Pfaff 3119 User manual

INSTRUCTION MANUAL
296-12-18 958/002
Betriebsanleitung engl. 06.09
This instruction manual applies to machines
from software version 0365/001 and serial
number 2 738 201 onwards
3119

This instruction manual applies to all versions and subclasses listed under
"Specifications".
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.
PFAFF Industriesysteme
und Maschinen AG
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern

Index
Contents ..................................................................................Page
1Safety .................................................................................................................................... 7
1.01 Regulations ............................................................................................................................ 7
1.02 General notes on safety......................................................................................................... 7
1.03 Safety symbols ...................................................................................................................... 8
1.04 Important notes for the user.................................................................................................. 8
1.05 Notes for operating and technical staff ..................................................................................9
1.05.01 Operating staff ....................................................................................................................... 9
1.05.02 Technical staff ........................................................................................................................ 9
1.06 Danger warnings.................................................................................................................. 10
2Proper use............................................................................................................................11
3Specifications ..................................................................................................................... 12
3.01 General information ............................................................................................................. 12
3.02 Stitch formation of the various sub-classes ......................................................................... 13
4Disposal of Machine .......................................................................................................... 14
5Transportation, packing and storage ................................................................................ 15
5.01 Transportation to customer‘s premises ............................................................................... 15
5.02 Transportation inside the customer‘s premises................................................................... 15
5.03 Disposal of packing materials ..............................................................................................15
5.04 Storage ................................................................................................................................ 15
6Explanation of symbols..................................................................................................... 16
7Controls .............................................................................................................................. 17
7.01 Main switch ......................................................................................................................... 17
7.02 Switch for separate compressor (optional) .......................................................................... 17
7.03 Pedal .................................................................................................................................... 18
7.04 Preventing knife engagement .............................................................................................. 18
7.05 Control panel........................................................................................................................ 19
7.05.01 Display symbols................................................................................................................... 19
7.05.02 General key functions .......................................................................................................... 19
7.05.03 Further key functions in the buttonhole mode ..................................................................... 21
7.05.04 Other key functions in the bartack mode............................................................................. 22
7.05.05 Further key functions in the activated sequence mode ....................................................... 23
8Mounting and commissioning the machine.................................................................... 24
8.01 Installation............................................................................................................................ 24
8.01.01 Adjusting the table height.................................................................................................... 24
8.01.02 Installation variants .............................................................................................................. 25
8.01.03 Table top drilling template (installed parallel to the table edge) ........................................... 26
8.01.04 Table top drilling template (installed crosswise to the table edge) ...................................... 27
8.01.05 Connecting the plug connections and earth cables ............................................................. 28

Index
Contents ..................................................................................Page
8.01.06 Fitting the reel stand ............................................................................................................ 29
8.02 Commissioning .................................................................................................................... 29
8.03 Switching the machine on / off ............................................................................................29
8.04 Setting up the machine control unit ..................................................................................... 30
8.04.01 Establishing the sub-class.................................................................................................... 30
8.04.02 Setting parameter "202" ....................................................................................................... 31
9Setting up ........................................................................................................................... 32
9.01 Inserting the needle............................................................................................................. 32
9.02 Winding the bobbin thread / adjusting the preliminary thread tension ................................ 33
9.03 Threading the bobbin case / adjusting the bobbin thread tension ....................................... 34
9.04 Changing the bobbin............................................................................................................ 35
9.05 Threading the needle thread................................................................................................36
9.06 Selecting the operating mode.............................................................................................. 37
9.07 Selecting the type of buttonhole / bartack .......................................................................... 38
9.08 Adjusting the needle thread tension.................................................................................... 39
9.09 Adjusting the work clamp pressure ..................................................................................... 40
9.10 Inserting and removing the SD-memory card...................................................................... 40
9.11 Position of the needle to the workpiece .............................................................................. 41
9.12 Activating the sequence mode ............................................................................................ 42
10 Sewing ................................................................................................................................ 43
10.01 Sewing in the buttonhole mode........................................................................................... 43
10.01.01 Control panel with speed or buttonhole model display ....................................................... 43
10.01.02 Selecting the buttonhole...................................................................................................... 44
10.01.03 Entering the knife length and cut overlap ............................................................................ 45
10.01.04 Altering the buttonhole width and seam correction............................................................. 46
10.01.05 Altering the cutting width and cutting length correction...................................................... 47
10.02 Sewing in the bartack mode ................................................................................................ 48
10.01.01 Control panel with speed or bartack type display ................................................................ 48
10.02.02 Selecting the bartack ........................................................................................................... 49
10.03 Error messages.................................................................................................................... 50
11 Input .................................................................................................................................... 51
11.01 Summary of the function groups and parameters ............................................................... 51
11.02 Selecting the function group and altering the parameters................................................... 52
11.03 Entering / altering the access code...................................................................................... 53
11.04 Allocating access rights ....................................................................................................... 54
11.05 Variable programs ................................................................................................................ 55
11.05.01 Copying programs................................................................................................................ 55
11.05.02 Creating / modifying vario programs in the buttonhole mode.............................................. 57
11.05.03 Creating / modifying vario programs in the bartack mode ................................................... 58
11.05.04 Buttonhole and bartack model ............................................................................................. 59
11.05.05 Table for entering a buttonhole program.............................................................................. 63
11.05.06 Table for entering a bartack program ................................................................................... 64

Index
Contents ..................................................................................Page
11.06 Sequences ........................................................................................................................... 65
11.06.01 Creating sequences ............................................................................................................. 65
11.07 Selecting programs.............................................................................................................. 68
11.08 Special programs ................................................................................................................. 69
11.09 SAM (Sewing Application Manager) .................................................................................... 69
11.10 Program Management.........................................................................................................69
11.10.01 Calling up the program management ..................................................................................70
11.10.02 Display of the data in the machine memory ........................................................................ 71
11.10.03 Display of the data on the SD-memory card........................................................................ 72
11.10.04 Copying data onto the SD-memory card.............................................................................. 73
11.10.05 Copying data into the machine memory ..............................................................................74
11.10.06 Deleting data in the machine memory................................................................................. 75
11.10.07 Deleting data from the SD-memory card............................................................................. 76
11.10.08 Formatting the SD-memory card ......................................................................................... 77
12 Care and maintenance....................................................................................................... 78
12.01 Maintenance intervals.......................................................................................................... 78
12.02 Cleaning the machine .......................................................................................................... 78
12.03 Cleaning the hook compartment ......................................................................................... 79
12.04 Cleaning the air filter of the air-filter / lubricator .................................................................. 80
12.05 Checking/adjusting the air pressure..................................................................................... 80
12.06 Check oil level for needle drive unit ..................................................................................... 81
12.07 Check oil level for the hook.................................................................................................. 81
12.08 Check oil level for the compressor....................................................................................... 81
13 Adjustment ......................................................................................................................... 82
13.01 Notes on adjustment ........................................................................................................... 82
13.02 Tools, gauges and other accessories ................................................................................... 82
13.03 Abbreviations ....................................................................................................................... 82
13.04 Toothed belts of the hook drive unit .................................................................................... 83
13.05 Drive rods of the bobbin thread trimming device ................................................................ 84
13.06 Switch for sewing start ........................................................................................................ 85
13.07 Basic position of the feed drive unit..................................................................................... 86
13.08 Preliminary adjustment of the work clamp .......................................................................... 87
13.09 Toothed belts of the main drive unit .................................................................................... 88
13.10 Preliminary adjustment of the needle height....................................................................... 89
13.11 Position of the needle plate in relation to the needle .......................................................... 90
13.12 Controlling the stitch symmetry........................................................................................... 91
13.13 Sensor board of the needle drive ( in dismantled state ) ..................................................... 92
13.14 Basic setting of the needle drive unit................................................................................... 94
13.15 Basic position of the work clamp ( lengthwise to the arm )................................................. 95
13.16 Basic position of the work clamp ( crosswise to the arm ) .................................................. 96
13.17 Upper take-up lever position (reference position) ................................................................ 97
13.18 Lifting elbow on the work clamp.......................................................................................... 98
13.19 Work clamp stroke............................................................................................................... 99

Index
Contents ..................................................................................Page
13.20 Lifting cylinder of the work clamp...................................................................................... 100
13.21 Cutting pressure of the knife unit ( in dismantled state ) ....................................................101
13.22 Position of the knife bracket and lower knife stop ............................................................ 102
13.23 Upper knife stop ............................................................................................................... 104
13.24 Knife control switch ........................................................................................................... 105
13.25 Knife motion....................................................................................................................... 106
13.26 Distance of the knife to the needle bar.............................................................................. 107
13.27 Changing the knife / knife height ....................................................................................... 108
13.28 Functional test of needle thread cutter .............................................................................. 109
13.29 Needle thread cutter ( vertical and horizontal adjustment ).................................................110
13.30 Cam guide unit....................................................................................................................111
13.31 Needle thread cutter stroke ................................................................................................112
13.32 Needle thread cutter switch................................................................................................113
13.33 Needle thread cutter release ..............................................................................................114
13.34 Catch...................................................................................................................................115
13.35 Swing out motion of the needle thread cutter ....................................................................116
13.36 Needle bar rise and hook-to-needle clearance....................................................................117
13.37 Needle bar height and needle guard...................................................................................119
13.38 Bobbin case holder ............................................................................................................ 120
13.39 Hook lubrication ................................................................................................................. 121
13.40 Knife position ..................................................................................................................... 122
13.41 Knife guard......................................................................................................................... 123
13.42 Needle thread tension release........................................................................................... 124
13.43 Needle thread puller .......................................................................................................... 125
13.44 Side thread tension and slack thread regulator.................................................................. 126
13.45 Bobbin winder.................................................................................................................... 127
13.46 Retainer position (only for 3119-2/62 and -2/63)................................................................. 128
13.47 Carrying out a cold start..................................................................................................... 129
13.48 Parameter settings............................................................................................................. 130
13.48.01 Selecting and altering parameters ..................................................................................... 130
13.48.02 List of parameters.............................................................................................................. 131
13.49 Malfunctions ...................................................................................................................... 138
13.49.01 Error messages.................................................................................................................. 138
13.49.02 Motor errors....................................................................................................................... 140
14 Wearing parts ................................................................................................................... 141
15 Circuit diagrams............................................................................................................... 143

Safety
7
1 Safety
1.01 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!
1.02 General notes on safety
This machine may only be operated by adequately trained operators and only after having●
completely read and understood the Instruction Manual!
All Notes on Safety and Instruction Manuals of the motor manufacturer are to be read be-●
fore operating the machine!
The danger and safety instructions on the machine itself are to be followed!●
This machine may only be used for the purpose for which it is intended and may not be●
operated without its safety devices. All safety regulations relevant to its operation are to
be adhered to.
When exchanging sewing tools, when threading the machine, when leaving the machine●
unattended and during maintenance work, the machine is to be separated from the
power supply by switching off the On/Off switch or by removing the plug from the mains!
Everyday maintenance work is only to be carried out by appropriately trained personnel!●
Repairs and special maintenance work may only be carried out by qualified service staff●
or appropriately trained personnel!
Work on electrical equipment may only be carried out by appropriately trained personnel!●
Work is not permitted on parts and equipment which are connected to the power supply!●
The only exceptions to this rule are found in the regulations EN 50110.
Modifications and alterations to the machine may only be carried out under observance●
of all the relevant safety regulations!
Only spare parts which have been approved by us are to be used for repairs! We express-●
ly point out that any replacement parts or accessories which are not supplied by us have
not been tested and approved by us. The installation and/or use of any such products can
lead to negative changes in the structural characteristics of the machine. We are not liable
for any damage which may be caused by non-original parts.

Safety
8
1.03 Safety symbols
Danger!
Special points to observe.
Danger of injury to operating or technical staff!
Caution
Do not operate without finger guard and safety de-
vices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.
1.04 Important notes for the user
This instruction manual belongs to the equipment of the machine and must be available●
to the operating staff at all times.
This instruction manual must be read before the machine is operated for the first time.●
Both operating and technical staff must be instructed on the safety devices of the mach-●
ine and on safe working methods.
It is the duty of the user to operate the machine in perfect running order only.●
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..
I

Safety
9
1.05 Notes for operating and technical staff
1.05.01 Operating staff
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:
The notes on safety in this instruction manual must always be observed!●
Any working methods, which adversely affect the safety of the machine, must be avoi-●
ded.!
Loose-fitting clothing should be avoided. No jewellery, such as chains and rings, should●
be worn!
Ensure that only authorised persons enter the danger area of the machine!●
Any changes occurring on the machine, which may affect its safety, must be reported to●
the user immediately.
1.05.02 Technical staff
Technical staff are persons who have been trained in electrical engineering/electronics and
mechanical engineering. They are responsible for lubricating, servicing, repairing and adjus-
ting the machine.
The technical staff is obliged to observe the following points:
The notes on safety in this instruction manual must always be observed!●
Before carrying out any adjustment or repair work the main switch must be switched off●
and measures taken to prevent it from being switched on again!
Never work on parts or equipment still connected to the power supply! Exceptions are●
only permissible in accordance with the regulations EN 50110.
All safety covers must be replaced after the completion of maintenance or repair work!●

Safety
10
1.06 Danger warnings
A working area of 1mmust 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. Danger of injury from the knife!
Do not operate the machine without the take-up lever guard 2!
Danger of injury from the movement of the take-up lever.
Do not operate the machine without eye shield 3 or 4!
Danger of injury from needle splinters! The type of eye shield is dependent on
the way the machine is installed.
Only operate the machine with cover 5 closed.
Danger of injury from the hook!
Fig. 1 - 01 83-002
115-001
1
2
3
4
5
3

Proper use
11
2 Proper use
The PFAFF 3119-1/51, PFAFF 3119-1/52 and PFAFF 3119-2/52 are used for sewing raised or
flat buttonholes with two flat or raised square bars on fine materials in the linen and clothing
The PFAFF 3119-2/53, PFAFF 3119-3/51 and PFAFF 3119-4/51 are used for sewing raised
or 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.
The PFAFF 3119-5/51 is used for producing openings for safety belts in the automobile in-
dustry.
Any use of these machines which is not approved by the manufacturer shall be
considered as improper use! The manufacturer shall not be liable for any dam-
age arising out of improper use! Proper use shall also be considered to include
compliance with the operation, adjustment, service and repair measures speci-
fied by the manufacturer!

Specifications
12
3 Specifications▲
3.01 General information
Max. sewing speed:.................................................................................................. 4200 min-1
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. 70 mm x 6.0 mm
Length of buttonhole cut:............................................................................ 6.4 mm – 64.6 mm
Zig-zag stitch: ........................................................................................................max. 6.0 mm
Number of stitches: ..................................................................................freely programmable
Feed type: ............................................................................................................... intermittent
Power supply: ................................................................. 230 V ± 10%, 50/60 Hz, single phase
Power consumption:.............................................................................................max. 0.6 KVA
Input power rating:.........................................................................................................0.7 kVA
Fuse protection: ....................................................................................................1 x 16A, inert
Software status:......................................................................................... see parameter "104"
Working air pressure:......................................................................................................... 6 bar
Air consumption............................................................................................ ~1.2 l / work cycle
Noise data:
Emission sound level at workplace with a sewing cycle of
4 sec. On and 2 sec. Off: ................................................................................ LpA = 78 dB(A) n
(Noise measurement in accordance with DIN 45 635-48-B-1, ISO 11204, ISO 3744, ISO
4871)
Sewing head dimensions:
Length:............................................................................................................. approx. 514 mm
Width: .............................................................................................................. approx. 200 mm
Height: ............................................................................................................. approx. 450 mm
Weight of sewing head:........................................................................................approx. 65 kg
Dimensions of base:
Length:........................................................................................................... approx. 1060 mm
Width: .............................................................................................................. approx. 600 mm
Height .............................................................................................................. approx. 820 mm
Weight of base incl. control box: ..........................................................................approx. 45 kg
Needle system:.................................................................................................................... 438
Needle size for fine materials: ........................................................................................ 60 - 70
Needle size for medium-weight materials: ................................................................ 80 - 100 0
▲Subject to alteration
■K
pA = 2,5 dB

Specifications
13
3.02 Stitch formation of the various sub-classes
Sub-class
-1/51
-1/52
-2/51
-2/62
-2/53
-2/63 -3/51 -4/51 -5/51
Cut-out size in work
clamp [mm]
30,0 x 5,6 40,0 x 5,6
44,0 x 6,0
40,0 x 6,7
44,0 x 7,0 46,0 x 6,7 55,0 x 7,0 77,0 x 7,0
Buttonhole
size [mm]
min.
9,0 x 2,0
max.
24,0 x 4,4
min.
9,0 x 2,0
max.
34,0 x 4,4
min.
9,0 x 2,0
max.
34,0 x 5,4
min.
9,0 x 2,0
max.
40,0 x 5,4
min.
9,0 x 2,0
max.
48,0 x 5,4
min.
9,0 x 2,0
max.
70,0 x 6,0
Length of buttonhole cut [mm]
6,4
9,5
11,0
12,7
14,0
16,0
17,5
6,4
9,5
11,0
12,7
14,0
16,0
17,5
19,0
22,2
25,4
6,4
9,5
11,0
12,7
14,0
16,0
17,5
19,0
22,2
25,4
6,4
9,5
11,0
12,7
14,0
16,0
17,5
19,0
22,2
25,4
28,6
31,7*
6,4
9,5
11,0
12,7
14,0
16,0
17,5
19,0
22,2
25,4
28,6
31,7*
33,7
35,0
36,5
38,1
6,4
9,5
11,0
12,7
14,0
16,0
17,5
19,0
22,2
25,4
28,6
31,7
33,7
35,0
36,5
38,1 to 45*
64,6
* On subclasses -3/51 and -4/51, for a cutting length of 31.7 mm and more, the knife must
be at least 16.0 mm long. On the subclass -5/51, for a cutting length of 45 mm and more,
the knife must be at least 22.2 m long.
Each time parts are changed, the control unit must be adapted to the sub-class,
see Chapter Kapitel 8.04 Setting up the machine control unit. An incorrect
setting can cause the knife or needle to strike the work clamp.

Disposal of Machine
14
4 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.
The machine is to be disposed of according to the locally valid pollution control regula-ti-●
ons; if necessary, a specialist ist to be commissioned.
Care must be taken that parts soiled with lubricants are disposed of separately
according to the locally valid pollution control regulations!

Transportation, packing and storage
15
5 Transportation, packing and storage
5.01 Transportation to customer‘s premises
The machines are delivered completely packed.
5.02 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.
5.03 Disposal of packing materials
The packing materials of this machine comprise paper, cardboard and VCE fibre. Proper dis-
posal of the packing material is the responsibility of the customer.
5.04 Storage
If the machine is not in use, it can be stored as it is for a period of up to six months, but It
should be protected against dust and moisture.
If the machine is stored for longer periods, the individual parts, especially the surfaces of
moving parts, must be protected against corrosion, e.g. by a film of oil.

Explanation of symbols
16
6 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)

Controls
17
Fig. 7 - 01
7 Controls
7.01 Main switch
The machine is switched on or off by tur-●
ning the main switch 1.
0
56-067
1
Fig. 7 - 02
7.02 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.
If the pressure is too low, an
error message will appear on
the display.
1

Controls
18
Fig. 7 - 03
7.03 Pedal
-1 = Prevent knife engagement at end of
current sewing cycle
0 = Neutral position
+1 = Work clamp lowered
+2 = Sewing
113-005
0
-1
+1
+2
83-005
Fig. 7 - 04
7.04 Preventing knife engagement
By operating push button●1, knife enga-
gement at the end of the current sewing
cycle is prevented.
By moving lever●2 in the direction of the
arrow, the knife is mechanically locked.
This prevents knife engagement during
setting-up, maintenance and adjustment
work.
1
2

Controls
19
7.05 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.
Fig. 7 - 05
1
7.05.01 Display symbols
7.05.02 General key functions
Plus/minus keys
By pressing and holding the corresponding plus/minus key, the function displayed above it
is carried out or the value located above it is altered.
To begin with the value is changed slowly by pressing and holding the key. If the plus/minus
key is held down longer, the value changes more quickly.
In the following description each of the plus/minus keys mentioned are shown as illustrated
opposite.
Maximum speed Bartack width
Cutting length Stitch density
Piece or reverse counter Bartack extension
Buttonhole or bartack model Machine memory
"Enter" function SD-memory card
"Cut open" function

Controls
20
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 figure 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
Tacting in reverse through the whole sewing cycle step by step.●
When entering the code number, this key corresponds to the number●2
Tacting forwards
Tacting forwards through the whole sewing cycle step by step.●
When entering the code number, this key corresponds to the number●3.
Basic position
In the operational mode Sewing the machine moves to the basic position.●
When entering the code number, this key corresponds to the number●4.
Work clamp raised / lowered
In the operational mode Sewing the work clamp is raised/lowered.●
When entering the code number, this key corresponds to the number●5.
P1
Quick selection key for variable and special programs.●
When entering the code number, this key corresponds to the number●6.
P2
Quick selection key for variable and special programs.●
When entering the code number, this key corresponds to the number●7.
P3
Quick selection key for variable and special programs.●
When entering the code number, this key corresponds to the number●8.
P4
Quick selection key for variable and special programs.●
When entering the code number, this key corresponds to the number●9.
Scrolling
In the sewing mode this key is used to switch between speed display and seam pattern●
display.
Using the keys described below, each of which has an LED, depending on the
mode selected, further functions can be called up. When the LED lights up
the corresponding function is activated / switched on.