Pfaff 3811-3/55, 3811-15/65, 3811-16/65 Instruction Manual
296-12-18 591/002
Instruction Manual engl. 07.17
This instruction manual applies to machines
from the serial number2 792 321 and
software version 0352/013 onwards.
INSTRUCTION MANUAL
3811
-3/55; -15/65; -16/65
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.
Table of Contents
Contents ..................................................................................Page
1 Safety .................................................................................................................................... 7
1.01 Directives ............................................................................................................................... 7
1.02 General safety instructions .................................................................................................... 7
1.03 Safety symbols ...................................................................................................................... 8
1.04 Special points of attention for the owner-operator ................................................................ 8
1.05 Operating personnel and technical staff ................................................................................ 9
1.05.01 Operating personnel .............................................................................................................. 9
1.05.02 Technical staff ........................................................................................................................ 9
1.06 Danger warnings ..................................................................................................................10
2 Proper Use ..........................................................................................................................11
Proper Use 11
3 Technical Data
.............................................................................................................................................................................................. 12
3.01 PFAFF 3811 ......................................................................................................................... 12
4 Disposal of the Machine .................................................................................................... 13
5 Transportation, Packaging and Storage .......................................................................... 14
5.01 Transport to the customer's premises ................................................................................ 14
5.02 Transportation within the customer's premises .................................................................. 14
5.03 Disposal of the packaging materials ....................................................................................14
5.04 Storage ................................................................................................................................ 14
6 Work Symbols ....................................................................................................................15
7 Operating Controls ............................................................................................................16
7.01 Main switch ......................................................................................................................... 16
7.02 Pedal .................................................................................................................................... 16
7.03 Hand lever to raise the presser foot .................................................................................... 17
7.04 Knee switch ......................................................................................................................... 17
7.05 Edge guide (only with PFAFF 3811-3/55 and PFAFF 3811-15/65) ....................................... 18
7.06 Lever for releasing thread tension ....................................................................................... 18
7.07 Keypad ................................................................................................................................. 19
1 19
1 19
7.08 Control panel ........................................................................................................................20
8 Set-up and Initial Start-up ............................................................................................. 21
8.01 Set-up .................................................................................................................................. 21
8.01.01 Setting the table height ....................................................................................................... 21
8.01.07 Assembling the reel stand ................................................................................................... 25
8.01.08 Mounting the control panel on the table top ....................................................................... 25
8.02 Initial commissioning ........................................................................................................... 26
8.03 Switching the machine on/off .............................................................................................. 26
9 Set-up .................................................................................................................................. 27
9.01 Inserting the needle ............................................................................................................ 27
Table of Contents
Contents ..................................................................................Page
9.02 Threading the needle/adjusting the needle thread ............................................................. 28
9.03 Threading the looper thread/adjusting the looper thread ..................................................... 29
9.04 Selecting program numbers ................................................................................................ 30
9.05 Inputting fullness ................................................................................................................. 31
9.06 Entering/changing the template code .................................................................................. 32
9.07 Setting the control panel ......................................................................................................34
10 Sewing .............................................................................................................................. 35
10.01 Manual sewing .................................................................................................................... 35
10.02 Sewing with fi xed programs ................................................................................................ 37
10.03 Programmed sewing ........................................................................................................... 39
10.04 Error messages .................................................................................................................... 41
11 Input ................................................................................................................................... 42
11.01 Entering seam programs .....................................................................................................43
11.02 Examples for setting seam program .................................................................................... 50
11.03 Managing seam programs ................................................................................................... 58
12 Maintenance and Care ....................................................................................................... 60
12.01 Maintenance intervals .......................................................................................................... 60
12.02 Cleaning the machine .......................................................................................................... 60
12.03 Machine oil level .................................................................................................................. 61
12.04 Cleaning/lubricating the top feed joints ............................................................................... 61
12.05 Checking/setting the air pressure ........................................................................................ 62
12.06 Cleaning the maintenance unit air fi lter .............................................................................. 62
12.07 Cleaning the blower air fi lter ................................................................................................ 63
13 Adjustment ......................................................................................................................... 64
13.01 Notes on adjustment ........................................................................................................... 64
13.02 Tools, gauges and other accessories .................................................................................. 64
13.03 Abbreviations ....................................................................................................................... 64
13.04 Explanation of symbols ........................................................................................................ 64
13.05 Checking and adjustment aid ............................................................................................... 65
13.06 Adjusting basic machine ...................................................................................................... 66
13.07 Adjusting the edge cutting equipment. ............................................................................ 105
13.08 Adjusting the thread trimmer ............................................................................................. 110
13.09 Parameter settings ............................................................................................................ 117
13.10 Sewing motor errors .......................................................................................................... 122
13.11 Error message explanations .............................................................................................. 123
13.12 Inputs table ........................................................................................................................ 124
13.13 Outputs table ..................................................................................................................... 124
13.14 Service menu ..................................................................................................................... 125
13.15 Run cold start ..................................................................................................................... 126
13.16 Internet update of machine software ................................................................................ 127
14 Wear and Tear Parts ........................................................................................................ 128
Table of Contents
Contents ..................................................................................Page
15 Circuit Diagrams ..............................................................................................................129
15.01 Pneumatic circuit diagram (version 12/01/2006) 91-196 282-95 ...................................... 129
15.02 Circuit diagrams .......................................................................................................................
130
Reference list for circuit diagrams 91-191 493-95 .............................................. 130
16 Table Top ..........................................................................................................................135
16.01 Table top cutout ................................................................................................................. 135
16.02 Table top assembly ............................................................................................................ 136
Table of Contents
Contents ..................................................................................Page
Safety
7
1 Safety
1
.01 Directives
The machine was built in compliance with the European regulations specifi ed in the
declaration of conformity and declaration of incorporation.
As a supplement to this instruction manual, please also observe the generally applicable,
legal and other regulations and legislation – also in the country of use – and the valid
environmental 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
associated instruction manual and only by operating personnel who have received
appropriate training!
Always read the safety instructions and the instruction manual of the motor manufacturer
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 qualifi ed personnel!
Repairs and special maintenance work may only be carried out by technical staff or
people with appropriate training!
Work on electrical equipment may only be carried out by qualifi ed technical staff!
Work on parts and equipment under voltage is not permitted!
Exceptions are regulated by the EN 50110 standards.
Modifi cations 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 damage caused by the use of
non-Pfaff parts.
Safety
8
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
Caution!
Do not operate without fi nger guard and safety covers!
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
operating personnel at all times. The instruction manual must have been read before the
initial start-up.
The operating personnel and technical staff must be instructed about the machine's
safety covers and about safe working methods.
The owner-operator may only operate the machine in a fl awless 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
9
1.05 Operating personnel and technical staff
1
.05.01 Operating personnel
Operating personnel are persons responsible for equipping, operating and cleaning the
machine 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-fi tting 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
10
5
Fig. 1 - 01
4
1
7
2
7
1.06 Danger warnings
A work area of 1 m must be kept free in front of and behind the machine during
operation to ensure 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 fl ying 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 fi nger guard 2!
Risk of injury from the needle!
Do not operate the machine without the belt guard 3 and 4!
Risk of injury due to the rotating driving belt!
Do not operate the machine without the anti-tipping device 5!
Risk of injury from crushing between the sewing head and the table top!
Do not operate the machine without the support 6! Risk of damage due to the
top-heavy sewing head! Machine can tip over backwards when moving it!
Do not operate machines with edge trimmer without fi nger guard 7!
Do not reach into the cutting area between the needle plate and the blade!
Risk of injury due to the cutting motion of the blade!
6
3
Proper Use
11 11
2 Proper Use
Proper Use
The PFAFF 3811-3/55 is an integrated work station that is used in the shoe industry for the
incorporation of fullness into one material layer.
The PFAFF 3811-15/65 is an integrated work station that is used in the upholstery industry
for the incorporation of fullness into one material layer.
The PFAFF 3811-16/65 is an integrated work station that is used in the upholstery industry
for the incorporation of fullness into one material layer while simultaneously trimming the
material edge.
Any usage not approved by the manufacturer is deemed misuse!
The manufacturer shall assume no liability for damage caused by misuse!
Proper use also includes compliance with the operating, maintenance,
adjustment and repair measures specifi ed by the manufacturer!
Technical Data
12
3 Technical Data
3.01 PFAFF 3811
Stitch type: .......................................................................................... 401 (Double chainstitch)
Needle system:
3811-15/65; 3811-16/65: ............................................................................................... 4463-35
3811-3/55 ................................................................................................................... 4463-KKD
Needle size in 1/100 mm .............................................................................................. 80 - 110
Basic stitch length:
3811-3/55 .......................................................................................................................2.2 mm
3811-15/65; 3811-16/65: ........................................................................................3.0 - 4.0 mm
Differential feed - feed motion
3811-3/55 ...............................................................................................................2.2 - 6.5 mm
3811-15/65; 3811-16/65: ........................................................................................4.0 - 8.0 mm
Speed max.: ............................................................................................... 3200 stitches/min
Clearance beneath the presser foot:
3811-3/55 ..........................................................................................................................7 mm
3811-15/65; 3811-16/65: ...................................................................................................1 mm
Sewing head dimensions
Length: ........................................................................................................... approx. 1250 mm
Width: ..............................................................................................................approx. 600 mm
Height (with spool holder): ............................................................................. approx. 1700 mm
Working air pressure: ......................................................................................................... 6 bar
Air consumption: .................................................................................... 0,3 - 0,5 l / work cycle
Connection data:
Operating voltage: ...............................................................................230 V ± 10 %, 50/60 Hz
Max. input power: ...........................................................................................................400 VA
Fuse protection: ...................................................................................................1 x 16 A, inert
Noise data:
Emissions sound pressure level in the workplace at n = 2600 min-1: .............. LpA = 79 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1,
ISO 11204, ISO 3744, ISO 4871)
Net weight: .......................................................................................................... approx. 97 kg
Gross weight: .................................................................................................... approx. 132 kg
Subject to alterations
Depending on the material, workstep and stitch length
KpA = 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 Transportation 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
position.
5.03 Disposal of the packaging materials
The packaging materials of these machines consists of paper, cardboard and VCI fl eece.
It is up to the customer to dispose of the packaging properly.
5.04 Storage
The machine can be stored for up to 6 months 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 fi lm.
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 Operating Controls
7
.01 Main switch
Before switching on the ma-
chine, raise the take-up lever as
far as possible.
Turning the main switch 1 switches the
machine on and off.
Fig. 7 - 01
1
7.02 Pedal
With the main switch turned on
0 = Neutral position
+1 = presser foot raised / feed
bridle tape
+2 = Sewing
1 = Raise presser foot
-2 = Thread trimming (Option)/
need up/edge knife off (if parameter 210 is at "ON", see
Chapter 13.07 Parameter
settings)
0
-2
-1
Fig. 7 - 02
+1
+2
Operating Controls
17
Fig. 7 - 03
7.03 Hand lever to raise the presser foot
Turning the hand lever 1 raises the
presser foot.
1
7.04 Knee switch
When sewing with fi xed programs:
Actuating the knee switch 1 switches
between two predefi ned fullness
settings
With programmed sewing:
By actuating the knee switch 1, the
fullness is switched according to the
program specifi cation.
Fig. 7 - 04
1
Operating Controls
18
7.05 Edge guide (only with PFAFF 3811-3/55 and PFAFF 3811-15/65)
By pushing down lever 1 the edge guide
is switched on.
By lifting lever 1 the edge guide is
switched off.
1
Fig. 7 - 05
7.06 Lever for releasing thread tension
Press down lever 1 to release thread
tension.
Fig. 7 - 06
1
Operating Controls
19
7.07 Keypad
Keypad 1 is used to quickly operate the machine during sewing. Each key can be assigned
an individual fullness value, see Chapter 9.05 Input fullness. By means of the respective
light-emitting diode of the 20 keys, activated key functions are displayed (function activated
= luminous diode).
Fig. 7 - 07
Numeric keys (0 - 15)
The pre-assigned fullness value is retrieved by pressing the key.
The corresponding average value is called by pressing two adjacent numeric keys at the
same time.
In the basic setting of the keypad, the set range is divided into 15 sub-steps
from "0" to "max." The basic setting is e.g. after a cold start, see Chapter 13.13
Cold start.
Tape brake (option)
The tape brake is switched on or off by pressing the key.
When the belt brake is engaged, the gathering of the material is enhanced.
Edge trimmer
The edge trimmer device is switched on or off by pushing the key.
Correction value +/correction value -
By pressing the key the value for the multiple width is increased or decreased by 2
steps.
1
9
3
8
7
5
1
6
2
4
0
1
1
1
2
1
3
1
4
1
5
1
0
1
1
Operating Controls
20
Fig. 7 - 08
2 GB
max.
7.08 Control panel
The current operating statuses are indicated on the control panel 1. The machine
is operated with constant dialogue between the control unit and the operator; different
pictograms and / or texts are displayed for this purpose according to the operating status of
the machine. Pictograms or texts with a border represent
functions that can be called up by pressing on the respective point on the monitor. Pressing
the respective function causes its immediate actuation or activation/deactivation or another
menu will appear, e.g. for entering a value. Activated functions are indicated by pictograms
shown inversely. Apart from the bobbin change function, the pictograms and texts without
border are only for display purposes and cannot be called up by pressing them.
SD card 2 in the control panel can be used to import seam programs.
Presentation of functions
Normal pictogram = Function deactivated (inactive)
Inverse pictogram = Function activated (active)
1
2
Set-up and Initial Start-up
21
8 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.
Adequate stability of the stand must be guaranteed, even during the sewing
operations.
8.01 Set-up
Suitable electrical supply connections must be provided at the erection site, see Chapter 3
Technical data. The erection site must also have a fi rm and level subsurface and adequate
lighting.
The table top is lowered for packaging purposes.
The adjustment of the table height is described below.
8.01.01 Setting the table height
Fig. 8 - 01
Loosen the screws 1 and 2
Move the table top to the desired working height by pulling it out and pushing it in and
align the table top horizontally.
Adjust the stand on both sides evenly to prevent it tilting.
The stand must have all four feet fi rmly on the ground to make sure it is positioned
securely.
Firmly tighten the screw 1.
Adjust and tighten the desired pedal position on the screws 2.
1
1
2
Set-up and Initial Start-up
22
8.01.02 Tension v-belt
Fit the V-belt.
Loosen the nut 1 and tension the V-belt
by turning the motor bracket 2 out of po-
sition.
Tighten nut 1.
Fig. 8 - 02
2
1
8.01.03 Mounting the upper V-belt guard
Screw in screws 1 and 2.
Screw in screw 3 together with spacing
bush 4.
Slide belt guard halves 5 with their slots
behind the heads of the screws 1 and 3.
Gently tighten screw 1 .
Take note that the lug of the belt guard
half 6 is located between belt guard half
5 and spacing bush 4, align the complete
belt guard and tighten screws 1, 2 and 3.
Fig. 8 - 03
5
1
2
3
6
4
Set-up and Initial Start-up
23
Fig. 8 - 04
Loosen screws 2 and align the belt guard bracket 1 so that the motor pulley and v-belt
run freely.
Tighten screws 2.
Secure the belt guard 3 with screw 4
1
2
2
4
3
8
.01.04 Mounting the lower V-belt pulley
Fig. 8 - 05
8.01.05 Fitting the position sensor
Attach the position fi nger 1 with the
screws 2.
Slide the synchroniser 3 onto the shaft
so that the position fi nger 1 is positioned
in the groove of the synchroniser 3, see
arrow.
Gently tighten the screws 4.
Insert the synchroniser plug on the fe-
male coupling of the control box.
Set synchroniser 3, see Chapter
13.05.01 Home position of the machine.
1
2
3
4
Set-up and Initial Start-up
24
8.01.06 Connecting the plug-in connections and ground cable
Insert all plugs on the control box 1 in accordance with their designation.
Insert the "motor" into the bushing X 3 and the bushing X 8.
Caution
Inserting the plug incorrectly can damage the control unit!
Attach the following ground cables in order to discharge static electricity
Securely attach ground cable from sewing head to ground point A.
Securely attach the ground cable from the control point B to ground point B.
Securely attach the ground cable from the main switch 3 to ground point C.
Securely attach the ground cable from the stand 4 to ground point D.
Securely attach the ground cable 5 from the motor to ground point E.
5
E
A
B
C
D
4
D
1
Fig. 8 - 06
B
0
3
Set-up and Initial Start-up
25
8.01.07 Assembling the reel stand
Assemble the reel stand as shown in the
adjacent illustration.
Then insert the stand into the
hole in the table top and secure it with
the enclosed nuts.
Fig. 8 - 07
8.01.08 Mounting the control panel on the table top
Mount control panel bracket 1 on table
plate 4 with screws 2 and washers 3.
Screw control panel 5 to control panel
bracket 1 with screws 6.
Connect the connecting cable 7 to the
control unit together with the control
panel 5 and the provided plug-in
connection.
Fig. 8 - 08
1
2
3
X1/A
2
3
5
4
A2
6
7
6
Set-up and Initial Start-up
26
8.02 Initial commissioning
Before initial commissioning,
remove the protective fi lm from
the sight glass 1.
Clean the machine thoroughly and then
check the oil level, see Chapter 12
Maintenance and Care.
Inspect the machine, particularly the
electric cable, for any damage.
Arrange for technical staff to check
whether the machine's motor may be
operated at the existing mains voltage
and whether it is connected properly.
Never operate the machine if there are any differences.
The machine must only be connected to a grounded socket!
With the machine running, the handwheel must turn towards the operator, otherwise ar-
range for technical staff to adjust the motor, see Chapter 13.07 Parameter settings.
For machines with pneumatic devices, the machine must be connected to the
compressed air system. The manometer should show a pressure of 6 bar. Or set this
value (see Chapter 12.04 Checking/setting the air pressure).
8.03 Switching the machine on/off
Switch machine on and off (see Chapter 7.01 Main switch).
Perform test run
Fig. 8 - 09
1
Set-up
27
9 Set-up
Observe and comply with all regulations and instructions 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!
Switch off the machine!
Risk of injury due to accidental
machine start-up!
Only use needles of the system
intended for the machine, see
Chapter 3 Technical Data!
9.01 Inserting the needle
Bring the needle bar to the top position.
Loosen the screw 1 and insert the nee-
dle 2 until you feel it stop. The long
groove must point forwards.
Tighten the screw 1.
Fig. 9 - 01
2
1
Set-up
28
9.02 Threading the needle/adjusting the needle thread
Switch off the machine!
Risk of injury due to accidental machine start-up!
Thread the needle as shown in Fig. 9-02.
Adjust the needle thread tension by turning the knurled thumb screw 1.
1
+
-
Fig. 9 - 02
approx. 7 cm
Set-up
29
9.03 Threading the looper thread/adjusting the looper thread
Fig. 9 - 03
Switch off the machine!
Risk of injury due to accidental machine start-up!
Open the looper compartment cover and swing out the thread guide plate1.
Thread the looper thread according to Fig. 9-03 and 9 - 09 and pull it under guide plate 2.
Use tweezers 3 to thread in the looper.
Adjust the looper thread tension by turning the knurled thumb screw 4.
4
1
2
-
+
Fig. 9 - 04
3
Set-up
30
9.04 Selecting program numbers
Switch the machine on.
Call up the menu to input the program number.
Select the desired program number.
Confi rm the selection and leave the selection menu.
The selection of the program number determines the type of sewing, see
Chapter 10 Sewing.
Program number 0: Manual sewing
Program numbers 1 and 2: Sewing with fi xed programs
Program numbers 3 to 49: Programmed sewing
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