Page 1: Instruction Manual
3119 INSTRUCTION MANUAL This instruction manual applies to machines from software version 0365/001 and serial number 2 738 201 onwards 296-12-18 958/002 Betriebsanleitung engl. 06.09...
Page 2 This instruction manual applies to all versions and subclasses listed under "Speciﬁ cations". Reprinting, copying or translation of PFAFF instruction manuals, whether in whole or in part, is not permitted without our prior permission and not without written indication of the source.
Page 3: Table Of Contents
Index Contents ..................Page Safety ............................ 7 Regulations ..........................7 General notes on safety ......................7 Safety symbols ........................8 Important notes for the user ....................8 Notes for operating and technical staff .................. 9 .05.01 Operating staff ........................9 .05.02 Technical staff ........................
Page 4 Index Contents ..................Page .01.06 Fitting the reel stand ......................29 Commissioning ........................29 Switching the machine on / off .................... 29 Setting up the machine control unit ..................30 .04.01 Establishing the sub-class ....................30 .04.02 Setting parameter "202" ....................... 31 Setting up ...........................
Page 5 Index Contents ..................Page Sequences ........................... 65 .06.01 Creating sequences ......................65 Selecting programs ......................68 Special programs ......................... 69 SAM (Sewing Application Manager) ..................69 Program Management ......................69 .10.01 Calling up the program management .................. 70 .10.02 Display of the data in the machine memory ................ 71 .10.03 Display of the data on the SD-memory card ................
Page 6 Needle thread tension release ................... 124 Needle thread puller ......................125 Side thread tension and slack thread regulator ..............126 Bobbin winder ........................127 Retainer position (only for 3119-2/62 and -2/63) ..............128 Carrying out a cold start ..................... 129 Parameter settings ......................130 48.01 Selecting and altering parameters ..................
Page 7: Safety
Safety Safety Regulations This machine is constructed in accordance with the European regulations indicated in the conformity and manufacturer‘s declarations. In addition to this instruction manual, please also observe all generally accepted, statutory and other legal requirements, including those of the user‘s country, and the applicable pol-lu- tion control regulations! The valid regulations of the regional social insurance society for occupational accidents or other supervisory authorities are to be strictly adhered to!
Page 8: Safety Symbols
The user must ensure that none of the safety devices are removed nor put out of work- ing order. ● The user must ensure that only authorized persons operate and work on the machine. For further information please refer to your PFAFF agency..
Page 9: Notes For Operating And Technical Staff
Safety Notes for operating and technical staff Operating staff .05.01 Operating staff are the persons responsible for setting up, operating and cleaning the machi- ne and for eliminating any malfunctioning in the sewing area. The operating staff is obliged to observe the following points: ●...
Page 10: Danger Warnings
Safety Danger warnings A working area of 1 m must be kept free both in front of and behind the mach- ine, so that easy access is possible at all times. Never put your hands in the sewing area during sewing! Danger of injury by the needle! During maintenance and adjustment work the knife must be secured with lo- cking device 1.
Page 11: Proper Use
ﬂat buttonholes with two ﬂat or raised square bars on medium materials in the linen and clothing industry. The PFAFF 3119-2/6 and PFAFF 3119-2/63 are used for sewing raised or ﬂat buttonholes with two ﬂat or raised square bars on delicate knitted fabrics in the linen and clothing industry.
Page 12: Speciﬁ Cations
Speciﬁ cations ▲ Speciﬁ cations General information Max. sewing speed:....................4200 min Stitch type: ........................... 304 Needle bar stroke:......................34.5 mm Max. thickness of workpiece: ..................max. 3 mm Max. work clamp clearance: ................max. 12.5 mm Fabric clearance (crosswise to sewing arm): ..............235 mm Fabric clearance (lengthwise to sewing arm): ..............30 mm Stitch formation..............buttonhole, max.
Page 13: Stitch Formation Of The Various Sub-Classes
Speciﬁ cations Stitch formation of the various sub-classes -1/51 -2/51 -2/53 -3/51 -4/51 -5/51 -1/52 -2/62 -2/63 40,0 x 5,6 40,0 x 6,7 30,0 x 5,6 46,0 x 6,7 55,0 x 7 ,0 77 ,0 x 7 ,0 44,0 x 6,0 44,0 x 7 ,0 min.
Page 14: 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 15: Transportation, Packing And Storage
Transportation, packing and storage Transportation, packing and storage Transportation to customer‘s premises The machines are delivered completely packed. Transportation inside the customer‘s premises 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 16: 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 17: Controls
Controls Controls Main switch ● The machine is switched on or off by tur- ning the main switch 1. Fig. 7 - 01 Switch for separate compressor (optional) ● Turn the compressor on or off by turning switch 1. Before starting the machine, switch on the compressor and wait until the manometer dis- plays a pressure of 6 bar.
Page 18: Pedal
Controls Pedal -1 = Prevent knife engagement at end of current sewing cycle 0 = Neutral position +1 = Work clamp lowered +2 = Sewing Fig. 7 - 03 Preventing knife engagement ● By operating push button 1, knife enga- gement at the end of the current sewing cycle is prevented.
Page 19: Control Panel
Controls Control panel The keys on control panel 1 are used for selecting machine functions for setting-up purpo- ses, for sewing operations and for entering parameters. The functions of the program keys depend among other things on the selected operating mode and whether the sequence mode is activated, see Chapter 9.06 Selecting the operating mode or Chapter 9.11 Activa- ting the sequence mode.
Page 20 Controls Stop ● When operated during a sewing cycle, the machine is stopped. ● If operated outside a sewing cycle, the winding operation is started/stopped. ● When entering the code number this key corresponds to the ﬁ gure 1. When moving step-by-step through the sewing cycle, all cutting procedures will be carried out! Danger of injury if the knife engages! Tacting in reverse ●...
Page 21: Further Key Functions In The Buttonhole Mode
Controls Further key functions in the buttonhole mode .05.03 When selecting lthe buttonhole mode, see Chapter 9.06 Selecting the operating mode, the function of the keys depends on the screen display, see Chapter 10 Sewing. If the program number is shown on the display instead of the cutting length, the following 3 keys serve as station keys for vario and special programs.
Page 22: Other Key Functions In The Bartack Mode
Controls Other key functions in the bartack mode .05.04 When the bartack mode has been selected, see Chapter 9.06 Selecting the operating mode, the function of the keys depends on the screen display, see Chapter 10 Sewing. If the program number is shown on the display instead of the bartack length, the following 3 keys serve as station keys for vario and special programs.
Page 23: Further Key Functions In The Activated Sequence Mode
Controls Further key functions in the activated sequence mode .05.05 When the sequence mode has been activated, see Chapter 9.11 Activating the sequence mode, the other keys have the functions described below. The following 3 keys serve as station keys for the sequences, also see Chapter 11.06.01 Creating sequences.
Page 24: Mounting And Commissioning The Machine
Mounting and commissioning the machine Mounting and commissioning the machine The machine must only be mounted and commissioned by qualiﬁ ed personnel! All relevant safety regulations are to be observed! If the machine is delivered without a table, be sure that the frame and the table top which you intend to use can hold the weight of the machine and the motor.
Page 25: Installation Variants
Mounting and commissioning the machine Installation variants .01.02 The PFAFF 3119 can be installed in two different ways. ● Version A: Sewing crosswise to the table edge ● Version B: Sewing parallel to the table edge 83-042 Fig. 8 - 02 When the machine is installed for "Sewing parallel to the table edge", the eye...
Page 26 Mounting and commissioning the machine Table top drilling template .01.03 (installed parallel to the table edge)
Page 27 Mounting and commissioning the machine Table top drilling template .01.04 (installed crosswise to the table edge)
Page 28: Connecting The Plug Connections And Earth Cables
Mounting and commissioning the machine Connecting the plug connections and earth cables .01.05 Fig. 8 - 03 ● Connect all plugs 1 - 8 as labelled in the control box. ● Screw earth cable from the machine and the motor to earth point ●...
Page 29: Fitting The Reel Stand
Mounting and commissioning the machine Fitting the reel stand .01.06 ● Fit the reel stand as shown in Fig. 8 - 04. ● Afterwards insert the stand in the hole in the table top and secure it with nuts pro- vided.
Page 30: Setting Up The Machine Control Unit
Chapter 8.04 Setting parameter "202". Fig. 8 - 05 Work clamp cut-out Sub-class Value for parameter "202" 30,0 x 5,6 3119-1/51, -1/52 40,0 x 5,6 3119-2/51 44,0 x 6,0 3119-2/62 40,0 x 6,7 3119-2/53 44,0 x 7 ,0...
Page 31: Setting Parameter "202
● Using the corresponding plus/minus key select the value for the established sub-class, e.g. "3" for sub-class 3119-2/53, see Chapter 8.04.01 Establishing the sub-class. ● Conclude parameter input by switching to operational mode Sewing (LED in the key goes off).
Page 32: Setting Up
Setting up Setting up All instructions and regulations in this instruction manual must be observed. Special attention must be given to all safety regulations! All setting-up work must only be done by personnel with the necessary training. For all setting-up work the machine must be isolated from its power supply by turning off the on/off switch or removing the machine plug from the electric power socket! Inserting the needle...
Page 33: Winding The Bobbin Thread / Adjusting The Preliminary Thread Tension
Setting up Winding the bobbin thread / adjusting the preliminary thread tension Fig. 9 - 02 ● Place an empty bobbin 1 on winder spindle 2. ● Thread up as shown in Fig. 9 - 02 and wind the thread a few times clockwise around bob- bin 1.
Page 34: Threading The Bobbin Case / Adjusting The Bobbin Thread Tension
Setting up Threading the bobbin case / adjusting the bobbin thread tension Fig. 9 - 03 ● Insert the bobbin 1 in the bobbin case. ● First guide the thread into slot 3 and under spring 4. ● Then guide the thread into slot For purl buttonholes: ●...
Page 35: Changing The Bobbin
Setting up Changing the bobbin Switch off the machine! Lock the knife mechanically with the knife engagement pre- vention device! Danger of injury from the needle and the knife! ● Open the cover of the hook compart- ment. Removing the bobbin: ●...
Page 36: Threading The Needle Thread
Setting up Threading the needle thread Fig. 9 - 05 83-012 Switch off the machine! Lock the knife mechanically with the knife engagement prevention device! Dan- ger of injury from the needle and the knife! ● Thread the needle thread as shown in Fig. 9-05.
Page 37: Selecting The Operating Mode
Setting up Selecting the operating mode ● Switch on the machine. ● Select the input mode (LED in the key is on). 1 0 0 ● Select the function group " 100" with the appropriate plus / minus key. ● Conﬁ...
Page 38: Selecting The Type Of Buttonhole / Bartack
Setting up Selecting the type of buttonhole / bartack Depending on the selected operating mode, see Chapter 9.06 Selecting the operating mode, the type of buttonhole or bartack is selected as described below. ● Switch on the machine. ● Select the input mode (LED in the key is on). 1 0 0 ●...
Page 39: Adjusting The Needle Thread Tension
Setting up Adjusting the needle thread tension 56-017b 83-013 56-017a Fig. 9 - 06 ● Shread and insert the bobbin case according to the required type of buttonhole, see Chapter 9.03 Inserting the bobbin case / adjusting the bobbin thread tension. ●...
Page 40: Adjusting The Work Clamp Pressure
Setting up Adjusting the work clamp pressure ● Adjust the work clamp pressure by tur- ning adjustment screw 1. The sewing pressure depends on the material of the workpi- ece and must be adapted to this. It is set correctly when the workpiece is fed reliably and shows no feed marks.
Page 41: Position Of The Needle To The Workpiece
Setting up Position of the needle to the workpiece ● Switch on the machine and sew one buttonhole. ● Insert the workpiece and lower the work clamp with this key. ● Select the input mode (LED in the key is on). 6 0 0 ●...
Page 42: Activating The Sequence Mode
Setting up Activating the sequence mode To activate the sequence mode, at least one sequence must have been created beforehand, see Chapter 11.06.01 Creating sequences. ● Switch on the machine. ● Select the input mode (LED in the key is on). 1 0 0 ●...
Page 43: Sewing
Sewing Sewing The machine must be installed and connected in accordance with Chapter 8 Installation and Commissioning. ● Set-up the machine, see Chapter 9 Setting-up. ● Switch on the machine, see Chapter 7.01 On/off switch. The machine is automatically in the operational mode Sewing. ●...
Page 44: Selecting The Buttonhole
Sewing In addition, previously selected cut lengths, variable or special programs can be selected with the corresponding plus/minus key (also see Chapter 11.07 Selecting programs). Selected programs are marked on the display with an " * ". 1500: Piece counter / reverse counter Depending on the activated function (piece counter or reverse counter) the number of buttonholes already sewn or the number still to be sewn is displayed.
Page 45: Entering The Knife Length And Cut Overlap
Sewing ● Select the stitch density. ● If necessary adjust the buttonhole width, see Chapter 10.01.04 Altering the buttonhole width and seam correction ● If necessary adjust the cut width (left)/seam extension (right), see Chapter 10.01.05 Alte- ring the cutting width and cutting length correction Entering the knife length and cut overlap .01.03 To avoid premature wear of the cutting equipment we recommend the use of a...
Page 46: Altering The Buttonhole Width And Seam Correction
Sewing Enter cut overlap VA L 2 0 8 0 . 5 ● Select Parameter " 208" with the corresponding plus/minus key. ● With the corresponding plus/minus key select the cut overlap, e.g. 0.5 mm. ● Conclude parameter input by switching to operational mode Sewing (LED in the key goes off).
Page 47: Altering The Cutting Width And Cutting Length Correction
Sewing Buttonhole width seam length 1/2 bartack 1/2 bartack correction correctionr A seam correction value under the minimum cut distance to the bartack (see parameter "210") or over the value for the appropriate subclass, is not valid. Altering the cutting width and cutting length correction .01.05 The cutting width and cutting length are only valid in the buttonhole mode and must always be set up from the centre of the buttonhole.
Page 48: Sewing In The Bartack Mode
Sewing Total cutting length Cutting width Cutting length Cutting length correction A cutting length correction value under the minimum value of the installed knife or over the maximum value for the appropriate subclass, is not valid.. Sewing in the bartack mode Control panel with speed or bartack type display .01.01 4 0 0 0 1 2 .
Page 49: Selecting The Bartack
Sewing To assign a program key, after selecting a variable or special program , press one of the 3 program keys longer (approx. 2 seconds). It is also possible to call up previously selected bartack lengths, vario or special programs with the corresponding plus/minus key (also see Chapter 11.07 Selecting programs ).
Page 50: Error Messages
Sewing Error messages If a malfunction occurs, an error code appears on the display together with short instruc- tions. In addition the diode in the memory card slot lights up red (see arrow). An error mes- sage may be caused by incorrect settings, defective elements or seam programs, as well as by overload conditions.
Page 51: Input
Input Input In the operational mode Input the values of the machine parameters can be altered, e.g. for setting up the machine or for creating/modifying seam programs. Summary of the function groups and parameters Operational mode Input (LED in the key is on) 100 Operating staff 101 Knife suppression I off...
Page 52: Selecting The Function Group And Altering The Parameters
Input Selecting the function group and altering the parameters ● Switch on the machine. After the machine is switched on, the operational mode Sewing is activated automatically. ● Select the input mode (LED in the key is on). 1 0 0 ●...
Page 53: Entering / Altering The Access Code
Conﬁ rm input with the "Enter" function by pressing the right plus key. ● Enter code. The numbers are entered with the corresponding function keys as described. The factory code setting is "3119". VA L 8 2 0 3 1 1 9 ●...
Page 54: Allocating Access Rights
Input Allocating access rights ● Switch on the machine ● Select the input mode (LED in the key is on). 8 0 0 ● Select the function group " 800" with the appropriate plus / minus key. ● Conﬁ rm input with the "Enter" function by pressing the right plus key.
Page 55: Variable Programs
Input Variable programs 39 variable programs can be stored in the machine. A variable program can be selected with the program number 1 to 39. Variable programs can be created by copying and altering the desired parameters of an exis- ting program or by entering completely new parameters.
Page 56 Input 2 0 6 ● Call up the desired program number with the corresponding plus/minus key. ● Conﬁ rm the input with the "Enter" function by pressing the corresponding plus/minus key. The next steps for altering the program are described in Chapter 11.05.02 Creating/ modifying variable programs.
Page 57: Creating / Modifying Vario Programs In The Buttonhole Mode
Input Creating / modifying vario programs in the buttonhole mode .05.02 A variable program is written with the parameters of the function group "300". The variable program can be adapted to individual requirements by altering individual para- meters. As illustrated below variable programs consist of 4 sections: ●...
Page 58: Creating / Modifying Vario Programs In The Bartack Mode
Input Creating / modifying vario programs in the bartack mode .05.03 A variable program is written with the parameters of the function group "300". The variable program can be adapted to individual requirements by altering individual para- meters. As illustrated below, vario programs consist of 2 sections ●...
Page 59: Buttonhole And Bartack Model
Input Buttonhole and bartack model .05.04 In the following table, in addition to the bartack model, all buttonhole models are shown with their appropriate bartacks. Number Buttonhole model Bar B Bar D width B width D width B width D width B width D width B1...
Page 60 Input Number Buttonhole model Bar B Bar D width B1 width D width B width D width B1 width D width B maximum width width B1 width D width D width B width D1 width B1 width D width B width D1 width D width B...
Page 61 Input Number Buttonhole model Bar B Bar D maximum width width B1 width D width D1 width D width B width B1 width D width B width D width B width D width B width B1 width D width B maximum width width B1 width D...
Page 62 Input Number Buttonhole model Bar B Bar D width D width B1 width B width D1 width D width B width D1 width D width B width D1 width B1 width D width B width D1 maximum width width D width B1 width D1 Number...
Page 63: Table For Entering A Buttonhole Program
Input Table for entering a buttonhole program .05.05 Program number Cut length (mm) Buttonhole model Distance of left seam from centre of cutting line (needle penetration right) = distance A (mm) Width of left seam = width A (mm) Length of left seam (same length as right purl seam) = length A (mm) Number of stitches in left seam = number of stitches A...
Page 64: Table For Entering A Bartack Program
Input Second width of 2nd bar = width D1 Length of 2nd bar = length D (mm) Second length of 2nd bar = length D1 (mm) Number of stitches in second bar = number of stitches D Distance of second bar to centre of cutting line = distance D (mm) Secondary thread tension of 2nd bar Table for entering a bartack program...
Page 65: Sequences
Input Sequences In a maximum of 3 different sequences, up to 33 vario programs in each sequence can be combined in any order and processed later. Before sequences can be generated, appropriate vario programs (buttonhole or bartack programs) have to be created, see Chapter 11.05 Vario programs.
Page 66 Input S EQ 1 I E X I T ● Call up next sequence position with the corresponding plus/minus key. ● Select the next desired vario program, e.g. buttonhole program "B1" with the correspon- ding plus/minus key. ● Switch off the "cutting" function with the corresponding plus/minus key.
Page 67 Input S EQ 4 0 0 0 3 / 1 In the sequence mode the number of programs belonging to the sequence is shown on the display together with the current program. It is also possible to switch to the individual pro- grams by hand with the corresponding plus/minus key.
Page 68: Selecting Programs
Input Selecting programs By selecting currently required programs, the display of too many programs can be reduced to a minimum. ● Switch on the machine. VA L 1 1 0 1 2 . 7 ● Call up parameter " 110" (selecting programs). ●...
Page 69: Special Programs
Input Special programs The programs 40 to 49 are reserved for special programs. With the programming software PSP the seam contours are freely programmed on a PC in the available sewing area, which depends on the sub-class. The images are then transferred by connecting the PC to the ma- chine.
Page 70: Calling Up The Program Management
Input Calling up the program management .10.01 ● Switch on the machine. ● Select the input mode (LED in the key is on). ● Call up the program management. D I R After the program management has been called up, the ﬁ rst menu item appears (display of data in the machine memory).
Page 71: Display Of The Data In The Machine Memory
Input Display of the data in the machine memory .10.02 ● Call up the program management, see Chapter 11.10.01 Calling up the program management. D I R ● Press the left plus/minus keys until the corresponding menu item appears. ● Conﬁ...
Page 72: Display Of The Data On The Sd-Memory Card
Input Display of the data on the SD-memory card .10.03 ● Call up the program management, see Chapter 11.10.01 Calling up the program management. D I R ● Press the left plus/minus keys until the corresponding menu item appears. ● Conﬁ...
Page 73: Copying Data Onto The Sd-Memory Card
Input Copying data onto the SD-memory card .10.04 ● Call up the program management, see Chapter 11.10.01 Calling up the program management. COP Y ● Press the left plus/minus keys until the corresponding menu item appears. ● Conﬁ rm the selection of the menu item with the "Enter" function by pressing the right plus key.
Page 74: Copying Data Into The Machine Memory
Input Copying data into the machine memory .10.05 ● Call up the program management, see Chapter 11.10.01 Calling up the program management. COP Y ● Press the left plus/minus keys until the corresponding menu item appears. ● Conﬁ rm the selection of the menu item with the "Enter" function by pressing the right plus key.
Page 75: Deleting Data In The Machine Memory
Input Deleting data in the machine memory .10.06 ● Call up the program management, see Chapter 11.10.01 Calling up the program management. D E L ● Press the left plus/minus keys until the corresponding menu item appears. ● Conﬁ rm the selection of the menu item with the "Enter" function by pressing the right plus key.
Page 76: Deleting Data From The Sd-Memory Card
Input Deleting data from the SD-memory card .10.07 ● Call up the program management, see Chapter 11.10.01 Calling up the program management. D E L ● Press the left plus/minus keys until the corresponding menu item appears. ● Conﬁ rm the selection of the menu item with the "Enter" function by pressing the right plus key.
Page 77: Formatting The Sd-Memory Card
Input Formatting the SD-memory card .10.08 ● Call up the program management, see Chapter 11.10.01 Calling up the program management. F O RMA T ● Press the left plus/minus keys until the corresponding menu item appears. ● The formatting process is started with the "Enter" function by pressing the right plus key.
Page 78: Care And Maintenance
Care and maintenance Care and maintenance Maintenance intervals Clean the hook compartment ..................daily Clean the entire machine ..................once a week Clean air ﬁ lter of air ﬁ lter / lubricator ..............as required Check the air pressure ................daily, before use Check the oil level ..................daily, before use These maintenance intervals are calculated for the average running time of a single shift operation.
Page 79: Cleaning The Hook Compartment
Care and maintenance Cleaning the hook compartment Fig. 12 - 01 Switch off the machine! Lock knife mechanically to prevent knife engagement! Danger of injury from the needle and knife! ● Open hook compartment cover ● Clean the hook and hook compartment daily, more often if in continuous use.
Page 80: Cleaning The Air Fi Lter Of The Air-Fi Lter / Lubricator
Care and maintenance Cleaning the air ﬁ lter of the air-ﬁ lter / lubricator Switch the machine off! Disconnect the air hose at the air-ﬁ lter / lubricator. To drain water bowl 1: ● Water bowl 1 drains itself automatically whe the compressed-air hose is discon- nected from the air-ﬁ...
Page 81: Check Oil Level For Needle Drive Unit
Only use oil with a medium vis- cosity of 10.00 mm /s at 40ºC and a density of 0.847 g/cm 15ºC. We recommend PFAFF sewing machine oil, part no. 280-1-120 105. Fig. 12 - 04 Check oil level for the hook...
Page 82: Adjustment
Adjustment Adjustment Unless otherwise stipulated, the machine must be disconnected from the mains by switching it off at the on/off switch or by pulling out the mains plug, and the knife must be locked mechanically to prevent knife engagement. Notes on adjustment All following adjustments are based on a fully assembled machine and may only be carried out by expert staff trained for this purpose.
Page 83: Toothed Belts Of The Hook Drive Unit
Adjustment Toothed belts of the hook drive unit Requirement Tensioner 1 should lightly touch the toothed belt. Fig. 13 - 01 ● Loosen the machine’s screw connection to the table. ● Tilt the machine backwards and dismount the pan. ● Adjust tensioner 1 ( nut 2 ) according to the requirement. If there are operational noises, repeat the adjustment.
Page 84: Drive Rods Of The Bobbin Thread Trimming Device
Adjustment Drive rods of the bobbin thread trimming device Requirement When cylinder 5 is fully extended, roller 3 should be positioned at a small distance (approx. 0.3 mm) from the curve bottom of slotted lever 4. 56-050 Fig. 13 - 02 ●...
Page 85: Switch For Sewing Start
Adjustment Switch for sewing start Requirement When cylinder 5 is fully extended, switch 1 should be operated. 83-043 Fig. 13 - 03 ● Adjust switch 1 or bracket 2 ( screws 3 or 4 ) according to the requirement.
Page 86: Basic Position Of The Feed Drive Unit
Adjustment Basic position of the feed drive unit Requirement Switch 2 should operate when slide block 4 is 1.6 mm away from clamp 5. 1,6 mm Fig. 13 - 04 ● Set the distance of 1.6 mm by turning spindle 1. ●...
Page 87: Preliminary Adjustment Of The Work Clamp
Adjustment Preliminary adjustment of the work clamp Requirement When the feed unit is in its basic position 1. The drive lever 1 should be flush with marking 8 on shaft 5, 2. The front edge of drive lever 1 should be flush with guide pin 4 and 3.
Page 88: Toothed Belts Of The Main Drive Unit
Adjustment Toothed belts of the main drive unit Requirement 1. Toothed belt wheels 1 and 5 should be in alignment. 2. There should be a hardly noticeable amount of play between the toothed belt wheels 1 and 5 and the toothed belt 6. Fig.
Page 89: Preliminary Adjustment Of The Needle Height
Adjustment Preliminary adjustment of the needle height Requirement When the needle bar is at b.d.c. there should be a distance of 11 mm between the lower edge of the needle bar 1 and the needle plate. Fig. 13 - 07 ●...
Page 90: Position Of The Needle Plate In Relation To The Needle
Adjustment Position of the needle plate in relation to the needle Requirement Needle plate base 3 should rest on the edge of the bed-plate cutout ( see arrows ). Seen in the direction of sewing the needle should enter the needle hole in the centre. 57-056a Fig.
Page 91: Controlling The Stitch Symmetry
Adjustment Controlling the stitch symmetry Requirement Both the left and right point of penetration should be the same distance from the basic position of the needle (middle point of penetration). Fig. 13 - 08a ● Switch on the machine. ● Call up parameter 606. ●...
Page 92: Sensor Board Of The Needle Drive ( In Dismantled State )
Adjustment Sensor board of the needle drive ( in dismantled state ) Requirement 1. The counter-sinking in eccentric 1 should match the locking hole in the supporting bracket. 2. The axis of the switch lug of eccentric 1 should be centred to the hybrid light barrier of the sensor board.
Page 93 Adjustment ● Completely remove the needle drive unit (plugs remain connected). ● Loosen screws 2. ● Block eccentric 1 with blocking pin 3 (part no. 13-030 272-05) in the blocking hole of the supporting bracket. ● Switch machine off, then on again and wait until the stepping motor has stopped (ignore error signal on the control panel).
Page 94: Basic Setting Of The Needle Drive Unit
Adjustment Basic setting of the needle drive unit Requirement As seen crosswise to the direction of sewing, the needle should be positioned in b.d.c. needle bar, and when eccentric 1 is blocked, in the centre of the needle hole. 56-010a Fig.
Page 95: Basic Position Of The Work Clamp ( Lengthwise To The Arm )
Adjustment Basic position of the work clamp ( lengthwise to the arm ) Requirement When the clamp 1 is in its basic position, there should be a distance of 5 mm, or 9 mm on machines with sub-class -2/62 and -2/63, from the centre of the needle hole to the work clamp. 56-048a Fig.
Page 96: Basic Position Of The Work Clamp ( Crosswise To The Arm )
Adjustment Basic position of the work clamp ( crosswise to the arm ) Requirement 1. When the pressure roller 1 is in guide unit 5, the cut-out of work clamp 6 should be centred to the needle hole. 2. When the work clamp 6 is in motion, it should always be parallel to the needle plate insert. 83-021 Fig.
Page 97: Upper Take-Up Lever Position (Reference Position)
Adjustment Upper take-up lever position (reference position) Requirement The take-up lever should position 1.8 - 2.0 mm before its t.d.c. and one of the screws 1 should be accessible. 56-057a Fig. 13 - 13 ● Remove the needle and switch on the machine. ●...
Page 98: Lifting Elbow On The Work Clamp
Adjustment Lifting elbow on the work clamp Requirement 1. The lifting elbow 1 should be parallel to pressure roller 3. 2. When work clamp 4 is lifted, there should be a slight amount of play between pressure roller 3 and lifting elbow 1. Fig.
Page 99: Work Clamp Stroke
Adjustment Work clamp stroke Requirement When the lifting cylinder is completely extended, there should be a space of 15 mm between lifting piece 4 and clamp 1. Fig. 13 - 15 ● Reduce the work clamp pressure completely, see Chapter 9.09 Adjusting the work clamp pressure.
Page 100: Lifting Cylinder Of The Work Clamp
Adjustment Lifting cylinder of the work clamp Requirement The lifting and dropping motion of the work clamp should be carried out as quickly as possible. Fig. 13 - 16 ● Adjust the throttles 1 ( dropping motion ) and 2 ( lifting motion ) according to the requirement.
Page 101: Cutting Pressure Of The Knife Unit ( In Dismantled State )
Adjustment Cutting pressure of the knife unit ( in dismantled state ) Requirement 1. In its basic position ( retracted ), the knife cylinder 1 should have a length of 98.5 mm. 2. The knife 5 should cut perfectly, but the pressure on knife 5 should be as low as possible.
Page 102: Position Of The Knife Bracket And Lower Knife Stop
Adjustment Position of the knife bracket and lower knife stop Requirement 1. Knife bracket 5 should be adjusted so that adjustment gauge 2 is parallel and 2. in the centre of the knife slot. 3. When the knife cylinder is extended, screw 4 should be accessible through the hole in the machine case and adjustment gauge 2 should be touching the needle plate insert.
Page 103 Adjustment ● Push down knife bar 3 by hand ( the adjustment gauge 2 must be touching the needle plate insert ) and turn stop screw 8 until it touches the knife arm. ● Tighten screw 7 and remove adjustment gauge 2.
Page 104: Upper Knife Stop
Adjustment Upper knife stop Requirement When the adjustment gauge 1 is resting on the needle plate insert, the arm of the knife should be touching the upper knife stop. 56-042a 56-042 Fig. 13 - 19 ● Fit adjustment gauge 1 ( Part no. 61-11 635-93 ). ●...
Page 105: Knife Control Switch
Adjustment 13.24 Knife control switch Requirement When the cutting device is in its neutral position, switch 1 should be reliably activated. Fig. 13 - 20 ● Adjust switch 1 ( screw 2 ) according to the requirement.
Page 106: Knife Motion
Adjustment 13.25 Knife motion Requirement 1. The fabric must be cut perfectly. 2. The cutting motion should be carried out as quickly as possible. Fig. 13 - 21 ● Adjust the throttles 1 ( dropping motion ) and 2 ( lifting motion ) according to the requirements.
Page 107: Distance Of The Knife To The Needle Bar
Adjustment Distance of the knife to the needle bar Requirement There should be a distance of 0.2 - 0.5 mm between the knife 3 and the needle bar 4. 0,2 - 0,5 mm 83-031 Fig. 13 - 22 ● Adjust knife holder 1 ( screws 2 ) according to the requirement. ●...
Page 108: Changing The Knife / Knife Height
Adjustment Changing the knife / knife height Requirement When the punching or cutting device is in its neutral position, knife 2 should be 23 mm (punching device) or 22 mm (cutting device) away from needle plate 6. 83-047 56-061a 56-061b Fig.
Page 109: Functional Test Of Needle Thread Cutter
Adjustment Functional test of needle thread cutter Requirement 1. An inserted thread should be cut cleanly by needle thread cutter 1. 2. After cutting, the thread end should be clamped in such a way that the needle thread cutter 1 is held on the thread. Fig.
Page 110: Needle Thread Cutter ( Vertical And Horizontal Adjustment )
Adjustment Needle thread cutter ( vertical and horizontal adjustment ) Requirement 1. The distance between the lower edge of the needle thread cutter 1 and the work clamp 5 must be 0.5 mm. 2. The opened needle thread cutter 1 should catch the needle thread reliably. During sewing the opening cutter must not collide with the needle.
Page 111: Cam Guide Unit
Adjustment Cam guide unit Requirement The starting thread should be sewn over with no problem. Fig. 13 - 26 ● Bring the machine into its basic position and retract the cutter cylinder completely. ● Adjust the cam guide unit 1 ( screws 2 and 3 ) according to the requirement. ●...
Page 112: Needle Thread Cutter Stroke
Adjustment Needle thread cutter stroke Requirement The stroke length between the extended and retracted cutter cylinder 3 should be 4.5 mm. 4,5 mm Fig. 13 - 27 ● Adjust nut 1 ( locking nut 2 ) according to the requirement.
Page 113: Needle Thread Cutter Switch
Adjustment Needle thread cutter switch Requirement When the cutter cylinder 3 is retracted, switch 1 should be reliably activated. Fig. 13 - 28 ● Adjust switch 1 ( screw 2 ) according to the requirement.
Page 114: Needle Thread Cutter Release
Adjustment Needle thread cutter release Requirement 1. Adjustment hole 6 must match the hole in the mounting plate 7. 2. There should be a distance of approximately 1 mm between the lower edge of pawl 5 and the upper edge of catch 8. ( The thread should not be cut until the needle thread tension is open.
Page 115: Catch
Adjustment Catch Requirement When the cutter frame 1 is at the highest point of the cam guide unit 2, there should be a space of 0.2 mm between catch 3 and pawl 6. 56-038b Fig. 13 - 30 ● Connect the machine to the compressed air system and switch on the machine. ●...
Page 116: Swing Out Motion Of The Needle Thread Cutter
Adjustment Swing out motion of the needle thread cutter Requirement 1. Before the swing out motion begins, the needle thread cutter 4 should have clamped and cut the thread reliably. 2. When the needle thread cutter 4 swings out, it should not touch the needle point. 56-057a Fig.
Page 117: Needle Bar Rise And Hook-To-Needle Clearance
Adjustment Needle bar rise and hook-to-needle clearance Requirement When the needle penetrates the right side of the left seam, the needle bar rise should be 2.4 mm. In this position, the point 5 of the hook should be exactly in the centre of the needle 6 and there should be a clearance of 0.1 mm between the needle and the hook point.
Page 118 Adjustment 0,1 mm 56-070a 56-070b Fig. 13 - 33 ● Loosen the screw clamp 1, slide up as far as possible and tighten it again. ● Remove the needle rise gauge. ● Turn the balance wheel in the direction of sewing until screw clamp 1 has contact. ●...
Page 119: Needle Bar Height And Needle Guard
Adjustment Needle bar height and needle guard Requirement 1. When the needle penetrates the right side of the right seam, there should be a clearance of 0.5 mm between the top edge of the needle eye and the hook point 2 at the end of the needle rise.
Page 120: Bobbin Case Holder
Adjustment Bobbin case holder Requirement The bobbin case holder should be scarcely but reliably held. Fig. 13 - 35 ● Adjust bobbin case holder 1 ( screws 2 ) according to the requirement. ● Move the needle plate against the stop and screw tight.
Page 121: Hook Lubrication
Adjustment Hook lubrication Requirement 1. After approx. 10 sewing cycles, a fine oil streak should appear on a piece of paper held below the hook. 2. The felt ring should lightly touch the spring-loaded metal disc. Fig. 13 - 36 ●...
Page 122: Knife Position
Adjustment Knife position Requirement 1. ( When the bobbin thread trimming device is in its neutral position ), knife 1 should be parallel to the edge of the needle hole with a clearance of 0.5 mm. 2. During the cutting motion, the catcher 3 should move as near as possible to knife guard 5 without touching it.
Page 123: Knife Guard
Adjustment Knife guard Requirement 1. When the bobbin thread trimming device is in its neutral position, knife guard 3 should be parallel to the edge of the knife 4. 2. The stud 5 should not touch the bottom of the cam ( set clamp 1 in a vertical position ). 56-063a Fig.
Page 124: Needle Thread Tension Release
Adjustment Needle thread tension release Requirement 1. When the thread tension unit 8 is in its neutral position, release magnet 9 should be at a distance of approx. 2- 3 from case 3. 2. When the thread tension unit 8 is open, the tensions disks 11 should be approx. 0.5 mm apart.
Page 125: Needle Thread Puller
Adjustment Needle thread puller Requirement 1. When sewing starts, the needle thread should not be pulled out of the needle thread cutter. 2. The loose needle thread must be used up after the first stitch. 83-013 Fig. 13 - 40 ●...
Page 126: Side Thread Tension And Slack Thread Regulator
Adjustment Side thread tension and slack thread regulator Requirement Thread check spring 5 should be 1. flush with the top edge of bar 6 and 2. rise slightly from its position rest when the thread loop through the hook is at its largest. 83-038 Fig.
Page 127: Bobbin Winder
Adjustment Bobbin winder Requirement 1. When the bobbin winder is activated, the friction wheel 5 should be driven reliably. 2. When the bobbin winder is deactivated, the drive wheel 1 should not touch friction wheel 5. 3. When the bobbin is filled up to 1 mm from the edge, the bobbin winder should switch off automatically.
Page 128: Retainer Position (Only For 3119-2/62 And -2/63)
Adjustment Retainer position (only for 3119-2/62 and -2/63) Requirement Retainer 1 should 1. be positioned parallel to the cutting slot with its front edge flush with the needle hole and 2. as near as possible over the workpiece without restricting it.
Page 129: Carrying Out A Cold Start
Adjustment Carrying out a cold start When a cold start is carried out, all newly created or modified programs, and all altered parameter settings are deleted! The machine memory is deleted or reset to the status at the time of delivery. ●...
Page 130: Parameter Settings
Adjustment Parameter settings All variable machine functions are listed in the parameter list (Chapter 13.48.02). An example of how to select the parameters and how to alter the values is given below (Chapter 13.48.01). Selecting and altering parameters .48.01 Example: Switching on the needle thread monitor ●...
Page 131: List Of Parameters
Adjustment List of parameters .48.02 Group Parameter Meaning Setting Standard value Knife suppression permanent ( I =OFF, II = ON ) I, II Stop for needle thread fault I, II ( I =OFF, II = ON ) Display software version 0312/xxx ▲...
Page 132 Software version motor control unit Control panel key tone I, II (I = OFF; II = ON) Delete vario programs Subclass 1: 3119-1/51 und 1/52 1 - 7 2: 3119-2/51 und 2/62 3: 3119-2/53 und 2/63 4: 3119-3/51 5: 3119-4/51...
Page 133 Adjustment Group Parameter Meaning Setting Standard value ▲ Width of left seam = width A [mm] 0,5 - 5,5 ■ Width of 1 seam [mm] 0,0 - 6,0 Length of left seam (same length as 1,0 - 48,0 14,8 ▲ right seam) = length A [mm] ■...
Page 134 Adjustment Group Parameter Meaning Setting Standard value Number of stitches in right seam = number of stitches C 1 - 255 Secondary thread tension right seam (II = on; I = off) I, II Width of 2 bar = width D (mm) 1.0 - 5.5 Second width of 2 bar = width D1 (mm)
Page 135 Adjustment Group Parameter Meaning Setting Standard value Display inputs (0123456789ABCDEF) Meaning of the display: 0 = Error bobbin thread monitor 1 = Error needle thread monitor 2 = Needle in material ( NIS ) 3 = Reference needle ( needle centre ) 4 = not assigned ( E12 ) 5 = not assigned ( E11 ) 6 = not assigned ( E10 )
Page 136 Adjustment Group Parameter Meaning Setting Standard value P-quota speed controller 1 -50 I-quota speed controller 0 - 100 P-quota position controller 1 - 50 D-quota position controller 1 - 100 Time for position controller 0 - 100 P-quota position controller for rest brake 1 - 50 D-quota position controller for rest brake 1 - 50...
Page 137 Right of access key buttonhole width 0 - 1 Right of access key cutting width 0 - 1 Right of access key double 0 - 1 sewing cycle Key for right of access 0 - 1 "Program management" Enter access code 0 to 9999 3119...
Page 138: Malfunctions
Adjustment Malfunctions Error messages .49.01 Error System fault in the control unit Error Defect on sewing motor Time out + motor defect Time out + motor defect Speed + motor defect StopX + motor defect Reset stitch counter + motor defect Write parameter + motor defect Position tdc shortest path + motor defect Position tdc backwards + motor defect...
Page 139 Adjustment Error Sewing area larger than the work clamp cutout Program does not fit into sewing area Error Output not connected (in seam program) Error Input not incoming (in seam program) Error Delay time when the sewing drive is running not permitted Error Cutting before previous sewing Error...
Page 140: Motor Errors
Adjustment Motor errors .49.02 Error No. Description Brake path too short Communication error Init not ready Extint low bei Init Short circuit Extint low in operation No increments Motor blocking No incremental connector Motor running interrupted Controller locked Invalid transmission Zero mark invalid Interior start error Time-out monitoring...
Page 141: 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.de/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 142 Wearing parts 91-269 245-91 91-000 094-25 91-269 243-91 91-000 369-15 (3x) 91-138 525-05 91-000 390-05 91-000 998-15 91-267 251-05 11-173 086-15 91-138 550-05 System 438 99-137 151-45...
Page 143 91-269 272-95 Circuit diagram pneumatics Version 30.09.99 Schaltpläne...
Page 144: Circuit Diagrams
Circuit diagrams Reference list for the circuit diagrams Controller Quick P 320MS Control panel BDF-S3D 3119 Sewing head identification (OTE) Thread sensor Hybrid light barrier needle reference Sewing lamp Sewing motor Stepping motor needle Stepping motor work clamp Main switch...
Page 145 Circuit diagrams Stepping motor work clamp Thread monitor Key knife suppression Key reference work clamp Key basic position cutter Key work clamp lowered Key basic position knife Key knife suppression Hybrid light barrier Solenoid valve work clamp Solenoid valve thread tension Solenoid valve knife on Solenoid valve cutter Solenoid valve hook and eye stop 1...
Page 146 Circuit diagram - general plan 91-191 503-95 Version 21.06.06 Part 1...
Page 147 91-191 503-95 Circuit diagram - general plan Part 2 Version 21.06.06...
Page 148 Circuit diagram - general plan 91-191 503-95 Version 21.06.06 Part 3...
Page 149 91-191 503-95 Circuit diagram - general plan Part 4 Version 21.06.06...
Page 150 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 Hotlines: Technical service: +49 - 175/2243-101 Application consultance: +49 - 175/2243-102 Spare-parts hotline:...

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