Pfaff powerLine 2595 Manual

296-12-19 005/002
Aufstellanleitung engl. 09.12
2595
2596
SET-UP INSTRUCTIONS

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

Index
Contents ..................................................................................Page
1General Notes ...................................................................................................................... 4
1.01 Explanation of the symbols.................................................................................................... 4
2Scope of delivery ................................................................................................................. 5
2.01 Sewing machine accessories.................................................................................................5
2.02 Accessories for the sewing machine drive EcoDrive P74 ED-L.............................................. 8
3Stand and table top ........................................................................................................... 10
3.01 Table top cutout (PFAFF 2595 / 2596 PLUS with tilted work base) ..................................... 10
3.02 Table top cutout (PFAFF 2595 / 2596 BASIC + PLUS without tilted work base................... 11
3.03 Table top cutout (PFAFF 2595 / 2596 BASIC with clutch motor
- without tilted work base) ................................................................................................... 12
3.04 Assembly drawing for the table top (PFAFF 2595 / 2596 PLUS
- with and without tilted work base) .................................................................................... 13
4Installation .......................................................................................................................... 14
4.01 Assembling the stand and table top .................................................................................... 14
4.02 Adjusting the table-top height.............................................................................................. 15
4.03 Assembling the EcoDrive control unit P74 ED-L .................................................................. 16
4.04 Setting the sewing machine into the stand ......................................................................... 17
4.05 Assemble the mounted motor............................................................................................. 18
4.06 Apply drive belt and tension ................................................................................................ 19
4.07 Mounting the belt guard of the flange motor ...................................................................... 19
4.08 Connecting the safety switch .............................................................................................. 20
4.09 Checking the start inhibitor function .................................................................................... 20
4.10 Assembling the LED lamp (optional).................................................................................... 21
4.11 Fitting the transformer to the LED lamp ..............................................................................22
4.12 Assembling the thread guide and take-up lever guard......................................................... 23
4.13 Assembling the top V-belt guard and sewing head support................................................. 24
4.14 Mounting the control panel.................................................................................................. 25
4.15 Connecting the plug-in connections and earth cables ......................................................... 26
4.16 Block diagram PFAFF 2595/96 PLUS with EcoDrive P74 ED-L ............................................ 27
4.17 Mounting / connecting the maintenance unit ...............................................................................28
5Commissioning .................................................................................................................. 29
5.01 Switching the machine on/off ..............................................................................................29

4
1 General Notes
The machine may only be set-up and commissioned by qualified personnel!
All notes in Chapter 1Safety of the Instruction Manual must be observed!
There must be suitable electrical connections at set-up site, see Chapter 3
Specifications of the Instruction Manual. A firm, level surface and adequate
lighting must also be available at the set-up site.
If the machine was delivered without a table, both the stand and the table top
intended for use must be constructed for a weight of at least 100 kilos.
1.01 Explanation of the symbols
In these Set-Up Instructions, symbols emphasize operations to be carried out or
important information. The symbols used have the following meaning:
Note, information
Service, repair, adjustment, maintenance
(work to be carried out by qualified staff only
Safety symbols
Danger!
Points to be observed.
Danger of injury for operating and specialist personnel!
General Notes

5
2 Scope of delivery
The scope of delivery of the machine depends on the order.
Before setting up the machine, check whether all the required parts have been included.
The following description only applies to one special sewing machine, for which all individual
components have been delivered by the PFAFF Industrie Maschinen AG.
2.01 Sewing machine accessories
Sewing machine accessories Description / No. of pieces
Thread guide and take-up lever
guard with screws and nuts(1x)
V-belt and
belt guard with screws (1x)
Bobbin (5x)
Reel stand complete (1x)
Scope of delivery

6
Scope of delivery
Sewing machine accessories Description / No. pieces
Rear rubber pads with screws (2x)
Front rubber pads (4x)
Hinge with screws (2x)
Sewing head support
Tilt lock (1x)
Oil pan with 5screws and washers
Oilcan (1x),
Sachet with 80 ml oil,
Dusting brush (1x)
Allan key 3mm (1x),
Screwdriver large (1x),
Screwdriver small (1x)
Sewing head protective cover

7
Sewing machine accessories Description / No. of pieces
Earth cable (3x) ,
Screw and washers
Motor bracket with fixing screws
Drive wheel, drive belt, belt guard
and approach barrier switch with
Fixing screws
Set-up instructions,
instruction manual to the machine
Scope of delivery

8
2.02 Accessories for the sewing machine drive EcoDrive P74 ED-L
Scope of delivery
Control package EcoDrive P74 ED-L Description
Motor
Control box with switch,
fastening screws and cable
Adapter cable for synchronizer

9
Control package EcoDrive P74 ED-L Description
AB C D
F1
+
-
TE
PM
Control panel bracket with control
panel and fastening screws
Speed control unit with holder
and fastening screws, and
connecting rod to the pedall
Scope of delivery

10
Stand and table top
- 0,5
115
107
4
R22
209 0
+0,4
644
R23 (2x)
R9 (4x)
14 0
+0,4 (2x)
14 0
+0,4 (2x)
R8 (4x)
R1 5 (2x)
50 0
+0,4
(2x)
R9(2x)
50 0
+0,4
(2x)
-0,5
N.M. AA
B
B
A-A
17 -0,5 (2x)
B-B
0
3 Stand and table top
3.01 Table top cutout (PFAFF 2595 / 2596 PLUS with tilted work base)

11
Stand and table top
3.02 Table top cutout (PFAFF 2595 / 2596 BASIC + PLUS without tilted work base
- 0,5
- 0,5
- 0,5
115
106
92 364
40 (2x)
99 (2x)
562,50
60° (4x)
R22
206 +0,4
233,5 +0,4 (2x)
80 -0,4 (2x)
R10 (4x)
208 +0,4 (2x)
644
R23 (2x)
R9 (4x)
14 +0,4 (2x)
14 +0,4 (2x)
R8 (4x)
R15 (2x)
50 +0,4 (2x)
50 +0,4 (2x)
66 (2x)
77,3 (2x)
R9(4x)
R9(2x)
40
-0,5
AA
B
B
18,7 - 0,5
0
A-A
B-B
17,5 - 0,5(2x)

12
115
80
106
60
240,5
92 364
517,5
30
40
(2x)
99
(2x)
R 2 2
46
60°
(4x)
R 2 2
22
R 9
(4x)
5
206 +0,4
233,5
+0,4 (2x)
80
- 0,4 (2x)
R 1 0 (4x)
208
+0,4 (2x)
644
R 2 3
(2x)
R 9
(4x)
14
+0,4 (2x)
14
+0,4 (2x)
R8 (4x)
R 1 5 (2x)
50
+0,4 (2x)
50
+0,4 (2x)
66
(2x)
77,3
(2x)
R 9
(4x)
-0,5
AA
B
B
- 0,5
- 0,5 - 0,5
20
18,7- 0,5
0
A-A
17,5
-0,5 (2x)
B-B
906-4001-151
Vers. 08.04.08
Stand and table top
3.03 Table top cutout (PFAFF 2595 / 2596 BASIC with clutch motor
- without tilted work base)

13
Stand position
906-3750-010/895
30
100
230
275,6
90 56 70
7587
360
20
30
115
0/ 1
Stand and table top
View: Underside table top
Speedcontrolunit
Controlbox P 321 P 74 ED-L
3.04 Assembly drawing for the table top (PFAFF 2595 / 2596 PLUS
- with and without tilted work base)

14
6x40 (4x)
3x20 (6x)
Stand
906-3750-010/895
4,2x13 (4x)
M10x20 (4x)
4x30 (4x)
Installation
4 Installation
4.01 Assembling the stand and table top
●Assemble the stand (part no. 906-3750-010/895) and table top as shown in the following
illustration.
The stand and table top must
be constructed for a weight of
at least 100 kg.
●When assembling the table top,
please observe the assembly drawing
(Chapter 3.04 ).
Fig. 4 - 01

15
●Loosen screw 1.
●Adjust the table tap to the required working height by increasing or reducing the height
of the stand and then level the table-top horizontally.
To avoid the stand tilting, adjust it evenly on both sides.
●To guarantee that the stand is standing securely, it must be positioned securely on the
ground with all four legs.
●The height can be adjusted with screw 2.
4.02 Adjusting the table-top height
Installation
Fig. 4 - 02
1
2
1

16
Installation
4.03 Assembling the EcoDrive control unit P74 ED-L
●Fit the control box 1to the table top with four screws 6x30.
●Attach the mains switch 2to the table top with two screws 6x30.
●Screw the mains cable of the control box 1to the table top with a mains lead cleat.
●Assemble the speed control unit 3and attach it to the table top with two screws 6x30.
●Mount the pedal on the stand’s cross-bar, aligning the middle of the pedal with the
centre of the needle.
●Fit connection rod 4to speed control unit 3and to the pedal.
●The slant of the pedal can be adjusted after loosening screw 6(slant angle approx. 10°).
Fig. 4 - 03
6x30 (2x)
6x30 (2x)
6x30 (2x)
3
4
5
5
1
6x30 (4x)
2

17
Installation
4.04 Setting the sewing machine into the stand
●Attach each of the hinges 1to the sewing head with two screws M6x 16.
●On the PFAFF 2595 and 2596 attach tilt lock 2with a M5x 6screw.
●Set the sewing machine into the table top.
Fig. 4 - 04
1
2

18
Fig. 4 - 05
4.05 Assemble the mounted motor
●Fix bearing plate 1on to motor 2using screws 3, as shown in fig. 4-05.
●Remove the wedge from motor shaft 4.
●Attach angle bracket 5with screws 6.
●Mount drive belt wheel 7onto motor shaft 4so that screw 8is positioned with the hub in
the drive shaft slot.
●Screw threaded bolts 9into bearing plate 1.
●Use screw 10 ( Fig. 4- 06 to fix motor 2bearing plate 1to the machine housing.
Tighten screws 10 only a little.
The threaded bolts 9 and the screws 6 and 10 can be screwed into the
respective holes Aor Bdepending on the table top:
Hole A= table top without tilt base
Hole B= table top with tilt base.
1
2
3
4
5
6
7
9
8
A
B
AB
A
B
A
B
A
B
10
10
Installation

19
4.06 Apply drive belt and tension
●Lay on the drive belt 11 .
●Pivot the motor bearing plate 2so that the drive belt 11 is taut.
●In this position, tightly fix screw 10.
Fig. 4 - 07
4.07 Mounting the belt guard of the flange motor
●Attach belt guard 1 with screws 2 and 3.
3
2
1
Fig. 4 - 06
11
10
2
10
A
B
Version A
Version B
Installation

20
4.08 Connecting the safety switch
●Connect plug 1of safety switch 2as
shown in Fig. 4- 08.
When the machine head is
tilted back,the safety switch
prevents the machine from star-
ting when the main switch is
on.
Fig. 4 - 08
4.09 Checking the start inhibitor function
●Switch the machine on at the main switch and tilt back the sewing head.
●The error message "Err: 9" must appear on the control panel.
●If the message does not appear, check the setting of safety switch 2.
●After the sewing head has been returned to the upright position, the machine is ready for
operation again.
1
2
Installation