Brother rh-918a User Manual

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RH-981A

ELECTRONIC EYELET BUTTON HOLER

ENGLISH

Page 2

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 m achines, it is norm al to carr y out work while posit ioned direct ly in front of m oving parts suc h as the needle and thread tak e-up lever, and consequently there is a lways a danger of injury that can be caused by these 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 it correctly.

SAFETY INSTRUCTIONS

Safety indications and their meanings

This instruction m anual and the indications and s ymbols that are used on the mac hine 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

Symbols

DANGER CAUTION

........................................This symbol ( ) indicates something that you should be careful of. The

........................................This symbol (

........................................This symbol ( ) indicates something that you must do. The picture

(For example, the symbol at left means “you must make the ground

The instructions which follo w this term indic ate situations where f ailure to f ollow the instructions will almost certainly result in death or severe injury .

The instructions which follo w this term indic ate situations where f ailure to f ollow the instructions could cause injury when using the machine or physical damage to equipment and surroundings.

picture inside the triangl e indic ates t he na ture of the caution that m ust be taken. (For example, the symbol at left means “beware of injury”.)

) indicates something that you must not do.

inside the circle indicates the nature of the thing that must be done.

connection”.)

RH-981A

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Notes on safety

Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before o severe injury.

ening the face plate of the control box. Touching areas where high voltages are present can result in

DANGER

CAUTION

Environmental requirements

Use the sewing machine in an area which is f ree from sources of stron high-frequency welders. Sources of stron problems with correct operation.

Any fluctuations in the power supply voltage should be within the machine. Voltage fluctuations which are greater than this may cause problems with correct operation.

The

ower supply capacity should be greater than the requirements for the sewing machine’s electrical consumption. Insufficient problems with correct operation.

The

reater than the requirements for the sewin machine's total air consumption. Insufficient cause problems with correct operation.

ower supply capacity may cause

neumatic delivery capability should be

neumatic delivery capability ma

electrical noise such as

electrical noise may cause

10% of the rated voltage for

Installation

Machine installation s hould only be carried out b a qualified technician.

Contact your Brother dealer or a qualified electrician for any electrical work that may need to be d one.

The sewin The installation should be carried out by two or more people.

Do not connect the complete, otherwise the machine m ay operate if the start swit ch is pressed by mistake, which could result in injury.

Be sure to connect the connection is not secure, you run a high risk of receiving a serious electric shock, and problem s with correct operation may also occur.

machine weighs more than 87 kg.

ower cord until installation is

round. If the ground

The ambient temperature should be within the range of 5 to 35 during use.

eratures which are lower or higher than this

Tem may cause problems with correct operation.

The relative humidit 45% to 85% durin should occur in any devices. Excessively dry or humid environm ents and dew formation ma operation.

Avoid exposure to direct sunlight during use.

osure to direct sunlight may cause problems

Ex with correct operation.

In the event of an electrical storm, turn off the

ower and disconnect the power cord from the wall outlet. Li

htning may cause problems with correct

operation.

All cords should be secured at least 25 mm awa from any moving parts. Furthermore, do not excessively bend the cords or secure them too firml

with staples, otherwise there is the danger

that fire or electric shocks could occur. Install the belt covers to the machine head and

motor. If usin

casters should be secured in such a way so that they cannot move.

Be sure to wear when handlin 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 under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children.

a work table which has casters, the

should be within the range of

use, and no dew formation

cause problems with correct

rotective goggles and gloves

the lubricating oil and grease, so

rease

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CAUTION

y op

Sewing

This sewing machine should only be used by operators who have received the necessary training in safe use beforehand.

The sewin applications other than sewing.

Be sure to wear protective goggles when using the machine. If goggles are not worn, there is the d anger that if a needle breaks, enter your eyes and injury may result.

Turn off the power switch at the foll owing times, otherwise the machine ma switch is injury.

When threading the needle When replacing the needle When not using the machine and when leavin the machine unattended

machine should not be us ed for an

arts of the broken needle ma

erate if the start

ressed by mistake, which could result in

Cleaning

Turn off the power switch before carrying out cleaning, otherwise the machine may operate if the start swit ch is result in injury.

ressed by mistake, which could

If using a work table which has casters, the casters should be secured in such a wa they cannot move.

Attach all safet machine. If the machine is used without these devices attached, injury may result.

Do not touch an objects against the machine while se wing, as this

result in personal injury or damage to the

ma machine.

If an error occurs in machine o noises or smells ar e not ice d, im medi atel

ower switch. Then contact your nearest Brother

dealer or a qualified technician. If the machine develo

nearest Brother dealer or a qualified technician.

Be sure to wear protective goggles and gloves when handlin that the skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under an vomiting and diarrhoea. Keep the oil out of the reach of children.

do not get into your eyes or onto your

devices before using the sewin

of the moving parts or press an

eration, or if abno rmal

s a problem, contact your

the lubricating oil and grease, so

circumstances, as they can cause

so that

turn off the

Maintenance and inspection

Maintenance and inspection of the sewing machine should only be carried out b y a qualified technician.

Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspecti on of the electrical system.

Turn off the power switch and disconnect the power cord from the wall outlet at the following times, otherwise the m achine may operate if the start switch is pressed by mistake, which could result in injury.

When carrying out inspection, adj ustment and maintenance When replacing consum able par ts such as the loopers and knife

Disconnect the air hoses from the air supply and wait for the needle on the pres sure gauge to dr op to “0” before carrying out inspection, adjustment and repair of any parts which use the pneumatic equipment.

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.

iii

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3. W a rnin g lab e ls

The following warning labels appear on the sewing machine. Please follow the in str uc tions on the labe ls at a ll t imes when using the machine. If the labels hav e bee n removed or are difficult to read, please contact your nearest Brother dealer.

Do not touch the knif e or press any objects against the machine while sewing, as this may result in personal injury or damage to the machine.

Be careful not to clamp your fingers when closing the front cover.

Be sure to connect the ground. If the ground connection is not secure, you run a high risk o receiving a serious electric shock, and problems with correct operation may also occur .

Safety devi ces

Eye guard Finger guard Needle bar guard Belt cover, etc.

3122Q

Direction of operation

Eye guard

Needle bar guard

Belt cover

(Rear)

Finger guard

Belt cover

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1. NAMES OF EACH P A RT

2. SPECIFICATIONS

2-1. Specifications ...................................................... 2

2-2. Sewing shape ..................................................... 3

2-3. Optional parts ...................................................... 3

2-4. PD-9810, Programmer ....................................... 3

2-5. Replacement parts list for

specification changes ......................................... 4

3. INST ALLATION

3-1. Table processing diagram ................................ 5

3-2. Installing the motor ............................................ 6

3-3. Installing the motor pulley ................................. 7

3-4. Installing the control box ................................... 7

3-5. Installing the machine head .............................. 8

3-6. Installing the oil container ............................... 10

3-7. Installing the operation panel .......................... 10

3-8. Tightening the V-belt ....................................... 11

3-9. Installing the spool stand ................................ 12

3-10.Installing the hand switch ................................ 12

3-11.Installing the air unit and the valve unit .......... 12

3-12.Connecting the wiring...................................... 13

3-12-1. Connections inside the control box......... 14

3-12-2. Connecting the motor cables................... 15

3-12-3. Connecting the air tubes.......................... 15

3-12-4. Securing the cables.................................. 16

3-13.Connecting the air tubes ..................................17

3-13-1. Adjusting the air pressure........................ 17

3-14.Connecting the power cord ............................. 18

3-15.Installing the programmer

(sold separately)............................................... 19

3-16.Installing the foot switch (option)..................... 19

3-17.Installing the indexer (option) .......................... 20

3-17-1. Installing the indexer main unit................ 20

3-17-2. Installing the upper thread presser ......... 21

3-17-3. Replacing the plate presser and

presser plate ............................................ 21

3-17-4. Installing the valve unit ................................ 21

3-17-5. Connecting the connectors.......................... 22

3-17-6. Connecting the air tubes ............................. 23

3-17-7. Securing the air tubes and cables............... 23

3-17-8. Installing the hand switch............................. 24

4. LUBRICATION

4-1. Adding oil ......................................................... 25

4-2. Lubrication ....................................................... 25

.............................................. 2

.................................................... 5

...................................................... 25

................................ 1

5. CORRECT USE

5-1. Data initialization............................................... 27

5-2. Changing the lower thread and

gimp trimming .................................................. 27

5-3. Installing the needle ......................................... 28

5-4. Threading the upper thread ............................. 28

5-5. Threading the lower thread.............................. 29

5-6. Threading the gimp ......................................... 30

5-7. Setting the material .......................................... 31

5-8. Setting the installation position

for cloth feed plate (L) (-52 specifications)...... 33

5-9. Replacing the PROMs ..................................... 34

6. OPERATION

6-1. Name and function of

each operation panel item................................ 35

6-2. Starting up......................................................... 36

6-3. Program setting method .................................. 37

6-3-1. Parameter table ( Taper bar )..................... 37

6-3-2. Parameter table ( Straight bar tacking )......40

6-4. Cy cle program.................................................. 43

6-5. Production counter ........................................... 44

6-6. Using the program memos.............................. 44

7. SEWING

7-1. Automatic sewing............................................. 45

7-2. Using the EMERGENCY STOP switch ......... 46

7-3. Adjusting the thread tension ............................ 47

7-4. Needle and knife position................................. 48

7-5. Setting the feed bracket to

7-6. Switching between single-pedal

7-7. Using test feed mode....................................... 50

7-8. Using manual mode......................................... 51

7-9. Changing the mode during an operation ........ 52

7-10.Moving the cloth feed bar

CLEANING AND MAINTENANCE

8-1. Cleaning ........................................................... 53

8-2. Draining the oil ................................................. 54

8-3. Checking the air filter........................................ 54

................................................................ 45

the front position............................................... 49

and dual-pedal operation ................................. 49

(-52 specifications) ........................................... 52

9. STANDARD ADJUSTMENTS

9-1. Adjusting the height of the

spreader and looper......................................... 55

9-2. Adjusting the needle and looper timing........... 56

9-3. Adjusting the loop stroke.................................. 57

9-4. Adjusting the height of the needle bar............. 58

................................................. 27

......................................................... 35

............

....................... 55

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9-5. Adjusting the clearance between the

looper and needle ............................................ 58

9-6. Adjusting the needle guard.............................. 59

9-7.

Adjusting the spreader mounting positions

9-8. Adjusting the spreader timing.......................... 60

9-9. Adjusting the needle racking width

(stitch width)...................................................... 60

9-10.Changing the knife cutting length

(Replacing the hammer).................................. 61

9-11.Adjusting the contact between the knife

and the hammer .............................................. 62

9-12.Replacing the knife .......................................... 63

9-13.

Adjusting the cutting pressure ........................ 63

Adjusting the position of the work

9-14.

clamp plate ........................................................64

9-15.

Adjusting the cloth opening amount ............... 65

Adjusting the trimming

9-16.

of the upper thread .......................................... 66

9-17.Adjusting the trimming

of the lower thread and gimp .......................... 66

9-18.Adjusting the gimp length after trimming

(-02, -52 specifications) ................................... 67

9-19.Lower thread presser

(-02

specifications) .................................... 67

, -52

........ 59

9-20.Auxiliary clamp arm

(-02, -52 specifications).................................... 68

9-21.Adjusting the cloth feeding speed

(-52 specifications) ........................................... 68

9-22.Adjusting the cloth feed bar home position

(-5 2 s pe ci fi cat io ns )............................................. 69

9-23.Adjusting the indexer hole spacing

(-52 specifications) ........................................... 70

9-24.Adjusting the position of limit switch L

(-52 specifications) .......................................... 71

9-25.Adjusting the position of limit switch R

(-52 specifications) .......................................... 71

10. CHANGING FUNCTIONS USING THE MEMORY SWITCHES

10-1.Memory switch table ........................................ 73

........................ 72

11. CHA NGING FUNCTIONS USING THE DIP SWITCHES

11-1. Panel DIP switches....................................... 74

11-2. Circuit board DIP switches............................ 75

.................................... 74

12. LIST OF ERROR CODES

13. TROUBLESHOOTING

................................... 80

............................ 77

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1. NAMES OF EACH PART

3123Q

(1) Front cover (2) Hand switch (3) Cloth presser switch (4) Start switch (5) EMERGENCY STOP switch (6) Upper shaft pulley (7) Feed bracket (8) Spool stand (9) Power switch (10) Motor (11) Operation panel (12) Control box

Fly indexer (-52 specifications)

Fly indexer

2380Q

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2. SPECIFICATIONS

2-1. Specifications

2. SPECIFICATIONS

Upper thread trimmer

-00 -- -

-01 --

-02 - -

-52 -

* -02 and -52 specifications are further divided into L1 - L7

specifications in accordance with the stitch lengt h. Please be sur e to specify the stitch length when ordering.

Specification RH-981A-00 RH-981A-01 RH-981A-02, RH-981A-52

Application Men’s clothes and ladies’ clothes Jeans and work clothes

Sewing speed 1,000 - 2,200rpm (100-rpm steps)

Stitch length 5 - 50 mm 5 - 38 mm

Stitch pitch 0.5 - 2.0 mm

Stitch width 1.5 - 3.2 mm

Tacking length 0 - 20 mm

Work clamp height 12 mm 16 mm

Starting method Dual switch (cloth presser switch and start switch) or single switch

Feed method

Needle DO X 558 Nm 80 - Nm 120 (Schmetz 558)

Safety equipment

Motor Inverter-type induction motor

Air pressure

Air consumption 43.2 l/ min. (8 cycles/min.)

Noise level 85dB at max. speed of 2,200r pm, measured according to ISO 10821

Dimensions 1,200 mm (W) X 590 mm(D) X 1,120 mm (H)

Work table legs T-shape height-adjustable type

Power supply

Weight 163.5 kg

Built-in emergency stop function and automatic stopping device which stops the machine

Intermittent feed by three pulse motors (X, Y, θ)

when the safety circuit is activated

Main regulator: 0.5MPa

Knife pressure regulator: 0.3MPa

Single-phase 220 V

3-phase 220 V, 380 V, 400 V

Maximum electric power consumption: 1kvA

Lower thread trimmer

Long type Short type

L1 14 - 18 mm L5 28 - 32 mm L2 18 - 22 mm L6 32 - 36 mm L3 22 - 26 mm L7 36 - 40 mm L4 26 - 30 mm

Fly indexer specifications (-52 specifications)

Standard Large size

Max. hole spacing

Max. overall feed amount

No. of holes 3 - 4*

Horizontal sewing margin 9 - 21 mm (9 - 11 mm*2)

Vertical sewing margin 30 - 40 mm

*1 The cloth feed bar F assembly (sold separately) can be

processed and used so that 1 to 9 buttonholes can be sewn.

50.8 mm (2 inch)

152.4 mm

(2 inch X 3)

57.15 mm

(2 1/4 inch)

285.75 mm

(2 1/4 inch X 5)

3 - 6*

Hole spacing

No. of holes

Overall feed amount

Vertical sewing margin

Fly indexer

Horizontal sewing margin

0792Q

*2 L5 - L7 specifications

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2. SPECIFICATIONS

2-2. Sewing shape

Eyelet buttonhole Straight buttonhole

Without bar

tacking

With taper With straight bar

tacking (*)

* The DIP switch settings must be changed. (Refer to page 74.)

2-3. Optional parts

Parts name Parts code

Two-pedal foot switch S42838-101 Waist belt presser

Cloth presser (L3W) set Cloth presser (L4W) set

Upper thread nipper

S43701-001 S43704-001

S43406-301

Fly indexer

Fly indexer assembly for L1, L2 and L5 specification s

Fly indexer assembly for L3, L4, L6 and L7 specification s

Special lapel cutting dev i ce

S44279-101 S44281-101

S53906-201

This allows the work clamp to raised and lowered and the sewing machine to be started by pedal operation.

When sewing eyelet buttonholes into wa ist belts with which have differences in thickness, this presser provides secure clamping for the differ ent thickness. It prevents an y slippage of the material during sewing.

This device prevents the thread from pulling out at the sewing start, thus contributing to a m ore accurate and higher-qual ity seam finish.

This is an indexer which is specially for use when sewing flys. It allows from one to nine buttonholes to be set, and automatically feeds the mater ial. Using this de vic e makes the sewing of buttonholes for flys much quicker.

Eyelet buttonhole and straight buttonhole can be sewn automatically without replacing hammer and knife. It is effective for men’s jacket cycle sewing (eyelet buttonholeflower hole).

Without bar

tacking

With taper With straight bar

tacking (*)

2-4. PD-9810, Programmer

You can use the icon keys to retrieve p arameter s at a single touch, and to displa y them as ic ons on the LED screen so that the settings can be changed easil y. It allows you to easily transfer data between different sewing machines.

2381

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2. SPECIFICATIONS

2-5. Replacement parts list for specification changes

The sewing machine can be cha nged to an y one of L1 - L7 f or - 02 and -52 specif icatio ns by rep lacing the s pecif ied parts with the appropriate parts given below.

-02 specifications

(buttonhole length)

(14 - 18 mm)

(18 - 22 mm)

(22 - 26 mm)

(26 - 30 mm)

(28 - 32 mm)

(32 - 36 mm)

(36 - 40 mm)

Replacement parts set

S44238-001

S44239-001

S44240-001

S44271-001

S44272-001

S44273-001

S44274-001

Plate R assemblySpecifications

Plate L assembly

S38576-301 S37702-001 (S12)L1 S38577-201 S37704-001 (S16) S38578-301 S37704-001 (S16)L2 S38579-201 S37706-001 (S20) S38580-301 S37706-001 (S20)L3 S38581-201 S37708-001 (S24) S38582-301 S37708-001 (S24)L4 S38583-201 S42053-001 (S28) S41470-101 S37197-001 (26)L5 S41471-101 S37199-001 (30) S41472-101 S37199-001 (30)L6 S41473-101 S37201-001 (34) S41474-101 S37201-001 (34)L7 S41475-101 S35093-001 (38)

Hammer Specification harnes s

S43337-000

S43338-000

S43339-000

S43340-000

S43341-000

S43342-000

S43343-000

0797Q

0799Q

Note: There is 10 mm of difference in the knife cutting position between L1 - L4 and L5 - L7 specifications. (Refer to

page 63.)

-52 specifications

Plate R assemblySpecifications

(buttonhole length)

Plate L assembly

S38576-301 S37702-001 (S12)L1

(14 - 18 mm)

S38577-201 S37704-001 (S16) S38578-301 S37704-001 (S16)L2

(18 - 22 mm)

S38579-201 S37706-001 (S20) S38580-301 S37706-001 (S20)L3

(22 - 26 mm)

S38581-201 S37708-001 (S24) S38582-301 S37708-001 (S24)L4

(26 - 30 mm)

S38583-201 S42053-001 (S28) S41470-101 S37197-001 (26)L5

(28 - 32 mm)

S41471-101 S37199-001 (30) S41472-101 S37199-001 (30)L6

(32 - 36 mm)

(36 - 40 mm)

S41473-101 S37201-001 (34) S41474-101 S37201-001 (34) S41475-101 S35093-001 (38)

Note: There is 10 mm of differenc e in the knif e cutting pos ition betwe en L1 - L4 and L5 - L7 spec ific ations. (R efer

to page 63.)

Hammer Specification harness Cloth feed plate R

S43360-000 S43809-001

S43361-000 S43809-001

S43362-000 S42139-101

S43363-000 S42139-101

S43364-000 S43809-001

S43365-000 S42139-101

S43366-000 S42139-101

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3. INSTALLATION

CAUTION

Machine installation should only be carried o ut 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 weighs mor e than 87 kg. The installation should b e carried out by two or more people.

Do not connect the power cord until installat ion is complete, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury.

All cords should be secured at least 25 mm away from any moving parts. Furthermore, do not excessivel y bend the cor ds or secure them too firmly staples, otherwise there is the danger that fire or electric shocks could occur.

Be sure to connect the ground. If the ground connection is not secure, you run a high risk of receiving a serious electric shock, and problems with correct operation may also occur.

Install the belt covers to the machine head and motor.

3-1. Table processing diagram

The top of the table should be 50 mm in thickness and should be strong enough to hold the weight and withstand the vibration of the sewing machine. Drill holes in the table as shown in the diagram below.

* There is the special table indicated below.

Model code

Table/legs assembly 127-981-04902

0800Q

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3-2. Installing the motor

3. INSTALLATION

3124Q

1. Insert the four nuts (1) into the work table.

2. Turn the work table upside down to make it easier to install the motor (2).

3. Align the holder plate (3) and the motor plate (4) with the nuts (1), and t hen install them with the four washers (5), the four spring washers (6) and the four bolts (7).

4. Place the eight accessory cushions (7) and the four accessory cushion collars (8) onto the motor base plate (9), and then install the motor as shown in the illustration.

3125Q

Note: The vibration of the motor may cause the bolts

to come loose. Make sure that the bolts are securely tightened.

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3. INSTALLATION

3-3. Installing the motor pulley

3126Q

1. Place the motor pulley (1) onto the shaft of the motor (2) so that the key grooves are alig ned, and then tighten the set screws (3) so that the center of the V groove in the motor pulley (1) is aligned as closely as possible with the center of the belt hole in the power table.

2. Install the m otor rear cover support (4) with the two flat washers (5) and the two screws (6).

Note: Check that the motor rear cover support (4)

does not touch the motor pulley (1) or the edge of the motor.

3-4. Installing the control box

3127Q

1. Insert the four nuts (1) into the work table.

2. Open the front and rear covers of the control box (2).

3. Align the control box (2) with the nuts (1), and then install it with the four flat washers (3), spring washers (4) and bolts (5). Note: Be careful not to drop any small parts such

as washers onto the circuit board when installing the bolts.

3128Q

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3-5. Installing the machine head

3. INSTALLATION

2980Q

2981Q

1. Insert the accessory bed base cushions A (1) into the bed base, and then plac e the machine head on top of the work table.

Note: When placing the machine head on top of the work table, have two or more people there to hold the

handles and rear of the head as indicated in the illustration.

2. Open the front cover (2), and then use the bolt (3), washer (4), rubber s heet (5), bed stand cushion A (1) , large washer (6) and nut (7) to attach the front right corner of the bed base to the work table.

3. Attach the bed base to the work table in two places inside the base in the same way as in step 2. above.

4. Remove the bolt (8) and the washer.

Note: The bolt (8) and washer should be kept, as they will be needed again if the machine head is moved.

5. Raise the machine head, and then attach the front left corner of the bed base to the work table in the same way as in the steps above.

Note: Make sure that steps 2. to 4. above have been completed before raising the machine head.

6. Install the bed base cover (9) to the rear of the bed (10) with the four screws (11).

Note: Be careful not to injure yourself on the spring hinge.

RH-981A

2982Q

Page 16

3. INSTALLATION

Raising the machine head

When machine head is lowered

2983Q

2984Q

1. While holding the handles of the machine head (1) with both hands, gently raise the machine head.

Note: Be sure to turn the power supply off before raising the machine head.

2. If you wish to keep the machine head in the raised position, i nsert the head support lever (2) securely into the hinge lever support shaft (3).

Note: Always check that the head support lever (2) and the hinge lever support shaft (3) are meshed.

Lowering the machine head

Pull the machine head down toward you gently, remove the head support lever (2) from the hinge lever support shaft (3), and then gently lower the machine head.

Note: Do not hold the mac hine head by the feed bracket (4) or X feed shaft A (5) when it is bein g raised and

lowered.

When machine head is raised

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3-6. Installing the oil container

2985Q

3-7. Installing the operation panel

Top of work table

Table

2986Q

2987Q

3. INSTALLATION

1. Install the oil draining cap suppor t (2) to th e base of the bed base (1) with the two screws (3).

2. Sc rew the oil container (4) into the oil draining cap support (2).

3. Push the oil draining spring pin (5) into the bed base (1) until the pin is flush with the surface of the base.

4. Lower the machine head. (Refer to "Lowering the machine head" on previous page.)

The operation panel ca n be installed to either the top or bottom of the work table.

1. Install the rear frame (1) to the work table (top or

bottom) with the four wood screws (2).

2. Install the front frame assembly (3) to the rear

frame (1) with the four screws (4).

* The vertical orientation of the front frame

assembly (3) is the same whether it is installed to the top or the bottom of the work table.

* Pull the harnesses such as the ground harness

out of the way so that t he operation panel side cover (5) can be opened and closed.

3. Insert the connector cord (6) into the control box

through the hole at the side of the box.

Bottom of work table

Table

2988Q

RH-981A

Page 18

3. INSTALLATION

3-8. Tightening the V-belt

Approx.10 mm

2990Q

2991Q

1. Open the rear cover.

2. Pass the V-belt (1) through the base of the bed base and through the hole in the work table.

3. Place the V-belt (1) onto the motor pulley (2).

4. Check that there is approximately 10 mm of deflection in the V-belt (1) when it is pushed in the middle with a load of 10 N.

If the tightness needs adjusting, loosen the t wo nuts (3) and move the m otor up or down. After adjusting, t ighten the nuts (3). Note: Check that the motor rear cover support (4) does not touch the motor pulley (1) or the edge of the motor.

5. Install the motor cover (5) with the three screws (6). Note: After a long period of use, the V-belt will become run in and will loosen around the motor pulley. When

this happens, turn off the power and adjust by the procedure given in step 4. above.

RH-981A

Page 19

3-9. Installing the spool stand

3-10. Installing the hand switch

3. INSTALLATION

1. To assemble the spool stand (1), follow the instructions in the m anual that c ame with the spool stand (1).

2. Secure the spoo l stand (1) to the rear right corner of the work table with the washer and nut (2).

2989Q

Install the hand switch (1) with the two screws (2).

3129Q

3-11. Installing the air unit and the valve unit

2387Q

Valve unit

Air unit

2992Q

1. Install the air unit (1) to the underside of the work table with the two screws (2).

2. Install the valve unit (3) with the two screws (4).

3. Connect air tube No. 15 to the intermediate joint (5) of the air un it (1) and to the j o int (6) of the va lv e un it ( 3), and connect air tube No. 16 to joints (7) and (8).

Installation position

Connecting the valve cables

Insert the cable (9) which is coming out of the valve unit to the 2-pin connector (10) of the valve cable assembly.

RH-981A

Page 20

3. INSTALLATION

3-12. Connecting the wiring

2994Q

1. Pass the cable and air tube which are coming out of the belt cover (1) and the machine head ( 2) thro ugh the cable hole (3) in the work table.

2. Pass the cables and air tube which are com ing out of the feed bracket (4) and the lef t side of the bed base (5) and the cable for the hand switch (6) through the cable hole (7) in the work table. Note: Leave enough looseness in the cables so

that they will not be pulled when the machine head is tilted back.

Adjust the looseness after all connections to

the control box are complete.

3130Q

3. Connect the hand switch connector (8) to the control box connector.

4. Install th e power switch (9) to the underside of the work table with the two screws (10).

5. Secure the cables using staples (11) (in four locations).

3131Q

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Page 21

3-12-1. Connections inside the control box

3. INSTALLATION

2997Q

1. Open the rear cover (1) of the control box.

2. Pass the cables through the holes (2) and (3) in th e side of the control box.

3. Loosen the screw (5), and then connect the three ground cables (4) that are coming f rom the m ac hine head.

4. Securely insert each of the connectors (6) - (14) as indicated below.

Machine head

connectors

Connector (6) (12-pin with [1] mark)

Connector (7) (5-pin with [2] mark)

Connector (8) (9-pin with [3] mark)

Connector (9) (12-pin with [4] mark)

Connector (10) (5-pin with [6] mark)

Connector (11) (5-pin with [7] mark)

Connector (12) (16-pin with [8] mark)

Connector (13) (18-pin with [9] mark)

Connector (14) (10-pin)

(Connection indications)

* This is indicated on the P.C. board.

P1 (ORG)

P2 (SYNCHRO)

P3 (HEAD)

P4 (AIR)

P6 (YPM) (BLUE)

P7 (XPM)

P8 (EXINA)

P9 (EXINB)

P18 (PANEL)

2998Q

PMD circuit Board

2999Q

RH-981A

5. Insert the connector (15) (6-pin with [1][R] mark) to the connector (16).

6. Loosen the middle screw (19) and then install the ground cable (17) and the thr ee ground cables (18) from the operation panel.

7. Secure the cables with the c abl e clamp as shown in the illustration. Note: W hen secur ing the cables, do not l et any of

the cables touch the components on the circuit board or the heat s ink. Furthermore, adjust the lengths of the cables from outside the control box so that there is no looseness in the cables inside the control box.

Page 22

3. INSTALLATION

3-12-2. Connecting the motor cables

1. Remove the screws (1), and then open the terminal

block cover (2) of the motor.

2. Loosen the screw (3) and connect the ground cable

(4) for the motor.

3. Loosen the screw (5) and connect the ground cable

(6) from the control box.

4. Connect the cables so that the cable m arks (U, V,

W) match the symbols on the screw terminals.

5. Close the cover (2).

Note: Be careful not to clamp the cables when

closing the cover.

3000Q

3-12-3. Connecting the air tubes

Connect the air tubes to the joints of the solenoid valve assembly, using the illustration below as a reference. Numbers are marked on each of the air hoses which come out of the sewing machine.

Plug 4

0827Q

Label No.

5 4 3

2 1

*1 If the lower thread trimmer is not

installed, solenoid valve [3] is not used.

*2 The auxiliary clamp arm can only be

used for machines with -02 specification.

Solenoid valve

Upper thread trimming

Upper thread tightening

Lower thread trimming *1

Cloth spreading

(Auxiliary clamp arm *2)

Wor k clamp

< -00, -01 >

0826Q

< -02 >

0828Q

0829Q

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Page 23

3-12-4. Securing the cables

3. INSTALLATION

3132Q

Note: Leav e enough loos eness in t he cables s o that

they will not be pulled when the machine head is tilted back.

1. Pass the cable through the cable holder (1), and then secure the cable holder (1) to the und erside of the work table with the screw.

2. Pass the air tube and the hand switch cable through the cable holder (2), and then secure the cable holder (2) to the underside of the work table with the screw.

3. Place the machine head cable together with the valve cable assembly and motor cable, pas s them all through the cable holder (3), and th en sec ur e the cable holder (3) to the underside of the work table with the screw.

3002Q

3003Q

Insert the specific ation harnes s (1) into the control box connector (2). Note: Check that the label number on the

specification harness (1) matches the movable knife (R) (3), movable knife (L) (4), thread handler (5), work clamp (R) (6), work clamp (L) (7) and movable knife driving cam (8) numbers before inserting the spec ification harness (1). (If a connector with an incorrect label n umber is connected, it may cause problem s such as damage to the sewing machine or thread trimming errors.)

Right/left work clamp No. Right/left mo v abl e knife No. Thread handler No.

Specification

Label No.

of harness

-00, -01 0 L1 1 1 L2 2 2 L3 3 3

-02

L4 4 4 L5 5 5 L6 6 6 L7 7 7

* There is 10 mm of difference in the knife installat ion

positions between L1 - L4 and L5 - L7.

3004Q

RH-981A

Page 24

3. INSTALLATION

3-13. Installing the air tubes

Connect the air tube from the compressor to the air unit underneath the work table.

1. T urn the nut (1) at the end of the air tube, and the n connect the tube to the valve (2).

2. Open the air cock (3) on the compressor. Check that there is no air leaking from the valve connection.

Open

Closed

3005Q

3-13-1. Adjusting the air pressure

Set the air pressure for the k nife pres sur e adj ustment regulator (3) to the lowest pressur e at which the knife can still cut the material. Set the standard air pressure for the main regulator (1) to 0.5 MPa.

3. Open the cock (3) by turning it in the direction of the arrow. The meter needle will move clockwise.

4. Adjust the air pressure.

To increase the air pressure

(0.5MPa)

To decrease the air pressure

To close

To loosen

To tighten

(0.5Mpa)

(0.3MPa)

(0.3Mpa)

3006Q

3007Q

1. Gently lif t the k nob (2 ) of the m ain r egulator (1) and

turn it in the direction of the arrow in the illustration. The pressure will increase when the knob (2) is

turned clockwise.

2. Gently lift the knob (4) of the knife pressure

adjustment regulator (3) and turn it in the dir ection of the arrow in the illustration. The pressure will increase when the knob (4) is turned clockwise. * The pressure for the knife pressure adjustment

regulator (3) is adjusted to 0.3 MPa. Be careful not to increase this pressure needlessly, otherwise poor cutting performanc e or damage to the knife may result.

1. Close the cock (5). (The needle will remain at the

high pressure position.)

2. Turn the knob screw (6) in the d irec tion of the ar row

in the illustration to loosen it. Make sure that you

turn it in the correct direction. The air will escape from the reservoir and the needle will drop.

3. Tighten the knob screw (6).

4. To reduce the air pressure, gently lift knob (2) or knob (4) and turn it counterclockwise.

5. Open the cock (5). Air will enter the reservoir and the needle will move

RH-981A

Page 25

3-14. Connecting the power cord

Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done. Be sure to connect the ground. If the gr ound connection is not secure, you run a high risk of receiving a

serious electric shock, and problems with correct operation may also occur. 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.

CAUTION

3. INSTALLATION

Single phase

Green and yellow wire (ground wire)

3133Q

0838Q

1. Attach an appropriate plug to the power cord (1). (The green and yellow wire is the ground wire.)

2. Insert the plug into properly-grounded AC power supply.

Note: Do not use extension cords, otherwise

machine operation problems may result.

Three phase

Green and yellow wire (ground wire)

3134Q

RH-981A

Page 26

3. INSTALLATION

3-15. Installing the programmer (sold separately)

[Vertical]

3010Q 3011Q

[Flat]

1. Install the programmer support (2) to the work table with the two screws (1).

2. Insert the programmer connector (4) securely into the left side of the operation panel (3).

3-16. Installing the foot switch (option)

3012Q

3135Q

Insert the connector (3) of the foot switch (2) into the control box connector (1).

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Page 27

3-17. Installing the indexer (option)

3-17-1. Installing the indexer main unit

3015Q

3. INSTALLATION

1. After disconnecting air tubes [20] and [21], insert the two plugs (3) into joints (1) and (2). In addition, remove parts (4), (5) and (6) indicated in the illustration.

2. Remove the screws (7) from feed bracket cover (L) (8), and then install feed base (L) (9).

3016Q

3017Q

3. Remove the screws (10) from feed bracket cover (R) (11), and then install feed base (R) (12).

4. Pas s the cloth feed bar (13) bet ween the rollers of feed bar guide (R) (14) and feed bar guide (L) (15), and place it on top of feed base (L) (9) and feed base (R) (12). * Push down the chuck pin (16) and c heck that it

goes smoothly into all of the holes in the cloth feed bar (13). If it does not go in smoothly, re-adjust the installation positions of feed base (L) (9) and feed base (R) (12).

3018Q

RH-981A

Page 28

3. INSTALLATION

3-17-2. Installing the upper thread presser

3019Q

1. Loosen the screw (1), and then remove the thr ead

guide (2).

2. Ins tall the upp er thread pres s er s uppor t (3) with the

screw (1). * Adjust the height of the upper thread presser

support (3) so that it presses against the u pper thread presser plate (5) when the upper thread take-up lever (4) is lowered.

3020Q

3-17-3. Replacing the plate presser and presser plate

Remove the plate presser (1) and presser plate (U) (2), and replace them with plate presser (I) (3) and presser plate (I) (4).

3-17-4. Installing the valve unit

3022Q

3021Q

Installation position

2400Q

1. Install the valve unit (1) with the screw (2).

2. Remove the stopper plug (with the P mark) (4) from the valve unit (3), and then install the joint (5).

3. Connect the 6mm-diameter air tube (7) to joints (5) and (6).

RH-981A

Page 29

3-17-5. Connecting the connectors

3023Q

3. INSTALLATION

1. Insert the 3-pin connectors [8], [9] and [10] of the valve harness into th e solenoid valves of the valve unit (1) so that the label numbers match.

2. Insert the 15-pin connector (2) into the conn ector of the indexer cord (3).

3. Open the rear cover (4) of the control box.

4. Insert the connector (5) of the indexer cord (3) in the position shown in the illustration.

5. Secure the cord with the cord clamp.

3024Q

6. Insert the two pins of limit switch (R) ( 6) and the tw o pins of limit s witch (L) (7) into the 15-pi n connector terminals with matching numbers.

7. Connect the three pins of the cylinder sensor (8) into the 15-pin connector so that the cable colors m atch the connector numbers as given in the table below. * If the cable colors are red, white a nd black, refer

to the colors in brackets.

Note: First disconnect the connector before

inserting the pins, and then after inserting the pins, re-connect the connector.

Limit switch (R) (6) Limit switch (L) (7)

Cylinder sensor (8)

Switch pin

No.

7White7 12 Black 12 10 White 10 15 Black 15

Cable color

15-pin

Connector

Brown (Red) 4

Black (White) 9

Blue (Black) 14

8. Secure the cable with the cable clamp (9).

3025Q

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Page 30

3. INSTALLATION

3-17-6. Connecting the air tubes

0855Q

Connect air tubes [50], [51], [52] and [53] to the places with the corresponding numbers on the valve unit.

Label No. Solenoid valve type

[50], [51] For cloth feed drive cylinder

[52] For chucking cylinder [53] For holding cylinder

3-17-7. Securing the air tubes and cables

0856Q

3026Q

1. Remove the screw (length 8 mm) (1).

2. Secure the air tube (2) and cable (3) with the cord holder (4), screw (length 16 mm) (5) and washer (6). * Leave enough slack in the air tube (2) and c able (3) at th is tim e to allo w for the movem ent of the f eed brack et

(7).

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Page 31

3. INSTALLATION

3003Q

3004Q

Insert the indexer specification harness (1) into the control box connector (2). * If another specification harness has been inserted

into this connector, firs t disconnec t this harness and then insert the indexer specification harness (1).

Note: Check that the label number on the indexer

Right/left work clamp No. Right/left mov abl e knife No. Thread handler No.

Specification

Label No.

of harness

L1 1 1 L2 2 2 L3 3 3

-52

L4 4 4 L5 5 5 L6 6 6 L7 7 7

* Ther e is 10 mm of difference in the knif e installation

positions between L1 - L4 and L5 - L7.

* If using both an upper thre ad clam ping de vice and a

fly indexer, L5 to L7 cannot be used.

3-17-8. Installing the hand switch

1. Install the hand switch support plate (1) with the two screws (2) in the position shown in the illustration.

2. Install the hand switch (3) to the hand switch support plate (1) with the two screws (4).

3027Q

RH-981A

Page 32

4. LUBRICATION

CAUTION

Turn off the power switch before starting lubricating, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury.

Be sure to wear protective goggles and gl oves when handling the l ubricating oil and gr ease, 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 greas e under any circum stances, as they can c ause vom iting and diarrhoea. Keep the oil out of the reach of children.

Use only specified Brother oil (Nisseki Mitsubishi Sewing Lube 10 N; VG 10) for the machine oil.

4-1. Adding oil

Check the oil level by looking at the sight glass. If the oil level is low, replenish the oil supply.

Filling the arm oil tank Filling the bed base oil tank

3028Q

Pour approximately 10 cc of machine oil into the arm oil tank (1) (until it is about four-fifths full).

1. Raise the machine head.

2. Pour approximately 20 cc of machine oil into the bed base oil tank (2) (until it is about four-fifths full).

3. Lower the machine head.

3029Q

4-2. Lubrication

Oil these parts once a day. Oil the moving parts of the needle bar , looper and spreader m echanism s and also the cam gr oove, roller, the f elt at the base of the wick and the wick before using the se wing machine for the first time, and also after long periods of non-use. When oiling, some oil will get onto the thread. Carry out a test s ewing to ensure that your material does not get stained with oil.

Oiling the needle bar and cam

Add 2-3 drops of oil in the places indicated by the arrows.

0861Q

RH-981A

Page 33

Oiling the looper, spreader and looper base

4. LUBRICATION

3031Q

3030Q

3032Q

1. Turn the upper shaft pulley (1) toward you until the m ark on the pulley (A) is aligned with the n otch in the pu lley cover (2).

2. Move the feed bracket (3) toward you.

3. Turn the left and right plate pressers (4) in the directions indicated by the arrows.

4. Lift up the clamp lever (6) and the notched section (7) of the right work clamp plate (5), remove the right work clamp plate (5) from the pin (8), and then pull the right work clamp plate (5) toward you to remove it. Note: If the lower thread tr immer has been installed, move presser plate U (9) to a position where it can be

removed without its touching the needle. Raise presser plate U (9), pass the needle through the hole, and then remove presser plate U (9) from the pin (8).

5. Remove the left work clamp plate (10) in the same way as the right work clamp plate (5) was removed.

3035Q

0865Q 3033Q

3034Q

6. Open the front cover.

7. T urn the looper base and add a few drops of oil to the spreader driving cam (11), and to the supp orts for the looper link (12) and spreader link (13).

8. Add a few drops of oil to the shafts of the right spreader (14), left spreader (15) and LS-holder bracket (16).

9. Fill the felt tank (17) on the looper base with oil also.

10. Add 5 - 6 drops of oil to the felt (18) which is attached to the sliding surfaces of the looper base and the bed.

11. Close the front cover.

12. Install the work clamp plates by carrying out the steps 5., 4. and 3. in that order.

RH-981A

Page 34

5. CORRECT USE

5-1. Data initialization

When using the sewing machine for the first time, initialize the data by following the procedure below.

1. While pressing the RESET key (1), turn on the power switch.

* While the data is being initialized, all LEDs will

illuminate and the buzzer will sound a series of short beeps.

* All parameters, memory switches, cycle

programs and the production counter will be initialized.

2. When the data writing is complete, the buzzer will stop and the machine will go to the normal startingup condition.

Note: The data is retained for approximately one

month after the power supply is turned off. If more than one month passes s ince the power supply was last turned on, "E-59" may be

3036Q

displayed the next tim e the power is turned on. If this happens, you will need to re-initial ize the data.

5-2. Changing the lower thread and gimp trimming

The sewing machine is set to lower thread and gimp trimming when it is shipped from the factory. (DIP switch C (3) No. 6 is set to ON.) For setting the lower thread and gimp thread trimming to OFF, carry out the following procedure. Note: For -00 specification, be sure to set the lower thread and gimp thread trimming to OFF.

1. Turn off the power.

Trimming

No trimming

3037Q

2. Remove the six screws (1).

3. Open the rear plate (2) of the control box.

4. Set DIP switch C (3) No. 6 on the circuit board to

OFF.

5. Close the rear plate (2) and tighten the six screws

(1).

RH-981A

Page 35

5-3. Installing the needle

Turn off the power switch before installing the needle, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury.

CAUTION

5. CORRECT USE

5-4. Threading the upper thread

Turn off the power switch before threading the thread, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury.

3039Q

3040Q3038Q

CAUTION

Use only Schmetz DO x 558 Nm80 - Nm120 needles.

1. Raise the finger guard (1).

2. Loosen the screw (2), and then rem ove the needle

(3).

3. Insert the new needle (3) as far as it will go so that

the groove is facing toward you.

4. Securely tighten the screw (2).

5. Remove the work clamp plates. (Refer to page 26.)

Note: After removing the work clamp plates, check

6. Lower the finger guard (1).

that the index mark (4) on the mac hine head is aligned with the index mark (5) on the looper base before inserting the needle (3) (when the looper base is turned fully to the right).

Thread the upper thread as shown in the illustration below. *Use the accessory needle threader (1).

0875Q

0876Q

<-52 specifications>

(1)

0874Q

2403Q 0878Q

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Page 36

5. CORRECT USE

5-5. Threading the lower thread

Remove the work clamp plates ( refer to page 26), and then thread the lo wer thread as shown in the illustration below.

For upper thread trimming specifications (-00)

0880Q

0879Q

For upper and lower thread trimming specifications (-01, -02 and -52)

0881Q

0883Q

0882Q

0881Q

RH-981A

Page 37

5. CORRECT USE

5-6. Threading the gimp

Remove the work clamp plates (refer to page 26), and then thread the gimp as shown in the illustration below. Once threading is complete, replace the work clamp plates.

<-00,-01>

0884Q

0885Q

<-02,-52>

Pass the gimp through the hole of the thread tension stud (1).

3041Q

Refer to “9-18. Adjusting the gimp length after trimming” (Page 67).

RH-981A

Page 38

5. CORRECT USE

5-7. Setting the material

<-00, -01, -02 specifications>

10 - 30 mm

3042Q

3043Q

1. Insert the material so that it touches the right and left cloth guides (1).

2. The sewing margin can be adjusted to within 10 - 30 mm.

3. Loosen the screws (2) at left and right and move the cloth guides (1) back and forth to adjust the sewing margin.

<-52 specifications>

0892Q

9 - 21 mm for L1 - L4 9 - 11 mm for L5 - L7

3044Q

30 - 40 mm

1. Place the material (fly) on top of the feed bracket ( 1), and then f eed the material (fly) in unti l it reac hes h ori zontal cloth set guide (L) (2) and horizontal cloth set guide (R) (3).

* Check that the right edge of the material (fly) is straight against the left edge of the vertical cloth set guide (4) at

this time.

2. The vertical sewing margin can be adjusted between 9 - 21 mm for L1 - L4 and 9 - 11 mm for L5 - L7. Loosen the four screws (5), and th en move horizontal cloth set guide (L) ( 2) and hor izon tal c l oth set gu ide ( R) (3) forward or back to adjust.

3. The horizontal sewing margin can be adjusted between 30 - 40 mm. Loosen the two screws (6), and move the vertical cloth set guide (4) to the left or right to adjust.

RH-981A

Page 39

Cloth setting position

5. CORRECT USE

Left setting position

0893Q

Right setting position

0894Q

The sewing start position can be set to either the left setting position or the horizontal setting position. (Refer to page

73.)

When set to the left setting position

This is the normal setting position for the cloth. * After the last buttonhole is sewn, the cloth feed bar returns to the left setting position.

Horizontal setting position

The cloth is set to both the left setting position and right setting position.

* The next piece of cloth is set at the position that the last buttonhole was sewn.

RH-981A

Page 40

5. CORRECT USE

. Setting the installation position for cloth feed pla te (L) (-52 specificat ions)

5-8

The installation position for cloth feed plate (L) can be set to one of four positions depending on the spacing between buttonholes and the number of buttonholes to be sewn. When the s pacing between buttonho les and the num ber of buttonholes sewn have been changed, the installation position for cloth feed plate (L) should also be changed. Refer to the illustration and table below at this time.

Standard Large size

3045

Install the cloth feed plate (L) (1) to the cloth feed bar (3) with the screws (2).

Installation position

Hole spacing

No. of holes

3 (D) (D) (C) 4(C)(B)(A)

Hole spacing

No. of holes

3 (L) (K) (L) (L) 4 (L) (K) (J) (I) 5 (J) (I) (H) (F) 6(G)(F)(E)

0897Q

38.1 mm 44.45 mm 50.8 mm

38.1 mm 44.45 mm 50.8 mm 57.15 mm

(A) 207- 217 mm (E) 346.5 - 356.5 mm (B) 192.5 - 202.5 mm (F) 321.5 - 331.5 mm (C) 167.5 - 177.5 mm (G) 279.5 - 289.5 mm (D) 142.5 - 152.5 mm (H) 270.5 - 280.5 mm

3046

(I) 234.5 - 244.5 mm (J) 209.5 - 219.5 mm (K) 195 - 205 mm (L) 184.5 - 194.5 mm

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Page 41

5. CORRECT USE

5-9. Replacing the PROMs

Refer to the following when r eplacing the PROMs (for ex ample, when upgradin g the version num ber). At this time, be particularly careful not to make a mistake with the direction of the PROM.

The PROM which is marked “MN” is the main PROM. This PROM is mounted in position (1).

The PROM which is marked “MT” is the machine motor PROM.

3047Q

This PROM is mounted in position (2).

3048Q

The PROM which is marked “PL” is the panel PROM. This PROM is mounted in position (3).

* The figure inside the box indicates

the version number.

2430Q

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Page 42

6. OPERATION

6-1. Name and function of each operation panel item

(1) Power indicator

Illuminates when the power is turned on.

(2) Warning indicator

Illuminates when an error occurs.

(3) RESET key

Press to reset errors, and to clear the production counter.

(4) BEFORE indicator

Illuminates when cutting before sewing has been set.

(5) BEFORE key

Press to set cutting before sewing.

(6) OFF indicator

Illuminates when no cutting has been set.

(7) OFF key

Press to set no cutting.

(8) AFTER indicator

Illuminates when cutting after sewing has been set.

(9) AFTER key

Press to set cutting after sewing.

(10) Automatic m ode indic ator

Illuminates during automatic mode.

(11) Test feed mode indicator

Illuminates during test feed mode.

(12) Manual mode indicator

Illuminates during manual mode.

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(13) Program mode indicator

Illuminates during program mode.

(14) Cycle program mode indicator

Illuminates during cycle program mode.

(15) SELECT k ey

Press to change the mode.

• When an independent program (1 - 9) is selected, the mode changes in the following order. Automatic mode → Test feed mode → Manual mode → Program mode → Automatic mode

• When a cycle program (A - D) is selected, the mode changes in the following order. Automatic mode → Test feed mode → Manual mode → Cycle program mode → Automatic mode

(16) Program number display

Displays the program number and the parameter number.

(17) Program No. UP key ( key)

Press to increase the value in the program number display.

(18) Program No. DOWN key ( key)

Press to decrease the value in the program number display.

(19) Detail displ ay

• In automatic mode, this display shows the production counter or the stitch length.

However, if a cycle program is selected, the cycle program step number and setting details are displayed.

• In test feed mode and manual mode, the number of stitches remaining is displayed.

• In program mode, the parameter details are shown.

• In cycle program mode, the cycle program details are shown.

(20) Detail UP key ( key)

Press to increase the value in the detail display.

(21) Detail DOWN key ( key)

Press to decrease the value in the detail display.

(22) ENTER k ey

Press to accept the values appearing in the program number display and detail display.

6. OPERATION

6-2. Starting up

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3137Q

1. Press the power switch (23) to turn on the power. * The power indicator (1) will illuminate, and "--"

and "----" will appear in the program number display (16) and detail display (19) respectively.

Note: If "E-10" appears in the detail display, turn

the upper shaft pulley by hand to set the upper shaft to the needle up stop position.

2. Press the start switch (24). * The feed bracket will move to the cloth setting

position.

* The panel displays will return to the same

displays as when sewing last finished.

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6. OPERATION

6-3. Program setting method

3051Q

1. Press the SELECT key (1) to change the mode to automatic, manual or test feed mode.

2. Press the and keys to select the program number (1 - 9) for the independent progr am to be changed.

Note: Program mode is not available if a cycle program

has been selected.

3. Press the SELECT key (1). The program mode indicator (2) will illuminate. * The parameter number "00" will appear in the

program number displa y ( 3), and the parameter details will appear in the detail display (4).

4. Press the and keys to select the number of the parameter to be changed.

5. Press the and keys to change the parameter setting. (Refer to "Parameter table".)

* The flashing display indicates that the value has

not yet been accepted.

6. Press the ENTER key (5) to accept the changed setting. (The display will then illuminate steadily.)

7. Repeat steps 4 to 6 to change other parameter settings.

8. Press the SELECT key (1) to change the mode to automatic mode. * The program settings will be memorized.

6-3-1. Parameter table ( Taper bar )

The allowable setting range for s ome parameters may vary from the range specified, depending on the s ettings of other parameters.

No. Setting items Setting range Unit Default

00 Sewing speed 1,000 - 2,200 rpm 100 1,800 01 Eyelet pattern 1 - 6 1 2

02 Button hole length (*1) -00: 5 - 50 mm

-01: 5 - 38 mm

-02 (L1): 14 - 18 mm (L2): 18 - 22 mm (L3): 22 - 26 mm (L4): 26 - 30 mm (L5): 28 - 32 mm (L6): 32 - 36 mm (L7): 36 - 40 mm

03 Tacking length 0 - 20 mm 1 6

1 -00: 25 mm

-01: 25 mm

-02 (L1): 16 mm (L2): 20 mm (L3): 24 mm (L4): 28 mm (L5): 30 mm (L6): 34 mm (L7): 38 mm

*1 The Button hole length setting value and the default value vary depending on the machine sub-class.

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6. OPERATION

No. Setting items Setting range Unit Default

04 Offset 0.5 - 2.0 mm 0.1 1.5

05 Stitch pitch 0.5 - 2.0 mm 0.1 1.0

06 Number of eyelet stitches 4 - 20 stitches 1 9

07 Cutting space -0.3 - 0.5 mm 0.1 0

08 Knife X position compensation -0.5 - 0.5 mm 0.1 0

09 Knife Y position compensation -0.7 - 0.7 mm 0.1 0

10 Start tying stitches 0 - 2 1 0

11 End tying stitches 0 - 2 1 0

12 X alignment -1 - 6 1 0

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6. OPERATION

No. Setting items Setting range Unit Default

13 Y alignment -1 - 6 1 0

θ1 alignment

θ2 alignment

-3 - 3 1 0

16 Eyelet machine speed (*2) -600 - 0 rpm 100 0 17 Eyelet radius OFF, 1 - 5 1 OFF

18 Taper tact radius OFF, 1 - 5 1 OFF

19 Taper tact angle -5 - 5 1 0

20 Slow start stitches 0 - 3 stitches 1 0 21 Slow start speed (*3) 400 - 1,500 rpm 100 1,000 22 Stitch width correction -1.0 - 1.0 mm 0.1 0

29 Program copy OFF, 1 - 9

1OFF

(Specify copy source) *2 The standard eyelet machine speed is the value that has been set by parameter 00 (sewing speed). *3 If the sewing speed is set to a speed that is slower than the slow s tart speed, the slow start speed used for

sewing will be the same as the normal sewing speed.

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6. OPERATION

6-3-2. Parameter table ( Straight bar tacking )

The allowable setting range f or some param eters may vary from the range specified, de pending on the sett ings of other parameters.

No. Setting items Setting range Unit Default

00 Sewing speed 1,000 - 2,200 rpm 100 1,800 01 Eyelet pattern 1 - 6 1 2

02 Button hole length (*1) L1: 14 - 18 mm

L2: 18 - 22 mm L3: 22 - 26 mm L4: 26 - 30 mm L5: 28 - 32 mm L6: 32 - 36 mm L7: 36 - 40 mm

03 Tacking length

04 Tacking stitches 5 - 18 stitches 1 7

05 Stitch pitch 0.5 - 2.0 mm 0.1 1.0

2.0 - 6.0 mm ( Up to 3.0 mm on one side )

1 L1: 16 mm

L2: 20 mm L3: 24 mm L4: 28 mm L5: 30 mm L6: 34 mm L7: 38 mm

0.1 4.0

06 Number of eyelet stitches 4 - 20 stitches 1 9

07 Cutting space -0.3 - 0.5 mm 0.1 0

*1 The Button hole length setting value and the default value vary depending on the machine sub-class.

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6. OPERATION

No. Setting items Setting range Unit Default

08 Knife X position compensation -0.5 - 0.5 mm 0.1 0

09 Knife Y position compensation -0.7 - 0.7 mm 0.1 0

10 Start tying stitches 0 - 2 stitches 1 0

11 End tying stitches 0 - 2 stitches 1 0

12 X alignment -1 - 6 1 0

13 Y alignment -1 - 6 1 0

θ1 alignment

θ2 alignment

-3 - 3 1 0

16 Eyelet machine speed (*2) -600 - 0 rpm 100 0

*2 The standard eyelet machine speed is the value that has been set by parameter 00 (sewing speed).

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6. OPERATION

No. Setting items Setting range Unit Default

17 Eyelet radius OFF, 1 - 5 1 OFF

18 Width correction value -1.0 - 0 mm 0.1 0

19 Tacking overlap amount 0 - 2.0 mm 0.1 1.0

20 Slow start stitches 0 - 3 stitches 1 0 21 Slow start speed (*3) 400 - 1,500 rpm 100 1,000 22 Stitch width correction -1.0 - 1.0 mm 0.1 0

23 Tacking X alignment -1.0 - 1.0 mm 0.1 0

24 Tacking angle compensation -3 - 1 1 0

29 Program copy OFF, 1 - 9

1OFF

(Specify copy source)

*3 If the sewing speed is set to a speed that is slower than the slow start speed, the slow start speed used for sewing

will be the same as the normal sewing speed.

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6. OPERATION

6-4. Cycle program

Cycle programs can consist of up to a maximum of four independent programs (A to D). A single cycle program can contain up to a maximum of eight steps. The following shows an exam ple of storing a cycle program into c ycle program A that consists of four steps of program 1 with knife operation on, and one step of program 3 with knife operation off.

Step 1 Step 2 Step 3 Step 4 Step 5

Program No.11113

Knife operation ON ON ON ON OFF

3052Q

2410Q

1. Press the SELECT k ey (1) to change the m ode to automatic, manual or test feed mode.

2. Press the and keys to select cycle program "A". Note: Cycle program mode is not available if an

independent program has been selected.

3. Press the SELECT key (1). The cycle program mode indicator (2) will illuminate. * The cycle program number "A" and the step

number "1" will appear in the progr am number display (3), and the cycle program details will appear in the detail display (4).

4. Press the and keys to change the setting for step 1 to "1.", and then press the ENTER key (5) to accept the "1." setting. * "." signifies that knife operation is on.

* "-" signifies a clear status. If "-" is set, the setting

details for all subsequent steps will be cleared.

5. Press the and keys to change the step number to "2", and then repeat step 4 above.

6. Press the and keys to change the step number to "3", and then repeat step 4 above.

7. Press the and keys to change the step number to "4", and then repeat step 4 above.

8. Press the and keys to change the step number to "5".

9. Press the and keys to change the setting for step "5" to "3.".

10. Press the OFF key (6) so that the "." disappears, and then press the ENTER key (5) to accept the "3" setting.

11. Press the SELECT key (1). Cycle program m ode will end and the mode will change to automatic mode.

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6-5. Production counter

6. OPERATION

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1. Press the SELECT key (1) to change the mode to automatic mode.

2. Press the key and key simultaneously. * "PC" will flash in the program number displa y (2), and the production c ounter value will appe ar in the detail

display (3).

3. Press the keys to change the production counter setting. * The production counter setting will flash while the setting is being changed. * If you would like to set the production counter to "0", press the RESET key (4).

4. Press the ENT ER ke y (5). The production count er va lue wil l be accepted and the mode wil l return to a utom atic

mode.

* If you press the SELECT key (1) while the production counter value is still f lashing, the mode will return to

automatic mode without the production counter value being changed.

6-6. Using the program memos

Insert the program memos (1) into the rear of the operation box (2) for safekeeping.

Program memo contents

1. Easy reference guide

2. Error code table

3. Parameter table

4. Program notes Use a lead pencil to make any additions to the parameter table and for writing anything into the program notes. If you do so, additions can be removed using an eraser and the space can be re-used. The program notes are useful for recording what patterns have been entered into which programs.

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7. SEWING

CAUTION

Turn off the power switc h at the follo wing times, otherwise the machine m ay operate if the start switch is pressed by mistake, which could result in injury.

• When threading the needle

• When replacing the needle

• When not using the machine and when leaving the machine unattended. Do not touch any of the moving parts or pr ess any obj ects against the machine while sewing, as th is m ay

result in personal injury or damage to the machine.

7-1. Automatic sewing

When carrying out automatic sewing for the first time, be sure to carry out a test sewing first. In addition, if using the sewing machine when the ambient temperature is cold, carry out several test sewing operations to allow the motor to warm up.

3055Q

1. Press the SELECT key (1) to change the mode to automatic mode. * The program number will appear in the program number display (2), and the produc tion counter value will

appear in the detail display (3).

2. Use the and keys to select the desired program number.

* The program number changes in the order 1 → 2 → ... → 9 → A → B → C → D → 1 eac h time a key is

pressed. A to D are cycle programs.

3. Press the ENTER key (4) to accept the program number selection.

* The program number display will stop flashing and illuminate steadily.

4. If changing the knife operation (before/off/after), press the corresponding knife key ((5)/(6)/(7)).

* The corresponding knife indicator (BEFORE/OFF/AFTER) will illuminate.

5. Place the material to be sewn under the work clamp, and then press the cloth presser switch (8). The work

clamp will be lowered.

6. Press the start switch (9). Sewing will then start.

7. When sewing is finished, the work clamp will be raised.

* The production counter value in the detail display (3) will increase by 1.

8. To repeat this operation, repeat steps 5 and 6 above.

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7-2. Using the EMERGENCY STOP switch

7. SEWING

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1. Press the EMERGENCY STOP switch (1). * All sewing operati ons will stop and the buzzer will s ound. At this tim e, the warning indicator ( 2) will flas h and

"E-60" will flash in the detail display (3).

* If the upper shaft could not stop in the needle up stop position, "E-10" will flash in the detail display (3). In this

case, turn the upper shaf t pulley by hand to set the upper shaf t to the needle up stop position. (Align t he marks.)

2. Eliminate the cause of the problem.

3. Release the EMERGENCY STOP switch (1).

4. In automatic mode:

• If continuing on with sewing, press the and keys to determine the position to resume sewing from. Then

press the start switch (4). (Sewing will then restart.)

Note: The start switch (4) will not work unless you not press the key at least once.

• To stop sewing, press the RESET key (5). (The feed bracket will return to the cloth setting position.)

In test feed mode or in manual mode:

• Press the RESET key (5). (The feed bracket will return to the cloth setting position.)

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7. SEWING

7-3. Adjusting the thread tension

Turn off the power. Never adjust the thread tension while sewing.

Woolen materials + wool gimps

Upper thread tension 0.9 N 1.0 N Lower thread tension 0.3 N 0.8 N

Thread take-up spring tension 0.05 N 0.07N

Thread take-up spring stroke 8 mm 8 mm

Upper and lower thread # 30 polyester # 30 cotton

* If you change the type of material being used, it may be necessary to change the thread tension.

The upper thread tension given above is the tension when the upper thread is pulled out from the thread path hole of the thread take-up lever, and the lower thread tens ion is when the lower thread is pul led out from the needle hole in the throat plate.

Upper thread te n sion Lower thread te n sion

Denim (3 layers)

3059Q

Turn the upper thread te nsion adjustment knob (1) in the direction indicated by the arrow to increase the upper thread tension.

Turn the lower thread tension adjustment knob (2) in the direction indicated by the arrow to increase the lower thread tension.

Adjusting the lower thread take-up spring tension and stroke

Tension adjustment

Loosen the screw (3) and turn the thread take-up spring support (4) in the direction indicated by the arrow to increase the tension of the spring (5).

Stroke adjustment

Loosen the screw (6) and turn the thread take-up spring guide (7) in the direc tion indicate d b y the ar row to increase the stroke of the spring (5).

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7. SEWING

7-4. Needle and knife position

The feed bracket is electronically controlled by means of pulse motors. It is not necessary to change the position of the knife when switching between cutting before sewing and cutting after sewing. It is not necessary to change the needle do wn position in order to k eep enough s pace f or cutting when cuttin g after sewing has been selected.

Relationship between knife position and eyelet shape

1. When cutting before sewing, the inside needle down position must be aligned accurately with the straight line section of the eyelet (when the cutt ing space is 0).

This is set correctly at the time of shipment from the factory.

2. The shape of the eyelet is automatically changed according to the shape of the knife for cutting before and after sewing and for no cutting.

Eyelet shape (c X d)

Cutting before

sewing or no cutting

Cutting after

sewing

Knife No.

Cutting shape

(a X b)

1 2.1 X 3.2 1.7 X 2.7 2.5 X 3.8 2 2.8 X 4.3 2.4 X 3.8 3.2 X 4.9 3 3.0 X 4.6 2.6 X 4.1 3.4 X 5.2 4 3.2 X 5.4 2.8 X 4.9 3.6 X 6.0 5 Straight Straight Straight 6 3.8 X 4.3 3.4 X 3.8 4.2 X 4.9

Cutting shape (a x b)

0936Q

Straight section

Knife

Eyelet shape (c x d)

0937Q

3. At the t ime of shipm ent, the installation pos ition for the knife is adjusted to the position shown in the illustration at left (when the cutt ing space value is "0").

(When cut ting before sewing)

(When cutting after sewing)

Explanation of the cutting space function

When cutting after sewing, this function m oves the outer needle d own positions in acc ordance with the k nife shape so that the seam is not cut by the knife.

0938Q

When cutting after sewing, set the cutt ing space to an appropriate value so that the seam is not cut by the knife. * T he cutting space should generall y be set to around

0.2. (Refer to “6-3 Program setting method.”)

Cutting space

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7. SEWING

7-5. Setting the feed bracket to the front position

Setting the material will be easier if the feed bracket is moved forward from the standard cloth setting position. Cycle time will be reduced with this setting, particularly if cutting after sewing is selected.

2418Q

3141Q

1. Turn off the power.

2. Set panel DIP switch No. 3 to ON.

3. Turn on the power and press the start switch (1). * The feed bracket will move to the home position and then to the front position.

4. Sewing can then be carried out as normal. (Refer to “7-1. Automatic sewing”.)

7-6. Switching between single-pedal and dual-pedal operation

The work clamp can be lowered and the machine can start sewing just by pressing the start switch, without having to use the cloth presser switch.

2419Q

1. Turn off the power.

2. Change the setting of panel DIP switch No. 5. OFF: To use both pedals (cloth presser switch and start switch)

ON: To use only one pedal (start switch)

3. Turn on the power and press the start switch (1). * The feed bracket will move to the cloth setting position.

4. Sewing can then be carried out as normal. (Refer to “7-1. Automatic sewing”.)

Note:

During single pedal operat ion, when the start sw itch is pressed, the work clamp is lowered an d sewing starts straight away. If you would like to reset the material, set to dual-pedal operation.

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7-7. Using test feed mode

In this mode, the feed bracket can be moved while the needle stopped. It is useful for checking the relative positions of the needle and the work clamp.

7. SEWING

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3142Q

1. Press the SELECT key (1) to change the mode to test feed mode. * The program number will appear in the program number display (2), and the number of stitches will appear in

the detail display (3).

2. Use the and keys to select the desired program number. * If an independent pr ogram has been selected, the pr ogram number changes in the ord er 1 → 2 → .. . → 9 →

* If a c ycle program has been selec ted , the pr o gram number changes in the order A 1 → A2 → ... → A8 → A1.

However, steps that have not been programmed will be skipped.

3. Press the ENTER key (4) to accept the program number selection. * The program number display will stop flashing and illuminate steadily.

4. Press the cloth presser switch (5) to lower the work clamp.

5. Press the start switch (6). * The feed bracket (7) will move to the sewing start position.

6. After releasing the start switch (6), press it once more (or press the key). * The feed bracket (7) will move to the next sewing start position. * The number of stitches in the detail display (3) will decrease by 2. * To return the feed bracket to the cloth setting position while sewing:

1) Press the EMERGENCY STOP switch (8) and then release it.

2) Press the RESET key (9).

7. If you would lik e to return the feed bracket (7) to the previous sewing position during tes t feeding, press the key. * The number of stitches in the detail display (3) will increase by 2.

8. When the final stitch is reached, the buzzer will sound.

9. After releasing the start switch (6), press it once more. * The feed bracket (7) will return to the cloth setting position.

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7. SEWING

7-8. Using manual mode

In this mode, the feed bracket can be moved one stitch at a time by turning the upper shaft pulley by hand. This is useful when carrying out timing adjustment.

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3144Q

1. Press the SELECT key (1) to change the mode to manual mode.

* The program number will appear in the program number display (2), and the number of stitches will appear in

the detail display (3).

2. Use the and keys to select the desired program number.

* If an independent program has been selected, the program number changes in the order 1 → 2 → ... → 9 → 1. * If a c ycle program has been selec ted , the pr o gram number changes in the order A 1 → A2 → ... → A8 → A1.

However, steps that have not been programmed will be skipped.

3. Press the ENTER key (4) to accept the program number selection.

* The program number display will stop flashing and illuminate steadily.

4. Place the material to be sewn under the work clam p, and then press the cloth presser switch (5). The work

clamp will be lowered.

5. Press the start switch (6).

* The feed bracket (7) will move to the sewing start position.

Note: If cutting before sewing has been selected, the hammer will operate.

6. Turn the upper shaft pulley toward you.

* The feed bracket (7) will m ove to the next se wing start position in accordance with the r otation of the u pper

shaft.

Note: If the upper shaft pulley is turned in the wrong direction, the feed bracket timing may become disrupted.

* The number of stitches in the detail display (3) will decrease by 1. * To return the feed bracket to the cloth setting position while sewing:

1) Press the EMERGENCY STOP switch (8) and then release it.

2) Press the RESET key (9).

7. When the final stitch is reached, the buzzer will sound.

8. When the needle up position is reached, press the start switch (6).

* Thread trimming will be carried out, and then the machine will return to the cloth setting position.

Note: If cutting after sewing has been selected, the hammer will operate.

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7-9. Changing the mode during an operation

• If you press the SELECT key (1) during test feeding, you can change the mode to manual sewing in manual sewing mode.

• If you press the SELECT key (1) while pressing and holding the ENTER ke y (2) during test f eeding, you can change the mode to resewing enabled in automatic sewing mode.

• If you press the SELECT key (1) during manual sewing mode, you can change the mode to test feeding in test feeding mode.

• If you press the SELECT key (1) while pressing and holding the ENTER k ey (2) during manual sewing, you can change the m ode to resewing enabled in automatic sewing mode.

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7. SEWING

7-10. Moving the cloth feed bar (-52 specifications)

While pressing the RESET ke y (1), press the key or the key. The cloth feed bar will then move in the right direct ion or the left direction. * This operation is only possible when the cloth feed

plate is in the left setting position (home condition).

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8. CLEANING AND MAINTENANCE

CAUTION

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.

8-1. Cleaning

If using an air gun, do not use it while the machine head is tilted back, otherwise oil and thread scraps may adhere to the cutter sensor and timing belt, resulting in operating problems.

0848

1. Turn off the power.

2. Turn the air cock to stop the air. * Turn the knob to release the air.

3. Remove any thread scraps and dust, etc. from the thread paths for the needle thread, looper thread and gimp. In particular, the looper thread path should be cleaned every day to keep it free from thread scraps and dust.

4. Check the oil level by looking at the sight glass. If the oil level is low, replenish the oil supply.

<-52 specifications>

0931Q 0940Q

0849Q

5. Remove any thread scraps and dust which have collected in the holes of the cloth feed bar.

6. Wipe away any thread scraps and dust which are adhering to the feed guide shaft.

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8-2. Draining the oil

8-3. Checking the air filter

8. CLEANING AND MAINTENANCE

When the oil container (1) is full of oil, rem ove the oil container (1) and let the oil drain out. Note: Clean up any oil that may have been spilt onto

the floor.

3145Q

1. Close the air cock (1).

2. Turn the screw (2) to release any air and water in the drain.

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9. STANDARD ADJUSTMENTS

CAUTION

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 maintenanc e and inspection of the electrical system.

Turn off the power switch and disconnect the power cord from the wall outlet at the f ollowing times, otherwise the machine may operate if the start switch is pressed b y mistake, which could result in injury.

When carrying out inspection, adjustment

and maintenance.

When replacing consumable parts such as

the loopers 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.

If the power switch and air need to be left on when carrying out some adjustment, be extremely careful to observe all safety precautions.

If any safety devices have been removed, be absolutely sure to re-install them to their original positions and check that they operate c orrectly before using the machine.

9-1. Adjusting the height of the spreader and looper

Spreader height

The clearance between the left spreader (forked spreader) and the eye looper must be set to match the thickness of the lower thread. The clearance between the right spreader and the right looper should be as small as possible while still letting the parts slide.

3071Q

1. The right spreader (1) and left spreader (2) move b y means of springs (3). Adjust s o that the spreaders move smoothly between the right s preader st opper ( 4), the left spreader stopper (5) and the L S- hold er br ac k et ( 6) , with no looseness.

2. If adjustment is necessary, loosen the screw (7) and then move the right spreader stopper (4) or left spreader stopper (5) up or down.

3072Q

Looper height

3073Q

1. Set the clearance between the e ye looper (8) and the left spreader (2) to the sam e distance as the thickness of the lower (looper) thread.

2. The clearance between the right looper (9) and the right spreader (1) should be as small as possible.

3. If adjustment is necessary, loosen the screw (10) and then move the eye looper (8) and right looper (9) up or down.

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9. STANDARD ADJUSTMENTS

9-2. Adjusting the needle and looper timing

The distance by which the needle bar rises from its lowest position to the position where the tip of the eye looper and the center of the needle are aligned should be the same as the distance from its lowest position to the position where the tip of the right looper and the center of the needle are aligned. Before adjusting the looper timing, first adjust the stitch width (needle racking width). * Refer to "Adjusting the needle racking width (stitch width)" on page 60. The standard width is 3 mm.

3075

Lowest position of needle bar

0952

When center of needle and

er tip are aligned

loo

3076

1. Move the needle bar to its lowest position.

2. Use calipers to measure the distance between th e end of the needle bar (1) and the top of the holder bas e (2)

when the needle bar is at its lowest position.

3. Turn the upper shaft pulley until the tip of the eye looper (4) and the center of the needle (3) are aligned when the

needle (3) is at the ins ide sewing position, a nd then us e the ca lipers to take the same meas urement as taken in step 2. Find the difference between the measurements taken in this step and in step 2.

4. Follow the same procedure as in step 3. above to find the difference between the two m easurements when the

needle (3) is at the outside sewing position.

* When the needle (3) is at the inside sewing position, the tip of the eye looper (4) should be aligned with the

center of the needle (3), and when the needle (3) is at the outside sewing position, the tip of the right looper (5) should be aligned with the center of the needle (3).

* The distance from the end of the needle bar (1) and the top of the holder base (2) should be the same when the

needle (3) is at both the inside sewing position and the outside sewing position.

3077Q

5. If adjustment is necessary, turn the looper base (6) in the direction indicated by the arrow in the illustration, loosen the screw (7), and then move the looper link c lamp (8) up or down to tilt the LS-holder brack et (9) to the left or right (in the direction of the arrow).

RH-981A

3078Q

Page 64

9. STANDARD ADJUSTMENTS

9-3. Adjusting the loop stroke

The loop stroke is the distanc e the needle bar r ises f rom its lowest position to the pos ition where t he tips of the e ye looper and right looper are aligned with the center of the needle. The standard loop stroke is 2.7 mm. (The loop stroke may need changing depending on the material and thread being used.) * Carry out the adjustment in "9-2. Adjusting the needle and looper timing" before making this adjustment.

2.7 mm

3079Q

1. In the same way as in "9-2. Adjusting the needle and looper tim ing", move the needle bar to its lo west position

with the needle at the inside se wing pos ition, and then use caliper s to m easure the dist ance between the end of the needle bar (1) and the top of the holder base (2).

2. Add 2.7 mm to the value obtained in step 1. above.

3. Touch the end of the calipers (A) against the top of holder base (2) , and then turn the upper shaf t pulle y until the

end of the needle bar (1) touches the e dge of the calipers (B). Chec k that the ti p of the eye looper is align ed with the center of the needle at this time.

4. In the same way, check that the tip of the right looper is aligned with the center of the needle when the needle is at

the outside sewing position.

3080Q

3081Q

5. If the tips of the loopers are not aligned with the center of the needle, carry out the adjustment below.

Raise the machine head. Loosen the two screws (3) of the lower shaft timing pulley, hold the upper shaft pulley so that it doesn't move, and then turn the lower shaft cam (4) in the direction indicated by the arrow until the tip of the eye looper (5) is aligned with the center of the needle (6). Once they are aligned, tighten the two screws (3). After adjusting, check that the screws have been adequately tightened. Once this adjustment has been carried out, repeat the pr ocedure given in "9-2. Adjusting the needle and looper timing".

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9. STANDARD ADJUSTMENTS

9-4. Adjusting the height of the needle bar

The standard height for the n eedle bar is 2.5 mm . (The needle bar height ma y need changing depending on the material and thread being used.)

2.5 mm

3082Q 3083Q

0961Q

1. Align the tip of the eye looper (1) with the center of the needle (2) when the needle (2) is at the inside sewing

position.

2. Remove the face plate.

3. Loosen the screw (3) of the needle bar clamp (5) and adjust the height of the needle bar (4). * After aligning the tip of the eye looper (1) with the top edge of the needle hole, lower the needle bar (4) 2.5 mm.

4. Adjust so that there is as little play as possible, and so that the needle bar clamp (5) and the needle bar level feed

link (6) can maintain their oil films. This will help to ensure that the needle bar turns smoothly.

9-5. Adjusting the clearance between the looper and needle

Be sure to carry out this adjustment after changing the size of the needle. The clearance between the tip of the looper and the needle should be 0.05 - 0.2 mm.

0.05 - 0.2mm

3084Q 0963Q

Loosen the looper screw (1) and then adjust the clearance. * This clearance must be uniform while the looper base is rotating (through 360

If the clearance is not uniform, adjust the turning center for the needle bar. (This adjustment is made at the time of

shipment from the factory.)

* After mak ing the adjustment in step 1. above, carr y out the adjustment procedure giv en in "9-7. Adjusting the

spreader mounting positions".

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Page 66

9. STANDARD ADJUSTMENTS

9-6. Adjusting the needle guard

Be sure to carry out this adjustment after changing the size of the needle. The needle must remain stationary with respect to the needle guard until the tip of the looper reaches the needle.

Loosen the screw (1) and th en move the needle guard (3) in the directions indicated by the arrows by an appropriate amount in accordanc e with the thickness of the needle (2).

Note: Adjust so that the looper clasps the upper

thread securely.

3085Q

9-7. Adjusting the spreader mounting positions

3086Q

1. Loosen the screw (3) and adjust the position of the left spreader stopper (4) so that the fork of the left spreader (1)

is aligned with the lower thread guide hole of the eye looper (2).

2. Loosen the screw (7) and adjus t the pos ition of the rig ht spreader stopp er ( 8) so that the tip of the right spreader

(5) is aligned with the tip of the right looper (6).

Note: Both the left spreader (1) and right spreader (5) should be installed so that they do not project past the tips

of the eye looper (2) and right looper (6) respectively.

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9. STANDARD ADJUSTMENTS

9-8. Adjusting the spreader timing

When the needle is at the inside sewing posit ion, the left s preader should touch the lef t spreader stopper and stop immediately before the needle bar reaches its lowest position. When the needle is at the outside sewing position, the right stopper should touch the right spreader stopper and stop immediately before the needle bar reaches its lowest position.

1. Raise the machine head.

2. Loosen the screw (1) and the nut (2), and then turn the adjusting screw (3) to adjust the spreader timing.

3. After adjusting, tighten the nut (2) and the screw (1).

3087Q

9-9. Adjusting the needle racking width (stitch width)

The needle racking width is set to 3 mm at the time of shipment from the factory.

0967Q

Needle racking width 1.5 - 3.2 mm

Becomes smaller

Becomes larger

3088Q

Loosen the needle racking adjus tment nut (1) and then adjust the needle rac king width by sliding the adjustm ent screw (2) vertically along the oval slot. The stitch width becomes smaller as the adjustment screw (2) is moved upward. Note: If the needle racking width is changed greatly, you should re-adjust the timing between the need le and the

loopers.

(Refer to "9-2. Adjusting the needle and looper timing".)

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Page 68

9. STANDARD ADJUSTMENTS

9-10. Changing the knife cutting length (Replacing the hammer)

Illustration (A)

3089Q

0970Q

1. Grind or replace the hammer after changing the knife cutting length.

2. Loosen the screw (1), and then remove the hammer (2). Because the knife c utting l ength is set in accordance with the length of the h am m er , grind the hammer as shown

in (A) in the above illustration. Hammer length A = Knife cutting length + 1.5 mm

3. When installing the hammer, push in the pin (3) and then tighten the screw (1).

* Do not use knives with different number s on the same hammer. If knives with different numbers are us ed,

accurate cutting will not be possible and the knife will be damaged.

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Page 69

9. STANDARD ADJUSTMENTS

9-11. Adjusting the contact between the knife and the hammer

1. Knife incision is correct

2. Knife incision is too dee

3. Two knife incisions

0971Q

4. Partial knife incision

3090Q

1. Remove the hammer. (Refer to the previous page.)

2. If the k nif e inc ision on t he s ur f ac e of the hammer is very deep, if there are t wo or mor e inc isions on the hammer because different knives were used, or if only part of the incision h as been made, grind the surface of the hamm er smoothl y until a si ngle k nife incision can still be seen faintly.

3. The c utting pr ess ur e over the whole of the hammer should be uniform so that the material will be cut cleanly. Grind the surface of the ham mer so that the knife incision will be uniform over the whole of the hammer.

* The hammer can be filed until its height is 19 mm.

4. If the material cannot be cut cleanly even though the hammer has been ground correctly, check whether the tip of the knife is worn.

* If the tip is worn, replace the knife.

Do not use the old hammer after the knife has been replaced, otherwise it m ay damage the tip of the knife.

Adjusting the contact between the knife and the hammer

To see the knife incision more easily, color the cutting surface of the hammer with a marker pen.

1. Operate the hammer three times with the knife making a mark on it each time.

2. Adjust the position of the hammer or contact between the knife and the hammer until the knife consistently makes a mark in the same place.

Filing the cutting surface of the hammer

Use a flat file for filing.

1. Filing the cutting surface of the hammer on which the knife incision breaks off or is shifted

1-1.Grip the hammer in a vise. 1-2. File the surface of the hammer smoothly until the knife incision is erased away.

2. Filing the cutting surface of the hammer in which knife incision is deep

2-1. Grip the hammer in a vise. 2-2. File the surface of the hammer smoothly until a single knife incision can still be seen faintly.

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Page 70

9. STANDARD ADJUSTMENTS

9-12. Replacing the knife

(L1 - L4)

3091Q

3092Q

1. After checking that there is no clearance bet ween the stopper plate (1) and the knife (2) , loosen the bolt (3) and then remove the knife (2).

2. Insert the new knife (2) into the stopper plate (1), and then tighten it with the bolt (3).

Note: For L1 - L4 specifications, secure the stopper plate (1) in the position closest to you (the position

indicated by the dotted lines).

* When replacing the knife (2), make sure that the knife number matches the number for the eyelet shape.

Replace the knife and hammer as a set. If knives with different numbers are used on the same hammer, accurate cutting will not be possible, and damage to the knife may result.

9-13. Adjusting the cutting pressure

Adjust the cutting pressure to the minimum pressure that still allows the material to be cut. * If the knife cutting length is 20 mm, sufficient cutting performance can be obtained with an air pressure of 0.2 MPa.

To adjust the cutting pressure, adjust the air pressure of the knife pressure adjustment regulator (1) which is mounted underneath the work table.

* If the cutting press ure is increased to more than is

necessary, it will cause the hammer to become worn or the knife to become damaged.

* If the material cannot be cut cleanly, do not increase

the cutting pressure over the m aximum lim it. Check the contact between the knife and the hammer, while referring to "9-11. Adjusting the contact between the knife and the hammer".

3093Q

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9. STANDARD ADJUSTMENTS

9-14. Adjusting the position of the work clamp plate

Adjust so that the throat plate (1) and the needle plate R (2) do not make contact during sewing. The standard clearance between the throat plate (1) and the needle plate R (2) is 1.3 mm (when the cutting space is set to 0).

Increase

1.3mm

Decrease

3094Q

3095Q

1. Use the parameter settings to set the cutting space to "0".

2. Select the test feed mode, and press the start switch.

3. Keep pressing the start switch, and m ake sure that the clearance between the throat plate (1) and the needle

plate R (2) is 1.3 mm.

4. If the clearance is not 1.3 mm, loosen the nut (3), and turn the bolt (4) to adjust the clearance.

Note: Adjust the clearance between the throat plate (1) and the needle plate L in the same manner.

* If the maximum stitch width cor rection am ount is set to 2.0 mm, adjust the distance bet ween the throa t plate and

the needle plate to more than 2.0 mm.

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9. STANDARD ADJUSTMENTS

9-15. Adjusting the cloth opening amount

3096Q

3097Q

1. Loosen the screw (1), and then inser t a screwdriver into the notch in the side of the feed bracket and turn the adjusting screw (2) to adjust the opening amount.

2. After tightening the screw (1), measure the opening amount. Note: Adjust so that the opening amounts for the left and right work clamp plates are equal.

* It is usually sufficient for one work clamp plate to open by 0.8 mm.

Measuring the opening amount

3098Q

1. Switch the mode to test feed mode. (Refer to page 50.)

2. Lower the work clamp and then use calipers to measure the distance a.

3. Press the start switch. The feed bracket will move and then the left and right work clamp plates will open.

4. Use calipers to measure the distance b.

5. The difference between a and b is the opening amount. (Opening amount = a - b)

3099Q

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Page 73

9-16. Adjusting the trimming of the upper thread

The upper thread should be trimmed at the correct time after sewing is completed.

<-00, -01> Adjust so that the upper movable knife (1) cuts only one of the threads in front of the right looper (2). Note: If both strands of the thread loop are cut, the

thread remaining in the needle m ay become too short and skipped stitches may result.

3100Q

<-02,-52> Adjust so that the upper movable knife (3) cuts only one of the threads in front of the right looper (4). Note: If both strands of the thread loop (forward and

back) are cut, the thread remaining in the needle may become too short and skipped stitches may result .

9. STANDARD ADJUSTMENTS

3101Q

9-17. Adjusting the trimming of the lower thread and gimp

<-00, -01> The lower thread and gim p should be trim med at the corr ect time after the feed bracket has returned to the home position. Thread trimming operation can b e checked in steps while manual m ode is active. (Refer to “7-8. Using manual mode”.)

3102Q

1. The mechanism is adj usted so that the lo wer thread and gim p are separated f rom each other and spread b y the thread handler (1).

2. The lower thread is held between thread nipper M (2) and thread nipper D (3) on the plate spring.

The gimp is held between thread nipper M (2) and thread nipper U (4) on the plate spring.

3. Adjust so that the edge of the fixed knife (6) and the index mark (8) on the movable knife (7) are aligned when the thread trimmer arm (5) is at the maximum stroke.

3103Q

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Page 74

9. STANDARD ADJUSTMENTS

<-02,-52> The lower thread and gimp should be trimm ed at the correct time after the work clamps rise at the feed hom e position. Thread trimming operation can b e checked in steps while manual m ode is active. (Refer to “7-8. Using manual mode”.)

1. The mechanism is adjusted so that the lower thread and gimp are spread by the thread handler (1).

2. The movable knife driving cam (2) operates, and the right movable knife (3) and left movable knife (4) mesh and the thread is cut.

3104Q

9-18. Adjusting the gimp length after trimming

(-02, -52 specifications)

Approx. 4 mm

3105Q

Becomes shorter

Becomes longer

Adjust so that approxim ately 4 mm of the gimp thr ead is coming out from the throat plate (1).

1. Loosen the screw (2) and move the gimp thread guide J (3) in the direction of the arrow to adjust the length.

9-19. Lower thread presser (-02, -52 specifications)

The lower thread presser (1) operates at the same time as upper thread trimming is carried out. The end of the lower thread is securely held bet ween the lower thread presser (1) and the throat plate (2).

3106Q

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Page 75

9. STANDARD ADJUSTMENTS

9-20. Auxiliary clamp arm (-02, -52 specifications)

Trimming of the lower thread and gimp is c arried out when the work clamps rise. The auxiliary clamp arm (1) endures that the material does not move during thread trimming, in order to maintain a stable thread length after trimming.

3107Q

9-21. Adjusting the cloth feeding speed (-52 specifications)

Becomes slow er

Becomes slower

Approx.

9.6 mm

Becomes faster

Maximum height (approx. 11.6 mm)

Approx.

9.1 mm

3108Q

Turn the A-side needle valve (1) or B-side needle valve (2) to adjust the cloth feeding speed. Note: The cloth feeding speed is adjusted to an

appropriate speed at the time of shipment from the factory, and should not be change d unnecessarily.

At the time of shipment

A- side needle valve

At a height of approximately 9.6 mm from the surface of the valve body (turned 6 full rotations from the maximum height)

B- side needle valve

At a height of approximately 9.1 mm from the surface of the valve body (turned 7 full rotations from the maximum height)

3109Q

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9. STANDARD ADJUSTMENTS

9-22. Adjusting the cloth feed bar home position (-52 specifications)

The cloth feed bar home position is adjusted by means of the bolt which is installed to feed base L. After carrying out this adjustment, adjust the installation position for limit switch (R). (Refer to page 71.)

3110Q

1. Loos en the nut (1) and then turn the bolt (2) so that

it moves to the left.

2. Pull the cylinder rod (4) of the cylinder (3) as far to

the right as it will go.

3. Insert the pin (5) into the home position hole (7)

(refer to page 70) in the cloth feed bar (6).

4. T urn the bolt (2) to move it to th e right until it gent ly

touches the cloth feed bar (6)

5. Tighten the nut (1) to secure the bolt (2) in position.

6. Check that the pin (5) fits smoothly into the home

position hole (7) when the cloth feed bar (6) is touching the bolt (2).

* If the pin (5) is not fitting smoothly, repeat the

procedure in steps 1. to 5.

3111Q

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9. STANDARD ADJUSTMENTS

9-23. Adjusting the indexer hole spacing (-52 specifications)

Before carrying out this adjustment, check that the home position adjustment for the cloth feed bar has been carried out correctly. (Refer to page 69.)

Standard

Home position hole

Large size

Home position hole

3112Q

3113Q

1. Loosen the bolt (1).

2. Push the cloth feed bar (2) against the bolt (3).

3. Move the feed movable block (4) so that the pin (5) goes sm oothly into the indexer holes (38. 1 mm - (A), 44.45 mm - (B), 50.8 mm - (C), 57.15 mm - (D)).

4. Place the stopper block (6) firmly against the feed m ovable block (4), and then tig hten the bolt (1) to secure it in place.

Using the set screw collar

Using the set screw collar m akes it eas y to change between two different hole s pacing settings . The right-han d set screw collar can be used to set the smaller hole spacing, and the left-hand screw collar can be used to set the larger hole spacing.

3114Q

Example: For spac ing of 38.1 mm (1-1/2”) and 44.45

mm (1-3/4”)

1. set the hole spacing to 38.1 mm (1-1/2”).

2. Place the right-hand set screw collar (1) against the stopper block (2), and then secure it by tightening the screw (3).

<38.1 mm>

<44.45 mm>

3115Q

RH-981A

3. Set the hole spacing to 44.45 mm (1-3/4”).

4. Place th e left-hand set screw collar (4) agains t the stopper block (2), and then secure it by tightening the screw (5).

5. F rom now on, if you want to have hole intervals of

38.1 mm (1-1/2”), move the stopper block (2) so that it is against the right-hand s et screw collar (1) and secure it in this position, and if you want to have hole intervals of 44.45 mm (1-3/4”), move the stopper block (2) so that it is against the left-hand set screw collar (4) and secure it in this position.

Use the same setting method if using other combinations of different hole intervals.

Page 78

9. STANDARD ADJUSTMENTS

9-24. Adjusting the position of limit switch L (-52 specifications)

Limit switch L must turn on when the feed movable block is touching the stopper block.

3116Q

1. Loosen the two bolts (1).

2. Place the feed movable block (2) and the stop block (3) firmly against each other.

3. Adjust the position of the switch setting plate (7) so that limit switch L (4) turns on when the roller (5) is pressed by the dog (6) of the feed movable block (2).

4. Tighten the two bolts (1).

9-25. Adjusting the position of limit switch R (-52 specifications)

Limit switch R must turn on when the cloth feed bar is at the left setting position.

3117Q

1. Loosen the two screws (1).

2. Move the cloth feed bar (2) to the left setting position.

3. Adj ust the position of f eed bar guide R ( 7) so that lim it switch R (3) turns on when the r oller (4) is pres sed b y the

dog (6) of cloth feed plate R (5).

4. Tighten the two screws (1).

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Page 79

10. CHANGING FUNCTIONS USING THE MEMORY SWITCHES

The memory switches are valid for all programs.

1. Press the SELECT key (1) to change the mode to program or cycle program mode.

2. While pressing the ENTER key (2), press the key.

* The program mode indicator (3) and the cycle program mode indicator (4) will illuminate. * The memory switch num ber "00" will appear in the progr am num ber displa y (5), and the m em ory switch s etting

will appear in the detail display (6).

3. Press the keys to select the number for the memory switch to be changed.

4. Press the keys to change the memory switch setting.

* The memory switch setting will flash while it is being changed.

5. Press the ENTER key (2) to accept the new setting.

*The memory switch setting will stop flashing.

6. Repeat steps 3 to 5 to change other memory switch settings.

7. Press the SELECT key (1) to change the mode to automatic mode.

*The memory switch settings will be memorized.

3118Q

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10. CHANGING FUNCTIONS USING THE MEMORY SWITCHES

10-1. Memory switch table

The memory switch settings are applied immediately to all programs once the settings have been changed. However, memory switches marked with * are only applied after the power is turned on.

No. Setting items Setting range Unit Default

00. Cloth presser down oper atio n when f eed br ac ket is forward

01. Cloth presser stays down after sewing OFF, ON - OFF

02. Number of home position start cycles (Note 1) OFF, 1 - 9 1 1

03. Cutting block ON time 25 - 200 ms 25 ms 25 ms

04.

05.

06. Test feeding deceleration speed OFF, 1 - 4 1 OFF

07. Increased amount of upper thread remaining OFF, 1 - 3 1 OFF

08. Stitch length display in automatic mode OFF, ON - OFF

09.* Max. stitch length of L7 40 mm, 42 mm 2 mm 40 mm

10. Feed timing correction -10 - 10 1 0

11.* Number of eyelet buttonholes when fly indexer is

Timer for checking raising of hammer (Timer for determining if the cuttin g bl oc k has been raised to a position where it will not touch t he next feed bracket to operate)

Feed operation timing correction after hammer is raised (After checking that the hammer is raised, the timer interval is added so that the hammer and feed bracket do not touch.)

used

OFF, ON - OFF

OFF (Determined from number of slit signals),

200 - 500 ms 0 - 150 ms 25 ms 0

OFF (Fly indexer is not used),1 - 9

50 ms OFF

12.* Cloth setting position when fly indexer is used 1: Left setting position

2: Horizontal setting

position

13. Program number selected when buttonhole sensor is ON when using the special lapel cutting device

14. Program number for operating the straight

buttonhole hammer regardless of eyelet shape setting (parameter No. 01) and whether the buttonhole sensor is ON or OFF (Note 2)

(Note 1) If home position s tarting is not carried out for each piece of material, there is the danger that the feed

bracket may become overloaded for some reason and come off, which will affect the next piece to be sewn. Accordingly it is recommended that you set home position starting to be carried out each time (setting "1").

(Note 2) If a program number has been set for memory switch No. 13, it will be ignored if a program number has

been set for memory switch No. 14.

OFF, 1 - 9 1 OFF

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11. CHANGING FUNCTIONS USING THE DIP SWICHES

11. CHANGING FUNCTIONS USING THE DIP SWITCHES

Always turn off the power supply before changing any of the DIP switch settings.

11-1. Panel DIP switches

The ON/OFF positions of the DIP switches inside the operation panel ar e checked only once when the power is turned on. Any changes to the DIP switch positions will not be effective until the power is switched off and back on again.

No. ON/OFF Setting items Default

ON Program mode disabled

8**

OFF Program mode enabled

OFF Normal

ON Set the feed bracket to the front position

OFF Set the feed bracket to the back position

ON -

OFF -

ON Single-pedal operation

OFF Dual-pedal operation

ON -

OFF -

ON -

OFF -

ON Maximum stitch width correction amount = 2.0 mm

OFF Maximum stitch width correction amount = 1.0 mm

Switches between taper bar ←→ straight bar tacking

OFF

2425Q

* If program mode is disabled, operation becomes as follows.

• Program numbers, knife operations and the production counter cannot be changed.

• The modes change in the order Automatic → Test feed → Manual → Automatic.

** If the m aximum stitch width corr ection amount is set to 2.0 mm, carr y out the adjustment in "9-14. Adjusting the

position of the work clamp plate". If this adjustment is not carried out, the throat plate and needle plate may interfere with each other. If the stitch width correction am ount is set to m ore than 1.0 mm , the sewing speed will be l imited in acc ordance with the value set.

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11. CHANGING FUNCTIONS USING THE DIP SWICHES

11-2. Circuit board DIP switches

Wait at least 5 minutes after turning of f the power switch and disconnecting the power cord f rom the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury.

The ON/OFF positions of the DIP switc hes inside the control box are checked only onc e when the power is turne d on. Any changes to the DIP switch positions will not be effective until the power is switched off and back on again.

DANGER

Circuit board DIP switch C

2426Q

No. ON/OFF Setting items Default

ON Special lapel cutting device enabled

* If the maximum straight bar tack ing length is set to 9.0 mm, it will be necess ary to proces s the work c lam p plate.

Consult with your local Brother sales office for further details. If the work clam p plate is not proc essed, the thr oat plate may interfere with the needle plate and work clamp plate.

OFF Special lapel cutting device disabled

ON Button hole sensor of special lapel cutting device enabled

OFF Button hole sensor of special lapel cutting device disabled

ON With pressure sensor

OFF Without pressure sensor

ON -

OFF -

ON Upper thread nipper enabled

OFF Upper thread nipper disabled

ON Lower thread trimming enabled

OFF Lower thread trimming disabled

ON -

OFF -

ON Maximum straight bar tacking length = 9.0 mm

OFF Maximum straight bar tacking length = 6.0 mm

OFF

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Page 83

Circuit board DIP switch D

11. CHANGING FUNCTIONS USING THE DIP SWICHES

1001Q

No. ON/OFF Setting items Default

ON -

OFF -

OFF

ON -

OFF -

OFF

ON -

OFF -

OFF

ON -

OFF -

OFF

ON -

OFF -

OFF

ON -

OFF -

OFF

ON -

OFF -

OFF

ON -

OFF -

OFF

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Page 84

12. LIST OF ERROR CODES

DANGER

When an error occurs, the warning indicator and the error code display flash and the buzzer sounds.

Errors after power is turned on

Code Explanation R ese tti ng me tho d

1. Release the EMERGENCY STOP switch.

E-00 EMERGENCY STOP switch was pressed.

E-02 Machine head is tilted back.

E-03 Cloth presser switch was pressed.

E-04 Start switch was pressed.

E-05 Air pressure is insufficient.

E-06 Feed plate home position sensor is OFF.

E-07

E-09

E-10

E-12

E-15

E-26

E-27 External RAM error Turn off the power.

E-28 Panel communication start error

E-29 Machine motor communication start erro r Turn off the power.

Feed plate left range sensor is OFF.

Specification that machine does not support is set.

Needle bar is not at the highest position.

Cutter sensor is ON.

Lower thread trimming OFF sensor is OFF.

PER terminal connection error

2. If an error still occurs after 1. is carr ie d o ut, ch ec k that connector P3 on the control circuit board is properly connected.

1. Turn off the power.

2. Return the machine head to its origina l positi on.

3. If an error still occurs after 1. is carr ie d o ut, ch ec k that connector P8 on the control circuit board is properly connected.

1. Release the cloth presser switch.

2. If an error still occurs after 1. is carr ie d o ut, ch ec k that connector P19 on the control circuit board is pro perly connected.

1. Release the start switch.

2. If an error still occurs after 1. is carr ie d o ut, ch ec k that connector P19 on the control circuit board is pro perly connected.

1. Turn off the power.

2. Check the air pressure.

3. Check that connector P1 on the control circuit board is properly connected.

1. Move the cloth feed bar to the left so that the feed plate home position sensor turns ON.

2. If an error still occurs after 1. is carr ie d o ut, ch ec k that connector P9 on the control circuit board is properly connected.

Turn off the power and check that connector P9 on the control circuit board is properly connected.

1. Turn off the power.

2. Check the specification harness and PROM.

3. Check that connector P26 on the c ont rol circ uit bo ard is properly connected.

1. Turn the pulley by hand to raise the needle bar to its highest position.

2. If an error still occurs after 1. is carr ie d o ut, ch ec k that connector P2 on the control circuit board is properly connected.

Turn off the power and check that connector P3 on the control circuit board is properly connected.

Turn off the power and check that connector P8 on the control circuit board is properly connected.

1. Turn off the power.

2. Check that connector P20 on the c ont rol circ uit bo ard is properly connected.

3. Check that connector P2 on the power supply circuit board is properly connected.

1. Turn off the power.

2. Check that connector P18 on the c ont rol circ uit bo ard is properly connected.

3. Check that connector P1 on the panel circuit board is properly connected.

RH-981A

Page 85

12. LIST OF ERROR CODES

Errors before operation and after the EMERGENCY STOP switch is pressed

Code Explanation Resetting method

E-30

E-32 Machine head is tilte d bac k. E-35 Air pressure is insufficient. Turn off the power and check the air pressure. E-36

E-37

E-38

E-40

E-42 Cutter sensor is ON.

E-45 Lower thread trimming OFF sensor is OFF.

E-50

E-51

EMERGENCY STOP switch was pressed.

Feed plate home position sensor is OFF when it should be ON.

Feed plate left range sensor is OFF when it should be ON.

Feed plate right range sensor is OFF when it should be ON.

Needle up sensor is OFF when it should be ON.

X home position sensor is OFF when it should be ON.

Y home position sensor is OFF when it should be ON.

Release the EMERGENCY STOP switch and then press the RESET key.

Turn off the power and return the machine head to its original position.

Turn off the power and check that connector P9 on the control circuit board is properly connected.

Turn the pulley by hand to raise the needle bar to its highest position, and then press the RESET key.

Turn off the power and check that connector P3 on the control circuit board is properly connected.

Turn off the power and check that connector P8 on the control circuit board is properly connected.

Turn off the power and check that connector P1 on the control circuit board is properly connected.

E-52

Code Explanation Resetting method

E-59 Sewing data error Turn off the power and initialize the data.

Code Explanation Resetting method

E-60 EMERGENCY STOP switch was pressed.

E-62

E-66

E-67

E-68

E-70

θ home position sensor is OFF when it should be ON.

Errors during operation

Machine head is tilted back. (Head sensor is OFF.)

Feed plate home position sensor is not activated within a specified time.

Feed plate left range sensor is not activated within a specified time.

Feed plate right range sensor is not activated within a specified time.

Needle up sensor is not activated within a specified time.

Turn off the power and check that connector P9 on the control circuit board is properly connected.

Data errors

Release the EMERGENCY STOP switch and then press the RESET key.

Turn off the power and return the machine head to its original position.

Turn off the power and check that connector P9 on the control circuit board is properly connected.

1. Turn off the power.

2. Check that air is reaching the valve.

3. Check that connector P9 on the control circuit board is properly connected.

1. Turn off the power.

2. Check that air is reaching the valve.

3. Check that connectors P9 and P21 on the control circuit board are properly connected.

Turn off the power and check that connector P2 on the control circuit board is properly connected.

RH-981A

Page 86

12. LIST OF ERROR CODES

Errors during operation

Code Explanation Resetting method

E-71

E-72

E-75

E-76

E-77

E-80

E-81

E-82

E-89 Machine motor reverse operation error

Needle down sensor is not activated within a specified time.

Cutter sensor is not activated within a specified time.

Lower thread trimming OFF sensor is not activated within a specified time.

Needle up sensor is OFF during test feeding. Synch signal is not activated within a

specified time. X home position sensor is not set to ON

within a specified time of searching home position.

Y home position sensor is not set to ON within a specified time of searching home position.

θ home position sensor is not set to ON within a specified time of searching home position.

Turn off the power and check that connector P2 on the control circuit board is properly connected.

1. Turn off the power.

2. Check that air is reaching the valve.

3. Check that connectors P3 and P4 on the control circuit board are properly connected.

1. Turn off the power.

2. Check that air is reaching the valve.

3. Check that connector P8 on the control circuit board is properly connected.

Turn off the power and turn the pulley by hand to raise the needle bar to its highest position.

Turn off the power and check that connector P2 on the control circuit board is properly connected.

Turn off the power and check that connector P7 on the control circuit board is properly connected.

Turn off the power and check that connector P6 on the control circuit board is properly connected.

1. Turn off the power.

2. Check that connectors P11 and P13 on the control circuit board are properly connected.

3. Check that connectors P1, P2 and P3 on the θ axis PMD circuit board are properly connected.

Turn off the power and check that the motor cord is properly connected.

Hardware errors

Code Explanation Resetting method

1. Turn off the power.

E-90

E-91 Machine motor running error

E-92 Abnormal voltage error

E-93

E-94 Fan (small) lock error

E-95 X motor overcurrent error

E-96 Y motor overcurrent error

E-97 Control circuit board temperature rise error

E-98 Power supply relay error

E-99 Power supply circuit board overcurrent error

Communication error (against machine motor CPU)

Fan (large) lock error

2. Check that connector P18 on th e cont rol c irc uit board is properly connected.

3. Check that connector P1 on the panel circuit board is properly connected.

Turn off the power and check that connector P2 on the control circuit board is properly connected.

1. Turn off the power.

2. Check that the power supply voltage matches the rated voltage.

3. Check that connector P20 on th e cont rol c irc uit board is properly connected.

Turn off the power and check that connector P10 on the control circuit board is properly connected.

Turn off the power and check that connector P25 on the control circuit board is properly connected.

Turn off the power and check that connector P7 on the control circuit board is properly connected.

Turn off the power and check that connector P6 on the control circuit board is properly connected.

Turn off the power and check that the inside of the control box is being properly ventilated.

Turn off the power and check that connector P20 on the control circuit board is properly connected.

Turn off the power and check that connectors P12 and P13 on the control circuit board are properly connected.

RH-981A

Page 87

13. TROUBLESHOOTING

If there is a problem with operation, first check that the threads are correctly threaded and that the needle is correctly installed.

CAUTION

Turn off the power switch and disconnect the power cor d before carrying out troubleshooti ng, otherwise the machine will operate if the start switch is pressed by mistake, which could result in injury.

MACHINE HEAD

Problem Cause Remedy Page

Thread breaks.

Skipped stitches occur.

Thread tension control nut pressure is too strong.

Thread is of poor quality. Use a better-quality thread. Thread is too thick for the

needle. Needle groove or needle hole

are not smooth.

Needle and looper adjustment is incorrect.

Needle, looper, throat plate or thread path is damaged.

Thread tension control nut pressure is too strong or too weak.

Needle point is broken or bent. Replace with a new needle. 28

Adjust to an appropriate pressure.

Use a differently-size needle.

Replace with a new needle. 28

Adjust the needle bar height or the looper and spreader height.

Repair the damage with an oilstone or buffer, or replace the damaged part.

Adjust to an appropriate pressure.

Needle breaks.

Needle and looper adjustment is incorrect, or clearance is incorrect.

Needle and needle guard adjustment is incorrect.

Looper tip is blunt.

Needle is bent. Replace with a new needle. 28 Needle and looper adjustment is

incorrect. Needle and needle guard

adjustment is incorrect.

RH-981A

Adjust correctly. 56

Adjust correctly. 59 Repair with an oilstone or

replace the looper with a new one.

Adjust the needle bar height or the looper and spreader height.

Adjust correctly. 59

Page 88

13. TROUBLESHOOTING

Problem Cause Remedy Page

Upper thread is not cut.

Lower thread is not cut.

Knife is blunt. Replace with a new knife. 63 Knife does not move to the full

stroke because air pressure is

Adjust the air pressure. 63

too weak.

Upper thread trimmer knife is not picking up the upper thread.

Movable knife is not picking up the needle thread because the last stitch is being skipped.

Movable knife position is incorrect.

Install the upper thread trim mer knife so that it cuts only one side of the upper thread loop.

Refer to the remedies given under “Skipped stitches occur” in this troubleshooting chart.

Adjust the position of the movable knife or the loop spreader.

66, 67

Knife is blunt. Replace with a new knife. 63 Knife does not move to the full

stroke because air pressure is

Adjust the air pressure. 63

too weak. Movable knife position is

incorrect.

Adjust the position of the movable knife or the loop spreader.

66, 67

Thread slips out of the needle at the sewing start.

Material is not being cut cleanly.

Thread nipper spring force is too weak.

Upper thread length is too short after trimming.

Needle and looper adjustment is incorrect.

Not enough upper thread is being fed out.

Cutting pressure is too weak.

Knife and hammer are not contacting properly.

Adjust the force of the thread nipper spring.

66, 67

Install the upper thread trim mer knife so that it cuts only one side

of the upper thread loop. Adjust the needle bar height or

the looper and spreader height. Adjust the amount of upper

thread being fed out. Adjust the cutting pressure so

that it is strong enough.

Grind the hammer surface. 62

Knife is blunt. Replace with a new knife. 63

RH-981A

Page 89

INSTRUCTION MANUAL

Printed in Japan

118-981

SA0279-101

2003.01.H (1)

Brother rh-918a User Manual

SAFETY INSTRUCTIONS

Safety indications and their meanings

Notes on safety

3. W a rnin g lab e ls

CONTENTS

1. NAMES OF EACH PART

2. SPECIFICATIONS

2-1. Specifications

2-2. Sewing shape

2-3. Optional parts

2-4. PD-9810, Programmer

2-5. Replacement parts list for specification changes

3. INSTALLATION

3-1. Table processing diagram

3-2. Installing the motor

3-3. Installing the motor pulley

3-4. Installing the control box

3-5. Installing the machine head

3-6. Installing the oil container

3-7. Installing the operation panel

3-8. Tightening the V-belt

3-9. Installing the spool stand

3-10. Installing the hand switch

3-11. Installing the air unit and the valve unit

3-12. Connecting the wiring

3-12-1. Connections inside the control box

3-12-2. Connecting the motor cables

3-12-3. Connecting the air tubes

3-12-4. Securing the cables

3-13. Installing the air tubes

3-13-1. Adjusting the air pressure

3-14. Connecting the power cord

3-15. Installing the programmer (sold separately)

3-16. Installing the foot switch (option)

3-17. Installing the indexer (option)

3-17-1. Installing the indexer main unit

3-17-2. Installing the upper thread presser

3-17-3. Replacing the plate presser and presser plate

3-17-4. Installing the valve unit

3-17-5. Connecting the connectors

3-17-6. Connecting the air tubes

3-17-7. Securing the air tubes and cables

3-17-8. Installing the hand switch

4. LUBRICATION

4-1. Adding oil

4-2. Lubrication

5. CORRECT USE

5-1. Data initialization

5-2. Changing the lower thread and gimp trimming

5-3. Installing the needle

5-4. Threading the upper thread

5-5. Threading the lower thread

5-6. Threading the gimp

5-7. Setting the material

5-9. Replacing the PROMs

6. OPERATION

6-1. Name and function of each operation panel item

6-2. Starting up

6-3. Program setting method

6-3-1. Parameter table ( Taper bar )

6-3-2. Parameter table ( Straight bar tacking )

6-4. Cycle program

6-5. Production counter

6-6. Using the program memos

7. SEWING

7-1. Automatic sewing

7-2. Using the EMERGENCY STOP switch

7-3. Adjusting the thread tension

7-4. Needle and knife position

7-5. Setting the feed bracket to the front position

7-6. Switching between single-pedal and dual-pedal operation

7-7. Using test feed mode

7-8. Using manual mode

7-9. Changing the mode during an operation

7-10. Moving the cloth feed bar (-52 specifications)

8. CLEANING AND MAINTENANCE

8-1. Cleaning

8-2. Draining the oil

8-3. Checking the air filter