapter 1 06 04 Position of the thread catcher Check requirement 3 and if necessary readjust the bobbin thread retaining spring 2 in ...

Page 33: ...read counter 2591 PREMIUM only 0 99999 12000 106 Bobbin thread remaining counter 2591 PREMIUM only 0 999 100 107 Stitch length adjustment 0 2mm 0 2mm 0 0mm 0 2 0 2 mm 0 108 Display main processer software version 109 Display step motor processor software version 110 Display control panel software version 111 Display sewing drive component software ver sion 112 Control panel key tone 2591 PREMIUM o...

Page 34: ...stop and lift roller presser 2591 ME only I OFF II ON I II I 207 Open thread tension after trimming and lift roller presser I OFF II ON I II I 3 301 Thread carrier position t d c 0 127 124 302 Needle position under b d c 0 127 16 303 Thread trimmer magnet position on 0 127 16 304 Thread trimmer magnet position pulse 0 127 93 305 Thread trimmer magnet position off 0 127 113 306 Reverse rotation pos...

Page 35: ... Needle mid point E16 1 Needle mid point E15 2 Intermittent coding E14 3 Free E13 4 Free E12 5 Free E11 6 Free E10 7 Free E9 8 Emergency button E8 9 Free E7 A Knee switch E6 B Photo cell E5 C Starting inhibitor E4 D Single stitch button on machine head E3 E Half stitch button on machine head E2 F Reverse button on machine head E1 603 Adjust sewing motor on sewing head Needle coming from above to n...

Page 36: ...ainder brake 1 50 15 708 Maximum torque for remainder brake 0 100 0 709 Minimum machine speed 3 64 6 710 Maximum machine speed 1 35 35 711 Maximum motor speed 1 35 35 712 Positioning speed 3 25 18 713 Acceleration ramp 1 50 35 714 Braking ramp 1 50 30 715 Reference position 0 127 10 716 Dead man time 0 255 40 717 Motor starting current 3 10 8 718 Vibration filter 1 10 6 719 Assign direction of rot...

Page 37: ...authorisation Times 0 1 1 805 Function group 500 access authorisation Counter and revolution speed 0 1 1 806 Function group 600 access authorisation Service 0 1 1 807 Function group 700 access authorisation Sewing motor 0 1 1 808 Function group 800 access authorisation Access authorisation 0 1 1 809 Programming access authorisation 0 1 1 810 Input access code 0 9999 2500 ...

Page 38: ...ation 39 Establishing contact when turned on xxx sewing motor control unit error byte see Motor Errors E 3 Section E 4 End of section E 5 Pedal or half stitch button or single stitch button on machine head activated when machine turned on E 6 Communication error with the step motor processor E 7 End of ramp E 8 Needle drive end point not found E 9 Needle drive mid point not found E 10 Step motor p...

Page 39: ...mand overrun 64 Mains off during initialisation 65 Excess current directly after mains on 66 Short circuit 68 Excess current during operation 70 Motor blocked 71 No incremental plug 74 Incremental transducer missing for transmission reduction 173 Motor blocked in 1st stitch 175 Interior starting error 222 Dead man monitoring ...

Page 40: ...on 3 25 on and the appropriate control software for the machine type must be installed on a PC The transfer of the data to the machine can be carried out with a null modem cable part no 91 291 998 91 or with an SD card The SD card must be formatted in the FAT16 format and must not exceed a capacity of 2 GBytes The PFP boot program and the control software of the machine type can be downloaded from...

Page 41: ...sal in the file PFPHILFE TXT which can be called up from the PFP boot program by pressing the help but ton 1 10 02 Updating 2591 PREMIUM with SD card After downloading the PFP tool and the control software open the PFP program Select the machine type and under control unit SD CARD The software version is displayed under report 2591 SD CARD Ausgewählt Maschinentyp 2591 Steuerung P321 Softwareversio...

Page 42: ...t not be switched off When the update has been completed switch off the machine and remove the SD card Switch on the machine A plausibility control is carried out and if necessary a cold start To update the step motor software please contact your PFAFF representa tive More information and assistance is at your disposal in the file PFPHILFE TXT which can be called up from the PFP boot program by pr...

Page 43: ...control unit S20 Knee switch S24 Starting inhibitor button S41 Hand operation front button S42 Single stitch button change needle position S43 Thread tension release FSL S44 Automatic presser foot lift PFA X1 Mains plug X1A RS232 control panel interface 1 X1B VSS OTE X3 Incremental encoder sewing motor X4A Feed wheel step motor X4B Roller presser step motor X5 Inputs X6A Needle step motor X6B RS23...

Page 44: ...44 Circuit diagrams ...

Page 45: ...45 Circuit diagrams ...

Page 46: ...46 Circuit diagrams ...

Page 47: ...47 Circuit diagrams ...

Page 48: ...fo pfaff industrial com Hotlines Technical service 49 175 2243 101 Application consultance 49 175 2243 102 Spare parts hotline 49 175 2243 103 Printed in Germany PFAFF Industriesysteme und Maschinen AG 2009 PFAFF is the exclusive trademark of VSM Group AB PFAFF Industriesysteme und Maschinen AG is an authorized licensee of the PFAFF trademark ...