Brother S-6200A Instruction Manual

INSTRUCTION MANUAL

S-6200A

Please read this manual before using the machine. Please keep this manual within easy reach for quick reference.

SINGLE NEEDLE STRAIGHT LOCK STITCHER WITH THREAD TRIMMER

Thank you very much for buying a BROTHER sewing machine. Before using your new machine, please read the safety instructions and the explanations given in the instruction manual.

With industrial sewing machines, it is normal to carry out work while positioned directly in front of moving parts such as the needle and thread take-up, and consequently there is always 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.

S-6200A

SAFETY INSTRUCTIONS

[1] Safety indications and their meanings

This instruction manual and the indications and symbols that are used on the machine itself are provided in order to ensure safe operation of this machine and to prevent accidents and injury to yourself or other people. The meanings of these indications and symbols are given below.

Indications

DANGER

CAUTION

Symbols

· · · · ·

The instructions which follow this term indicate situations where failure to follow the instructions will result in death or serious injury.

The instructions which follow this term indicate situations where failure to follow the instructions could cause injury when using the machine or physical damage to equipment and surroundings.

This symbol ( ) indicates something that you should be careful of. The picture inside the triangle indicates the nature of the caution that must be taken. (For example, the symbol at left means “beware of injury”.)

This symbol ( ) indicates something that you must not do.

This symbol ( ) indicates something that you must do. The picture inside the circle indicates the nature of the thing that must be done. (For example, the symbol at left means “you must make the ground connection”.)

S-6200A

i

[2] Notes on safety

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

DANGER

CAUTION

Environmental requirements

Use the sewing machine in an area which is free from sources of strong electrical noise such as electrical line noise or static electric noise. Sources of strong electrical noise may cause problems with correct operation.

Any fluctuations in the power supply voltage should be within ±10% of the rated voltage for the machine. Voltage fluctuations which are greater than this may cause problems with correct operation.

The power supply capacity should be greater than the requirements for the sewing machine's power consumption. Insufficient power supply capacity may cause problems with correct operation.

Machine installation should only be carried out by a qualified technician.

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

The sewing machine weighs approximately 38 kg (84lb). The installation should be carried out by two or more people.

Do not connect the power cord until installation is complete. The machine may operate if the treadle is depressed by mistake, which could result in injury.

Turn off the power switch before inserting or removing the plug, otherwise damage to the control box could result.

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.

When securing the cords, do not bend the cords excessively or fasten them too hard with staples, otherwise there is the danger that fire or electric shocks could occur.

The ambient temperature should be within the range of 5°C to 35°C during use. Temperatures which are lower or higher than this may cause problems with correct operation.

The relative humidity should be within the range of 45% to 85% during use, and no dew formation should occur in any devices. Excessively dry or humid environments and dew formation may cause problems with correct operation.

In the event of an electrical storm, turn off the power and disconnect the power cord from the wall outlet. Lightning may cause problems with correct operation.

Installation

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

Secure the table so that it will not move when tilting back the machine head. If the table moves, it may crush your feet or cause other injuries.

Use both hands to hold the machine head when tilting it back or returning it to its original position. If only one hand is used, the weight of the machine head may cause your hand to slip, and your hand may get caught.

Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhea. Keep the oil out of the reach of children.

ii

S-6200A

CAUTION

Sewing

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

The sewing machine should not be used for any applications other than sewing.

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

Turn off the power switch at the following times. The machine may operate if the treadle is depressed by mistake, which could result in injury.

y When threading the needle y When replacing the bobbin and needle y When not using the machine and when leaving

the machine unattended

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

Turn off the power switch before carrying out cleaning. The machine may operate if the treadle is depressed by mistake, which could result in injury.

Secure the table so that it will not move when tilting back the machine head. If the table moves, it may crush your feet or cause other injuries.

Use both hands to hold the machine head when tilting it back or returning it to its original position. If only one hand is used, the weight of the machine head may cause your hand to slip, and your hand may get caught.

Attach all safety devices before using the sewing machine. If the machine is used without these devices attached, injury may result.

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

Secure the table so that it will not move when tilting back the machine head. If the table moves, it may crush your feet or cause other injuries.

Use both hands to hold the machine head when tilting it back or returning it to its original position. If only one hand is used, the weight of the machine head may cause your hand to slip, and your hand may get caught.

If an error occurs in machine operation, or if abnormal noises or smells are noticed, immediately turn off the power switch. Then contact your nearest Brother dealer or a qualified technician.

If the machine develops a problem, contact your nearest Brother dealer or a qualified technician.

Cleaning

Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhea. Keep the oil out of the reach of children.

Use only the proper replacement parts as specified by Brother.

Maintenance and inspection

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

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

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

y When carrying out inspection, adjustment and

maintenance

y When replacing consumable parts such as the

rotary hook

Always be sure to turn off the power switch and then wait one minute before opening the motor cover. If you touch the surface of the motor or the motor bracket, it may cause burns.

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

S-6200A

Secure the table so that it will not move when tilting back the machine head. If the table moves, it may crush your feet or cause other injuries.

Use both hands to hold the machine head when tilting it back or returning it to its original position. If only one hand is used, the weight of the machine head may cause your hand to slip, and your hand may get caught.

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

[3] Warning labels

The following warning labels appear on the sewing machine. Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are difficult to read, please contact your nearest Brother dealer.

1

2

3

Touching areas where high voltages are present can result in severe injury. Turn off the power before opening the cover.

4

5

Be careful not to get your hands caught when returning the machine head to its original position after it has been tilted.

Be careful to avoid injury from the moving thread take-up.

* Safety devices: (A) Finger guard (C) Pulley cover

(B) Thread take-up cover (D) Motor cover

Oil pan

Control box

6

7

8

Transformer box (100 V/400 V system only)

High temperature warning display

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.

Direction of operation

1952B

iv

S-6200A

CONTENTS

1. MACHINE SPECIFICATIONS................ 1

2. NAMES OF MAJOR PARTS .................. 2

3. INSTALLATION.......................................... 3

3-1. Table processing diagram .............................. 4

3-2. Installation ...................................................... 4

3-3. Lubrication ...................................................... 8

3-4. Connecting the cords...................................... 9

3-4-1. Opening the control box cover............ 9

3-4-2. Connecting the cords .......................... 10

3-5. Test operation (Operating the treadle) ........... 14

3-6. Adjusting the treadle operation....................... 15

4. PREPARATION BEFORE SEWING ....16

4-1. Installing the needle........................................ 16

4-2. Removing the bobbin case............................. 16

4-3. Winding the lower thread................................ 17

4-4. Installing the bobbin case............................... 18

4-5. Threading the upper thread............................ 19

4-6. Adjusting the stitch length............................... 20

4-7. Using the thread wiper (-40[] specifications)... 20

4-8. Using the knee lifter........................................ 20

5. USING THE G1A OPERATION PANEL

(BASIC OPERATIONS)............................ 21

5-1. Names and functions...................................... 21

5-2. Sewing start and end backtack stitches ......... 22

5-3. Sewing continuous backtack stitches............. 23

6. USING THE G1A OPERATION PANEL

(ADVANCED OPERATIONS) ................ 24

6-1. Changing the needle stop position ................. 24

6-2. Slow start........................................................ 25

6-3. Correction sewing........................................... 26

6-4. Thread trimming lock...................................... 27

6-5. Setting the maximum sewing speed............... 28

6-6. Adjusting the needle up stop position............. 29

6-7. Lock function .................................................. 30

6-8. Resetting all settings to their defaults............. 30

8. USING THE G5A OPERATION PANEL

(ADVANCED OPERATIONS).................39

8-1. Names and functions ......................................39

8-2. Adjusting the needle up stop position .............40

8-3. LOCK key........................................................41

8-4. Resetting all settings to their defaults .............42

9. SEWING.........................................................43

9-1. Sewing ...............................................................43

9-2. Backtacking.....................................................43

10. THREAD TENSION....................................44

10-1. Adjusting the thread tension .........................44

10-2. Adjusting the presser foot pressure ..............45

10-3. Adjusting the trailing length after thread

trimming ........................................................45

11. CLEANING....................................................46

12. REPLACING THE FIXED KNIFE

AND MOVABLE KNIFE............................48

13. STANDARD ADJUSTMENTS ................49

13-1. Adjusting the safety switch position ..............49

13-2. Adjusting the thread take-up spring ..............50

13-3. Adjusting arm thread guide R .......................50

13-4. Adjusting the presser foot height ..................51

13-5. Adjusting of the feed dog height ...................52

13-6. Adjusting the feed dog angle ........................52

13-7. Adjusting the needle bar height ....................53

13-8. Adjusting the needle and feed

mechanism timing .........................................53

13-9. Adjusting the needle and rotary hook timing ... 54 13-10. Adjusting the rotary hook lubrication

amount ........................................................55

14. TROUBLESHOOTING ..............................56

14-1. Sewing ..........................................................56

14-2. Error code displays .......................................60

15. 7-SEGMENT DISPLAY .............................64

7. USING THE G5A OPERATION PANEL

(BASIC OPERATIONS)............................ 31

7-1. Names and functions...................................... 31

7-2. Sewing start and end backtack stitches ......... 33

7-3. Sewing continuous backtack stitches............. 34

7-4. Sewing fixed stitches ...................................... 35

7-5. Sewing name labels .......................................36

7-6. Sewing pleat presser stitches......................... 37

7-7. Using the lower thread counter ...................... 38

S-6200A

1. MACHINE SPECIFICATIONS

Quick reverse Thread wiper

3 5 Use For medium-weight materials For heavy-weight materials

Max. sewing speed 5,000 sti/min 4,000 sti/min Start backtacking and continuous

backtacking speed End backtacking speed 1,800 sti/min Max. stitch length 4.2 mm 5 mm

Presser foot height

Feed dog height 0.8 mm 1.2 mm Needle (DB x 1, DP x 5) #11 - #18 #19 - #22 Motor AC servo motor (4-pole, 450W) Control circuit Microprocessor

Lifting lever 6mm Knee lifter 13mm

220 - 3,000 sti/min

3 4

○ ○

○

1

S-6200A

2. NAMES OF MAJOR PARTS

G1A operation panel (basic function LED)

G5A operation panel (advanced function LCD)

(1) Needle plate (2) Presser foot (3) Needle bar (4) Pretension (5) Spool pin (6) Knee lifter assembly (7) Power switch (8) Thread wiper (-40[] specifications) (9) Lifting lever (10) Machine pulley (11) Reverse lever (13) Actuator switch (15) Cotton stand

Safety devices (17) Finger guard (18) Thread take-up cover (19) Pulley cover (20) Motor cover

(12) Stitch length dial (14) Operation panel (16) Control box

2. NAMES OF MAJOR PARTS

1953B

S-6200A

2

3. INSTALLATION

CAUTION

Machine installation should only be carried out by a qualified technician.

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

The sewing machine weighs approximately 38 kg (84lb). The installation should be carried out by two or more people.

Do not connect the power cord until installation is complete. The machine may operate if the treadle is depressed by mistake, which could result in injury.

About the machine set-up location

・ Do not set up this sewing machine near other equipment such as

televisions, radios or cordless telephones, otherwise such equipment may be affected by electronic interference from the sewing machine.

・ The sewing machine should be plugged directly into an AC wall

outlet. Operation problems may result if extension cords are used.

Secure the table so that it will not move when tilting back the machine head. If the table moves, it may crush your feet or cause other injuries.

Use both hands to hold the machine head when tilting it back or returning it to its original position. If only one hand is used, the weight of the machine head may cause your hand to slip, and your hand may get caught.

Carrying the machine

・ The sewing machine should be carried by the arm and the

machine pulley by two people as shown in the illustration.

* Do not hold by any part other than the machine pulley. If this is

not observed, it may result in damage to the sewing machine.

Tilting back the machine head

・ Hold section (A) with your foot so that the table does not move,

and then push the arm with both hands to tilt back the machine head.

Returning the machine head to the upright position

1. Clear away any tools, etc. which may be near the table holes.

2. While holding the face plate with your left hand, gently return the machine head to the upright position with your right hand.

2086M

1955B

2101B

3

2089M

S-6200A

3. INSTALLATION

3-1. Table processing diagram

・ The top of the table should be 40 mm in thickness and should be strong enough to hold the weight and with-stand the

vibration of the sewing machine.

・ Drill holes as indicated in the illustration below.

*

* NOTE:

Check that processing has been carried out accurately to these dimensions (4 places). If the dimensions are too deep, the safety switch may become damaged when setting up the machine head.

Control box mounting hole

Cotton stand hole

Cord hole

1956B

3-2. Installation

S-6200A

1. Control box

(1) Control box (2) Bolts [3 pcs] (3) Nuts [3 pcs] (4) Spring washers [3 pcs] (5) Washers [3 pcs]

2. Connecting rod

(6) Connecting rod (7) Nut

1957B

4

3. INSTALLATION

Left side: White

Right side: Black

Operator

4065M

3. Oil pan

(1) Head cushions (left) [2 pcs] (2) Head cushions (right) [2 pcs] (3) Oil pan (4) Magnet

4. Rubber cushions

(1) Rubber cushions [2 pcs] (2) Nails [4 pcs]

]

5. Knee lifter complying bar

(3) Knee lifter complying bar

3830M

6. Machine head

(1) Hinges [2 pcs] (2) Machine head

* Bind the cords together and pass

them through the cord hole.

1958B

5

S-6200A

3. INSTALLATION

7. Operation panel

(1) Operation panel (2) Screws [2 pcs]

1959B

8. Knee lifter plate

(1) Knee lifter plate (2) Bolt

* Loosen the bolt (2) and then adjust

the position of the knee lifter plate (1) so that it is easy to use.

3832M

1. Turn the machine pulley so that the feed dog is below the top of the needle plate.

2. Lower the presser foot (5) by using the lifting lever (4).

3877M

3834M

3. Loosen the nut (6).

4. Turn the screw (8) to adjust so that the amount of play in the knee lifter (7) is approximately 2 mm when the knee lifter plate (1) is gently pressed.

5. Securely tighten the nut (6).

6. Loosen the nut (9).

7. Turn the screw (10) until the distance between the end of the screw (10) and the knee lifter (7) is approximately 8 mm.

8. Turn the adjusting screw (10) to adjust so that the presser foot (5) is at the desired position within a distance of 13 mm of the needle plate when the knee liter plate (1) is fully pressed.

9. After adjustment is completed, securely tighten the nut (9).

Within 13 mm

3878M

S-6200A

6

3. INSTALLATION

1961B

9. Motor cover

1. Use the two bands (2) to bind the cord (1) of the operation panel to the other cords as shown in the illustration, and then pass it through the cord hole in the table.

2. Install the motor cover (3) as shown in Figure [A], and then securely tighten it with the four screws (4).

* Fit the end of the pulley cover (5)

into the grooves in the motor cover (3) (in 3 places) as shown in Figure [B].

7

S-6200A

3-3. Lubrication

3. INSTALLATION

10. Cotton stand

(1) Cotton stand

NOTE: Securely tighten the nut (4) so that the two rubber cushions (2) and the washer (3) are securely clamped and so that the cotton stand (1) does not move.

3844M

CAUTION

Do not connect the power cord until lubrication has been completed, otherwise the machine may operate if the treadle is depressed by mistake, which could result in injury.

Be sure to wear protective goggles and gloves when handling the lubricating oil, so that it does not get into your eyes or onto your skin. If care is not taken, inflammation can result. Furthermore, do not drink the lubricating oil. Diarrhea or vomiting may result. Keep the oil out of the reach of children.

・ The sewing machine should always be lubricated and the

oil supply replenished before it is used for the first time, and also after long periods of non-use.

・ Use only the lubricating oil (Nippon Oil Corporation

Sewing Lube 10N; VG10) specified by Brother.

* If this type of lubricating oil is difficult to obtain, the

recommended oil to use is <Exxon Mobil Essotex SM10; VG10>.

1. Tilt back the machine head.

2. Slowly pour in lubricating oil until the oil level reaches the HIGH mark.

3846M

* If the oil level drops below the LOW mark, add more

lubricating oil.

S-6200A

8

3. INSTALLATION

3-4. Connecting the cords

DANGER

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

CAUTION

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

Do not connect the power cord until all cords have been connected. The machine may operate if the treadle is depressed by mistake, which could result in injury.

3-4-1. Opening the control box cover

When securing the cords, do not bend the cords

excessively or fasten them too hard with 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.

(1) Screw (2) Cover

4137M

9

S-6200A

3-4-2. Connecting the cords

Lower the tab (6).

Push in securely until the tabs (6) engage.

Raise the tab (6).

4139M

3. INSTALLATION

(1) 6-pin head detector unit connector (2) 12-pin operation panel connector (3) 10-pin resolver connector (4) 14-pin machine connector (5) 4-pin motor connector

Cords

Press the tab.

4140M

4141M

1. Binding the cords

(1) Repeat cable tie

NOTE:

・ Bind the cords in such a way that the

connector does not get pulled out.

・ All cords that come out from the

control box should be secured to the cord holder (2) using the repeat cable tie (1), otherwise vibration from the sewing machine may cause the cords to become disconnected, which can cause problems with the operation of the control box.

S-6200A

10

3. INSTALLATION

Ground symbol

Oil pan

Ground symbol

1963B

2. Ground wire

(1) Ground wire (2) Washer (3) Spring washer (4) Screw

Control box

Green and yellow wire (ground wire)

Leg

4143M

2129B

3. Other cords

Connect cords that match the voltage specifications.

< Europe specifications >

(1) Filter box (2) Screws [4 pcs] (3) Staples [7 pcs] (4) Power cord

1. Attach an appropriate plug to the power cord (4). (The green and yellow wire is the ground wire.)

2. Insert the power plug into a properly-grounded electrical outlet.

NOTE:

・ Take care when tapping in the

staples (3) to make sure that they do not pierce the cords.

・ Do not use extension cords,

otherwise machine operation problems may result.

11

S-6200A

3. INSTALLATION

Operator

4145M

1964B

<200 V system >

(1) Power switch (2) Screws [2 pcs]

(3) 3-pin power supply connector (4) Power cord (5) Staples [5 pcs]

1. Attach an appropriate plug to the

power cord (4). (The green and yellow wire is the ground wire.)

2. Insert the power plug into a

properly-grounded electrical outlet.

Green and yellow wire (ground wire)

NOTE:

・ Take care when tapping in the

staples (5) to make sure that they do not pierce the cords.

・ Do not use extension cords,

otherwise machine operation problems may result.

S-6200A

1965B

12

3. INSTALLATION

Operator

4145M

1966B

<100 V/400 V system >

(1) Power switch (2) Screws [2 pcs]

(3) Transformer box (4) Transformer box plates [2 pcs] (5) Screw [with washer] (6) 3-pin power supply connector (7) Staples [6 pcs] (8) Cord clamps [2 pcs] (9) Power cord

1. Attach an appropriate plug to the

power cord (9). (The green and yellow wire is the ground wire.)

2. Insert the power plug into a

properly-grounded electrical outlet.

Green and yellow wire (ground wire)

1967B

NOTE:

・ Take care when tapping in the

staples (7) to make sure that they do not pierce the cords.

・ Do not use extension cords,

otherwise machine operation problems may result.

13

S-6200A

3-5. Test operation (Operating the treadle)

CAUTION

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

3. INSTALLATION

3648M

2117M

2114M

1968B

1. Turning on the power

Press the ON power switch (1). The power indicator (2) will illuminate.

2. Test operation

1. Check that the machine sews at low speed when the treadle (1) is gently pressed to position (B).

NOTE:

If the sewing machine does not operate even when the treadle (1) is depressed, check the position of the safety switch. (Refer to “13-1. Adjusting the safety switch position”.)

2. Then check that it sews at high speed when the treadle (1) is gently pressed to position (C).

3. After pressing the treadle (1) forward, check that the needle is lowered to the top of the needle plate when the treadle (1) is returned to the neutral position (A). (when needle down stopping has been set.)

4. If the treadle (1) is pressed to position (D), thread trimming is carried out and the needle then rises above the needle plate and stops.

5. With the machine head tilted back, depress the treadle (1) and check that the sewing machine does not operate.

NOTE:

If the sewing machine operates when the treadle (1) is depressed while the machine head is tilted back, the safety switch is probably faulty. Contact the place of purchase.

S-6200A

14

3. INSTALLATION

3-6. Adjusting the treadle operation

4259M

If the machine starts running at low speed when your foot is simply resting on the treadle, or if the treadle pressure is felt to be too weak, adjust the position (a to c) at which the treadle spring (1) is hooked onto the treadle lever (2).

* a is the weakest position, and it becomes gradually

stronger at b, c and d respectively.

1. Loosen the nut (3) and turn the bolt (4).

* When the bolt (4) is tightened, the treadle operation

becomes heavier, and when it is loosened, the operation becomes lighter.

2. Tighten the nut (3).

Remove the nut (5), and then move the connecting rod joint (6) from the position in figure A to the position in figure B. The treadle stroke will then be increased by approximately 27 %. At this time, the treadle forward and backward depression sensitivity will change, so readjust if necessary.

4260M

15

S-6200A