Pfaff 3811-3/55 User manual

296-12-18 591/002
Instruction Manual engl. 07.17
This instruction manual applies to machines
from the serial number2792 321 and
software version 0352/013 onwards.
INSTRUCTION MANUAL
3811
-3/55; -15/65; -16/65

Reprinting, reproduction and/or translation of PFAFF instruction manuals
(including parts thereof) is only permitted with our prior agreement and
citation of the source.
PFAFF Industriesysteme
und Maschinen GmbH
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
This instruction manual applies to all models and subclasses listed in
Chapter 3 Technical Data.

Table of Contents
Contents ..................................................................................Page
1Safety .................................................................................................................................... 7
1.01 Directives............................................................................................................................... 7
1.02 General safety instructions .................................................................................................... 7
1.03 Safety symbols ...................................................................................................................... 8
1.04 Special points of attention for the owner-operator ................................................................ 8
1.05 Operating personnel and technical staff ................................................................................ 9
1.05.01 Operating personnel .............................................................................................................. 9
1.05.02 Technical staff........................................................................................................................ 9
1.06 Danger warnings.................................................................................................................. 10
2Proper Use.......................................................................................................................... 11
Proper Use 11
3 Technical Data.............................................................................................................................................................................................. 12
3.01 PFAFF 3811 ......................................................................................................................... 12
4Disposal of the Machine.................................................................................................... 13
5Transportation, Packaging and Storage .......................................................................... 14
5.01 Transport to the customer's premises ................................................................................ 14
5.02 Transportation within the customer's premises .................................................................. 14
5.03 Disposal of the packaging materials .................................................................................... 14
5.04 Storage ................................................................................................................................ 14
6Work Symbols.................................................................................................................... 15
7Operating Controls ............................................................................................................16
7.01 Main switch ......................................................................................................................... 16
7.02 Pedal .................................................................................................................................... 16
7.03 Hand lever to raise the presser foot .................................................................................... 17
7.04 Knee switch ......................................................................................................................... 17
7.05 Edge guide (only with PFAFF 3811-3/55 and PFAFF 3811-15/65)....................................... 18
7.06 Lever for releasing thread tension ....................................................................................... 18
7.07 Keypad ................................................................................................................................. 19
119
119
7.08 Control panel........................................................................................................................ 20
8 Set-up and Initial Start-up............................................................................................. 21
8.01 Set-up .................................................................................................................................. 21
8.01.01 Setting the table height ....................................................................................................... 21
8.01.07 Assembling the reel stand ................................................................................................... 25
8.01.08 Mounting the control panel on the table top ....................................................................... 25
8.02 Initial commissioning ........................................................................................................... 26
8.03 Switching the machine on/off.............................................................................................. 26
9Set-up.................................................................................................................................. 27
9.01 Inserting the needle ............................................................................................................ 27

Table of Contents
Contents ..................................................................................Page
9.02 Threading the needle/adjusting the needle thread ............................................................. 28
9.03 Threading the looper thread/adjusting the looper thread..................................................... 29
9.04 Selecting program numbers ................................................................................................ 30
9.05 Inputting fullness ................................................................................................................. 31
9.06 Entering/changing the template code.................................................................................. 32
9.07 Setting the control panel...................................................................................................... 34
10 Sewing .............................................................................................................................. 35
10.01 Manual sewing .................................................................................................................... 35
10.02 Sewing with fixed programs................................................................................................ 37
10.03 Programmed sewing ........................................................................................................... 39
10.04 Error messages.................................................................................................................... 41
11 Input................................................................................................................................... 42
11.01 Entering seam programs .....................................................................................................43
11.02 Examples for setting seam program.................................................................................... 50
11.03 Managing seam programs ................................................................................................... 58
12 Maintenance and Care....................................................................................................... 60
12.01 Maintenance intervals.......................................................................................................... 60
12.02 Cleaning the machine .......................................................................................................... 60
12.03 Machine oil level .................................................................................................................. 61
12.04 Cleaning/lubricating the top feed joints ............................................................................... 61
12.05 Checking/setting the air pressure ........................................................................................ 62
12.06 Cleaning the maintenance unit air filter .............................................................................. 62
12.07 Cleaning the blower air filter................................................................................................ 63
13 Adjustment ......................................................................................................................... 64
13.01 Notes on adjustment ........................................................................................................... 64
13.02 Tools, gauges and other accessories .................................................................................. 64
13.03 Abbreviations ....................................................................................................................... 64
13.04 Explanation of symbols........................................................................................................ 64
13.05 Checking and adjustment aid............................................................................................... 65
13.06 Adjusting basic machine ...................................................................................................... 66
13.07 Adjusting the edge cutting equipment. ............................................................................ 105
13.08 Adjusting the thread trimmer............................................................................................. 110
13.09 Parameter settings ............................................................................................................ 117
13.10 Sewing motor errors.......................................................................................................... 122
13.11 Error message explanations .............................................................................................. 123
13.12 Inputs table ........................................................................................................................ 124
13.13 Outputs table ..................................................................................................................... 124
13.14 Service menu..................................................................................................................... 125
13.15 Run cold start..................................................................................................................... 126
13.16 Internet update of machine software ................................................................................ 127
14 Wear and Tear Parts ........................................................................................................ 128

Table of Contents
Contents ..................................................................................Page
15 Circuit Diagrams ..............................................................................................................129
15.01 Pneumatic circuit diagram (version 12/01/2006) 91-196 282-95...................................... 129
15.02 Circuit diagrams .......................................................................................................................
130
Reference list for circuit diagrams 91-191 493-95.............................................. 130
16 Table Top.......................................................................................................................... 135
16.01 Table top cutout................................................................................................................. 135
16.02 Table top assembly............................................................................................................ 136

Table of Contents
Contents ..................................................................................Page

Safety
7
1 Safety
1.01 Directives
The machine was built in compliance with the European regulations specified in the
declaration of conformity and declaration of incorporation.
As a supplement to this instruction manual, please also observe the generally applicable,
legal and other regulations and legislation – also in the country of use – and the valid
environmental protection regulations! Always comply with the locally applicable regulations
of the professional associations and other supervisory authorities!
1.02 General safety instructions
The machine may only be operated after you have become acquainted with the
associated instruction manual and only by operating personnel who have received
appropriate training!
Always read the safety instructions and the instruction manual of the motor manufacturer
before starting up the machine!
Always follow the hazard and safety instructions attached to the machine!
The machine may only be operated for its intended purpose and only with the associated
safety covers, while adhering to all the relevant safety requirements.
The machine must always be disconnected from the power supply by pressing the main
switch or pulling out the mains plug when sewing tools are replaced (such as the needle,
presser foot, needle plate and bobbin) and when threading, leaving the workstation, or
performing maintenance!
The daily maintenance work may only be carried out by suitably qualified personnel!
Repairs and special maintenance work may only be carried out by technical staff or
people with appropriate training!
Work on electrical equipment may only be carried out by qualified technical staff!
Work on parts and equipment under voltage is not permitted!
Exceptions are regulated by the EN 50110 standards.
Modifications and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
Only the replacement parts approved by us for usage may be used for repairs! We warn
you expressly that spare parts and accessories that are not supplied by us are also not
tested and approved by us.
Fitting or using these products may therefore have negative effects on features which
depend on the machine design. We are not liable for any damage caused by the use of
non-Pfaff parts.

Safety
8
1.03 Safety symbols
Hazard point!
Special points of attention.
Risk of injury to operating personnel or technical staff!
Electric voltage!
Danger to operating personnel or technical staff
Danger of hands being crushed!
Danger to operating personnel or technical staff
Caution!
Do not operate without finger guard and safety covers!
Turn off the main switch before threading, changing the
bobbin or needle, cleaning, etc.!
1.04 Special points of attention for the owner-operator
This instruction manual is a part of the machine and must be made available to the
operating personnel at all times. The instruction manual must have been read before the
initial start-up.
The operating personnel and technical staff must be instructed about the machine's
safety covers and about safe working methods.
The owner-operator may only operate the machine in a flawless condition.
The owner-operator must ensure that no safety covers are removed or disabled.
The owner-operator must ensure that only authorised persons work on the machine.
Additional information can be requested from the responsible sales centre.
I

Safety
9
1.05 Operating personnel and technical staff
1.05.01 Operating personnel
Operating personnel are persons responsible for equipping, operating and cleaning the
machine and for fault clearance in the sewing area.
The operating personnel are obligated to comply with the following points:
The safety instructions provided in the instruction manual must be followed for all work!
Any work method jeopardising machine safety must be refrained from!
Tight-fitting clothing must be worn. The wearing of jewellery such as chains and rings is
prohibited!
Care must be taken to ensure that no unauthorised persons are located in the machine's
hazard zone!
Any changes occurring on the machine which impair its safety must be reported to the
owner-operator immediately!
1.05.02 Technical staff
Technical staff are persons with technical training in electricity/electronics and mechanics.
They are responsible for lubricating, servicing, repairing and adjusting the machine.
The technical staff are obligated to comply with the following points:
The safety instructions provided in the instruction manual must be followed for all work!
Turn off the main switch and secure it against reactivation before starting any adjustment
and repair work!
Never work on live parts and equipment!
Exceptions are regulated by the EN 50110 standards.
Reattach the safety covers following repair and maintenance work!

Safety
10
5
Fig. 1 - 01
4
1
7
2
7
1.06 Danger warnings
A work area of 1m must be kept free in front of and behind the machine during
operation to ensure unobstructed access at all times.
Do not reach into the needle range during the sewing operation!
Risk of injury from the needle!
Do not allow any objects to be placed on the table during the adjustment work!
The objects could become jammed or be slung away!
Risk of injury from parts flying around!
Do not operate the machine without the take-up lever guard 1!
Risk of injury due to the motion of the take-up lever!
Do not operate the machine without the finger guard 2!
Risk of injury from the needle!
Do not operate the machine without the belt guard 3and 4!
Risk of injury due to the rotating driving belt!
Do not operate the machine without the anti-tipping device 5!
Risk of injury from crushing between the sewing head and the table top!
Do not operate the machine without the support 6! Risk of damage due to the
top-heavy sewing head! Machine can tip over backwards when moving it!
Do not operate machines with edge trimmer without finger guard 7!
Do not reach into the cutting area between the needle plate and the blade!
Risk of injury due to the cutting motion of the blade!
6
3

Proper Use
1111
2 Proper Use
Proper Use
The PFAFF 3811-3/55 is an integrated work station that is used in the shoe industry for the
incorporation of fullness into one material layer.
The PFAFF 3811-15/65 is an integrated work station that is used in the upholstery industry
for the incorporation of fullness into one material layer.
The PFAFF 3811-16/65 is an integrated work station that is used in the upholstery industry
for the incorporation of fullness into one material layer while simultaneously trimming the
material edge.
Any usage not approved by the manufacturer is deemed misuse!
The manufacturer shall assume no liability for damage caused by misuse!
Proper use also includes compliance with the operating, maintenance,
adjustment and repair measures specified by the manufacturer!

Technical Data
12
3 Technical Data
3.01 PFAFF 3811
Stitch type:.......................................................................................... 401 (Double chainstitch)
Needle system:
3811-15/65; 3811-16/65: ............................................................................................... 4463-35
3811-3/55................................................................................................................... 4463-KKD
Needle size in 1/100 mm .............................................................................................. 80 - 110
Basic stitch length:
3811-3/55.......................................................................................................................2.2 mm
3811-15/65; 3811-16/65: ........................................................................................3.0 - 4.0 mm
Differential feed - feed motion
3811-3/55...............................................................................................................2.2 - 6.5 mm
3811-15/65; 3811-16/65: ........................................................................................4.0 - 8.0 mm
Speed max.:............................................................................................... 3200 stitches/min 
Clearance beneath the presser foot:
3811-3/55..........................................................................................................................7 mm
3811-15/65; 3811-16/65: ...................................................................................................1 mm
Sewing head dimensions
Length:........................................................................................................... approx. 1250 mm
Width: ..............................................................................................................approx. 600 mm
Height (with spool holder):.............................................................................approx. 1700 mm
Working air pressure:......................................................................................................... 6 bar
Air consumption:.................................................................................... 0,3 - 0,5 l / work cycle
Connection data:
Operating voltage: ...............................................................................230 V ± 10 %, 50/60 Hz
Max. input power:...........................................................................................................400 VA
Fuse protection:...................................................................................................1 x 16 A, inert
Noise data:
Emissions sound pressure level in the workplace at n = 2600 min-1:.............. LpA = 79 dB(A) 
(Noise measurement in accordance with DIN 45 635-48-A-1,
ISO 11204, ISO 3744, ISO 4871)
Net weight: .......................................................................................................... approx. 97 kg
Gross weight: .................................................................................................... approx. 132 kg
Subject to alterations
Depending on the material, workstep and stitch length
K
pA = 2,5 dB

Disposal of the Machine
13
4 Disposal of the Machine
It is up to the customer to dispose of the machine properly.
The materials used for the machine include steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
The machine must be disposed of in accordance with the locally valid environmental
protection regulations, with a specialised company being contracted if necessary.
Please ensure that parts coated with lubricants are disposed of separately in
accordance with the locally valid environmental protection regulations!

Transportation, Packaging and Storage
14
5 Transportation, Packaging and Storage
5.01 Transport to the customer's premises
All machines are completely packed for delivery.
5.02 Transportation within the customer's premises
The manufacturer assumes no liability for transport within the customer's premises or to
the individual usage sites. Please ensure that the machines are only transported in a vertical
position.
5.03 Disposal of the packaging materials
The packaging materials of these machines consists of paper, cardboard and VCI fleece.
It is up to the customer to dispose of the packaging properly.
5.04 Storage
The machine can be stored for up to 6 months when not in use. It must then be protected
from dirt and moisture. For longer storage periods, the machine's single components, espe-
cially its sliding surfaces, must be protected against corrosion, e.g. by an oil film.

Work Symbols
15
6 Work Symbols
Activities to be performed or important information in this instruction manual are
emphasised by symbols. The symbols used have the following meaning:
Note, information
Cleaning, care
Lubrication
Maintenance, repairs, adjustment, service work
(only to be carried out by technical staff)

Operating Controls
16
7 Operating Controls
7.01 Main switch
Before switching on the ma-
chine, raise the take-up lever as
far as possible.
Turning the main switch 1switches the
machine on and off.
Fig. 7 - 01
1
7.02 Pedal
With the main switch turned on
0 = Neutral position
+1= presser foot raised / feed
bridle tape
+2= Sewing
1= Raise presser foot
-2= Thread trimming (Option)/
need up/edge knife off (if pa-
rameter 210 is at "ON", see
Chapter 13.07 Parameter
settings)
0
-2
-1
Fig. 7 - 02
+1
+2

Operating Controls
17
Fig. 7 - 03
7.03 Hand lever to raise the presser foot
Turning the hand lever 1raises the
presser foot.
1
7.04 Knee switch
When sewing with fixed programs:
Actuating the knee switch 1 switches
between two predefined fullness
settings
With programmed sewing:
By actuating the knee switch 1, the
fullness is switched according to the
program specification.
Fig. 7 - 04
1

Operating Controls
18
7.05 Edge guide (only with PFAFF 3811-3/55 and PFAFF 3811-15/65)
By pushing down lever 1 the edge guide
is switched on.
By lifting lever 1 the edge guide is
switched off.
1
Fig. 7 - 05
7.06 Lever for releasing thread tension
Press down lever 1 to release thread
tension.
Fig. 7 - 06
1

Operating Controls
19
7.07 Keypad
Keypad 1 is used to quickly operate the machine during sewing. Each key can be assigned
an individual fullness value, see Chapter 9.05 Input fullness. By means of the respective
light-emitting diode of the 20 keys, activated key functions are displayed (function activated
= luminous diode).
Fig. 7 - 07
Numeric keys (0 - 15)
The pre-assigned fullness value is retrieved by pressing the key.
The corresponding average value is called by pressing two adjacent numeric keys at the
same time.
In the basic setting of the keypad, the set range is divided into 15 sub-steps
from "0" to "max." The basic setting is e.g. after a cold start, see Chapter 13.13
Cold start.
Tape brake (option)
The tape brake is switched on or off by pressing the key.
When the belt brake is engaged, the gathering of the material is enhanced.
Edge trimmer
The edge trimmer device is switched on or off by pushing the key.
Correction value +/correction value -
By pressing the key the value for the multiple width is increased or decreased by 2
steps.
1
9
3
8
7
5
1
6
2
4
0
111
2
1
3
1
4
1
5
1
0
1
1

Operating Controls
20
Fig. 7 - 08
2 GB
max.
7.08 Control panel
The current operating statuses are indicated on the control panel 1. The machine
is operated with constant dialogue between the control unit and the operator; different
pictograms and / or texts are displayed for this purpose according to the operating status of
the machine. Pictograms or texts with a border represent
functions that can be called up by pressing on the respective point on the monitor. Pressing
the respective function causes its immediate actuation or activation/deactivation or another
menu will appear, e.g. for entering a value. Activated functions are indicated by pictograms
shown inversely. Apart from the bobbin change function, the pictograms and texts without
border are only for display purposes and cannot be called up by pressing them.
SD card 2in the control panel can be used to import seam programs.
Presentation of functions
Normal pictogram = Function deactivated (inactive)
Inverse pictogram = Function activated (active)
12