Related Manuals for Brother DH4-B981
Summary of Contents for Brother DH4-B981
- Page 1 INSTRUCTION MANUAL DH4-B981 Please read this manual before using the machine. Please keep this manual within easy reach for quick reference. ELECTRONIC EYELET BUTTON HOLER...
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Page 2: Safety Instructions
Thank you very much for buying a BROTHER sewing machine. Before using your new machine, please read the safety instruc- tions below and the explanations given in the instruction manual. With industrial sewing machines, it is normal to carry out work while positioned directly in front of moving parts such as the needle and thread take-up lever, and consequently there is always a danger of injury that can be caused by these parts. - Page 3 Furthermore, do not excessively bend the cords or secure them too firmly with staples, Contact your Brother dealer or a qualified electrician otherwise there is the danger that fire or electric shocks for any electrical work that may need to be done.
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Page 4: Maintenance And Inspection
Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the Use only the proper replacement parts as specified by electrical system. -
Page 5: 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. Hazardous voltage... -
Page 6: Table Of Contents
D. Setting the knife operation method ....35 E. Setting the eyelet shape ......... 35 10-2. Circuit board DIP switches ......70 F . Setting the offset (setting the taper bar tacking overlap) ... 36 11. TROUBLESHOOTING ........72 G. Setting the cutting space ........ 36 DH4-B981... -
Page 7: Names Of Each Part
Cloth presser switch r Start switch t EMERGENCY STOP switch y Upper shaft pulley u Feed bracket i Spool stand o Power switch ! 0 Motor !1 Operation panel !2 Control box Fly indexer (-52 specifications) Fly indexer 0791Q DH4-B981... -
Page 8: Specifications
2. SPECIFICATIONS 2-1. Specifications Lower thread trimmer Upper thread trimmer Long type Fly indexer BROTHER INDUSTRIES, LTD. Short type DH4-B981- MADE IN JAPAN * -02 and -52 specifications are further divided into L1 - L7 specifications in accordance with the stitch length. Please be sure to specify the stitch length when ordering. -
Page 9: Optional Parts
Straight buttonhole Straight buttonhole without taper with taper without taper with taper 2-2. Optional parts The following optional parts are available for the DH4-B981. ™Select switch This switch is used to select one program from a choice ○ ○ ○ ○... -
Page 10: Replacement Parts List For Specification Changes
S37201-001 (34) S41474-101 S37201-001 (34) S43366-000 S42139-101 (36 - 40 mm) S41475-101 S35093-001 (38) NOTE: There is 10 mm of difference in the knife cutting position between L1 - L4 and L5 - L7 specifications. (Refer to page 60.) DH4-B981... -
Page 11: Installation
Furthermore, do not excessively bend the cable Contact your Brother dealer or a qualified or secure it too firmly staples, otherwise there is electrician for any electrical work that may need the danger that fire or electric shocks could occur. -
Page 12: Installing The Motor
4. Place the eight accessory cushions u and the four accessory cushion collars i onto the motor base plate o, and then install the motor as shown in the illustration. 0803Q DH4-B981... -
Page 13: Installing The Motor Pulley
3. Align the control box w with the nuts q, and then install it with the four flat washers e, spring washers r and bolts t. NOTE: Be careful not to drop any small parts such as washers onto the circuit board when installing the bolts. 0806Q DH4-B981... -
Page 14: Installing The Machine Head
Pull the machine head down toward you gently, remove the head support lever w from the hinge lever support shaft e, and then gently lower the machine head. NOTE: Do not hold the machine head by the feed bracket r or X feed shaft A t when it is being raised and lowered. DH4-B981... -
Page 15: Installing The Oil Container
5. Install the motor cover t with the three screws y. 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. DH4-B981... -
Page 16: Installing The Spool Stand
3. Connect air tube ⁄5 to the intermediate joint t of the air unit q and to the joint y of the valve assembly, and connect air tube ⁄6 to joints u and i. Connecting the valve cables Insert the cable o which is coming out of the valve unit to the 2-pin connector !0 of the valve cable assembly. DH4-B981... -
Page 17: Connecting The Wiring
3. Connect the hand switch connector i to the control box connector. 4. Install the power switch o to the underside of the work table with the two screws !0 . Secure the cables using staples !1 (in four locations). 0821Q DH4-B981... -
Page 18: Connections Inside The Control Box
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. PMD circuit board 0824Q DH4-B981... -
Page 19: Connecting The Motor Cables
Work clamp *1 If the lower thread trimmer is not installed, solenoid valve [3] is not used. *2 The auxiliary clamp arm can only be used Plug 4 for machines with -02 specification. 0826Q < -02 > 0829Q 0828Q DH4-B981... -
Page 20: Securing The Cables
Right/left work clamp No. Label No. of Right/left movable knife No. Specification harness Thread handler No. < -02 > -00, -01 * There is 10 mm of difference in the knife installation positions between L1 - L4 and L5- L7. 0833Q DH4-B981... -
Page 21: Installing The Air Tubes
4. To reduce the air pressure, gently lift knob w or knob To close r and turn it counterclockwise. 5. Open the cock t. Air will enter the reservoir and the (0.3 MPa) needle will move. (0.5 MPa) To loosen To tighten 0837Q DH4-B981... -
Page 22: Connecting The Power Cord
3. INSTALLATION 3-17. Connecting the power cord CAUTION Contact your Brother dealer or a qualified Do not turn on the power supply until cords have electrician for any electrical work that may need been connected, otherwise the machine may to be done. -
Page 23: Installing The Select Switch (Option)
5. Secure the cable with the cable clamp as shown in the illustration. P3-OPTION 0842Q 3-19. Installing the foot switch (option) 1. Insert the connector e of the foot switch w into the control box connector q. 0843Q DH4-B981... -
Page 24: Installing The Indexer (Option)
!3 . 4. * 4. * If it does not go in smoothly, re-adjust the installation positions of feed base (L) o and feed base (R) !2 . 4. * 0847Q DH4-B981... - Page 25 1. Install the valve unit q with the screw w. 2. Remove the stopper plug (with the P mark) r from the valve unit e, and then install the joint t. 3. Connect the 6 mm-diameter air tube u to joints t and y. DH4-B981...
- Page 26 0853Q Switch pin No. Cable color 15-pin Connector White Limit switch (R) y Black White Limit switch (L) u Black Brown (Red) Cylinder sensor i Black (White) Blue (Black) 8. Secure the cable with the cable clamp o. 0854Q DH4-B981...
- Page 27 2. Secure the air tube w and cable e with the cord holder r, screw (length 16 mm) t and washer y. * Leave enough slack in the air tube w and cable e at this time to allow for the movement of the feed bracket u. DH4-B981...
- Page 28 1. Install the hand start switch support plate q with the two screws w in the position shown in the illustration. 2. Install the hand start switch e to the hand start switch support plate q with the two screws r. 0858Q DH4-B981...
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Page 29: Lubrication
Keep the oil out of the reach of children. Use only specified Brother oil (Nisseki Sewing Lube 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. - Page 30 10.Add 5 - 6 drops of oil to the felt !8 which is attached to the sliding surfaces of the lopper 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. DH4-B981...
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Page 31: Correct Use
1 2 3 4 5 6 7 8 4. Set DIP switch C No. 4 e on the circuit board to OFF. 5. Close the rear plate w and tighten the six screws q. 1 2 3 4 5 6 7 8 No trimming 0870Q DH4-B981... -
Page 32: Installing The Needle
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. Thread the upper thread as shown in the illustration below. * Use the accessory needle threader q. 0876Q 0875Q <-52 specifications> 0874Q 0877Q 0878Q DH4-B981... -
Page 33: Threading The Lower Thread
Remove the work clamp plates (refer to page 24), and then thread the lower thread as shown in the illustration below. For upper thread trimming specifications (-00) 0880Q 0879Q 0881Q For upper and lower thread trimming specifications (-01, -02 and -52) 0883Q 0882Q 0881Q DH4-B981... -
Page 34: Threading The Gimp
1. Insert the material so that it touches the right and left cloth guides q. 2. The sewing margin can be adjusted to within 10 - 30 mm. 3. Loosen the screws w at left and right and move the cloth guides q back and forth to adjust the sewing margin. DH4-B981... - Page 35 * 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. DH4-B981...
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Page 36: Setting The Installation Position For Cloth Feed Plate (L) (-52 Specifications)
C 167.5 - 177.5 mm G 279.5 - 289.5 mm D 142.5 - 152.5 mm H 270.5 - 280.5 mm I 234.5 - 244.5 mm J 209.5 - 219.5 mm K 195 - 205 mm L 184.5 - 194.5 mm 0897Q DH4-B981... -
Page 37: Replacing The Proms
The PROM which is marked "DA" is the data PROM. B981 This PROM is mounted in position r. * The data PROM is only mounted when carrying out sewing based on data created using the BAS-PC/300. * The figure inside the box indicates the version number. 0901Q DH4-B981... -
Page 38: Using The Operation Panel
POWER indicator RESET indicator "Down" switch Panel DIP switch C Panel DIP switch A Panel DIP switch B 0904Q Select switch (option) part names RESET switch Switch C Indicator C Switch A Switch B Indicator A Indicator B 0905Q DH4-B981... -
Page 39: Setting The Buttonhole Length
KNIFE indicator is switched off, 1. * cutting is turned off. * The knife will not operate when cutting is turned off. Refer to page 35 for details on switching between cutting before sewing and cutting after sewing. 0907Q DH4-B981... -
Page 40: Setting By Changing The Panel Dip Switches
Cutting after sewing Cutting before sewing Cutting shape No. 2 (eyelet hole) Cutting after sewing Cutting before sewing Cutting shape No. 3 (eyelet hole) Cutting after sewing Cutting before sewing Cutting shape No. 5 (straight hole) Cutting after sewing DH4-B981... -
Page 41: Setting The Taper Bar Tacking Length
3. Change the settings for panel DIP switch B No. 2 and Eyelet hole (No. 2) No. 3 to set the desired knife operation method. Eyelet hole (No. 3) 4. Turn on the power. Straight hole (No. 5) 0912Q DH4-B981... -
Page 42: Setting The Offset (Setting The Taper Bar Tacking Overlap)
No. 7 No. 8 Sewing speed 3. Change the settings for panel DIP switch B No. 7 and 1,400 rpm No. 8 to set the desired sewing speed. 1,600 rpm 4. Turn on the power. 1,800 rpm 2,000 rpm 0915Q DH4-B981... -
Page 43: Setting The Mode
* When set to the left setting position, cloth setting is 4. * always carried out at the left setting position. * When set to the horizontal setting position, cloth 0918Q 4. * setting is carried out at both the left and right setting 4. * positions. DH4-B981... -
Page 44: Setting The Number Of Eyelet Buttonholes (-52 Specifications)
Accordingly, it is recommended that you set the home position starting to be carried out each time ("HA" displayed). DH4-B981... -
Page 45: Using The Select Switch (Option)
This completes the changing if the program settings. 0924Q 3. Using the RESET switch The RESET switch functions in the same way as the RESET switch on the operation panel. Operate it in the same way as the RESET switch on the operation panel. DH4-B981... -
Page 46: Moving The Cloth Feed Bar (-52 Specifications)
4 - 9, Spare A - F The version of the PROM is given as "B" or later. The version of the PROM is given as "C" or later. The version of the PROM is given as "D" or later. DH4-B981... -
Page 47: List Of Error Codes
Y axis is not at the home position. Turn off the power and check. axis is not at the home position. Turn off the power and check. Sewing data has been corrupted. Turn off the power and check. * -52 specifications only DH4-B981... - Page 48 Turn off the power and check. Control circuit board overheating error Turn off the power and check. Power supply relay error Turn off the power and check. Power supply circuit board overcurrent error Turn off the power and check. * -52 specifications only DH4-B981...
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Page 49: Sewing
2. Eliminate the cause of the problem. 3. Press the RESET switch e. * The RESET indicator will switch off, the "60" error code will be cleared from the number display window and the 3. * feed bracket will return to the cloth setting position. DH4-B981... -
Page 50: Sewing
NOTE: After you have finished with the machine and have turned the power off, the previous sewing data will still be retained in memory even when the power is turned back on again. Thus you can continue with the same type of sewing. Check the thread tension after sewing. Refer to the following page. DH4-B981... -
Page 51: Adjusting The Thread Tension
Stroke adjustment Loosen the screw y and turn the thread take-up spring guide u in the direction indicated by the arrow to increase the stroke of the spring t. 0935Q DH4-B981... -
Page 52: Needle And Knife Position
* The cutting space should generally be set to around 1. * 0.2. (Refer to page 36 for details on the setting 1. * method.) Cutting space DH4-B981... -
Page 53: Setting The Feed Bracket To The Front Position
5. Sewing can then be carried out as normal. (Refer to page 44.) NOTE: During single pedal operation, when the start switch is pressed, the work clamp is lowered and sewing starts straight away. If you would like to reset the material, set to dual-pedal operation. 0928Q DH4-B981... -
Page 54: Using Feed Mode
* To return the feed bracket e to the cloth setting position while sewing: 1) Press the EMERGENCY STOP switch t. 6. * 2) Press the RESET switch y. 6. * 6. * 2) NOTE: The knife will not operate during this time. DH4-B981... -
Page 55: Using Manual Mode
* The movement of the feed bracket e, lower thread trimming and operation of the work clamp will all be carried out as a single step. * The knife will operate only when cutting after sewing has been selected. DH4-B981... -
Page 56: Cleaning And Maintenance
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 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. DH4-B981... -
Page 57: Draining The Oil
NOTE: Clean up any oil that may have been spilt onto the floor. 0945Q 8-3. Checking the air filter 1. Close the air cock q. 2. Turn the screw w to release any air and water in the drain. 0946Q DH4-B981... -
Page 58: Standard Adjustments
"0" before carrying out inspection, adjustment and repair of any parts which use the pneumatic Ask your Brother dealer or a qualified electrician equipment. to carry out any maintenance and inspection of If the power switch and air need to be left on the electrical system. -
Page 59: Adjusting The Needle And Looper Timing
5. If adjustment is necessary, turn the looper base y in the direction indicated by the arrow in the illustration, loosen the screw u, and then move the looper link clamp i up or down to tilt the LS-holder bracket o to the left or right (in the direction of the arrow). DH4-B981... -
Page 60: Adjusting The Loop Stroke
Once they are aligned, tighten the two screws e. After adjusting, check that the screws have been adequately tightened. Once this adjustment has been carried out, repeat the procedure given in "9-2. Adjusting the needle and looper timing". DH4-B981... -
Page 61: Adjusting The Height Of The Needle Bar
If the clearance is not uniform, adjust the turning center for the needle bar. (This adjustment is made at the time 1. * of shipment from the factory.) * After making the adjustment in step 1. above, carry out the adjustment procedure given in "9-7. Adjusting the 1. * spreader mounting positions". DH4-B981... -
Page 62: Adjusting The Needle Guard
NOTE: Both the left spreader q and right spreader t should be installed so that they do not project past the tips of the eye looper w and right looper y respectively. DH4-B981... -
Page 63: Adjusting The Spreader Timing
The stitch width becomes smaller as the adjustment screw w is moved upward. NOTE: If the needle racking width is changed greatly, you should re-adjust the timing between the needle and the loopers. (Refer to "9-2. Adjusting the needle and looper timing".) DH4-B981... -
Page 64: Changing The Knife Cutting Length (Replacing The Hammer)
3. When installing the hammer, push in the pin e and then tighten the screw q. * Do not use knives with different numbers on the same hammer. If knives with different numbers are used, 3. * accurate cutting will not be possible and the knife will be damaged. DH4-B981... -
Page 65: Adjusting The Contact Between The Knife And The Hammer
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 smoothy until a single knife incision can still be seen faintly. DH4-B981... -
Page 66: Replacing The Knife
* If the material cannot be cut cleanly, do not increase the cutting pressure over the maximum limit. Check the contact between the knife and the hammer, while referring to "9-11. Adjusting the contact between the knife and the hammer". 0975Q DH4-B981... -
Page 67: Adjusting The Cloth Opening Amount
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) DH4-B981... -
Page 68: Adjusting The Trimming Of The Upper Thread
The gimp is held between thread nipper M w and thread nipper U r on the plate spring. 3. Adjust so that the edge of the fixed knife y and the index mark i on the movable knife u are aligned when the thread trimmer arm t is at the maximum stroke. DH4-B981... -
Page 69: Adjusting The Gimp Length After Trimming (-02, -52)
9-18. Lower thread presser (-02, -52) The lower thread presser q operates at the same time as upper thread trimming is carried out. The end of the lower thread is securely held between the lower thread presser q and the throat plate w. 0986Q DH4-B981... -
Page 70: Auxiliary Clamp Arm
B-side needle valve ... mm from the surface of the valve Maximum height B-side needle valve ... body (turned 7 full rotations from (approx. 11.6 mm) B-side needle valve ... the maximum height) Approx. Approx. 9.6 mm 9.1 mm 0989Q DH4-B981... -
Page 71: Adjusting The Cloth Feed Bar Home Position (-52 Specifications)
6. Check that the pin t fits smoothly into the home position hole u when the cloth feed bar y is touching the bolt w. * If the pin t is not fitting smoothly, repeat the procedure in steps 1. to 5. 0991Q DH4-B981... -
Page 72: Adjusting The Indexer Hole Spacing (-52 Specifications)
U s e t h e s a m e s e t t i n g m e t h o d i f u s i n g o t h e r 0996Q combinations of different hole intervals. DH4-B981... -
Page 73: Adjusting The Position Of Limit Switch L (-52 Specifications)
3. Adjust the position of feed bar guide R u so that limit switch R e turns on when the roller r is pressed by the dog y of cloth feed plate R t. 4. Tighten the two screws q. DH4-B981... -
Page 74: Summary Of Dip Switches
Taper bar tacking length = 7 mm 6, 7, 8 OFF,OFF,OFF Taper bar tacking length = 6 mm OFF,ON,ON Taper bar tacking length = 5 mm OFF,ON,OFF Taper bar tacking length = 4 mm OFF,OFF,ON Taper bar tacking length = 0 mm DH4-B981... - Page 75 No. of holes per cycle = 6 ON,OFF No. of holes per cycle = 5 7, 8* No. of holes per cycle = 4 OFF,OFF OFF,ON No. of holes per cycle = 3 * Valid only for -52 specifications DH4-B981...
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Page 76: Circuit Board Dip Switches
Upper thread nipper not present * The version of the PROM is given as "E" or later. The machine is shipped from the factory with the DIP switches set as follows. 1 2 3 4 5 6 7 8 1000Q DH4-B981... - Page 77 Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare The machine is shipped from the factory with the DIP switches set as follows. 1 2 3 4 5 6 7 8 1001Q DH4-B981...
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Page 78: Troubleshooting
Needle breaks. incorrect. looper and spreader height. N e e d l e a n d n e e d l e g u a r d Adjust correctly while referring to adjustment is incorrect. "9-6. Adjusting the needle guard." DH4-B981... - Page 79 Knife and hammer are not con- Grind the hammer surface. tacting properly. Adjust the cutting pressure so that Material is not being cut cleanly. Cutting pressure is too weak. it is strong enough. Knife is blunt. Replace with a new knife. DH4-B981...
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Page 80: Instruction Manual
INSTRUCTION MANUAL BROTHER INDUSTRIES, LTD. 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177 Printed in Japan 118-981 S91981-122 2001.03. H (2)