Page 1 3741 3745 DOKU-SEAM-SYSTEM 296-12-19 008/002 Betriebsanleitung engl. 06.12...
Page 2 The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or in part, is only permitted with our previous authorization and with written reference to the source. PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern...
Page 3: Table Of Contents
Index Contents ................Page Register 01 ....................5 Safety ............................ 7 Directives ..........................7 General notes on safety ......................7 Safety symbols ........................8 Important points for the user ....................8 Operating and specialist personnel ..................9 .05.01 Operating personnel ......................9 .05.02 Specialist personnel .......................
Page 4 .07 .03 Inserting the needle ......................53 .07 .04 Winding the bobbin thread, regulating the winder tension (PFAFF 3741+ 3745 PLUS) ..54 .07 .05 Winding the bobbin thread, regulating the winder tension (PFAFF 3745 PREMIUM) ..55 .07 .06 Bobbin-changing/threading, and regulating the bobbin thread tension ........
Page 5 Index Contents ................Page Register 04 ....................73 Adjustment ......................... 76 Notes on adjustment ......................76 Tools, gauges and other accessories for adjusting ............. 76 Abbreviations ........................76 Explanation of the symbols ....................76 Adjusting the basic machine ....................77 .05.01 Basic position of the balance wheel (adjustment aid) ............
Page 6 Recording the characteristic thread strength curve ............124 Checking the calibration (calibration result) ................ 127 Register 06 .....................127 Circuit diagrams ....................... 129 Pneumatics-switch diagram PFAFF 3741 + 3745 .............. 129 Block diagram PFAFF 3741 + 3745 (with control unit P374 ED) ......... 130 Circuit diagrams ......................... 132...
Page 9: Safety
Safety Safety Directives This machine is constructed in accordance with the European regulations contained in the conformity and manufacturer’s declarations. In addition to this Instruction Manual, also observe all generally accepted, statutory and other regulations and legal requirements and all valid environmental protection regulations! The regionally valid regulations of the social insurance society for occupational accidents or other supervisory organizations are to be strictly adhered to! General notes on safety...
Page 10: Safety Symbols
● It is the obligation of the user to ensure that none of the safety mechanisms are removed or deactivated. ● It is the obligation of the user to ensure that only authorized persons operate and work on the machine. Further information can be obtained from your PFAFF agent.
Page 11: Operating And Specialist Personnel
Safety Operating and specialist personnel Operating personnel .05.01 Operating personnel are persons responsible for the equipping, operating and cleaning of the machine as well as for taking care of problems arising in the sewing area. The operating personnel is required to observe the following points and must: ●...
Page 12: Danger Warnings
Safety Danger warnings A working area of 1 m must be kept free both in front of and behind the machi- ne, so that easy access is possible at all times. Never put your hands or ﬁ ngers in the sewing area during sewing! Danger of injury by the needle! While setting or adjusting the machine do not leave any objects on the table nor in the needle plate area! Objects may be trapped or ﬂ...
Page 13 PC-software: ..........Control software:............. Each person working on the PFAFF-DOKU-SEAM-SYSTEM must be familiar with and understand the contents of these technical documents. The operating and qualiﬁ ed personnel must be appropriately authorised to handle the machine, i.e. qualiﬁ ed and instructed. The operator promises to train his personnel accordingly.
Page 17 3741 3745 SHORT INSTRUCTIONS FOR THE INPUT This instruction manual applies to machines from software version 1.8 and serial number 2 763 625 onwards Kurzanleitung zur Eingabe engl. 06.12...
Page 18: Input
Input Input General information The effective pull of the needle thread (needle thread tension) is determined during sewing for each stitch by means of a sensor installed in the needle thread path of the sewing ma- chine. In the process, through a special measuring principle, measuring errors, caused for example by ﬂ...
Page 19: Overview Of The Functions
Input Overview of the functions...
Page 20: Description Of The Functions
Input Description of the functions Each function is selected by tapping the appropriate symbols on the touch- screen monitor. Overlapping functions .03.01 Mode selection The menu for selecting the operating mode is called up, see Chapter 2.03.02 Operating modes. Choice of language A menu for selecting the language setting is opened, see Chapter 8 Setting up in the In- struction Manual.
Page 21: Operating Modes
Input Operating modes .03.02 Selecting and conﬁ guring seam programs Functions for selecting, processing and creating seam programs are called up, see Chapter 2.04 Creating seam programs. Tools A menu is called up for selecting functions for the sewing head, control unit and printer. Change of user The box for entering the user is called up.
Page 22: Creating Seam Programs
Input Creating seam programs ● Log-in as supervisor. ● Call up the seam program selection function. Industrial 20.06.2006 20.06.2006 23.07.2006 24.07.2006 There are several possibilities of how to create a seam program. ● Select a seam program from the list. ●...
Page 23 Input Industrial ● Call up the Program Header function. Artikel 2b Material @ @ @ ● If necessary, enter/change the program number, process-ID and comment. ● Enter the value for the stitch length correction dependent on the material. ● Enter/change the value for the second stitch length (can be called up with the appropriate key on the machine head).
Page 24 Input Input Scan Options with wildcard characters in the program-header 1. With input of $$ before a character string or $$ after a character string, only the character string is controlled, true or not true. All characters before or after the character string are only documented Sample: Header input: $$123456789$$ Bar code :...
Page 25 Input ● Select the action and enter/change the appropriate values, see Chapter 2.04.02 Input of action at beginning of seam sector. ● Call up the menu for the input of the recognition of the end of the seam sector. Depend- ing on the function selected, the symbol may be different.
Page 26: Sewing Parameter Input
Input Sewing parameter input .04.01 ● In seam programming call up the menu for sewing parameter input. Description of the functions Stitch length input After tapping area 1, the input menu for the stitch length in the current seam sector is called Sewing foot lift input After tapping area 2, the input menu for the presser foot lift in the current seam sector is called up.
Page 27: Input Of Action At Beginning Of Seam Sector
Input Input of action at beginning of seam sector .04.02 ● Call up the menu for the input of the action at the beginning of the seam, see Chapter 2.04 Creating seam programs. 2 3 4 Description of the functions Start bartacks and condensed start stitches off After selecting function 1, neither a start bartack nor a condensed start stitch is sewn at the beginning of the seam sector.
Page 28: Input Of End Of Seam Sector
Input Input of end of seam sector .04.03 ● Call up the input for the recognition of the end of the seam sector, see Chapter 2.04 Cre- ating seam programs. 1 2 3 4 5 6 Description of the functions End of seam sector by pedal function After function 1 has been selected, the end of the seam sector is started with the pedal function.
Page 29: Input Of Action At End Of Seam Sector
Input Input of action at end of seam sector .04.04 ● Call up the menu for the input of the actions at the end of the seam, see Chapter 2.04 Creating seam programs. 2 3 4 Description of the functions End bartacks and condensed end stitches off After selecting function 1, neither an end bartack nor a condensed end stitch is sewn at the end of the seam sector.
Page 30 Input Print label on/off This function is used to switch the label printing function at the end of the seam sector on or off. Selection of the label The label, which is to be attached, can be selected in sector 7. Label payout The number of labels to be printed can be selected in range 8.
Page 31: Thread Force
Thread force .04.05 ● Call up the menu for entering the parameters for the sensor in the seam programming menu or from the service menu. 8 9 10 PFAFF 3745 PREMIUM Fadenkraft PFAFF 3741 PLUS PFAFF 3745 PLUS Fadenkraft Description of the functions Hard top limit value The limit value is entered in sector 1.
Page 32 The limit value is entered in sector 4 In the docu-seam area this value may be exceeded a few times. The number of tolerance stitches is entered in sector 7. Setpoint (only on the PFAFF 3745 PREMIUM) The Setpoint is entered in sector 5. Soft bottom limit The limit value is entered in sector 6.
Page 33: Service
Input Service In the service menu the states of the digital and analogue inputs are displayed. The outputs can be set and reset manually. In addition functions for adjusting the drives, the sensors and the edge guide can be called up, and information about the status of software and ﬁ rmware displayed.
Page 34: Cold Start
Input Version After this function has been selected, the current status of the machine’s software and ﬁ rmware is displayed. Scanner For scanner commissioning, please see chapter 4.07.03 in the settings manual. Camera For camera commissioning, please see chapter 4.07.04 in the settings manual. Cold start When a cold start is carried out, all altered parameter for the sewing head are deleted and set back to default values (status at the time of delivery)!
Page 35: Users - Rights
Input Users – rights A user ID must be entered at initial power up of the machine. On delivery of the machine, the user ID "pfaff" must be entered. Benutzer-ID pfaff Any number of users can be added and/or edited. The rights of individual users are deﬁ ned by allocating the users to relevant user groups.
Page 36 Input Function descriptions Docu-seam can be ended Label copy can be created Manual seam interruption can be switched on Test seam mode can be activated Seam programme can be activated Production can be interrupted Seam programme can be created Docu-seam error can be ignored...
Page 37: Backup - Restore
Input Backup – restore During a back-up the current database is saved. The backup can be saved on the hard disk of a PC or on an external data carrier (e.g. USB-stick). A backup should be carried out by the su- pervisor at regular intervals.
Page 38 Input Daten base explorer Shows the data base content. Daten base setting Select your data base type and the data base connection ( see window 3 and 4).
Page 39: Label-Editor
● Select the "tools" function. ● Call up the label editor. Industrial PFAFF 3745 Hochformat ● Select the desired label (label number) by tapping the arrow keys 1. ● If necessary, change the size of the label by tapping the selection boxes 2 and 3.
Page 40 Input Industrial Hochformat If a picture element is selected from list 13, the symbol 14 appears on the monitor. ● Select an appropriate label element (e.g. "picture 1) by tapping it on list 13. ● Select the desired picture ﬁ le with function 14. The picture appears as a preview. The picture element can be shifted as described above and the size changed.
Page 41: Deﬁ Ning Options And Interfaces
Input Deﬁ ning options and interfaces In this function, options like label printer, thread type, material type, service, and day coun- ter, as well as control interfaces can be deﬁ ned. ● Log on as administrator or setter. ● Select function "Tools". ●...
Page 42 Input ● Input number of stitches until neele change in window 6 (once preset threshold value 7 is reached, the error message "Change needle“ will be displayed; a re-set of the actual value will re-start the count). ● A daily or weekly parts counter can be speciﬁ...
Page 45: Betriebsanleitung
3741 3745 INSTRUCTION MANUAL This instruction manual applies to machines from software version 1.8 and serial number 2 763 625 onwards Betriebsanleitung engl. 06.12...
Page 46: Proper Use
Proper use Proper use The PFAFF 3741 PLUS is a workplace with a single-needle, lockstitch, special high-speed sewing machine with bottom and needle feed, mechanical tensioning, a mechanical bobbin winder, and a large hook and docu-seam system. The PFAFF 3745 PREMIUM is a workplace with a single-needle, lockstitch, special high- speed sewing machine with unison feed, electrically controlled tensioning, an electrical bobbin winder, and a large or extra large hook and docu-seam system.
Page 47: Speciﬁ Cations
Speciﬁ cations ❋ Speciﬁ cations Stitch type: ......................301 (lockstitch) Needle system: ......................134-35 Version: ........................BN9, CN9 Needle size in 1/100 mm Version BN9: ....................... 80 – 100 Version CN9: ......................110 – 140 Max. stitch length: Version CN9: ........................9 mm Max.thread size (synthetic): ▲...
Page 48: Disposal Of Machine
Disposal of Machine Disposal of Machine ● Proper disposal of the machine is the responsibility of the customer. ● The materials used for the machine are steel, aluminium, brass and various plastic materials. The electrical equipment comprises plastic materials and copper. ●...
Page 49: Transportation, Packing And Storage
Transportation, packing and storage Transportation, packing and storage Transportation to customer‘s premises .04.01 The machines are delivered completely packed. Transportation inside the customer‘s premises .04.02 The manufacturer cannot be made liable for transportation inside the customer‘s premises nor to other operating locations. It must be ensured that the machines are only transported in an upright position.
Page 50: Explanation Of Symbols
Explanation of symbols Explanation of symbols In this instruction manual, work to be carried out or important information is accentuated by symbols. These symbols have the following meanings: Note, information Cleaning, care Lubrication Maintenance, repairs, adjustment, service work (only to be carried out by technical staff)
Page 51: Controls
Controls Controls On/off switch / Sewing lamp switch .06.01 ● To switch the control system of the machine on or off, turn main switch 1. Please note that when activating the machine, the machine must be activated ﬁ rst, and then the power bar. ●...
Page 52: Keyboard On Machine Head
Controls Keyboard on machine head .06.03 Fig. 6 - 05 ● The machine has a keyboard with 8 keys to activate different functions. ● In the keys 2 – 7 there are yellow LEDs. These shine when the respective function has been allocated to key 1.
Page 53 Key 4: Calling up the pre-selected top feed lift (Diode on = 2nd lift, diode off = standard lift) This button is without function in the model PFAFF 3741. Key 5: Bartack suppression for one bartack (under Parameter 780 other functions can be assigned to this key)
Page 54: Pedal
Controls Pedal .06.04 ● With the on/off switch on Machine stop +1 = - 1 = Raise presserfoot - 2 = Trim thread (on machines with thread trimmer) Fig. 6 - 04 Lever for lifting the presser foot .06.05 ● The sewing foot can be lifted by raising lever 1.
Page 55: Knee Switch (Optional)
Controls Knee switch .06.06 (optional) ● If the knee switch is operated, the docu- seam sector is switched on or off. Fig. 6 - 06 Bobbin thread supply monitor .06.07 ● When the residual thread amount is reached, symbol lamp A ﬂ ashes. ●...
Page 56: Adjustment Of The Stand Height (Optional)
Controls Adjustment of the stand height .06.08 (optional) ● The stand height can be adjusted by ope- rating switch-key 1 accordingly. Fig. 6 - 08 Touch-screen monitor .06.09 ● All necessary inputs are carried out on the touch-screen monitor. The appropri- ate operating mode, messages, parame- ters etc.
Page 57: Label-Printer
Controls Label-printer .06.10 ● The label printer 1 is used for printing the label. Fig. 6 - 10 Hand-held scanner .06.11 ● With the aid of the hand-held scanner, af- ter pressing key 1 it is possible to read user and process data. For example, the user log-in, the input of material, needle thread and bobbin thread data can be car- ried out with the hand-held scanner.
Page 58: Setting Up
Setting up Setting up All instructions and regulations in this instruction manual must be observed. Special attention should be given to all safety regulations. All setting-up work may only be carried out by appropriately trained personnel. Log-in .07 .01 ● Switch on the machine on the power bar and wait until the PC has started. Industrial Benutzer-ID Max Mustermann...
Page 59: Inserting The Needle
Setting up Inserting the needle .07 .03 Only change the needle when the threading aid is activated! Danger of injury if the machine suddenly starts running! Only use needles from the sys- tem intended for the machine, see Chapter 3 Speciﬁ cations! Fig.
Page 60: Winding The Bobbin Thread, Regulating The Winder Tension (Pfaff 3741+ 3745 Plus)
Setting up Winding the bobbin thread, regulating the winder tension .07 .04 (PFAFF 3741+ 3745 PLUS) Fig. 7 -04 ● Draw the thread from the reel stand through guide hole 1 into the bobbin winder tension unit 2 and then behind the thread clamp 3.
Page 61: Winding The Bobbin Thread, Regulating The Winder Tension (Pfaff 3745 Premium)
Setting up Winding the bobbin thread, regulating the winder tension .07 .05 (PFAFF 3745 PREMIUM) Fig. 7 -05 The requirement for the following steps is that the machine is in the production mode, see Chapter 9 Sewing. ● Select the "winding" function.
Page 62: Bobbin-Changing/Threading, And Regulating The Bobbin Thread Tension
Setting up Bobbin-changing/threading, and regulating the bobbin thread tension .07 .06 Fig. 7 -06 Fig. 7 -06a Only change the bobbin when the threading aid is activated! Danger of injury if the machine suddenly starts running! ● Activate the threading aid on the machine head by pressing the key. ●...
Page 63: Threading The Needle Thread (Pfaff 3741 Plus + 3745 Plus)
Setting up Threading the needle thread .07 .07 (PFAFF 3741 PLUS + 3745 PLUS) Fig. 7 - 07 Only thread the needle thread when the threading aid is activated! Danger of injury if the machine suddenly starts running! ● Activate the threading aid on the machine head by pressing the key.
Page 64: Threading The Needle Thread (Pfaff 3745 Premium)
Setting up Threading the needle thread .07 .08 (PFAFF 3745 PREMIUM) Fig. 7 - 08 Only thread the needle thread when the threading aid is activated! Danger of injury if the machine suddenly starts running! ● Activate the threading aid on the machine head by pressing the key.
Page 65: Sewing
Sewing Sewing The machine may only be operated by appropriately trained personnel! The operating personnel must ensure that only authorised persons are in the danger zone of the machine! Following conditions must be fulﬁ lled for sewing: ● All safety equipment must be attached, see Chapter 1.06 Danger warnings. ●...
Page 66: Calling Up / Carry Out The Sewing Operation (With Camera For Bobbin Thread Monitor)
Sewing Calling up / carry out the sewing operation .08.02 (with camera for bobbin thread monitor) After the user’s log-in, following steps must be carried out: ● Call up the seam program selection function. Industrial Default-Programm 20.06.2006 Manual 29.03.2012 Unterfaden-Kamera 04.04.2012 Doku-Test 29.03.2012...
Page 67 Sewing ● A green bar above the image means - reading process is under way. ● Turn bobbin as needed to allow reading of DATA Matrix code. ● A red bar above the image means - reading process is not under way (camera error or bobbin cover 1 not in reading position).
Page 68: Regulating The Needle Thread Tension (Pfaff 3741 + 3745 Plus)
Sewing Regulating the needle thread tension .08.03 (PFAFF 3741 + 3745 PLUS) ● Call up the seam program selection function. Industrial 20.06.2006 20.06.2006 23.07.2006 24.07.2006 ● Select the desired program from the list. ● Call up the production function. Industrial ●...
Page 69 Sewing Fig. 8 - 01 ● Set the adjustment nut 1 with an Allen key 2 so that the upper thread tension is set to the median value of the monitoring range. ● The new value is stored by pressing the button "Trial Seam" again.
Page 70 Sewing Regulating the needle thread tension .08.04 (PFAFF 3745 PREMIUM) ● Call up the seam program selection function. Industrial 20.06.2006 20.06.2006 23.07.2006 24.07.2006 ● Select the desired program from the list. ● Call up the production function. Industrial ● Call up the function "Trial Seam".
Page 71 Sewing ● Set the value for the upper thread tension via the arrow keys 1, so that the upper thread tension is set to the median value of the monitoring range. ● The new value is stored by pressing the button "Trial Seam" again.
Page 72: Description Of The Functions
Sewing Description of the functions .08.05 After the production function has been selected, the following menu appears. Industrial Work instructions After this function has been selected, the work instructions for the selected seam program displayed. Display of the seam sectors The seam sectors of the seam program are shown in sector 1.
Page 73 No label is printed and no identiﬁ cation number is recorded in the databa- Bobbin winding ( only on the PFAFF 3745 PREMIUM) The winding operating is carried out, see Chapter 7.04 Winding the bobbin thread… Help mode After the help mode has been selected, the next function selected is described.
Page 74: Concluding The Sewing Operation
Sewing Concluding the sewing operation .08.06 ● To end the sewing operation, call up the next level. ● Shut down the PC. ● Switch off the machine on the power bar and at the main switch.
Page 75: Care And Maintenance
Care and maintenance Care and maintenance Servicing and maintenance intervals .09.01 Clean the hook compartment .......Daily, several times if in continuous use Check the oil level ............Daily, before starting the machine Check/adjust the air pressure ......... Daily, before starting the machine Clean the ﬁ...
Page 76: Lubricating
Oil level indicator 2 must not exceed the "MAX" marking. Only use oil with a medium viscosity of 22.0 mm²/s at 40° C and a density of 0.865 g/cm³ at 15°C! We recommend PFAFF sewing-machine oil, part No. 280-1-120 144.
Page 77: Checking/Regulating The Air Pressure
Care and maintenance Checking/regulating the air pressure .09.04 ● Check the air pressure on gauge 1 every time before operation. ● Gauge 1 must show a pressure of 6 bar. ● Regulate this pressure if required. ● To do so, pull knob 2 up and turn it accor- dingly.
Page 78: Wearing Parts
A detailed parts list for the complete machine is included with the accessories. In case of loss, the parts list can be downloaded from the internet address www.pfaff-industrial.com/pfaff/de/service/downloads As an alternative to the internet download the parts lists can also be ordered in book form under part no.
Page 79 Wearing parts PFAFF 3745 PREMIUM ø 32 ø 26 91-510 045-04 91-510 139-04 91-510 140-91 91-510 089-91 91-510 141-91 91-510 088-91 91-510 164-05 91-510 164-05 91-501 028-15 91-501 028-15 91-501 029-15 91-501 029-15 91-501 027-05 91-501 037-05 91-501 020-15 (3x)
Page 80 Wearing parts PFAFF 3745 PLUS PFAFF 3745 PLUS ø 26 91-501 288-05 91-501 017-91 91-501 030-91 91-501 026-05 91-501 028-15 91-501 029-15 91-501 037-05 91-501 020-15 (3x) 91-501 031-05 11-250 078-15 11-130 092-25 (2x) 91-501 034-05 11-330 280-15 (2x) 11-130 092-25...
Page 83 3741 ADJUSTMENT MANUAL This instruction manual applies to machines from software version 1.8 and serial number 2 763 625 onwards Justieranleitung engl. 06.12...
Page 84: Adjustment
Adjustment Adjustment Please observe all notes from Chapter 1 Safety of the instruction manual! In particular care must be taken to see that all protective devices are reﬁ tted properly after adjustment, see Chapter 4.06 Danger warnings of the instruc- tion manual! If not otherwise stated, the machine must be disconnected from the electrical power supply.
Page 85: Adjusting The Basic Machine
Adjustment Adjusting the basic machine Basic position of the balance wheel .05.01 (adjustment aid) Requirement When the needle bar is positioned at t.d.c., the marking "0" on the scale should be level with the top edge of the belt guard (see arrow). Fig.
Page 86: Zero Position Of The Bottom And Needle Feed
Adjustment Zero position of the bottom and needle feed .05.02 Requirement At stitch length setting "0" 1. turning the handwheel, the bottom transporter and the needle bar should not move, and 2. the bolt of lever 7 should be set to the middle position of recess 8. 3.
Page 87: Feed Dog Motion Of Bottom Feed Dog And Needle Feed
Adjustment Feed dog motion of bottom feed dog and needle feed .05.03 Requirement Bottom transporters, as well as the needle bar should not move, when stitch platen 3 is activated with handwheel at 190° or higher. Fig. 4 - 03 ●...
Page 88: Feeding Motion Of The Bottom Feed Dog
Adjustment Feeding motion of the bottom feed dog .05.04 Requirement When the balance wheel is positioned at 180°, the feed dog should be at t.d.c. Fig. 4 - 04 ● Adjust eccentric 1 (screws 2) in accordance with the requirement.
Page 89: Height Of The Bottom Feed Dog
Adjustment Height of the bottom feed dog .05.05 Requirement 1. When the needle bar is positioned at b.d.c. (balance wheel position 180°), the bottom feed dog should be positioned 0.5 mm horizontally above the top edge of the needle plate, when crank 6 is in the centre of the slot. 2.
Page 90: Feeding Stroke Difference
Adjustment Feeding stroke difference .05.06 Requirement With the maximum stitch length set, when the balance wheel is turned the feeding strokes of the needle and the bottom feed dog should be the same. Fig. 4 - 06 ● With connecting rod 1 (nut 2) increase ("+") or reduce (-) the needle feed stroke in accordance with the requirement.
Page 91: Preliminary Adjustment Of The Needle Height
Adjustment Preliminary adjustment of the needle height .05.07 Requirement When the needle bar is positioned at t.d.c. (balance wheel position 0°), the clearance be- tween the needle point and the needle plate should be 22 mm. 22 mm Fig. 4 - 07 ●...
Page 92: Needle Rise, Hook Clearance, Needle Height And Bobbin Case Position Fi Nger
Adjustment Needle rise, hook clearance, needle height and bobbin case position ﬁ nger .05.08 Requirement For stitch length setting "4.0" and needle bar position 2.0 mm to u.T. ( = handwheel position 202°): 1. The hook point should be positioned at needle centre with a needle cut clearance of 0.05 –...
Page 93: Bobbin Case Opener
Adjustment Bobbin case opener .05.09 Requirement 1. When turning the handwheel, the horn 4 should be lifted off the stitch platen 5 on the right turning point of the bobbin lift 1 by the thread thickness. 2. Bobbin lift upper edge, and lower bobbin upper edge should be at same level. 3.
Page 94: Bobbin Winder
Adjustment Bobbin winder .05.10 Requirement 1. When the bobbin winder is engaged, the winding spindle must be driven reliably. When it is disengaged, friction wheel 3 should not be touching drive wheel 1. 2. When it is switched off, the bobbin winder must click securely into its end position (knife raised).
Page 95: Thread Check Spring And Thread Regulator
Adjustment Thread check spring and thread regulator .05.11 Requirement 1. The movement of thread regulator 3 must be completed when the needle point enters the material (spring stroke approx. 7 mm). 2. When the thread loop is at its largest while being passed around the hook, the check thread spring 3 should rise slightly from the rest 1.
Page 96: Sewing Foot Pressure
Adjustment Sewing foot pressure .05.12 Requirement The material should be fed properly even at maximum speed and with the smallest stroke. Fig. 4 - 12 ● Turn adjustment wheel 1 in accordance with the requirement.
Page 97: Lubrication
Adjustment Lubrication .05.13 Requirement After 10 seconds operation at 800 rpm, a light oil strip should appear on a paper strip held to the clamp foot. Fig. 4 - 13 127-093 ● Check that the machine is ﬁ lled with oil and that the oil lines are free of air. ●...
Page 98: Reengaging The Slip Clutch
Adjustment Reengaging the slip clutch .05.14 Clutch 1 is pre-set by the manufacturer. If the thread jams, clutch 1 disengages in order to avoid damage to the hooks. Below is a description of how to engage clutch 1. 127-095 Fig. 4 - 14 ●...
Page 99: Adjusting The Thread Trimmer -900/81
Adjustment Adjusting the thread trimmer -900/81 Resting position of the roller lever / radial position of the control cam .06.01 Requirement 1. When the take-up lever is at t.d.c. (balance wheel position 60 °), control cam 1 should just have moved roller lever 5 into its basic position. 2.
Page 100: Position And Height Of The Thread Catcher
Adjustment Position and height of the thread catcher .06.02 Requirement When the needle bar is positioned at b.d.c. (balance wheel position 180°) the edges of thread catcher 3 and knife 5 should be ﬂ ush (see arrow). 127-096 Fig. 4 - 16 ●...
Page 101: Knife Pressure
Adjustment Knife pressure .06.03 Requirement When the front edge of thread catcher 3 is 5 – 6 mm in front of the knife blade, the knife 4 should be touching the catcher edge with slight pressure. Fig. 4 - 17 ●...
Page 102: Bobbin Thread Clamp Spring
Adjustment Bobbin thread clamp spring .06.04 Requirement When the thread trimmer is in its cutting position, the clamp spring should slightly touch the thread catcher and hold the thread reliably. Fig. 4 - 18 ● Adjust clamp spring 1 (screw 2) in accordance with the requirement. ●...
Page 103: Manual Cutting Test
Adjustment Manual cutting test .06.05 Requirement 1. When moving forward, thread catcher 1 must not move bobbin thread 3 2. When thread catcher 1 is at its front point of reversal, bobbin thread 3 should be in the centre of the marked area (see arrow). 3.
Page 104: Setup
Adjustment Setup Set reference position .07 .01 ● Log on as administrator or setter. ● Select function "Tools". ● Select function "Service". ● Select function "Drives". ● Select function "Reference" on button 2. ● Follow on-screen instruction on touch screen display. ●...
Page 105: Stitch Length Adjustment
Adjustment Stitch length adjustment .07 .02 Enter stitch length "0" in programme "Manual", and check that no transport feed occurs. Ad- just switching plate 1 (screws 2) to stepper motor if required. ● Select function "Tools". ● Select function "Service". ●...
Page 106: Commissioning The Scanner
Adjustment Commissioning the scanner .07 .03 ● Select function "Tools". ● Select function "Service". ● Select function "Scanner Commissioning". ● Switch the scanner on. ● Position the barcode. ● Set the scanner at the head of the machine in height and directionality, until the barcode is read continuously.
Page 107: Commissioning The Camera
Adjustment Commissioning the camera .07 .04 ● Select function "Tools". ● Select function "Service". ● Select function "Camera Commissioning". Explanation for symbols used in menu "Camera commissioning Switch on camera Pause Stop Video properties Set resolution Read DMC...
Page 108 Adjustment Code 08:34:20 0000000005 ● Switch on camera on ● Select function "Read DMC" ● Select 640 x 480 in the window "Resoluti- on". ● The DATA Matrix code must appear in the window "Code". ● Proceed as follows if "- - - - -" is displayed in the window "Code": Switch off camera light on control 1, adjust image focus on Focus 2,...
Page 109 Adjustment ● Call up video properties.Adjust settings as needed. ● The following image shows the factory settings. ● Call up the camera control.Adjust settings as needed. ● The following image shows the factory settings. ● Apply the settings. ● Finish input.
Page 110: Adjustment Of Edge Guide Photocell
Adjustment Adjustment of edge guide photocell .07 .05 LED control ● The LED 1 and 2 should be “on” without Material under the reﬂ ector area 3. ● The LED 1 and 2 should be “off” with Material under the reﬂ ector area 3. Start auto-teach function ●...
Page 111: Parameter Settings
Adjustment Parameter settings Selecting and altering the parameters .08.01 The parameter values can only be altered by the supervisor or the administrator. ● Log in as administrator or supervisor. ● Select the "tools" function. ● Call up the menu for altering parameter values Industrial ●...
Page 112: Parameter List
Adjustment Parameter list .08.02 Speed for seam start B, C ON - OFF ON = variable (pedal-related) OFF = constant Speed for seam start B, C ON - OFF ON = limited by program OFF = limited by parameter 607 No.
Page 113 Adjustment Speed of programmable end tack 100 - 1500 No. of repeats of programmable end tack 1 - 10 Start tack / ornamental start tack B, C ON - OFF ON = quadruple, OFF = double Input "stroke adjustment" (3745) B, C ON - OFF ON = switch operation...
Page 114 Adjustment Thread tension release in connection with press- ON - OFF er foot ON = yes OFF = no No. of knotting stitches 1 - 20 Bearing position before sewing ON - OFF ON = yes OFF = no Bobbin thread monitoring A,B,C 0 - 1 ON = off...
Page 115 Adjustment Needle position 6 (start cutting signal) 0 - 359 Start thread tension release 0 - 359 Needle position 3 (needle raised) 0 - 359 Switch-on time (ms) for thread wiper 0 - 2550 Switch on delay time for thread wiper [ms] 0 - 2000 Standstill brake tact (0 = brake off) 0 - 40...
Page 116 Adjustment Needle position 10 (bearing position) 0 - 359 Delay till start knotting stitches 0 - 2000 Selected machine class 1 - 1 Motor rotation direction with view of V-belt pul- 0 - 1 1 = anti-clockwise 0 = clockwise Reverse angle after seam end 10 - 200 Gear reduction main drive...
Page 117 Adjustment Variant MINI-motor 1 - 10 1 = long, 0 = short Variant MINI-Motor 0 - 1 1 = long, 0 = short Motor current limitation ON - OFF 1 = 15A, 0 = 10A Additional P-ampliﬁ cation of speed 1 - 30 controller (sewing motor) Cutting release-speed...
Page 118 Adjustment 1103 Max. current in % stepping motor 1 - 100 (feed regulator) 1104 Reducing current in % stepping motor (feed 0 - 100 regulator) 1105 Start stop time (time for one step at 5 - 1000 start stop speed) stepping motor (feed regulator) 1106 Roof time (time for one step at roof speed)
Page 119 Adjustment 20 2012 Measurement window measurement 1 in 0 - 100 +/-degrees 2013 Position measurement 2, t.d.c. take-up lever, in 0 - 359 degrees 0 – 359 2014 Measurement window measurement 2 in 0 - 100 +/-degrees) 2015 Fade-out stitches for missed stitch 2 - 50 A,B,C recognition...
Page 120: Description Of The Error Messages
Adjustment Description of the error messages Display Description Remedy Error: 1 Treadle not at rest Check treadle Error: 3 Stitch setter reference position not Check step motor and initiator Error: 30 Circuit board sensor defective Replace control Error: 38 Stitch setter setpoint/current posi- Stitch setter has moved to mech.
Page 121: Inputs / Outputs
Adjustment Inputs / Outputs Input Output Treadle position Outputs Inputs Input Function Output Function Ref. SM stitch setter Stroke adjustment 0 * E-winder Stop motion device reset Knee switch* (stroke adjustment) Stroke adjustment 1* Stroke adjustment 2* Knee switch Thread clamp (man.
Page 122: Pin Assignment
Adjustment Pin assignment AMP 4polig Motor connection Modular jack Light barrier/ 9polar Stop motion device UFW-Sensor 24V/15V SubD 9polar Motor incremental UFW-Laser encoder ADTC Y EXT SM EXT SM SubD 9polar Speed control unit SubD 9polar Control panel RXD in TXD out RTS out CTS in...
Page 123 Adjustment X5 SubD 37polar Inputs/oututs Service Port Name Function Poti for stroke adjustment* OTE (+5V) Laser stop motion device Ref. SM stitch setter E-winder: Bobbin full Knee switch (stroke adjustment)* I2C-SDA OTE (SDA) Knee switch (man. seam section) Stop (safety device) Stop motion device In10 Switch (slide - stitch platen)
Page 124 Adjustment 15pol. SubD-connector Service Port Name Function +24V Inputs (high +24V) In17 Bobbin lower thread spooler In18 Bobbin upper thread spooler In19 Error straight edge In20 24V/15V In21 In22 In23 Outputs (OC 0,35A) Out17 12_0 LED docu-seam in straight edge Out18 12_1 Out19...
Page 125: Importend Sevice-Information
Adjustment Importend Sevice-information Attension!! To avoid wrong monitoring, it is necessary to calibrate the system, after changing the thread-force-sensor 2 or the control box 1.
Page 129 3741 3745 CALIBRATION INSTRUCTIONS Kalibrieranleitung engl. 06.12...
Page 130: Calibration
(German Calibration Service) or by the Gauging Ofﬁ ce. The PFAFF calibration system uses a weight of 500 cN = 5 N (cN = centi Newton) as “stan- dard” , which results from the product of the weight of a body (SI-unit weight in kg = kilo- gram) and the gravitational acceleration ( g = 9.80992 m/s2).
Page 131: Gauging Ofﬁ Ce, German Calibration Ofﬁ Ce Dkd
Calibration Gauging ofﬁ ce, German Calibration Ofﬁ ce DKD .01.04 The standards used here, documented by calibration certiﬁ cates, represent the unquestio- nable proof of the traceability in accordance with DIN ISO 9000, and are internationally re- cognised through multilateral agreements. The higher-ranking institution for the entire calibration services in Germany is the PTB (Fe- deral Institute for scientiﬁ...
Page 132: Check / Adjust The Trigger Signals
Calibration Check / adjust the trigger signals .02.02 (Item 2 of the calibration certiﬁ cate) ● Call up the “tools” function. ● Call up the menu for adjusting the parameter values. Industrial ● By tapping the appropriate arrow symbol (“No. ” ) select parameter 607 for the maximum speed.
Page 133: Check The Zero Position Of The Monitor Power Signal
Calibration ● Switch on the monitor with function 1. ● Carry out a test seam. Industrial ● Check, whether the trigger signals with the largest hook loop and in t.d.c. take-up lever are both in the maximum range of the thread strength signal. ●...
Page 134: Checking The Setting Of The Sewing Head
Calibration Checking the setting of the sewing head .02.04 (Item 4 of the calibration certiﬁ cate) ● Check the mechanical setting of the sewing head in accordance with the Adjustment Ma- nual and adjust the sewing head if necessary. Recording the characteristic thread strength curve .02.05 (Item 5 of the calibration certiﬁ...
Page 135 Calibration _The calibration device must be fastend at the table top to place the calibration weight according to the picture _The length of the vertical thread piece after the two turn around the second bearing 8 should be approx. 250 mm _The rquired length of the calibration device 4 can be adjusted with the wing nut 9.
Page 136 Calibration Industrial ● Call up function 1. ● Do not attach a weight, or remove the weight. ● Acknowledge the measurement. The measured value appears in box 2. ● Record the value from box 2 in the calibration certiﬁ cate. ●...
Page 137: Checking The Calibration (Calibration Result)
Calibration Checking the calibration (calibration result) ● Carry out the calibration as described in Chapter 5.02 Calibration procedure. ● Call up the service menu. ● Call up the sensor function. ● Attach the calibration weight (500 cN) to the thread and wait until the pendulum move- ments have stopped.
Page 138 PFAFF Industriesysteme und Maschinen AG, 67661 Kaiserslautern Calibration certiﬁ cate fort the PFAFF-DOCU-SEAM-SYSTEM Customer:................................. Address:..................................Machine: PFAFF 3741........Serial-No.: ..................Machine: PFAFF 3741........Serial-No.: ..................PC-software: ..........Control software:................Reference value of weight for standard measuring range: 5 N = 500 cN Traceability to national standard, guaranteed iaw DIN ISO 9000 by Gauging Ofﬁ...
Page 141: Circuit Diagrams
91-510 083-95 Pneumatics-switch diagram Version 23.11.09 Circuit diagrams Pneumatics-switch diagram PFAFF 3741 + 3745 The control elements and valves are in the machine‘s basic position.Main switch -ON, compressed air -ON...
Page 142: Block Diagram Pfaff 3741 + 3745 (With Control Unit P374 Ed)
Block diagram Version 23.11.09 Block diagram PFAFF 3741 + 3745 (with control unit P374 ED) P374 ED = only 3745 = Version "PREMIUM" = Version "PLUS"...
Page 143 Block diagram Version 23.11.09 TFT / TouchScreen X 113 (BS-UF) Com 6 Com 5 X 114 (BS-OF) Com 4 X 115 (BS-LA) Com 3 X 99 (P374) frei frei frei Docu-seam-PC P374ED Control unit Monitor with touch-screen Main drive Label printer Incremental transmitter Barcode hand-held scanner (ID) Synchronizer...
Page 144: Circuit Diagrams
Circut diagrams Version 12.01.12 Circuit diagrams Reference list for the Circuit diagrams 91-191 528-95 .03.01 Controller P374 ED-L Control panel PicoTop (optional) Sewing head recognition (OTE) Oil sensor (I2C-Bus) Keyboard (I2C-Bus) Bobbin thread monitor Light barrier Thread strength sensor Initiator feed regulator Initiator slider monitoring Initiator camera-read position Oil sensor (I2C-Bus)
Page 145 Circut diagrams Version 12.01.12 Output-input plug Light barrier plug not assigned A20 bobbin thread monitor and B19 thread strength sensor Knee switch seam section (optional) Knee switch stroke adjustment (optional) Stepping motor thread tension XA14 A14 Sewing head recognition (OTE) XA15.1 A15 Oil sensor (I2C-Bus) XA15.2...
Page 146 Circut diagrams Version 12.01.12 Reference list for the Circuit diagrams 91-191 536-95 .03.02 Controller P374 ED-L A100 A101 Touchscreen monitor A104 Barcode label printer B102 Barcode hand-held scanner B110 Barcode scanner (label) B111 Barcode scanner (needle thread cop) B112 Barcode scanner (bobbin thread cop) Controller P374 ED-L A100 A101...
Page 147 91-191 528-95 Circut diagrams Part 1 Version 12.01.12...
Page 148 Circut diagrams 91-191 528-95 Version 12.01.12 Part 2...
Page 149 91-191 528-95 Circut diagrams Part 3 Version 12.01.12...
Page 150 Circut diagrams 91-191 528-95 Version 12.01.12 Part 4...
Page 151 91-191 528-95 Circut diagrams Part 5 Version 12.01.12...
Page 152 Circut diagrams 91-191 528-95 Version 12.01.12 Part 6...
Page 153 91-191 528-95 Circut diagrams Part 7 Version 12.01.12...
Page 154 Circut diagrams 91-191 536-95 Version 05.01.12...
Page 155 91-191 536-95 Circut diagrams Version 12.01.12...
Page 156 PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Phone: +49 - 6301 3205 - 0 Fax: +49 - 6301 3205 1386 E-mail: info@pfaff-industrial.com Printed in Germany...

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