Pfaff 1591 User manual

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

Reprinting, reproduction and/or translation of PFAFF instruction manuals (including parts
thereof) is only permitted with our prior agreement and citation of the source.
PFAFF Industriesysteme
und Maschinen GmbH
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
This instruction manual applies to all models and subclasses listed in chapter 3
Technical Data.
The adjustment manual for the machine can be downloaded at no charge under
www.pfaff-industrial.de/de/service-support/downloads/technical. As an al-
ternative to the Internet download, the adjustment manual can also be ordered
as a hard copy under order no. 296-12-19 931/002.

Table of Contents
Contents ..................................................................................Page
1Safety .................................................................................................................................... 6
1.01 Directives............................................................................................................................... 6
1.02 General safety instructions .................................................................................................... 6
1.03 Safety symbols ...................................................................................................................... 7
1.04 Special points of attention for the owner-operator................................................................. 7
1.05 Operating personnel and technical staff ................................................................................ 8
1.05.01 Operating personnel .............................................................................................................. 8
1.05.02 Technical staff ........................................................................................................................ 8
1.06 Danger warnings.................................................................................................................... 9
2Proper Use.......................................................................................................................... 10
3Technical Data.................................................................................................................... 11
3.01 PFAFF 1591.......................................................................................................................... 11
3.02 PFAFF 1593.......................................................................................................................... 12
4Disposal of the Machine.................................................................................................... 13
5Transportation, Packaging and Storage .......................................................................... 14
5.01 Transport to the customer’s premises ................................................................................. 14
5.02 Transport within the customer’s premises........................................................................... 14
5.03 Disposal of the packaging materials .................................................................................... 14
5.04 Storage ................................................................................................................................ 14
6Work Symbols.................................................................................................................... 15
7Operating Controls ............................................................................................................16
7.01 Main switch ......................................................................................................................... 16
7.02 Keys on the machine head................................................................................................... 16
7.03 Bobbin thread monitoring using stitch counting .................................................................. 17
7.04 Pedal .................................................................................................................................... 17
7.05 Hand lever to raise the roller presser................................................................................... 18
7.06 Swivelling out the roller presser ..........................................................................................18
7.07 Knee switch ......................................................................................................................... 19
7.08 Knee lever ............................................................................................................................ 19
7.09 Edge trimmer -725/04 for PFAFF 1591 ................................................................................ 20
7.10 Control panel........................................................................................................................ 21
8Set-up and Initial Start-up ................................................................................................. 22
8.01 Set-up .................................................................................................................................. 22
8.01.01 Setting the table height........................................................................................................ 22
8.01.02 Inserting the sewing machine into the stand....................................................................... 23
8.01.03 Assembling the anti-tipping device ......................................................................................24
8.02 Mounting the flange motor.................................................................................................. 24
8.02.01 Mounting the flange motor on the bearing plate ................................................................. 24

Table of Contents
Contents ..................................................................................Page
8.02.02 Mounting the flange motor on the machine ........................................................................ 25
8.02.03 Mounting the machine cover ............................................................................................... 25
8.02.04 Connecting the plug-in connections and ground cable ........................................................ 26
8.02.05 Machine drive home position / fitting the toothed belt ........................................................ 27
8.02.06 Mounting the flange motor belt guard................................................................................. 28
8.02.07 Connecting the safety switch .............................................................................................. 29
8.02.08 Checking the start inhibitor function .................................................................................... 29
8.03 Assembling the reel stand ................................................................................................... 30
8.04 Initial start-up ....................................................................................................................... 30
8.05 Switching the machine on / off ............................................................................................ 30
9Set-up.................................................................................................................................. 31
9.01 Inserting the needle ............................................................................................................ 31
9.02 Winding the bobbin thread, adjusting the thread tension.................................................... 32
9.03 Removing / inserting the bobbin case.................................................................................. 33
9.04 Inserting the bobbin case, adjusting the bobbin thread tension .......................................... 33
9.05 Threading the needle thread / adjusting the needle thread tension.................. 34
9.06 Selecting a program number ....................................................................................... 35
9.07 Setting stitch lengths ........................................................................................................... 36
9.08 Entering start and end backtacks......................................................................................... 37
9.09 Switching on / setting the bobbin thread monitoring using stitch counting............................ 39
9.10 Entering / changing the code number................................................................................... 41
9.11 Setting the control panel...................................................................................................... 43
9.12 Inserting and removing the SD memory card ..................................................................... 44
10 Sewing ................................................................................................................................ 45
10.01 Manual sewing..................................................................................................................... 45
10.02 Sewing with fixed programs ................................................................................................ 47
10.03 Programmed sewing............................................................................................................ 49
10.03.01 Program interruption ............................................................................................................ 51
10.04 Error messages.................................................................................................................... 51
11 Input .................................................................................................................................... 52
11.01 Entering seam programs .....................................................................................................53
11.01.01 Basic seam program input settings...................................................................................... 53
11.01.02 Seam program input via the “Create/correct program” function......................................... 55
11.01.03 Seam program input via the “Teach-in” function ................................................................. 57
11.02 Examples for setting seam programs .................................................................................. 59
11.02.01 Examples of seam program input using the “Create/correct program” function ................ 59
11.02.02 Example for seam program input via the “Teach-in” function.............................................. 61
11.03 Managing seam programs ................................................................................................... 63
11.04 Parameter settings............................................................................................................... 65
11.04.01 Overview of parameter functions ........................................................................................ 65
11.04.02 Example of a parameter entry ............................................................................................. 66
11.04.03 List of parameters for control P320 and 321 ....................................................................... 67

Table of Contents
Contents ..................................................................................Page
11.05 Error messages and description .......................................................................................... 71
11.06 Sewing motor errors ............................................................................................................ 72
12 Maintenance and Care....................................................................................................... 73
12.01 Maintenance intervals.......................................................................................................... 73
12.02 Cleaning the machine .......................................................................................................... 73
12.03 Oiling the hook......................................................................................................................74
12.04 Checking the oil level of the hook and front parts.................................................................74
12.05 Lubricating the bevel gears.................................................................................................. 75
12.06 Topping up the thread lubrication oil reservoir ..................................................................... 75
12.07 Lubricating the roller presser drive gear mechanism
(only for a diameter of 25 mm and 35 mm) ........................................................................................76
12.08 Cleaning the blower air filter ................................................................................................ 76
13 Table Top............................................................................................................................ 77
13.01 Tilt base ............................................................................................................................... 77
13.02 Table top cutout ................................................................................................................... 78
14 Wear and Tear Parts .......................................................................................................... 79

Safety
6
1 Safety
1.01 Directives
The machine was built in compliance with the European regulations specified in the declara-
tion of conformity and declaration of incorporation.
As a supplement to this instruction manual, please also observe the generally applicable, le-
gal and other regulations and legislation – also in the country of use – and the valid environ-
mental protection regulations! Always comply with the locally applicable regulations of the
professional associations and other supervisory authorities!
1.02 General safety instructions
The machine may only be operated after you have become acquainted with the associ-
ated instruction manual and only by operating personnel who have received appropriate
training!
Always read the safety instructions and the instruction manual of the motor manufactur-
er before starting up the machine!
Always follow the hazard and safety instructions attached to the machine!
The machine may only be operated for its intended purpose and only with the associated
safety covers, while adhering to all the relevant safety requirements.
The machine must always be disconnected from the power supply by pressing the main
switch or pulling out the mains plug when sewing tools are replaced (such as the needle,
presser foot, needle plate and bobbin) and when threading, leaving the workstation, or
performing maintenance!
The daily maintenance work may only be carried out by suitably qualified personnel!
Repairs and special maintenance work may only be carried out by technical staff or peo-
ple with appropriate training!
Work on electrical equipment may only be carried out by qualified technical staff!
Work on parts and equipment under voltage is not permitted!
Exceptions are regulated by the EN 50110 standards.
Modifications and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
Only the replacement parts approved by us for usage may be used for repairs! We warn
you expressly that spare parts and accessories that are not supplied by us are also not
tested and approved by us. 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.

Safety
7
1.03 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 finger guard and safety cov-
ers! Turn off the main switch before threading, changing
the bobbin or needle, cleaning etc.!
1.04 Special points of attention for the owner-operator
This instruction manual is a part of the machine and must be made available to the oper-
ating personnel at all times. The instruction manual must have been read before the ini-
tial start-up.
The operating personnel and technical staff must be instructed about the machine’s safe-
ty covers and about safe working methods.
The owner-operator may only operate the machine in a flawless condition.
The owner-operator must ensure that no safety covers are removed or disabled.
The owner-operator must ensure that only authorised persons work on the machine.
Additional information can be requested from the responsible sales centre.
I

Safety
8
1.05 Operating personnel and technical staff
1.05.01 Operating personnel
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:
The safety instructions provided in the instruction manual must be followed for all work!
Any work method jeopardising machine safety must be refrained from!
Tight-fitting clothing must be worn. The wearing of jewellery such as chains and rings is
prohibited!
Care must be taken to ensure that no unauthorised persons are located in the machine’s
hazard zone!
Any changes occurring on the machine which impair its safety must be reported to the
owner-operator immediately!
1.05.02 Technical staff
Technical staff are persons with technical training in electricity/electronics and mechanics.
They are responsible for lubricating, servicing, repairing and adjusting the machine.
The technical staff are obligated to comply with the following points:
The safety instructions provided in the instruction manual must be followed for all work!
Turn off the main switch and secure it against reactivation before starting any adjustment
and repair work!
Never work on live parts and equipment! Exceptions are regulated by the EN 50110
standards.
Reattach the safety covers following repair and maintenance work!

Safety
9
Fig. 1 - 01
1.06 Danger warnings
A work area of 1mmust 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
flying around!
Do not operate the machine without the take-up lever guard 1!
Risk of injury due to the motion of the take-up lever!
Do not operate the machine without the belt guard 2!
Risk of injury due to the rotating driving belt!
Do not operate the machine without the anti-tipping device 3!
Risk of injury from crushing between the sewing head and the table top!
Do not operate the machine without the support 4!
Risk of damage due to the top-heavy sewing head!
Machine can tip over backwards when moving it!
1
2
3
4

Proper Use
10
2 Proper Use
The PFAFF 1591 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 plus
feed-synchronised needle.
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.
The machines are used to create double lockstitch seams in the leather and upholstery in-
dustries.
Any usage not approved by the manufacturer is deemed misuse! The manufac-
turer shall assume no liability for damage caused by misuse! Proper use also
includes compliance with the operating, maintenance, adjustment and repair
measures specified by the manufacturer!

Technical Data
11
3 Technical Data
3.01 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:................................................................................................................. 120 - 150
Stitch length max ........................................................................................................... 7.0 mm
Speed max.:
Model BN7................................................................................................. 3500 stitches/min 
Model CN7................................................................................................. 2000 stitches/min 
Trimming margin (for -725/..)..................................................................................0.8 - 2.5 mm
Cutting speed (for -725/..) .................................................................................. 2800 cuts/min.
Clearance beneath the roller presser for a diameter of 30 mm:.......................................7 mm
Clearance beneath the roller presser for a diameter of 25 mm and 35 mm:....12 mm Passage
width:............................................................................................................................245 mm
Clearance height: .......................................................................................................... 115 mm
Post height....................................................................................................................180 mm
Bed plate dimensions: ................................................................................................518 x 177
Sewing head dimensions
Length:............................................................................................................. approx. 562 mm
Width: .............................................................................................................. approx. 250 mm
Height (above table): ........................................................................................ approx. 505 mm
Motor data: .................................................................................. see motor specification plate
Noise data
(Noise measurement in accordance with DIN 45 635-48-A-1,ISO 11204, ISO 3744, ISO 4871)
Model B:
Emissions sound pressure level in the workplace at n = 2800 min-1: .............. LpA = 80 dB(A) 
Model C:
Emissions sound pressure level in the workplace at n = 1600 min-1: ...............LpA = 74 dB(A )
Net weight of sewing head:..................................................................................approx. 64 kg
Gross weight of sewing head: .............................................................................. approx. 74 kg
Subject to alterations.
Depending on the material, workstep and stitch length.
K
pA = 2,5 dB

Technical Data
12
3.02 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 
Clearance beneath the roller presser for a diameter of 30 mm:.......................................7 mm
Clearance beneath the roller presser for a diameter of 25 mm and 35 mm:..................12 mm
Passage width:..............................................................................................................245 mm
Clearance height: .......................................................................................................... 115 mm
Post height....................................................................................................................180 mm
Bed plate dimensions: ................................................................................................518 x 177
Sewing head dimensions
Length:............................................................................................................. approx. 562 mm
Width: .............................................................................................................. approx. 250 mm
Height (above table): ........................................................................................ approx. 505 mm
Motor data: .................................................................................. see motor specification plate
Noise data
(Noise measurement in accordance with DIN 45 635-48-A-1,ISO 11204, ISO 3744, ISO
4871)
Emissions sound pressure level in the workplace at n = 2800 min-1: .............LpA = 80 dB(A) )
Net weight of sewing head:..................................................................................approx. 64 kg
Gross weight of sewing head: .............................................................................. approx. 74 kg
Subject to alterations.
Depending on the material, workstep and stitch length.
K
pA = 2,5 dB

Disposal of the Machine
13
4 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.
The machine must be disposed of in accordance with the locally valid environmental
protection regulations, with a specialised company being contracted if necessary.
Please ensure that parts coated with lubricants are disposed of separately in
accordance with the locally valid environmental protection regulations!

Transportation, Packaging and Storage
14
5 Transportation, Packaging and Storage
5.01 Transport to the customer’s premises
All machines are completely packed for delivery.
5.02 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.
5.03 Disposal of the packaging materials
The packaging materials of these machines consists of paper, cardboard and VCI fleece. It is
up to the customer to dispose of the packaging properly.
5.04 Storage
The machine can be stored for up to 6months when not in use. It must then be protected
from dirt and moisture. For longer storage periods, the machine’s single components, espe-
cially its sliding surfaces, must be protected against corrosion, e.g. by an oil film.

Work Symbols
15
6 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)

Operating Controls
16
7.02 Keys on the machine head
The machine sews backwards as long
as the key 1is pressed during the sew-
ing operation.
The keys 2can be assigned functions
using parameters “203” and “204”.
(See chapter 11.04 Parameter set-
tings).
The sewing lamp integrated onto the
machine head is switched on and off
with the key 3.
Fig. 7 - 02
7 Operating Controls
7.01 Main switch
Fig. 7 - 01
1
1
2
3
Before switching on the machine, raise the take-up lever as far as possible.
Turning the main switch 1switches the
machine on and off.

Operating Controls
17
7.03 Bobbin thread monitoring using stitch counting
The diode 1flashes on reaching the pre-
defined 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-
ing stitch counting.
Fig. 7 - 03
1
7.04 Pedal
With the main switch turned on
0 = Neutral position
+1= Sewing
-1= Raise roller presser
-2= Trim thread
Other pedal functions can be
set through the programming,
see chapter 10 Sewing.
0
-2
-1
Fig. 7 - 04
+1

Operating Controls
18
Fig. 7 - 05
7.05 Hand lever to raise the roller presser
Turning the hand lever 1raises the roll-
er presser.
7.06 Swivelling out the roller presser
The roller presser 1can be swivelled out
by gently pulling downwards when the
roller presser is in the raised position.
Fig. 7 - 06
1
1

Operating Controls
19
7.07 Knee switch
It is possible to choose between 2pre-
defined fullnesses or 2stitch 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.
The function of the knee switch
1must be activated on the con-
trol panel, see chapter 10 Sew-
ing.
Fig. 7 - 07
1
7.08 Knee lever
Pressing the knee lever 1in the direc-
tion shown by the arrow raises the roll-
er presser.
Fig. 7 - 08
1

Operating Controls
20
7.09 Edge trimmer -725/04 for PFAFF 1591
Fig. 7 - 09
1
3
2
4
Do not reach into the knife during operation! Risk of injury!
Switching on the knife drive:
Swivel the lever 1backwards; the knife moves to the operating position.
Switching off the knife drive:
Press the lever 1; the knife swivels away backwards.
Switching on the edge guide:
Swing in the edge guide 2by hand and press the lever 3; the edge guide 2moves to the
operating position.
Switching off the edge guide:
Raise the edge guide 2and allow it to engage; the edge guide 2is out of operation.
Raise the lever 4; the edge guide swivels away backwards.
Replacing knives:
The work described below may only be carried out by technical staff or people
with appropriate training!
Switch off the machine.
Release the screw 5and remove the knife 6.
Insert a new knife and slide it fully towards the needle plate insert 7.
Gently tighten the screw 5.
Adjust the knife as described in chapter 15.05.07 Knife position of the adjustment man-
ual and tighten the screw 5.
6
75