Pfaff 3801-3/07 User manual

This instruction manual applies to machines
from serial number 2 716 117 and software
version 0352/011 onwards.
INSTRUCTION MANUAL
296-12-18 590/002
Betriebsanleitung engl. 03.12
3801
-3/07, -3/071, -11/071

This Instruction Manual is valid for all models and subclasses listed
in the chapter "Specifications".
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

Contents
Contents ................................................................................. Chapter - Page
1Safety ........................................................................................................................... 1 - 1
1.01 Directives...................................................................................................................... 1 - 1
1.02 General notes on safety ................................................................................................ 1 - 1
1.03 Safety symbols ............................................................................................................. 1 -2
1.04 Important points for the user ........................................................................................ 1 - 2
1.05 Operating and specialist personnel ............................................................................... 1 - 3
1.05.01 Operating personnel...................................................................................................... 1- 3
1.05.02 Specialist personnel ......................................................................................................1- 3
1.06 Danger .......................................................................................................................... 1 - 4
2Proper use.................................................................................................................... 2 -1
3Specifications .............................................................................................................. 3 - 1
4Disposal of machines.................................................................................................. 4 - 1
5Transport, packaging and storage ............................................................................. 5 - 1
5.01 Transport to the customer’s premises .......................................................................... 5 - 1
5.02 Transport within the customer’s premises ................................................................... 5 - 1
5.03 Disposal of the packaging ............................................................................................. 5 - 1
5.04 Storage ......................................................................................................................... 5 - 1
6Explanation of the symbols........................................................................................ 6 - 1
7Controls ....................................................................................................................... 7- 1
7.01 Main switch ..................................................................................................................7- 1
7.02 Pedal ............................................................................................................................. 7 - 1
7.03 Lever for lifting the presser foot.................................................................................... 7 - 2
7.04 Knee switch ..................................................................................................................7- 2
7.05 Edge guide .................................................................................................................... 7 - 3
7.06 Lever for retracting the tape-feeding unit
(only on the PFAFF 3801-11/071) .................................................................................. 7 - 3
7.07 Reverse-feed control lever ............................................................................................ 7 - 4
7.08 Control panel................................................................................................................. 7 - 5
8Mounting and commissioning the machine ............................................................. 8 - 1
8.01 Mounting....................................................................................................................... 8 - 1
8.01.01 Adjusting the table-top height ....................................................................................... 8 - 1
8.01.02 Tightening the V-belt .....................................................................................................8- 2
8.01.03 Fitting the upper belt guard ........................................................................................... 8 - 2
8.01.04 Mounting the bottom V-belt guard ................................................................................ 8 - 3
8.01.05 Fitting the synchronizer................................................................................................. 8- 3
8.01.06 Connecting the plug-in connections and earth cables ................................................... 8 - 4
8.01.07 Fitting the reel stand ..................................................................................................... 8 - 5
8.02 Commissioning ............................................................................................................. 8 - 6
8.03 Switching the machine on/off ....................................................................................... 8 - 6

Contents
Contents ................................................................................. Chapter - Page
9Preparation .................................................................................................................. 9 - 1
9.01 Inserting the needle ...................................................................................................... 9 - 1
9.02 Threading the needle thread and regulating its tension................................................. 9 - 2
9.03 Threading the looper thread and regulating its tension.................................................. 9 - 3
9.04 Threading the bridle tape (on the PFAFF 3801-11/071).................................................. 9 - 4
9.05 Setting the seam depth................................................................................................. 9 - 5
9.06 Threading the bridle tape (on thePFAFF 3801-3/07 and -3/071) ..................................... 9 - 6
9.07 Selecting the program number...................................................................................... 9 - 7
9.08 Inputting fullness...........................................................................................................9- 7
9.09 Entering / altering the code number .............................................................................. 9 - 8
9.10 Entering the seam parameter ....................................................................................... 9 -10
9.11 Adjusting the control panel............................................................................................ 9 -12
10 Sewing ....................................................................................................................... 10 -1
10.01 Manual sewing............................................................................................................ 10 - 1
10.02 Sewing with fixed programs ....................................................................................... 10 - 3
10.03 Programmed sewing................................................................................................... 10 - 5
10.03.01 Fullness adjustment .................................................................................................... 10 -6
10.03.02 Selecting the garment size.......................................................................................... 10 - 7
10.03.03 Program interruption ................................................................................................... 10 -7
10.04 Error messages........................................................................................................... 10 - 8
11 Input ...........................................................................................................................11-11
11.01 Seam program input ................................................................................................... 11 - 2
11.01.01 Seam program input ................................................................................................... 11 - 2
11.01.02 Seam program input with the "Creating/adjusting a program" function ....................... 11 - 4
11.01.03 Seam program input with the "Teach-in" function........................................................ 11 - 6
11.02 Examples of how to create seam programs ............................................................... 11 - 8
11.02.01 Example of a seam program input using the............................................................... 11 - 8
"Creating/adjusting a program" function....................................................................... 11 - 8
11.02.02 Example of a seam program input using the "teach-in" function.................................. 11 -10
11.03 Seam program administration ..................................................................................... 11 -13
12 Care and Maintenance .............................................................................................. 12 - 1
12.01 Cleaning ...................................................................................................................... 12 - 1
12.02 Machine oil level ......................................................................................................... 12 -2
12.03 Cleaning/lubricating the top feed joints ....................................................................... 12 - 2
12.04 Checking/adjusting the air pressure ............................................................................ 12 - 3
12.05 Cleaning the air filter of the air-filter/lubricator............................................................. 12 - 3
13 Adjustment ................................................................................................................ 13 - 1
13.01 Notes on adjustment................................................................................................... 13 - 1
13.02 Tools, gauges and other accessories for adjusting...................................................... 13 - 1
13.03 Abbreviations .............................................................................................................. 13 -1
13.04 Checking and adjusting aids ........................................................................................ 13 - 2

Contents
Contents ................................................................................. Chapter - Page
13.05 Adjusting the basic machine ....................................................................................... 13 - 3
13.05.01 Basic position of the machine ..................................................................................... 13 - 3
13.05.02 Position of needle to needle hole ................................................................................ 13 - 4
13.05.03 Pre-adjusting the needle height................................................................................... 13 - 5
13.05.04 Neutral position of the main feed dog ......................................................................... 13 - 6
13.05.05 Zero position of the differential feed dog .................................................................... 13 - 7
13.05.06 Feeding motion of main- and differential feed dogs .................................................... 13 - 8
13.05.07 Lifting motion of main- and differential feed dogs....................................................... 13 - 9
13.05.08 Position of main- and differential feed dogs ................................................................ 13 -10
13.05.09 Zero position of feeding presser ................................................................................. 13 -11
13.05.10 Front driving link of feeding-presser drive ................................................................... 13 -12
13.05.11 Positioning the lifting presser...................................................................................... 13 -13
13.05.12 Feeding motion of the top feed dog............................................................................ 13 -15
13.05.13 Lift of feeding presser................................................................................................. 13 -16
13.05.14 Lifting stroke of feeding presser ................................................................................. 13 -17
13.05.15 Stitch length limitation ................................................................................................ 13 -18
13.05.16 Basic setting of the differential adjustment device ..................................................... 13 -19
13.05.17 Looper avoiding motion............................................................................................... 13 -20
13.05.18 Looper height and looper angle (for the 3801-3/07)..................................................... 13 -21
13.05.19 Looper height and looper angle (for the 3801-3/071 and -11/071) ............................... 13 -22
13.05.20 Distance of the looper from the needle (in sewing direction) ...................................... 13 -23
13.05.21 Looper-to-needle clearance (crosswise to sewing direction)....................................... 13 -24
13.05.22 Looper motion............................................................................................................. 13 -25
13.05.23 Final adjustment of the needle height ......................................................................... 13 -26
13.05.24 Height of rear needle guard......................................................................................... 13 -27
13.05.25 Clearance between the rear needle guard and the needle .......................................... 13 -28
13.05.26 The looper-eccentric guard.......................................................................................... 13 -29
13.05.27 Position of the front needle guard ............................................................................... 13 -30
13.05.28 Needle thread puller.................................................................................................... 13 -31
13.05.29 Basic setting of the needle thread regulator and the thread guide .............................. 13 -32
13.05.30 Looper thread regulators............................................................................................. 13 -33
13.05.31 Looper thread puller .................................................................................................... 13 -34
13.05.32 Top feed and presser foot pressure ............................................................................ 13 -35
13.06 Adjusting the thread trimmer ...................................................................................... 13 -36
Only on the PFAFF 3801-3/071 and –11/071. .............................................................. 13 -36
13.06.01 Preadjusting the thread catcher .................................................................................. 13 -36
13.06.02 Ball pin position ........................................................................................................... 13 -37
13.06.03 Thread catcher position with respect to needle .......................................................... 13 -38
13.06.04 Thread catcher guard .................................................................................................. 13 -39
13.06.05 Tension release........................................................................................................... 13 -40
13.06.06 Trimmer test ...............................................................................................................13-41
13.07 Adjusting the tape feeding device ............................................................................... 13 -42
13.07.01 Adjusting the knife ...................................................................................................... 13-42
13.07.02 Setting the evaluation function of the photoelectric beam .......................................... 13 -43

Contents
Contents ................................................................................. Chapter - Page
13.07.03 Adjusting the air jets ................................................................................................... 13-44
13.07.04 Fastening the light guides ........................................................................................... 13 -45
13.08 Parameter settings...................................................................................................... 13 -46
13.08.01 Overview of the parameter functions ......................................................................... 13 -46
13.08.02 Example of a parameter input ..................................................................................... 13 -47
13.08.03 List of parameters....................................................................................................... 13-48
13.09 Sewing motor errors ................................................................................................... 13 -50
13.10 Explanation of the error messages.............................................................................. 13 -51
13.11 Table of inputs ............................................................................................................ 13 -52
13.12 Table of outputs .......................................................................................................... 13 -52
13.13 Service menu .............................................................................................................. 13 -53
13.14 Carry out a cold start................................................................................................... 13 -54
13.15 Internet update of the machine software.................................................................... 13 -55
14 Wearing parts ............................................................................................................ 14 - 1
15 Circuit diagrams ........................................................................................................ 15 - 1

Safety
1 - 1
1 Safety
1.01 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!
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
before 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 (e.g. needle, presser foot and needle plate), 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!
Exceptions to this are only to be 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
expressly 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 shall not be liable for any damage which may be caused by non-original parts.

Safety
1 - 2
1.03 Safety symbols
Danger!
Points to be observed.
Danger of injury for operating and specialist personnel!
1.04 Important points for the user
●This Instruction Manual is a component part of the machine and must be available to the
operating personnel at all times.
●The Instruction Manual must be read before operating the machine for the first time.
●The operating and specialist personnel is to be instructed as to the safety equipment of
the machine and regarding safe work methods.
●It is the duty of the user to only operate the machine in perfect running order.
●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 at your PFAFF agent.
I
Caution
Do not operate without finger guard and safety devices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.

Safety
1 - 3
1.05 Operating and specialist personnel
1.05.01 Operating personnel
Operating personnel are persons responsible for the equipping, operating and cleaning of the
machine as well as taking care of faults arising in the sewing area.
The operating personnel is obliged to observe the following points and must:
●always observe the Notes on Safety in the Instruction Manual!
●never use any working methods which could limit the level of safety in using the
machine!
●not wear loose-fitting clothing or jewelery such as chains or rings!
●also ensure that only authorized persons have access to the potentially dangerous area
around the machine!
●always immediately report to the person responsible any changes in the machine which
may limit its safety!
1.05.02 Specialist personnel
Specialist personnel are persons with a specialist education in the fields of electrics,
electronics and mechanics. They are responsible for the lubrication, maintenance, repair and
adjustment of the machine.
The specialist personnel is obliged to observe the following points and must:
●always observe the Notes on Safety in the Instruction Manual!
●switch off the On/Off switch before carrying out adjustments or repairs, and ensure that
it cannot be switched on again unintentionally!
●never work on parts which are still connected to the power supply! Exceptions are
explained in the regulations EN 50110.
●replace the protective coverings afer all repairs or maintenance work!

Safety
1 - 4
Do not operate the machine without the take-up-lever guard 1!
Danger of injury due to the motion of the take-up lever!
Do not operate the machine without the finger guard 2!
Danger of injury by the needle!
Do not operate the machine without the belt guards 3and 4!
Danger of injury due to the rotating V-belt!
Do not operate the machine without tilt lock 5!
Danger of crushing between the sewing head and table top!
Do not operate machines with a tape feeding device when this is disengaged.
Danger of injury from the knife and needle!
1.06 Danger
A working area of 1 meter is to be kept free both in front of and behind the
machine while it is in operation so that it is always easily accessible.
Never reach into the sewing area while sewing!
Danger of injury by the needle!
Never leave objects on the table while adjusting the machine settings!
Objects can become trapped or be slung away!
Danger of injury!
Fig. 1 - 01
3
1
54-049
2
2
54-66a
5
4

Proper use
2 - 1
2 Proper use
The PFAFF 3801-3/07, the PFAFF 3801-3/071 and the PFAFF 3801-11/071 are integrated
workplaces for the clothing industry for the application of fullness in one material ply.
Any and all uses of this machine which have not been approved of by the
manufacturer are considered to be inappropriate! The manufacturer cannot be
held liable for any damage caused by the inappropriate use of the machine!
The appropriate use of the machine includes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!
Machinemodel Equipment
3801-3/07 (without options)
3801-3/071 with thread-trimming unit
3801-11/071 with thread-trimming unit and tape feeding device

Specifications
3 Specifications▲
Stitch type:.............................................................................. 401 (two-thread chainstitch)
Max. speed:: ................................................................................................... 3200 s.p.m.◆
Max. stitch length: .................................................................................................. 2.0mm
Differential stitch length:............................................................................................ 6 mm
Needle system:.......................................................................................................4463-35
Needle size in 1/100 mm:.............................................80 – 100 depending on the material
Sewing thread:.............................................................................................................. 120
Tape width (bei der PFAFF 3801-11/071):..................................................... 2; 2,5; 3 oder 4 mm
Eff. Balance wheel dia.:............................................................................................ 65 mm
Presser foot clearance:
3801-3/07: .................................................................................................................. 7 mm
3801-3/071: ................................................................................................................ 7 mm
3801-11/071: .............................................................................................................. 5 mm
Connection data:
Operating voltage:............................................230 V ± 10%, 50/60 Hz, alternating voltage
Max. power:............................................................................................................. 400 VA
Fuse protection: ............................................................................................ 1 x 16 A, inert
Working air pressure: .................................................................................................. 6 bar
Air consumption (on the Pfaff 3801-3/07 and the PFAFF 3801-3/071): ............... 0.3 – 0.5 l/work cycle
Noise data:
Emission sound pressure level at the workplace with
a sewing speed of 2600 spm: .................................................................... LpA < 79 dB(A) ■
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)
Machine dimensions:
Length:.................................................................................................... approx. 1250 mm
Width: ....................................................................................................... approx. 800 mm
Height(with reel stand):........................................................................... approx. 1700 mm
Net weight:approx.....................................................................................................140 kg
▲Subject to technical alterations
◆Depending on the material, work operation and stitch length
■KpA = 2,5 dB
3 - 1

Disposal of machines
4 Disposal of machines
●The proper disposal of the machines is the responsibility of the customer.
●The materials used in the machines are steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
●The machine is to be disposed of in accordance with the locally valid environmental
protection regulations. If necessary, a specialist is to be commissioned.
Special care is to be taken that parts soiled with lubricants are separately
disposed of in accordance with the locally valid pollution control regulations!
4 - 1

Transport, packaging and storage
5 Transport, packaging and storage
5.01 Transportation to customer's premises
All machines are delivered completely packed.
5.02 Transport within the customer’s premises
The manufacturer bears no liability for transport within the customer’s premises or to the in-
dividual locations of use.
Always ensure that the machine is only transported upright.
5.03 Disposal of the packaging
The packaging of these machines consists of paper, cardboard and VCE fiber. The proper
disposal of the packaging is the responsibility of the customer.
5.04 Storage
The machine can be stored for up to 6 months if not in use. During this time it should be
protected from dust and moisture.
For longer storage the individual parts of the machine, especially the moving parts, should be
protected agains corrosion, e.g. by a film of oil.
5 - 1

Explanation of the symbols
6 - 1
6 Explanation of the symbols
In this Instruction Manual, tasks to be carried out and important information are drawn to
your attention by symbols. The symbols have the following meanings:
Note, information
Cleaning, care
Lubrication
Servicing, repairing, adjustment, maintenance
(only to be carried out by specialist personnel)

7 - 1
Controls
7.02 Pedal
0= Machine stop
+1 = Presser foot down
+2 = Sew
-1 = Presser foot up
-2 = Cut thread
Fig. 7 - 02
0
-1 -2
+1+2
Fig. 7 - 01
7 Controls
7.01 Main switch
●The machine is switched on or off by
turning main switch 1.
1

Controls
7 - 2
7.03 Lever for lifting the presser foot
●The presser foot is raised by turning
lever 1.
Fig. 7 - 03
1
7.04 Knee switch
●When sewing with the fixed programs
(program numbers 1 and 2), it is possible
to change to the next seam section by
pressing knee switch 1.
This function is only available in
the programmed sewing mode
(program numbers 3 -49), if
parameter 202 is set at "ON",
see Chapter 13.08 Parameter
settings).
Fig. 7 - 04
1

7 - 3
Controls
7.05 Edge guide
●The edge guide is brought into operating
position by pushing up lever 1.
●By pressing switch-key 2, the edge guide
can be raised.
Fig. 7 - 05
2
1
7.06 Lever for retracting the tape-feeding unit
(only on the PFAFF 3801-11/071)
●The tape-feeding unit can be retracted
with lever 1.
6
8-004
1
Fig. 7 - 06

Controls
7 - 4
7.07 Reverse-feed control lever
●To sew condensed stitches, press
lever 1down.
Fig. 7 - 08 1

7 - 5
Controls
2 GB
max.
7.08 Control panel
The current operating conditions are displayed on control panel 1. Operation takes place in a
constant dialogue between the control unit and the operator. For this purpose, depending on
the operating condition of the machine, different symbols and/or texts are displayed. If the
symbols or texts are framed, these show functions which can be selected by pressing the
appropriate position on the monitor. By pressing the corresponding function this is carried
out or switched on or off immediately, or a further menu appears, e.g. for entering a value.
Activated functions are shown with inverted symbols. Unframed symbols or texts are only
used for display purposes and cannot be selected by pressing.
To read sewing programs or install machine software, use the sd-card 2in the control
panel.
Description of the functions
Normal symbol = function switched off (inactive)
Inverted symbol = function switched on (active)
Fig. 7 - 08
1
2