Brother BAS-761 User Manual

BAS-761
Please read this manual before using the machine. Please keep this manual within easy reach for quick reference.
AUTOMATIC POCKET SETTER <JEANS>
INSTRUCTION MANUAL
Thank you very much for buying a BROTHER sewing machine. Before using your new machine, please read the safety instructions below and the explanations given in the instruction manual.
With industrial sewing machines, it is normal to carry out work while positioned directly in front of moving parts such as the needle and thread take-up lever, and consequently there is always a danger of injury that can be caused by there parts. Follow the instructions from training personnel and instructors regarding safe and correct operation before operating the machine so that you will know how to use the machine correctly.

SAFETY INSTRUCTIONS

z Safety indications and their meanings
This instruction manual and the indications and symbols that are used on the machine itself are provided in order to ensure safe operation of this machine and to prevent accidents and injury to yourself or other people. The meanings of these indications and symbols are given below.
Indications
DANGER
CAUTION
Symbols
.................This symbol ( ) indicates something that you should be careful of. The picture
.................This symbol (
.................This symbol (
The instructions which follow this term indicate situations where failure to follow the instructions will almost certainly result in death or severe injury.
The instructions which follow this term indicate situations where failure to follow the instructions could cause injury when using the machine or physical damage to equipment and surroundings.
inside the triangle indicates the nature of the caution that must be taken. (For example, the symbol at left means "beware of injury".)
) indicates something that you must not do.
) indicates something that you must do. The picture inside the circle indicates the nature of the thing that must be done. (For example, the symbol at left means "you must make the ground connection".)
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x Notes on safety
Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury.
DANGER
CAUTION
Environmental requirements
Use the sewing machine in an area which is free from sources of strong electrical noise such as high-frequency welders. Sources of strong electrical noise may cause problems with correct operation.
Any fluctuations in the power supply volt­age should be within ±10% of the rated voltage for the machine. Voltage fluctuations which are greater than this may cause problems with correct op­eration.
The power supply capacity should be greater than the requirements for the sew­ing machine’s electrical consumption. Insufficient power supply capacity may cause problems with correct operation.
The pneumatic delivery capability should be greater than the requirements for the sew­ing machine’s total air consumption. Insufficient pneumatic delivery capability may cause problems with correct operation.
The ambient temperature should be within the range of 5°C to 35°C during use. Temperatures which are lower or higher than this may cause problems with correct operation.
The relative humidity should be within the range of 45% to 85% during use, and no dew formation should occur in any devices. Excessively dry or humid environments and dew formation may cause problems with correct operation.
Avoid exposure to direct sunlight during use. Exposure to direct sunlight may cause prob­lems with correct operation.
In the event of an electrical storm, turn off the power and disconnect the power cord from the wall outlet. Lightning may cause problems with correct operation.
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BAS-761
CAUTION
Installation
Machine installation should only be carried out by a qualified technician.
Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done.
The sewing machine weights more than 400 kg. The installation should be carried out by two or more people.
Do not connect the power cord until instal­lation is complete, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury.
Be sure to connect the ground. If the ground connection is not secure, you run the risk of receiving a serious electric shock.
This sewing machine should only be used by operators who have received the neccessary training in safe use beforehand.
The sewing machine should not be used for any applications other than sewing.
Be sure to wear protective goggles when using the machine.
If goggles are not worn, there is the danger that if a needle breaks, parts of the broken needle may enter your eyes and injury may result.
Attach all safety devices before using the sewing machine. If the machine is used without these devices attached, injury may result.
Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children.
Avoid setting up the sewing machine near sources of strong electrical noise such as high-frequency welding equipment. If this precaution is not taken, incorrect ma­chine operation may re
Have two people present to hold the machine head with both their hands when tilting it back or returning it to its original position.
Sewing
Turn off the power switch at the following times, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury.
• When replacing the needle
• When not using the machine and when leav­ing the machine unattended
Do not touch any of the moving parts or press any objects against the machine while sew­ing, as this may result in personal injury or damage to the machine.
If an error occurs in machine operation, or if abnormal noises or smells are noticed, im­mediately turn off the power switch. Then contact your nearese Brother dealer or a qualified technician.
BAS-761
If the machine develops a problem, contact your nearest Brother dealer or a qualified technician.
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CAUTION
Cleaning
Turn off the power switch before starting any cleaning work, otherwise the machine may operate if the start switch is pressed by mis­take, which could result in injury.
Maintenance and inspection
Maintenance and inspection of the sewing machine should only be carried out by a qualified technician.
Ask your Brother dealer or a qualified elec­trician to carry out any maintenance and inspection of the electrical system.
Turn off the power switch and disconnect the power cord from the wall outlet at the following times, otherwise the machine may operate if the start switch is pressed by mis­take, which could result in injury.
• When carrying out inspection, adjustment and maintenance
Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children.
If the power switch and air need to be left on when carrying out some adjustment, be ex­tremely careful to observe all safety precau­tions.
Use only the proper replacement parts as specified by Brother.
If any safety devices have been removed, be absolutely sure to re-install them to their origi­nal positions and check that they operate correctly before using the machine.
Any problems in machine operation which result from unauthorized modifications to the machine will not be covered by the warranty.
• When replacing consumable parts such as the rotary hook and knife
Disconnect the air hoses from the air sup­ply and wait for the needle on the pressure gauge to drop to "0" before carrying out in­spection, adjustment and repair of any parts which use the pneumatic equipment.
Have two people present to hold the machine head with both their hands when tilting it back or returning it to its original position.
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BAS-761
c Warning labels
The following warning labels appear on the sewing machine.
Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are difficult to read, please contact your nearest Brother dealer.
1
Moving parts may cause injury.
Operate with safety de vices . Turn off main switch before changing needle, cleaning etc.
Safety devices: Thread take-up cover,
Guard bar, Belt cover, etc.
2
Hazardous voltage will cause injury.
Turn off main switch and wait 5 minutes before opening this cover.
3
Hochspannung verletzungsgefahr!
Bitte schalten sie den hauptschalter aus und warten sie 5 minuten, bevor sie diese abdeckung ffnen.
Un voltage non adapt provoque des blessures.
Eteindrel’interrupteur et attendre 5 minutes avantd’ ouvrir le capot
Direction of operation
Un voltaje inadecuado puede provocar las heridas.
Apagar el interruptor principal y esperar 5 minutos antes de abrir esta cubierta.
1
Thread take-up cover
1
Belt cover Guard bar
3
2
Guard bar
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CONTENTS

1. Names of Machine Components .............................................................................................................. 1
2. Specifications ............................................................................................................................................. 2
3. Installation .................................................................................................................................................. 3
3-1. Installation of the machine table ..................................................................................................... 3
3-2. Removal of the fixing bolts from the machine .............................................................................. 4
3-3. Installation of the spool stand ......................................................................................................... 4
3-4. Connection of the foot-switch connector ....................................................................................... 5
3-5. Connection of the air hose ............................................................................................................... 5
3-6. Positioning of the front supporter ................................................................................................... 5
3-7. Installation positions for operation box and switch box ............................................................... 6
3-8. Installation of the folding group assembly .................................................................................... 7
4. Lubrication .................................................................................................................................................. 8
5. Correct operation ....................................................................................................................................... 9
5-1. Installing the needle ......................................................................................................................... 9
5-2. Upper threading ............................................................................................................................... 9
5-3. Bobbin case threading ..................................................................................................................... 10
5-4. Bobbin thread winding .................................................................................................................... 11
5-5. Thread tension .................................................................................................................................. 12
6. Button functions ........................................................................................................................................ 13
6-1. Operation box panel buttones ......................................................................................................... 13
6-2. Switch box panel buttones .............................................................................................................. 16
6-3. Foot switch ........................................................................................................................................ 17
6-4. RESTART buttones ........................................................................................................................... 17
7. Setting before sewing ............................................................................................................................... 18
7-1. Setting the folder mode ................................................................................................................... 18
7-2. Setting the sewing speed and the bar tacking speed .................................................................... 18
7-3. Setting the lower thread counter .................................................................................................... 20
7-4. Setting the piece counter ................................................................................................................. 21
7-5. Setting the stacker roller feed amount ........................................................................................... 21
7-6. Setting the date and time ................................................................................................................ 22
8. Preparation for sewing .............................................................................................................................. 23
9. Sewing ........................................................................................................................................................ 25
9-1. Sewing with the folder in automatic mode ....................................................................................25
9-2. Sewing with the folder in pattern matching mode ........................................................................ 26
9-3. Sewing with the folder in label attachment mode......................................................................... 27
9-4. Sewing with the folder in step mode .............................................................................................. 28
9-5. Test feeding ....................................................................................................................................... 29
9-6. Emergency stop ................................................................................................................................ 30
10. Adjustments ............................................................................................................................................... 31
10-1. Needle-bar height adjustment ......................................................................................................... 31
10-2. Needle and rotary hook timing ........................................................................................................ 32
10-3. Presser foot height adjustment........................................................................................................ 32
10-4. Removal of the fixed knife and the movable knife ......................................................................... 33
10-5. Stacker position adjustment ............................................................................................................ 34
10-6. Sewing clamp assembly number selection ....................................................................................35
11. Using the DIP switches.............................................................................................................................. 36
12. Table of error code ..................................................................................................................................... 38
BAS-761

1. Names of Machine Components

1. Names of Machine Components
i
!0
!1
o
u
@0
y
!9
@1
!2
!4
!3
!5
!7 !6
t
r
e
w
!8
q
q Foot-switch w Stacker e Guard bar
r Feed roller t Machine head y Spool stand
u Top cover i Control box o Switch box
!0 Folding group assembly !1 Mechanical valve !2 RESTART buttons
!3 Front supporter !4 Floppy drive !5 Programmer
!6 Air unit valve !7 Power switch !8 Blower Motor
!9 2-Step thread tension device @0 Thread breakage detector @1 Pocket support
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BAS-761

2. Specifications

2. Specifications
Applicable machine type
Use
Cycle time
Sewing speed
Bar tacking speed
Sewing range
Sewing pitch
Needle racking width
at first bar tacking
Cloth setting
Machine head drive
Machine body drive
Memory medium
Lock stitch and special cross stitch sewing machine with automatic thread trimmer
Sewing pockets on the various types of jeans
9 seconds approx. (depending on the pitch and rpm)
500 – 4250rpm (9-step button selectable; limited by sewing condition)
500 – 3500rpm (7-step button selectable; cannot exceed sewing speed)
250 (X) mm 250 (Y) mm Standard (when not using retractable work clamp)
250 (X) mm 200 (Y) mm For retractable work clamp (restrictions may occur because of shape)
0.05 – 6.00mm
Maximum of 3.5 mm
Overlapping possible
AC servo direct motor type
X-axis for a clamp shift, Y-axis for a machine shift, AC servo motor (750W).
3.5-2HD inch floppy disk
64 patterns (Maximum of 1,000 stitches for each pattern)
Jig attaching/
detaching method
Stacker
Programmer
Power source
Air pressure
Machine dimensions
Weight
Upper-thread breakage
detector
Label attachment device
Air chuck; one-touch operation requiring less than 2 minutes
Included (Stacking capacity 60 pieces)
Included
3-phase 200V, 220V, 380V, 400V, 415V ( 900W)
0.44 – 0.54MPa
(W) 2.108mm, (L) 1.919mm, (H) 970mm
400kg
Included
Included (option)
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3. Installation

3. Installation
CAUTION
Machine installation should only be carried out by a qualified technician.
Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done.
The sewing machine head weights more than 400 kg. The installation should be carried out by two or more people.
Co not connect the power cord until installa tion is complete, otherwise the machine may operate if the foot switch is depressed by mistake, which could result in injury.
Be sure to connect the ground. If the ground connection is not secure, you run the risk of receiving a serious electric shock.
Do not place any objects on top of the top cover, otherwise such objects may fall down onto the machine. If you need to put something on top of the top cover, place it inside a box or similar to se­cure it so as to stop it from falling down.
Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children.
Avoid setting up the sewing machine near sources of strong electrical noise such as high-frequency welding equipment. If this precaution is not taken, incorrect ma­chine operation may result.
Hold the machine head with both hands when tilting it back or returning it to its original po­sition. Furthermore, after tilting back the ma­chine head, do not push the face plate side or the pulley side from above, as this could cause the machine head to topple over, which may result in personal injury or damage to the machine.
Note:
¡ This sewing machine has a movable machine head and work clamp. Be careful not to place other objects within
the moving range of these parts.
¡ Supply power directly from a receptacle for the machine's exclusive use. ¡ Be sure to power off when installating.

3-1. Installation of the machine table

1. Secure the level adjusters q so that the table top re-
main level.
2. The table has eight level adjusters. If the table does not
sit well, loosen nuts w and turn the level adjusters q to level the table.
Note:
There are eight adjusting points.
To move the machine, turn up adjusters q, and the table
w
q
can be moved on its machine body casters e.
e
3
BAS-761

3-2.Removal of the fixing bolts from the machine

The machine head and the sewing clamp arm are fixed with bolts to secure them during transportation.
q
Remove fixing bolt q on the machine head through the hole in the front cover.
Note:
¡ Save removed fixing bolts q future use. ¡ Before transporting the machine be sure to secure it with the fixing bolts.
3. Installation

3-3. Installation of the spool stand

Install the spool stand as shown in the illustration at left.
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3. Installation

3-4. Connection of the foot-switch connector

q

3-5. Connection of the air hose

1. Attach air hose q to air unit valve w.
2. Move the upper cap of air unit valve w upward and ad-
3. After adjustment, move the cap downward and lock.
w
Connect connector q securely.
just the air pressure to 0.49 MPa.
q

3-6. Positioning of the front supporter

1. Loosen bolts q and position front supporter w in the most appropriate position.
2. Tighten bolts q to secure the supporter w.
w
q
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BAS-761

3-7. Installation positions for operation box and switch box

Loosen the mounting bolts e for the operation box q
w
q
e
and switch box w, and move them in the direction of the arrow to a position where they are comfortable to oper­ate.
3. Installation
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3. Installation

3-8. Installation of the folding group assembly

Before installation
¡ Apply air pressure. ¡ Turn on power switch q to return the machine to the home position. ¡ Turn valve switch w to OFF (lower) side and "E-820" will flash on the display.
t w
r
!0
o
i
e
y
u
!4
!3 !2
!1
@1
q
1. Install folding clamp assembly e onto folding base r.
2. Attach multi-connector t.
3. While pushing the folding clamp assembly e downwards with your hand, install the inner clamp assembly y to the folding base r. For models with a label attachment device u, install the plug i of the label attachment device u to the socket o. At this time, set the label attachment device u so that it is in a ready condition on top of the inner clamp assembly. (Refer to page 27.) If it is reversed, it will turn downward.
4. Install center blade assembly !0 on folding base r.
5. Install sewing clamp assembly !1 on sewing clamp assembly arm base !2.
6. Install the multi-connector !4 and the dual sensor harness assembly !3.
7. Set the valve switch w to ON (up position). The "E-820" indication will disappear from the display panel and the panel will return to its previous condition.
8. Move folding clamp assembly e, inner clamp assembly y, center blade assembly !0 and sewing clamp assembly !1 back and forth, and right and left, to ensure they are secured.
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BAS-761

4. Lubrication

4. Lubrication
Note:
Check for sufficient oil through oil gauge windows A and B on the machine head and the table. If the oil amount is not sufficient, be sure to replenish it.
How to oil the machine head
Replenish the oil through oil port q.
How to oil the machine table
1 Move the machine head forward so that the lubrication hole e in the needle plate bracket RR w and the lubri-
cation port r in the machine bed are aligned.
2 Apply oil to the lubrication port r in the machine bed through the lubricationhole e in the needle plate bracket
RR w.
Note:
Before initial operation of the machine or after a long interval, be sure to drip a few drops of oil onto the arrowed lubrication point C.
How to drain oil from the machine body
Remove poly-oiler t and drain the oil.
Rotary hook lubrication control
Turn the rotary hook lubrication adjustment valve y to adjust the lubrication amount.
C
t
q
w
A
e
r
B
y
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