Page 1 3811 -3/55; -15/65; -16/65 INSTRUCTION MANUAL his instruction manual applies to machines from the serial number2 792 321 and software version 0352/013 onwards. 296-12-18 591/002 Instruction Manual engl. 07.17...
Page 2 This instruction manual applies to all models and subclasses listed in Chapter 3 Technical Data. 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.
Page 3: Table Of Contents
Pedal ............................ 16 Hand lever to raise the presser foot ..................17 Knee switch ......................... 17 Edge guide (only with PFAFF 3811-3/55 and PFAFF 3811-15/65) ........18 Lever for releasing thread tension ..................18 Keypad ..........................19 Control panel ........................20 Set-up and Initial Start-up .....................
Page 4 Table of Contents Contents ..................Page Threading the needle/adjusting the needle thread ............. 28 Threading the looper thread/adjusting the looper thread ............. 29 Selecting program numbers ....................30 Inputting fullness ......................... 31 Entering/changing the template code .................. 32 Setting the control panel ...................... 34 Sewing ..........................
Page 5 Table of Contents Contents ..................Page Circuit Diagrams ......................129 Pneumatic circuit diagram (version 12/01/2006) 91-196 282-95 ........129 Circuit diagrams ........................Reference list for circuit diagrams 91-191 493-95 ..........130 Table Top .......................... 135 Table top cutout ......................... 135 16.02 Table top assembly ......................
Page 6 Table of Contents Contents ..................Page...
Page 7: Safety
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.
Page 8: Safety Symbols
Safety 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...
Page 9: Operating Personnel And Technical Staff
Safety Operating personnel and technical staff Operating personnel .05.01 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: ...
Page 10: Danger Warnings
Safety 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!
Page 11: Proper Use
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.
Page 12: Technical Data
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...
Page 13: Disposal Of The Machine
Disposal of the Machine 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. ...
Page 14: Transportation, Packaging And Storage
Transportation, Packaging and Storage Transportation, Packaging and Storage Transport to the customer's premises All machines are completely packed for delivery. 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.
Page 15: Work Symbols
Work Symbols 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)
Page 16: Operating Controls
Operating Controls Operating Controls 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 Pedal  With the main switch turned on 0 = Neutral position +1 = presser foot raised / feed bridle tape...
Page 17: Hand Lever To Raise The Presser Foot
Operating Controls Hand lever to raise the presser foot  Turning the hand lever 1 raises the presser foot. Fig. 7 - 03 Knee switch When sewing with ﬁ xed programs:  Actuating the knee switch 1 switches between two predeﬁ ned fullness settings With programmed sewing: ...
Page 18: Edge Guide (Only With Pfaff 3811-3/55 And Pfaff 3811-15/65)
Operating Controls 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. Fig. 7 - 05 Lever for releasing thread tension ...
Page 19: Keypad
Operating Controls 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).
Page 20: Control Panel
Operating Controls Control panel 2 GB max. Fig. 7 - 08 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.
Page 21: Set-Up And Initial Start-Up
Set-up and Initial Start-up 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.
Page 22 Set-up and Initial Start-up Tension v-belt .01.02  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 Mounting the upper V-belt guard .01.03 ...
Page 23 Set-up and Initial Start-up Mounting the lower V-belt pulley .01.04 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 Fitting the position sensor .01.05 ...
Page 24 Set-up and Initial Start-up Connecting the plug-in connections and ground cable .01.06 Fig. 8 - 06  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! ...
Page 25: Assembling The Reel Stand
Set-up and Initial Start-up Assembling the reel stand .01.07  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.
Page 26: Initial Commissioning
Set-up and Initial Start-up 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.
Page 27: Set-Up
Set-up 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! Inserting the needle Switch off the machine!
Page 28: Threading The Needle/Adjusting The Needle Thread
Set-up Threading the needle/adjusting the needle thread approx. 7 cm Fig. 9 - 02 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.
Page 29: Threading The Looper Thread/Adjusting The Looper Thread
Set-up Threading the looper thread/adjusting the looper thread Fig. 9 - 04 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. ...
Page 30: Selecting Program Numbers
Set-up 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.
Page 31: Inputting Fullness
Set-up Inputting fullness  Switch the machine on.  Call up the menu to input the program number.  Select program number "0".  Conﬁ rm the selection and leave the selection menu.  Enter the desired value using the corresponding arrow keys. Fig.
Page 32: Entering/Changing The Template Code
Set-up Entering/changing the template code  Switch the machine on.  Call up “Input” mode.  Call up parameter '800'.  Call up the code number input menu.  Enter the code number using the numeric keypad (code set at the factory is"3800").
Page 33  Call up the input menu for the code number and enter the desired code number.  Adopt new code number.  Conclude input. Remember the code! Protected functions cannot be called up without the corresponding code! In this case request support from the PFAFF service centre.
Page 34: Setting The Control Panel
Set-up Setting the control panel  Switch the machine on.  Call up “Input” mode.  Call up the service menu.  Call up the control panel functions.  Change the display contrast.  Switch the key tone off or on. Never reduce the display contrast to such an extent that the display can no longer be read!
Page 35: Sewing
Sewing Sewing In sewing mode, all settings relevant to the sewing process are shown on the display and can be altered there directly using the corresponding function. In the sewing mode a difference must be made between manual sewing, sewing with ﬁ xed programs and programmed sewing.
Page 36 Sewing Needle position raised If this function is on, the needle moves to top position when sewing stops. Thread trimming - When the function is activated, thread trimming with the pedal function is possible (optional). - When switched on this function enables the edge knife to be switched off via pedal function, see Chapter 7.02 Pedal.
Page 37: Sewing With Fi Xed Programs
Sewing Sewing with ﬁ xed programs Fixed programs are set under the program numbers 1 and 2. The ﬁ xed programs are are used for the quick and easy sewing of seams with different full- ness. When sewing with ﬁ xed programs, 2 or 3 seam areas are processed one after the oth- er.
Page 38 Sewing Needle position raised If this function is on, the needle moves to top position when sewing stops. Thread trimming - When the function is activated, thread trimming with the pedal function is possible (optional). - When switched on this function enables the edge knife to be switched off via pedal function, see Chapter 7.02 Pedal.
Page 39: Programmed Sewing
Sewing Programmed sewing Pre-programmed seams can be called up via program numbers 3 - 49. In the programmed sewing mode all seam zones are set in a seam program. The information on the seam program, such as the program number, the number of programmed seam zones, and the programmed comment are displayed.
Page 40 Sewing Current seam Serves for selecting and displaying the current seam (right/left). Automatic seam change Switches automatically between the right and the left seam with this function switched on. Material type The functions are used to select the material type, see Chapter 10.01.02 Selecting the ma- terial type.
Page 41: Error Messages
Sewing 10.03.01 Program interruption The "program interruption" function is used to interrupt the programmed seam sequence (e.g., in the case of a thread break).  Interrupt program sequence  Or sequence program forwards and backwards.  Or change values and perform the other functions as in manual sewing, see Chapter 10.01 Manual sewing.
Page 42: Input
Input Input The functions Parameter input, Info, Sewing program set/correct, Teach-in, Program management and Service are available In the operating mode Input.  Switch the machine on.  Call up “Input” mode. Description of the functions Sewing mode Quit the input mode and call up the sewing mode. Parameter selection Select the hundred and unit ﬁ...
Page 43: Entering Seam Programs
Input Entering seam programs Seam programs can be created by inputting parameters in the function “Create / correct seam programs” or sewing a seam sample with the “Teach in” function. Irrespective of which function is changed, the program number and basic settings of the sewing program to be processed must ﬁ...
Page 44 Input  Deﬁ ne the type of seam (by pressing the corresponding symbol multiple times until the respective type of seam is displayed). Explanation of symbols: Sewing program with left and right seam, beginning with right seam Sewing program only with left seam Sewing program only with right seam Sewing program with left and right seam, beginning with left seam ...
Page 45 Input Seam program input via the function "Create/correct program" .01.02 This function is used to enter the seam program by entering or changing the corresponding values on the keypad. This type of seam program input is particularly suitable for correcting already existing seam programs.
Page 46 Input  Or insert the seam zone. The current seam zone is copied and all subsequent seam zones are set backwards.  Or delete the current seam zone.  Or end the current seam entry and save the parameters in reverse order for the other seam (mirroring).
Page 47 Input Seam program input via the function "Teach In" .01.04 This function is used to create the seam program by sewing a sewing pattern. A new crea- tion is always made, meaning that when selecting an already existing program it is overwrit- ten.
Page 48 Input  After sewing, the following information and functions appear on the display:  Pressing the Enter key deﬁ nes the seam zone by stitch counting.  Actuating the pedal in position “2” executes the end of the seam zone by actuating the pedal, see Chapter 7.02 Pedal ...
Page 49 Input Seam zone input during seam programming .01.05 After calling up the corresponding function, the menu for inputting the functions and values for the end of the seam zone without stitch concentration appears.  If necessary switch off stitch concentration. ...
Page 50: Examples For Setting Seam Program
Input Examples for setting seam program Example of seam program input using the function "Create/correct program" .02.01 The seam program to be created should - contain 4 seam zones and - saved under program number 4 with the comment “PROG”. ...
Page 51 Input The ﬁ rst seam zone should - be worked without a fullness setting, - the end of the seam zone should be executed by the knee switch.  Enter value "0" for the fullness.  Call up the seam zone menu. ...
Page 52 Input  Enter value "242" for the actual length.  Enter value "140" for the target length.  Complete the entry of the target/actual length. The number of stitches (“37”) and the value for the fullness setting (“70”) are determined from the values entered. Since conversion must be based on whole stitches, the value for the target length ("141") must deviate slightly from the entered value.
Page 53 Input In the third seam zone, a target length of 160 mm is to be used for an actual length of 190 mm.  Call the menu for entering the target/actual length of the seam zone and enter the values for target and actual length.
Page 54 Input Example for seam program input via the function "Teach In" .02.02 The seam program to be created should - consist of one seam, - contain 10 seam zones and - saved under program number 11 with the comment “TEACH”. Sewing direction Seam zone 10 Gather setting: 12...
Page 55 Input  Set the sewing type (press until the corresponding symbol for the left or right seam appears).  Call up the comment input menu.  Enter "TEACH" using the keypad and numeric keypad.  Conclude the comment input.  Switch to the input of seam zone 1. The ﬁ...
Page 56 Input The second seam zone should be worked with gather setting “17”.  Enter value "17".  Sew the second seam zone using the pedal function.  Change to the third seam zone.  Inputs for the 3rd to 8th seam zones as described for zone 2 (observe the respective values in the diagram) and sew the individual seam sections.
Page 57 Input The tenth seam zone should be worked with gather setting “12”.  Enter value "12".  Sew the tenth seam zone using the pedal function.  Deﬁ ne the end of the seam zone via the pedal position “- 2”, see Chapter 7.02 Pedal ...
Page 58: Managing Seam Programs
Input Managing seam programs The program management displays the contents of the machine memory in the left-hand half of the screen and the SD card in the right-hand half of the screen, and is used to erase and copy programs. The selected programs are displayed in red. If the MDAT function is activated, the machine data of the machine can be set to be saved to the SD card or loaded from the SD card.
Page 59 Input Dialogue box The dialogue box is used to communicate the current operation. If necessary, additional keys are shown for answering questions. Enter key Approval for a program. All key Approval for one or all marked programs. Esc key Reject for one or all marked programs. Next key Next Reject a program.
Page 60: Maintenance And Care
Maintenance and Care Maintenance and Care Maintenance intervals Cleaning ............daily, several times if in continuous operation Clean the hook area ........daily, several times if in continuous operation Check oil level ..................daily, before start-up Lubricate the top feed joints ................once a week Check / set the air pressure ..............
Page 61: Machine Oil Level
22.0 mm /s at 40 °C and a density of 0.865 g/cm 15 °C. We recommend PFAFF sewing machine oil Order No. 280-1-120 144. Fig. 12 - 02 Cleaning/lubricating the top feed joints  Clean the areas marked in the illustra-...
Page 62: Checking/Setting The Air Pressure
Maintenance and Care Checking/setting the air pressure  Check the air pressure on the manome- ter 1 before every start-up.  The manometer 1 must show a pressure of 6 bar.  Adjust this value if needed.  To do this, pull up the button 2 and turn it so that the manometer 1 shows a pressure of 6 bar.
Page 63: Cleaning The Blower Air Fi Lter
Maintenance and Care Cleaning the blower air ﬁ lter  Remove the cover 1.  Remove the ﬁ lter element and blow it out with compressed air.  Insert the cleaned ﬁ lter element and ﬁ t the cover 1. Fig.
Page 64: Adjustment
Adjustment Adjustment Observe and comply with all instructions in the operating manual's chapter 1 Safety! In particular make sure that all safety covers are installed again correctly after making adjustments, see chapter 1.06 Operating manual hazard information! Unless otherwise stated, the machine must be disconnected from the mains before all adjustment work! Risk of injury due to accidental machine start-up! Notes on adjustment...
Page 65: Checking And Adjustment Aid
Adjustment Checking and adjustment aid By inserting the locating pins into the adjustment holes (ø 5 mm) 1, 3, 4, and 5 it is possible to precisely locate the needle bar position. Fig. 13 - 01  Turn the handwheel until the needle bar is approximately in the required position. ...
Page 66: Adjusting Basic Machine
Adjustment Adjusting basic machine Machine home position .06.01 With P323 MS control .06.01.01  Switch the machine on.  Call up “Input” mode.  Call up "Service"  Turn the handwheel in the sewing direction to determine the number of increments per revolution (this maximum value appears in the display under "POS"...
Page 67 Adjustment  Call up parameter '301'.  Turn the handwheel in the direction of rotation until the needle point (approaching from above) is ﬂ ush with the upper edge of the needle plate.  Conclude the input.  Switch the machine off. With P320 ED control .06.01.02 ...
Page 68 Adjustment  Call up "Motor Service"  Press this key to teach the ratio. Caution! On pressing this key the machine performs 3 stitches at a speed of 360 r.p.m.  Call up “Input” mode.  Call up parameter '301'. ...
Page 69 Adjustment .06.02 Needle to needle hole Rule 1. The needle 5 should pierce the middle of the stitch hole looking crossways to the sewing direction. 2. The clearance between the needle 5 and the front edge of the needle hole should be approximately 0.8 mm.
Page 70 Adjustment Pre-calibrating needle height .06.03 Rule When the needle bar is at t.d.c., Needle bar (adjustment hole 1), the clear- 3811 -3/55 ance X between the needle plate and the needle point should be 11 mm. When the needle bar is at t.d.c., Needle bar (adjustment hole 1), the clear- 3811 -15/65 ance X between the needle plate and the needle point should be 14 mm.
Page 71 Adjustment Zero position of the main feed dog .06.04 Rule The main feed dog 7 is not intended to perform a sliding movement when the stitch length regulation setting is "0" Fig. 13 - 04  Unscrew screw 1 (nut 2) (remove the stitch length limiting lever). ...
Page 72 Adjustment Zero position of the differential feed .06.05 Rule The differential feed 5 should not move with the stitch length regulation “0” and the ad- justment gauge 1 attached. Fig. 13 - 05  Set the stitch length to "0". ...
Page 73 Adjustment Sliding movement of the main and differential feed. .06.06 Rule With a stitch length regulation of “4”, needle bar position 0.8 before t.d.c. (Adjustment hole 4) and attached adjustment gauge 8 – when actuating the roller 5 the main and differ- ential feed should not move.
Page 74 Adjustment Lifting movement of main and differential feed .06.07 (only with PFAFF 3811-3/55) Rule When the needle bar is at t.d.c., Needle bar (adjusting hole 1) the cutout of the eccentrics 3 and 4 must point vertically downwards. Fig. 13 - 07 ...
Page 75 Adjustment Lifting movement of the main feed dog .06.08 Rule When the needle bar is at t.d.c., Needle bar (adjustment hole 1) the cutout of the eccen- trics 3 and 4 must point vertically downwards. Fig. 13 - 08  Loosen 2 screws 1. ...
Page 76 Adjustment Lifting movement of the differential feed .06.09 Rule In needle bar position 5.5 mm before t.d.c (Adjustment hole 5) the cutout of the eccentric 2 must point vertically downwards. Fig. 13 - 09  Loosen two screws 1.  Move needle bar to 5.5 mm before t.d.c. ...
Page 77 Adjustment Position of the main and differential feed for PFAFF 3811-3/55 .06.10 Rule When the needle bar is in t.d.c. (adjusting hole 1) is established and the largest stitch length is set, then 1. The main feed dog should be parallel at 1.4 mm and the differential feed should be parallel at 1.9 mm above the stitch plate,...
Page 78 Adjustment Position of the main and differential feed with PFAFF 3811-15/65 and 3811-16/65 .06.11 Rule At the largest stitch length and in its highest position, 1. The main feed dog should be parallel at 1.7 mm and the differential feed should be parallel at 2.0 mm above the stitch plate.
Page 79 Adjustment Zero position of the vibrating presser .06.12 Rule With the stitch length regulation “0” and the adjustment gauge 4 attached, the vibrating presser should not perform any sliding movement. Fig. 13 - 12 The stitch length limiting lever (screw 1 in Chapter 13.06.04 zero position of the main feed dog) must be lifted.
Page 80 Adjustment Front connecting rod of the top feed .06.13 Rule In needle bar position 0.8 mm before t.d.c (Adjustment hole 4) there should be a clear- ance of approximately 16.5 mm between the eye of connecting rod 2 and the machine housing 3.
Page 81 Adjustment Align the sewing foot .06.14 Rule 1. When the hand lever 1 is raised,the clearance between the presser foot 13 and needle plate 13 should be should be 5 mm. 2. The needle should pierce the centre of the needle hole in the presser foot 13. 3.
Page 82 Adjustment  Tighten screw 6.  Remove adjustment gauge 4 and ﬁ t the presser foot 13 onto the sewing plate.  Loosen the screw 14.  Swing lever 9 into the yoke of lever 10. (Lever 9 must move easily, otherwise adjust lever 10) ...
Page 83 Adjustment Sliding movement of the vibrating presser .06.15 Rule With a stitch length regulation of “4”, needle bar position 0.8 mm before t.d.c. (adjust- ment hole 4) lever 4 should not move when lever 2 is actuated. Fig. 13 - 15 ...
Page 84 Adjustment Lift of the vibrating presser .06.16 Rule With stitch length regulation “4” and attached adjustment gauge 12, the highest reversal point of the vibrating presser 2 should have a clearance of 3.2 mm to the sewing plate. Fig. 13 - 16 ...
Page 85 Adjustment Lifting movement of the vibrating presser .06.17 Rule With a stitch length regulation of “4” and attached setting gauge 3, the vibrating presser should ﬁ t against the bottom feed, once this has reached the upper surface of the sewing plate coming from below.
Page 86: Stitch Length Limitation
Adjustment Stitch length limitation .06.18 Rule 1. The lower rocker stop should be set so that the stitch length is 3811 -3/55 2.2 mm (x = 22 mm for 11 penetrations). 2. For the same stitch length the screw 4 should lightly abut on the casting.
Page 87 6.1 mm to the pressure sleeve 4. Fig. 13 - 19  Switch the machine on.  The following work step depends on the machine type. PFAFF 3811-15/65, -16/65: Press key "15" in keypad 1 (LED must illuminate). PFAFF3811-3/55 Set fullness to "0".
Page 88 Adjustment Setting the basic stitch length (not for PFAFF 3811-3/55) .06.20 Rule With stitch length regulation "and activated button “15” (cylinder 4 completely extended) the stitch length should be 3 mm. Fig. 13 - 20  Set stitch length “3” (lever 1) ...
Page 89 Adjustment Looper avoiding motion .06.21 Rule When the needle bar is at t.d.c., Needle bar (adjustment hole 1) the cutout of the eccentric 2 must point vertically downwards. Fig. 13 - 21  Loosen two screws 1.  Move the needle bar to t.d.c. ...
Page 90: Looper Motion
Adjustment Looper motion .06.22 Rule The hook point should be at the same height in the following positions: a) When the hook point is on the left side after turning the handwheel in the direction of rotation. b) When the hook point is on the right side after turning the handwheel back from position a).
Page 91 Adjustment Looper height and looper angle .06.23 Rule When the looper driver 2 is vertical 1. a clearance of 0.7 mm should be present between the highest point of the back of the hook and the stitch plate support, and 2.
Page 92 Adjustment  Place the looper adjustment 9 (order no. 61 111 643 06) on the left edge of the cover plate guide (see arrow) and push against the looper.  Move looper 7 (screw 8) to the hook adjustment gauge 9 (rule 2). Spacer Order no.
Page 93 Adjustment Hook to needle clearance in the sewing direction .06.24 Rule The clearance between the hook points and the needle in the direction of sewing should be approx. 0.1 mm. 0.1 mm Fig. 13 - 24  Turn the handwheel until the hook point reaches the left side of the needle from the right side.
Page 94 Adjustment Hook to needle clearance across the sewing direction .06.25 Rule At the right reversal point of the looper 1, the hook point across the sewing direction should have a clearance of 3.6 mm to the centre of the needle. 3.6 mm Fig.
Page 95 Adjustment .06.26 Readjusting needle height Rule If the hook point has reached the left side of the needle coming from the right side, the top edge of the needle eye should be 1.0 - 1.2 mm below the under edge of the looper. Fig.
Page 96 Adjustment Height of the rear needle guard .06.27 Rule When the needle bar is in b.d.c., Needle bar (adjustment hole 3) the vertical surface of the needle guard 1 should cover approximately 2/3 of the needle eye. Fig. 13 - 27 ...
Page 97 Adjustment Clearance between the rear needle guard and the needle. .06.28 Rule When the hook point touches the side of the needle coming from the right side, the nee- dle guard 3 should lightly touch the needle. Fig. 13 - 28 ...
Page 98 Adjustment Position of the front needle guard .05.29 Rule When the looper point1 is in the centre of the needle coming from the right side, the nee- dle guard bar should 4 1. have a lateral clearance 0.3 - 0.5 mm to the needle, 2.
Page 99 Adjustment Looper avoiding motion guard .06.30 Rule Eccentric 3 should not touch the guard 1 when moving. Fig. 13 - 30  Align the protective plate 1 (screws 2, accessible through the adjustment holes) accord- ing to the rule.
Page 100 Adjustment Needle thread puller .06.31 Rule 1. When the needle bar is in b.d.c., Needle bar (adjustment hole 3), there should be a clearance of approximately 0.3 mm between the needle thread puller 2 and the needle bar frame 3 2.
Page 101 Adjustment Home position of the needle thread controller and thread guide. .06.32 Rule 1. When the needle bar is in b.d.c., Needle bar (adjustment hole 3) the eye of the needle thread controller 1 and the hole in the needle thread puller 4 should be at the same height.
Page 102 Adjustment Looper thread regulator and looper thread controller .06.33 Rule 1. The clearance between the front edge of the thread regulator 1 and the rear stitch plate edge guide should be 29 mm. 2. The front edges of the thread controller 3 and thread regulator 1 should have approxi- mately 8 mm clearance.
Page 103: Looper Thread Puller
Adjustment Looper thread puller .06.34 Rule When the needle bar is at t.d.c., Needle bar (adjustment hole 1) both looper thread puller eyes 1 should stand on the front edge of the thread controller 4. Fig. 13 - 34  Move the needle bar to t.d.c. ...
Page 104 Adjustment Vibrating presser and pressure foot pressure .06.35 Rule The pressure exerted by the vibrating presser and the presser foot should be set so that the material being sewn is optimally transported at every sewing speed. approx. 12 mm Fig. 13 - 35 ...
Page 105: Adjusting The Edge Cutting Equipment
Adjustment Adjusting the edge cutting equipment. Cutting movement .07.01 Rule When the needle bar is at t.d.c., Needle bar the knife should be in its upper reversal point. Fig. 13 - 36  Turn the eccentric 1 (screw 2) according to the rule.
Page 106 Adjustment Zero point .07.02 Rule With cylinder 3 completely extended the knife should not move when the handwheel is turned. Fig. 13 - 37  Turn crank 1 (screws 2) according to the rule.
Page 107 Adjustment Cylinder drive home position .07.03 Rule With cylinder 3 fully retracted the nut 4 should have a clearance of 10 mm from the lower edge of cylinder 3. Fig. 13 - 38  Adjust stop 1 (screw 2) according to the rule.
Page 108 Adjustment Knife height .07.04 Rule At the knife 1 reversal point, the front edge of the knife 1 should be approximately 0.5 mm below the upper edge of the stitch plate. Fig. 13 - 39  Adjust the knife 1 (screw 2) according to the rule.
Page 109 Adjustment 13.07.05 Knife position crossways to sewing direction Rule 1. The knife 3 should abut the stationary knife with slight pressure. 2. In doing so knife 3 must not make contact with the sewing plate. Fig. 13 - 40  Adjust the knife to its lowest position and adjust the knife carrier 1 (screw 2) according to the rule.
Page 110: Adjusting The Thread Trimmer
Adjustment Adjusting the thread trimmer Pre-calibrating the thread catcher .08.01 Rule 1. The point of the thread catcher 4 should have a clearance of 32.5 - 33 mm from the front edge of the carrier plate 1. 2. The guide rails 5 should be parallel to carrier plate 1. 3.
Page 111 Adjustment Position of the ball pins .08.02 Rule In the vertical position the ball pins 1 should 1. be in the centre of the actuator 5 and 2 have a clearance of 0.5 mm from the root of actuator 5. Fig.
Page 112 Adjustment Thread catcher position to the needle .08.03 Rule When the thread trimmer device is in neutral position, the tip of the thread catcher 4 should have a clearance of 4 mm from the centre of the needle. 7 mm Fig.
Page 113 Adjustment Thread catcher guard .08.04 Rule 1. With the needle bar in the t.d.c. position the guide roller 3 should be in the centre of the cutout in the securing curve 2. 2. In the home position of the thread trimmer and the needle bar in the t.d.c. position there should be a clearance between the securing curve 2 and the guide roller 3 of 0.5 –...
Page 114 Adjustment Tension release .08.05 Rule With the cylinder fully actuated there should be a clearance between the upper edge of the slot in plate 1 and the guide pins 3 of approximately 0.5 mm. Fig. 13 - 45  Fully extend the thread trimmer cylinder. ...
Page 115: Test Cut
Adjustment Test cut .08.06 Rule 1. The point of the thread catcher 2 should reliably capture the looper thread and the rear part of the needle thread loop. 2. The thread must be undamaged with the cover plate 1 removed. 3.
Page 116 Adjustment Setting the position sensor .08.07 Rule After trimming the thread the machine should be at 0.3 – 0.4 mm before t.d.c. Position the needle bar. Fig. 13 - 47  Adjust position sensor 1 (screw 2) according to the operating manual for the motor, see also Chapter 13.09 Parameter settings.
Page 117: Parameter Settings
Adjustment Parameter settings Overview of the parameter functions .09.01 After switching the machine on, the input mode is called, in which the individual parameters can be directly called by pressing the desired function. All parameter groups or also individu- al ones can be protected by a code against unauthorised access. Select parameter User level Mechanic level...
Page 118 Adjustment 13.09.02 Example of a parameter input  Switch the machine on.  Call up “Input” mode.  E.g, call up parameter “113” (signal tone sounds at seam zone change on/ off).  E.g., signal tone when switching on (value “ON”). ...
Page 119: List Of Parameters
OFF - ON Maximum speed in every forward pedal position 3 - 5 Machine conﬁ guration 3 = 3811-3/55 4 = 3811-15/... 5 = 3811-16/... Fullness correction value (keypad) 0 - 9 Switch off the edge knife (at pedal posi- OFF - ON tion “-2”)
Page 120 Adjustment Group Parameter Description Setting Setting range range P-section speed regulator 1 – 50 I-section speed regulator 0 – 100 1 – 50 P-section position controller 1 – 100 P320 MS (40) D-section position controller P320 ED (10) Time for position controller 0 –...
Page 121 Adjustment Group Parameter Description Setting Setting range range Access rights for function group 700 0 – 1 Access rights for function group 800 0 – 1 0 – 1 Programming access rights 0 – 9999 3800) Input access code...
Page 122: Sewing Motor Errors
Adjustment Sewing motor errors Message Description Invalid parameter value Brake path too short Communication error with limit monitoring Switch-on sequence not complete Too many commands Mains off during initialisation Excess current directly after mains on Short circuit Overcurrent in operation No increments Motor blocked No incremental plug...
Page 123: Error Message Explanations
Adjustment Error message explanations Message Description E001 System error E002 Sewing motor E002/BB/xxx BB = 20: Deadman 02: Position forwards 03: Position in reverse 05: Position by shortest route 09: Write parameters 10: Speed 0A: Reset stitch counter 0B: Stop after xxx stitches 30: Timeout for increasing speed 31: Timeout from uncertain positioning 32: Timeout from deadman command...
Page 124: Inputs Table
Adjustment Inputs table Free free free Start inhibitor free Knee switch free free free free free free free free Light barrier tape feed (for machines with a tape feed) E 16 Reference for the fullness adjustment Outputs table Lift sewing foot (O1.1 and O1.2) Thread trimmer (O2.1 and O2.2) Tape brake Stitch length 4 mm / 3 mm...
Page 125: Service Menu
Adjustment Service menu Information about machine inputs and outputs as well as values for the pedal and the hand- wheel position are displayed in the service menu. In addition, the functions shown below can be performed.  Switch the machine on. ...
Page 126: Run Cold Start
Adjustment Run cold start  Switch the machine on.  Call up “Input” mode.  Call up the service menu.  Run cold start. After a cold start, all programmed values are reset to their as-delivered status. All seam programs are also deleted!
Page 127: Internet Update Of Machine Software
Adjustment Internet update of machine software The machine software can be updated using PFAFF ﬂ ash-programming. The PFP-boot pro- gram as well as the corresponding control software for the machine type must be installed on a PC for this purpose. The PC and machine control unit must be connected to an appro- priate null modem cable (order no.
Page 128: Wear And Tear Parts
A detailed parts list for the complete machine can be downloaded at www.pfaff-industrial.de/de/service-support/downloads/technical. As an alternative to the Internet download, the parts list can also be requested as a hard copy under order no. 296-12-18 591. PFAFF 3811-16/65 PFAFF 3811-3/55; -15/65 11-108 849-25 (2x) 12-305 074-25 (2x) 11-330 085-15 11-330 958-15...
Page 129: Circuit Diagrams
Circuit Diagrams Circuit Diagrams Pneumatic circuit diagram 91-196 282-95 (version 12/01/2006)
Page 130: Reference List For Circuit Diagrams 91-191 493-95
Initiator reference (SM1) Y1 910/.. Automatic presser foot Y2 900/.. Thread trimmer (option) Y3 Tape brake option Y4 Stitch length 3/4 mm only with PFAFF 3811-15/65, -16/65 Y7 Edge trimmer only with PFAFF 3811-16/65 910/.. Automatic presser foot 900/.. Thread trimmer (Option)
Page 131 Circuit Diagrams Circuit diagram Version 01/09/2005 91-191 493-95 Part 1...
Page 132 Circuit Diagrams 91-191 493-95 Part 2 Version 01/09/2005 Circuit diagram...
Page 133 Circuit Diagrams Circuit diagram Version 01/09/2005 91-191 493-95 Part 3...
Page 134 Circuit Diagrams 91-191 493-95 Part 4 Version 01/09/2005 Circuit diagram...
Page 135: Table Top
Table top assembly Table Top Table top cutout...
Page 136: Table Top Assembly
Table top cutout Table top assembly...
Page 137 Notes...
Page 138 PFAFF Industriesysteme und Maschinen GmbH Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Tel.: +49 6301 3205-0 Fax: +49 6301 3205-1386 E-mail: info@pfaff-industrial.com Printed in Germany...

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