Pfaff Industrial PowerLine 2595 Guide

This Adjustment Manual is valid for machines
from the following serial numbers onwards:
# 2 767 267
296-12-19 007/002
Justieranleitung 09.12
ADJUSTMENT MANUAL
2595
2596

The reprinting, copying or translation of PFAFF Adjustment Manuals, whether in whole or
in part, is only permitted with our previous authorization and with written reference to the
source.
PFAFF Industriesysteme
und Maschinen AG
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern

Index
Contents ..................................................................................Page
1Adjustment ........................................................................................................................... 4
1.01 Notes on adjustment ............................................................................................................. 4
1.02 Tools, gauges and other accessories for adjusting ............................................................... 4
1.03 Abbreviations ......................................................................................................................... 4
1.04 Explanation of the symbols.................................................................................................... 4
1.05 Adjusting the basic machine .................................................................................................. 5
1.05.01 Basic position of the balance wheel (adjustment aid)............................................................ 5
1.05.02 Balance weight ...................................................................................................................... 6
1.05.03 Zero position of the unison feed ........................................................................................... 7
1.05.04 Feeding motion of the unison feed ....................................................................................... 8
1.05.05 Lifting motion of the bottom feed dog ...................................................................................9
1.05.06 Height of the bottom feed dog ............................................................................................ 10
1.05.07 Feeding stroke difference .................................................................................................... 11
1.05.08 Top feed stroke .................................................................................................................... 12
1.05.09 Top-feed lifting motion ......................................................................................................... 13
1.05.10 Preliminary adjustment of the needle height....................................................................... 14
1.05.11 Needle rise, hook clearance, needle height and needle guard ............................................ 15
1.05.12 Bobbin lift travel ................................................................................................................... 16
1.05.13 Adjusting the shortened trim stitch......................................................................................17
1.05.14 Bobbin winder...................................................................................................................... 18
1.05.15 Thread check spring and thread regulator............................................................................ 19
1.05.16 Sewing foot pressure........................................................................................................... 20
1.05.17 Lubrication ........................................................................................................................... 21
1.05.18 Limiting the stitch length ..................................................................................................... 22
1.05.19 Re-engaging the slip-clutch.................................................................................................. 23
1.06 Adjusting the thread trimmer -900/81.................................................................................. 24
1.06.01 Resting position of roller lever/radial position of control cam .............................................. 24
1.06.02 Position and height of the thread catcher ............................................................................ 25
1.06.03 Knife pressure...................................................................................................................... 26
1.06.04 Bobbin thread clamp spring ................................................................................................. 27
1.06.05 Manual cutting test .............................................................................................................. 28
1.07 Parameter list....................................................................................................................... 29
2Circuit diagrams................................................................................................................. 30
2.01 Block diagram PFAFF 2595 2596 PLUS with control pack P74 ED-L ................................... 30
2.02 Circuit diagrams PFAFF 2595 and 2596 PLUS ..................................................................... 31

4
Adjustment
1 Adjustment
Please observe all notes from Chapter 1Safety of the instruction manual!
In particular care must be taken to see that all protective devices are refitted
properly after adjustment, see Chapter 1.06 Danger warnings of the instruc-
tion manual!
If not otherwise stated, the machine must be disconnected from the electrical
power supply. Danger of injury due to unintentional starting of the machine!
1.01 Notes on adjustment
All following adjustments are based on a fully assembled machine and may only be carried
out by expert staff trained for this purpose.
Machine covers, which have to be removed and replaced to carry out checks and adjust-
ments, are not mentioned in the text.
The order of the following chapters corresponds to the most logical work sequence for
machines which have to be completely adjusted. If only specific individual work steps are
carried out, both the preceding and following chapters must be observed.
Screws, nuts indicated in brackets ( ) are fastenings for machine parts, which must be
loosened before adjustment and tightened again afterwards.
1.02 Tools, gauges and other accessories for adjusting
●Screwdrivers with blade width from 2to 10 mm
●Spanners (wrenches) with jaw width from 7to 14 mm
●1set Allen keys from 1.5to 6mm
●1gauge for the top feed stroke 5.0mm (Part No. 61-111 633-60)
●1feed dog adjustment gauge, Part No. 61-111 689-04
●Metal rule (part No. 08-880 218-00)
●Sewing thread and test materials
1.03 Abbreviations
t.d.c. = top dead centre
b.d.c. = bottom dead centre
1.04 Explanation of the symbols
In this adjustment manual, symbols emphasize operations to be carried out or important in-
formation. The symbols used have the following meaning:
Note, information
Service, repair, adjustment, maintenance
(work to be carried out by qualified staff only)

5
Adjustment
1.05 Adjusting the basic machine
1.05.01 Basic position of the balance wheel (adjustment aid)
Requirement
When the needle bar is positioned at t.d.c., the marking "0" on the scale should be level
with the top edge of the belt guard (see arrow).
●Adjust the scale dial 1( depending on model screws 2or 3) in accordance with the re-
quirement.
Fig. 1 - 01
1
2
2
127-01
3
3

6
Adjustment
Fig. 1 - 02
1
2
1
2
1.05.02 Balance weight
Requirement
When the needle bar is positioned at b.d.c. (balance wheel position 180°) the largest ec-
centricity of the balance weight 1should be at the top.
●Adjust balance weight 1(screw 2) in accordance with the requirement.

7
Adjustment
Fig. 1 - 03
13
2
1.05.03 Zero position of the unison feed
Requirement
When the stitch length is set at "0", the top and bottom feed dogs and the needle bar
should not make any feeding motion when the balance wheel is turned.
●Remove spring 1.
●Adjust crank 2(screw 3) in accordance with the requirement.
●Replace the spring 1.

8
Adjustment
Fig. 1 - 04
1
2
1.05.04 Feeding motion of the unison feed
Requirement
When the needle bar is positioned at b.d.c. (balance wheel position 180°), and the maxi-
mum stitch length is set, the top and bottom feed dogs and the needle bar should not
make any feeding motion when the reverse-feed lever is pressed.
●Adjust eccentric 1(screws 2) in accordance with the requirement. Make sure that the
cut-out (see arrow) is visible.

9
Adjustment
Fig. 1 - 05
1
2
1.05.05 Lifting motion of the bottom feed dog
Requirement
When the balance wheel is positioned at 180°, the feed dog should be at t.d.c.
●Adjust eccentric 1(screws 2) in accordance with the requirement.

10
Adjustment
Fig. 1 - 06
●Rotate lifting crank 1( screws 2) and excenter sleeve 3(screws 4) in accordance with rule 1.
Align the transporter in the needle plate recess at the same time in accordance with rule 2.
The height of the bottom feed dog can also be increased or reduced as required
by moving crank 5(nut 6) up or down.
0,5 mm
12
3
4
127-091
6
5
1.05.06 Height of the bottom feed dog
Requirement
1. When the needle bar is positioned at b.d.c. (balance wheel position 180°), the bottom feed
dog should be positioned 0.5mm horizontally above the top edge of the needle plate,
when crank 6is in the centre of the slot.
2. In the direction of sewing, the bottom feed dog should be positioned in the centre of
the needle plate slot.

11
Adjustment
12
Fig. 1 - 07
1.05.07 Feeding stroke difference
Requirement
With the maximum stitch length set, when the balance wheel is turned the feeding
strokes of the needle and the bottom feed dog should be the same.
●With connecting rod 1(nut 2) increase ("+") or reduce (-) the needle feed stroke in
accordance with the requirement.

12
Adjustment
Fig. 1 - 08
7
5 mm
4
5 mm
23
56
1
1.05.08 Top feed stroke
Requirement
With adjustment wheel 1set at "5", the top feed dog 7and presser foot 4should each
rise by 5.0mm.
●Remove the bottom feed dog and set adjustment wheel 1at "5".
●Loosen the screws of the needle plate, place the metal gauge over the opening of the
needle plate slot so that both sewing feet can be lowered onto the metal gauge.
●For the preliminary adjustment, adjust crank 2(screw 3) so that there is a clearance of 5
mm between presser foot 4and the needle plate.
●Adjust crank 5(screw 6) so that top feed dog 7and presser foot 4have the same stroke.
●Check the adjustment in accordance with the requirement, and correct if necessary.

13
Adjustment
Fig. 1 - 09
2 mm
1
2
1.05.09 Top-feed lifting motion
Requirement
The top feed dog should just have reached the needle plate when the presser foot lift is
set at 5mm and the needle descending from above is 2mm above the needle plate.
●Turn eccentric 1(screw 2) in accordance with the requirement.

14
Adjustment
Fig. 1 - 10
22 mm
1
3
●Without turning it, re-position needle bar 1(screw 2) in accordance with the
requirement.
Make sure that needle bar 1and foot 3do not collide.
1.05.10 Preliminary adjustment of the needle height
Requirement
When the needle bar is positioned at t.d.c. (balance wheel position 0°), the clearance
between the needle point and the needle plate should be 22 mm.

15
Adjustment
Fig. 1 - 11
●Loosen screws 1and 2.
●Move column 3(screws 4) by turning the threaded bolts 5in accordance with rule 1.
●Turn cogwheel 6in accordance with rule 1and tighten screws 1.
●Move the needle bar without turning in accordance with rule 2; see also Chapter 1.05.10
Pre-calibrating the needle bar.
●Adjust needle guard 7(screw 8) according to rule 3.
0,8 mm
9
61
7
8
5
2
4
3
1.05.11 Needle rise, hook clearance, needle height and needle guard
Requirement
With the stitch length set at "4.5" and in the needle rise position (see table)
1. The hook point 9should be positioned at "needle centre" with a hook-to-needle clear-
ance of 0.05 – 0.10 mm.
2. The top of the needle eye should be positioned 0.8mm below hook point 9and
3. needle guard 7must touch the needle just lightly.
Needle rise position
Model C: Balance wheel position 202° / 2.0 mm
Model D: Balance wheel position 204° / 2.4 mm

16
Adjustment
Fig. 1 - 13
1.05.12 Bobbin lift travel
Requirement
When turning the handwheel,
1. the bobbin lift 3should stand in its left turning point when in handwheel position "10°".
2. the horn 5should be lifted by the thread thickness from stitch platen 6on the right
turning point of the bobbin lift 3.
●Turn excenter 1(screw 2) according to rule 1.
●Move bobbin lift 3(screw 4) in accordance with the rule 2.
The thread must pass freely between bobbin lift 3and bobbin case 7.
4
5
1
6
2
3
7

17
Adjustment
Fig. 1 - 14
1
22
1.05.13 Adjusting the shortened trim stitch
Requirement
For the trim stitch the machine should carry out a stitch length of 0.5– 1.0mm.
●Adjust lever 1(screws 2) in accordance with the requirement.

18
Adjustment
Fig. 1 - 15
2
1
3
1.05.14 Bobbin winder
Requirement
1. When the bobbin winder is engaged, the winding spindle must be driven reliably.
When it is disengaged, friction wheel 3should not be touching drive wheel 1.
2. When it is switched off, the bobbin winder must click securely into its end position
(knife raised).
●Adjust drive wheel 1(screw 2) in accordance with the requirement.

19
Adjustment
1
2
4
5
6
3
Fig. 1 - 16
1.05.15 Thread check spring and thread regulator
Requirement
1. The movement of thread regulator 3must be completed when the needle point enters
the material.
2. When the thread loop is at its largest while being passed around the hook, the check
thread spring 3should rise slightly from the rest 1.
●Position rest 1(screw 2) in accordance with requirement 1.
●Turn sleeve 4(screw 2) to adjust the tension of thread check spring 3.
●Position thread regulator 5(screw 6) in accordance with requirement 2.
For technical reasons it may be necessary to deviate from the indicated spring
stroke or spring tension.
Move thread regulator 5(screw 6) towards ("+") (= more thread) or ("-") (= less
thread).

20
Adjustment
Fig. 1 - 17
1
1.05.16 Sewing foot pressure
Requirement
The material should be fed properly even at maximum speed and with the smallest stroke.
●Turn adjustment wheel 1in accordance with the requirement.