Brother RH-981A, Service Manual

Page 1: ...RH 981A Please read this manual before using the machine Please keep this manual within easy reach for quick reference ELECTRONIC EYELET BUTTON HOLER SERVICE MANUAL ...

Page 2: ...o yourself or other people The meanings of these indications and symbols are given below Indications D A N G E R The instructions which follow this term indicate situations where failure to follow the instructions will almost certainly result in death or severe injury CAUTION The instructions which follow this term indicate situations where failure to follow the instructions could cause injury whe...

Page 3: ...h correct operation Avoid exposure to direct sunlight during use Exposure to direct sunlight may cause problems with correct operation In the event of an electrical storm turn off the power and disconnect the power cord from the wall outlet Lightning may cause problems with correct operation Installation Machine installation should only be carried out by a qualified technician Contact your Brother...

Page 4: ...tart switch is pressed by mistake which could result in injury Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin otherwise inflammation can result Furthermore do not drink the oil or eat the grease under any circumstances as they can cause vomiting and diarrhoea Keep the oil out of the reach of childr...

Page 5: ...uard Needle bar guard Belt cover etc 3 Do not touch the knife or press any objects against the machine while sewing as this may result in personal injury or damage to the machine 5 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 6 Direction of operation 3122Q 1 2 Belt c...

Page 6: ...eedle bar driving lever 27 3 8 4 Eliminating end play of the driving rod 28 3 8 5 The strength to tighten the set screw of ball bearing 25 20 28 3 8 6 Eliminating end play of the zigzag rock shaft 28 3 8 7 Eliminating end play of the zigzag lever 29 3 8 8 Attaching the needle bar yoke and the needle bar level feed link 29 3 8 9 Attaching the needle bar bush U and the needle bar 30 3 8 10 Eliminati...

Page 7: ...ing the knife engagement 69 4 23 2 Adjusting the knife pressure 70 4 23 3 Adjusting the gimp pull force 70 4 23 4 Adjusting the gimp tension 71 4 23 5 Using gimp thread work clamp 72 4 23 6 Adjusting the auxiliary clamp arm 73 4 23 7 Adjusting the length of the lower thread to be pulled for a safe sewing start 74 4 24 Adjusting the position of the lower thread presser 02 52 specifications 75 4 25 ...

Page 8: ...RH 981A ...

Page 9: ...tted to the V belt 2 the idler pulley 3 and the V belt 4 and finally to the pulley 5 2 When the pulley 5 rotates in the direction of the arrow its motion is transmitted to the upper shaft timing pulley 6 the timing belt 7 and the lower shaft tension pulley 8 and the lower shaft 9 causing the lower shaft cam 10 to turn in the direction of the arrow 3679Q ...

Page 10: ... the needle bar york 8 the needle bar level feed link 9 and the needle bar clamp 10 and then the needle bar 11 moves up and down 4 The needle bar 11 is guided by needle bar bush U 12 and the needle bar block 13 1 3 Thread take up mechanism 1 When the pulley 1 rotates in the direction of the arrow the needle bar gear 3 rotates via the upper shaft 2 2 The thread take up cam 4 which is attached to th...

Page 11: ...e needle bar 12 is fitted on the needle bar block 11 and the needle bar guide 14 is fitted in the notch of the needle bar block 11 When the needle bar block 11 moves up and down the needle bar 12 oscillates 1 5 Needle bar rocking mechanism 1 When pulse motor R 1 operates the motion is transmitted to the driving needle pulley assembly 2 timing belt D 3 and the looper pulley assembly 4 which then mo...

Page 12: ...e shafts 11 and 12 which are attached to X feed shaft holders L 7 and R 10 move the feed bar 13 in the X direction Y direction feeding 1 When pulse motor Y 14 rotates its motion is transmitted to the actuating gear 15 the idle gear 16 timing pulley A 17 that finally moves the Y timing belt 18 2 The Y timing belt 18 is secured by the Y driving shaft holder 19 and the belt holder 20 and that moves t...

Page 13: ...tted on clamp lever L 7 and the work clamp 9 attached to clamp arm L 8 lowers 3 When the cylinder 1 is returned by the presser spring 10 the work clamp 9 rises The speed controller 11 attached to the cylinder 1 controls the rising speed of the work clamp 9 The work clamp mechanism is activated by independently operated left and right cylinders that can equalize the pressure of the work clamp The p...

Page 14: ...he slide block on it 4 When the cylinder 16 X 15 assembly 2 operates and the stopper 13 of the opening driving lever 5 and the bolt 14 make contact the work clamp plate 12 moves in the direction of a consequently opening a button eyelet on the material 5 At this time there should be at least 1 3 mm clearance between the throat plate 15 and the needle plate 16 Adjust the clearance using the bolt 14...

Page 15: ...cuts the material requiring button eyelets 1 10 Looper mechanism 1 At the end of the looper link assembly 2 which has the looper link support shaft 1 as the pivot of the rocking motion the looper cam roller 3 is fitted in the groove in the lower shaft cam 4 The two looper link springs 5 are attached to the other end 2 The looper link springs 5 are secured by the looper driving plate 7 through whic...

Page 16: ...ce of the lower shaft cam 4 and the spreader driving lever 5 is attached to the other end using the screw 6 The forked part of the spreader driving lever 5 is fitted in the groove 8 of the spreader link shaft 7 2 When the lower shaft cam 4 rotates in the direction of the arrow the spreader cam lever 2 is rocked via the spreader cam roller 3 3 The spreader link shaft 7 moves up and down due to the ...

Page 17: ...ed to the loop base 4 regarded as the pivot 2 When the spreader link shaft 7 moves up and down the motion is transmitted to the spreader link base 8 and the spreader cam link 9 which then rocks the spreader differential cam 10 with the holder support shaft 5 secured to the loop base 4 regarded as the pivot 3 The rocking motions of the LS holder bracket 6 and the spreader differential cam 10 cause ...

Page 18: ...the pressure gauge to drop to 0 before disassembly of any parts which use the pneumatic equipment 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 modifi...

Page 19: ...support 3 which includes the X motor unit Y motor unit Loosen the screw 4 of the Y driving shaft holder pull out the Y shaft 5 toward you and remove the Y feed base 6 including the Y motor unit 2 3 Lubrication mechanism 1 Remove the wick supports 1 and 2 2 Remove the wicks 3 and 4 from the hole 3 Remove the two screws 5 and wick support L 6 3697Q 3698Q 3699Q Hole Oil tank ...

Page 20: ...n the needle at its lower position Pull the spreader link shaft 5 downward and remove the spreader cam lever 6 3 Remove the two bolts 7 and the looper link springs 8 4 Loosen the two set screws 10 of the set collar 9 and the two set screws 11 and remove the looper link support shaft 12 5 Slide the lower shaft cam 13 in the direction of the arrow and remove the looper link 14 3700Q 3701Q ...

Page 21: ... 4 then remove the tension pulley D assembly 5 and timing belt D 6 3 Remove the two screws 7 and the R sensor setting plate 8 4 Remove the four bolts 9 and the motor base 10 5 Loosen the bolt 12 of the vertical shaft T pulley U assembly 11 and the two set screws 14 of the set collar 13 6 Remove the driving looper shaft assembly 15 downward 3703Q 3702Q 3704Q 3706Q 3705Q ...

Page 22: ...ove the looper driving shaft 4 in the direction of the arrow 3 Remove the tension nut 5 pre tension spring B 6 the thread guide discs 7 and the L tension stud 8 Loosen the screw 10 of the looper pulley assembly 9 and remove the looper base 11 in the direction of the arrow Be careful not to drop the two ball bearings 12 when removing the looper pulley assembly 9 3707Q ...

Page 23: ...2 DISASSEMBLY RH 981A 15 2 7 Needle bar thread take up and zigzag mechanisms 3710Q 3711Q 3709Q 3708Q ...

Page 24: ...ever shaft 22 in the direction of the arrow 7 Remove the needle bar driving lever assembly 23 Zigzag mechanism 1 Loosen the bolt 25 of the needle bar block clamp 24 and remove the needle bar block 26 in the direction of the arrow 2 Remove the needle bar block clamp 24 the needle bar level feed links 27 and 28 and the needle bar block collar 29 3 Remove the rubber cap 30 Loosen the bolt 32 of the n...

Page 25: ...ore removing the cam shaft loosen the timing belt referring to 3 4 1 Adjusting the timing belt 1 Loosen the two set screws 2 of the lower shaft tension pulley assembly 1 2 Loosen the two set screws 4 of the lower shaft cam 3 3 Loosen the two set screws 6 of the set collar 5 4 Remove the cam shaft 7 in the direction of the arrow 3712Q 3713Q ...

Page 26: ...mbly B 5 3 Remove the two screws 6 and the NP support bracket B 7 2 11 Upper shaft mechanism 1 Remove ball bearing cap S 1 and the retaining ring 2 2 Loosen each set screw 2 each of the needle bar gear 3 the zigzag cam 4 and the upper shaft tension pulley assembly 5 3 Pull the upper shaft 6 in the direction of the pulley to remove it The upper shaft unit will come off 3714Q 3715Q ...

Page 27: ...ife lever cover 9 4 Remove the wick 10 and loosen the set screw 11 Remove the cylinder rod shaft 12 5 Loosen the set screw 13 and remove the link shaft A 14 and the combination of link A 15 link C 16 and link shaft C 17 downward 6 Remove the two air tubes 18 7 Loosen the two set screws 19 and remove the cylinder support shaft 20 and the cutter cylinder 21 2 13 Zigzag fork mechanism 1 Remove the tw...

Page 28: ...disassembly of any parts which use the pneumatic equipment 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 cove...

Page 29: ... 4 and the cylinder rod and secure it using the set screw 10 5 Insert the cutter lever shaft 11 with its slit facing the right into the hole in the bed the cutter lever 12 and the hole in the bed and tighten the set screw 13 on the screw flat of the cutter lever shaft 11 6 Tighten the two support screws 14 on each end of the cutter lever shaft 11 and secure it using the two nuts 15 7 Hook the exte...

Page 30: ...sing the retaining ring 10 5 Lightly press the needle bar gear 3 and the zigzag cam 4 toward the pulley so that the ball bearing 12 is pressed between the retaining ring 11 and the upper shaft collar 2 Tighten the set screw which comes first when the shaft is rotated in the rotation direction against the screw flat 6 Position the zigzag fork between the zigzag cam 4 and the thrust washer 5 so that...

Page 31: ...d the lower shaft cam 4 against the left ball bearing and tighten the two set screws 7 of the lower shaft cam 4 The screw flat should align with the set screw which comes first when the lower shaft is rotated in the rotation direction 4 When the screw flat of the upper shaft is at the top and the two set screws 8 of the lower shaft tension pulley assembly 3 are as shown in figure 1 loop the timing...

Page 32: ...he hole in the bed and tighten the adjusting screw 3 and the nut 4 until there is 2 7 mm between the nut and the head of the adjusting screw 3 5 Manually move the thread trimmer lever hammer 10 up and down and tighten the two set screws 11 where the thread trimmer lever hammer 10 motion is the smoothest 6 In the same way move the thread trimmer lever hammer 10 up and down manually and tighten the ...

Page 33: ...fe pipe Insert the knife pipe assembly 1 into the bed from below and secure it using the two screws 2 Knife bracket Insert a bar with a diameter of 4 mm into the hole 1 in the knife bracket to fix the knife bracket position and tighten the bolts 2 to 6 3727Q 3728Q ...

Page 34: ...gear Tighten the two set screws 3 of the set screw collar 2 with either set screw at the center of the screw flat on the driving gear shaft 1 Adjusting the backlash between the needle bar gear and the driving gear 1 The driving gear shaft 1 is eccentric Turn it to adjust the backlash The driving gear shaft 1 should be turned in the direction where its lubrication hole is moving upward 2 While pres...

Page 35: ...f the arm and the set screw collar 2 3 8 2 Applying grease to the ends of the thread take up spring 1 Apply grease to the ends 2 of the thread take up spring 1 2 Apply grease to the ends of the thread take up lever 3 and the spring hook 4 3 8 3 Eliminating end play of the needle bar driving lever Adjust the position of the set screw collar 2 to eliminate end play of the needle bar driving lever as...

Page 36: ...the needle bar gear 1 should be tightened as little as possible If it is tightened excessively unnecessary load may be applied to the needle bar gear 1 causing pulse motor R to go out of control Be sure to apply the screw lock to the circumference of ball bearing 25 20 2 before press fitting it 3 8 6 Eliminating end play of the zigzag rock shaft Insert the zigzag eccentric pin 2 into the zigzag cr...

Page 37: ... wick 4 through the zigzag lever 2 and fit the cap 5 3 Attach the needle bar level feed link 6 to the zigzag lever 2 vertically and turn it 90 3 8 8 Attaching the needle bar yoke and the needle bar level feed link 1 Combine the needle bar driving lever assembly 1 and the needle bar yoke 2 pass the wick 3 through the needle bar driving lever assembly 1 and fit the cap 4 2 Attach the needle bar leve...

Page 38: ...t forget to attach timing belt U 2 Insert the plate spring 8 into the hole in the arm and bind it using needle bar bush U 9 and the needle bar bush nut U 10 3 Temporarily attach holder base B 11 using the three bolts 12 4 Pass the needle bar assembly 13 through the arm from above 5 Insert the needle bar felt 14 the needle bar clamp 5 the needle bar level feed link 16 the needle bar block clamp 17 ...

Page 39: ...6 3 8 11 Adjusting the needle bar in the radial direction Insert the two needle bar guide collars 2 into the needle bar block 1 and adjust the position of the needle bar assembly 4 using the two set screws 3 so that the needle bar can move smoothly Note Position the needle bar assembly 4 so that the holder plate A 5 will face the front when the set screws 3 are facing the front When assembling the...

Page 40: ...r guides 2 into the hole in the needle bar block 3 on each side taking care of the white paint mark of the washer 1 2 Attach the two spring 4 using the needle bar guide support plate 5 and tighten the two screws 6 3 8 13 Adjusting the height of the needle bar 1 Turn the pulley to set the needle bar level feed link 1 at its highest position 2 Set the height of the needle bar 2 to approx 62 mm elimi...

Page 41: ... the shaft of the looper base 1 then the looper link clamp 6 into the looper driving shaft 5 and tighten the screw 7 3 Insert the spreader link shaft 8 into the hole in the looper driving shaft 5 then the spreader link base 9 into the spreader link shaft 8 Align the reference line 10 with the top surface of the spreader link base 9 and tighten the screw 11 4 Attach the L tension stud 12 the thread...

Page 42: ...per shaft assembly 1 2 Set the clearance between the set screw collar 3 and the bed 7 to 0 02 0 03 mm in the thrust direction and tighten the two set screws 8 3 Press the vertical shaft T pulley U assembly 4 and the washer 5 against the ball bearing 6 and tighten the screw 9 Be sure to pass the driving looper shaft assembly 1 through timing belt U 10 4 Attach the tension pulley arm U assembly 11 w...

Page 43: ... 2 Turn the needle rotation pulley assembly M 2 until the pin 3 makes contact with the motor base 3 Attach the timing belt 4 Make sure that the looper base 1 can rotate through 360 easily Tighten the screw of the looper pulley at the front Adjusting the timing belt tension Attach the timing belt D while the tension pulley arm D assembly is being pulled by a force of 68 6 N Deflection in the center...

Page 44: ... 2 of the vertical shaft T pulley U assembly 1 2 Align the match mark in the looper base 3 with that in the bed as shown in the figure 3 Orient the needle bar gear 4 in the direction shown in the figure and align it with gear support B 5 4 Tighten the bolt 2 of the vertical shaft T pulley U assembly 1 3752Q 3754Q Align 3753Q ...

Page 45: ... machanisms 1 Attach the looper oil guide 1 using the screw 2 2 Wind the wick 4 around the boss of the looper link 3 Be sure to pass the two wicks 5 under the wick 4 3 Wind the wick 6 around the spreader driving lever 7 as shown in the figure 3755Q ...

Page 46: ...that they lightly make contact then tighten the screw 14 on the screw flat at the front and another screw 15 7 Insert an allen wrench 2 5 mm across flats into the hole in the bed and the hole 16 in the lower shaft cam 12 Position the screw flat of the upper shaft at the top where the needle is at its lowest position and tighten the two set screws 17 of the lower shaft tension pulley assembly 13 8 ...

Page 47: ...ader driving lever 22 while pulling the former downward 10 Pass the looper link support shaft 24 through the spreader driving lever 22 and the set screw collar 23 and secure them using the two set screws 25 The split in the shaft should be facing the right 11 Tighten the two set screws 26 of the set screw collar 23 to eliminate the end play 3758Q ...

Page 48: ...ttach wick support L 7 using the two screws 8 At this time the emergency stop switch cord should be routed above wick support L 7 5 Using a pair of tweezers insert the wick 9 into the hole in the oil tank At this time insert the oil tube into the hole as shown in the figure 6 Pass the wick 4 under the felt 10 7 Push the felt 10 into the lubrication hole in the thread take up lever 11 3759Q Oil tan...

Page 49: ...r shaft 1 Oil is supplied to the driving gear shaft 2 through the wick 1 2 The wick 4 which is wound around the boss of the pin 3 makes contact with the felt 5 and oil is supplied to the pin 3 the eccentric wheel 6 and the driving rod 7 3760Q ...

Page 50: ...g the weight of pulse motor X 3 as shown in the figure above Tighten the four bolts 4 Adjusting the idle gear Adjust the positions of the X racks and the idle gear 1 Loosen the two set screws 5 of the idle gear 2 to adjust the engagement between the X rack 3 and the idle gear 4 based on the engagement between the X rack 1 and the idle gear 2 2 Engage the idle gears 2 and 4 with the X racks 1 and 3...

Page 51: ...instead to determine Y pulley support L 1 position the deflection will be 1 0 5 mm when the belt is pressed at the center with a force of 4 9 N The belt tension can be adjusted when the Y feed base is still attached to the bed Loosen the two bolts 2 of Y support L 1 and use the bolt 3 to adjust the belt tension The tension in this case should be the same value as that above 3763Q 3764Q ...

Page 52: ...tion plate assembly 4 should face the top Adjusting the backlash between the driving gear and the idle gear Remove the Y feed base 1 Adjustment should be carried out with the driving gear and the idle gear treated as a unit Adjust the backlash between the driving gear 2 and the idle gear 3 when they are engaged under the weight of pulse motor Y 4 as shown in the figure above Tighten the four bolts...

Page 53: ...ft 1 so that the shaft is still temporarily held in place 2 Insert the Y feed guide shafts 4 into the X feed shaft holder R 5 and the X feed shaft holder L assembly 6 and the feed bracket 7 and tighten the four set screws 8 3 Move the feed bracket 7 in the X direction a few times 4 Tighten the four bolts 2 and the two set screws 3 3767Q ...

Page 54: ...onizer assembly B 3 using the two screws 4 3 Tighten the set screw 5 in the V groove in the upper shaft and attach the pulley assembly 6 Then tighten another set screw 7 The set screw 5 should be tightened in the front hole which comes first when the pulley is rotated in the rotation direction 4 After attaching the synchronizer check the machine torque 3768Q ...

Page 55: ...over 4 the top cover 5 the belt cover F 6 the belt cover R 7 and the face plate 8 3 Attach the needle 9 3 16 Safety switch 1 Switch to the input check mode 2 Adjust the height of the safety switch 1 using the two screws 2 so that the LED does not go off even if the machine head is lowered and the bed is shaken up and down 3771Q 3770Q 3769Q 3772Q 3773Q LED is lit ...

Page 56: ...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 modi...

Page 57: ...e 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 make 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 plat...

Page 58: ...g 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 1 Switch the mode to test feed mode 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 t...

Page 59: ...ovement of the work clamp can be respectively adjusted The work clamp should be centrally positioned as to the needle movement Back and forth movement Loosen the bolt 1 and adjust the position of the clamp arm 2 Sideways movement Loosen the two screws 3 and adjust the position of the clamp lever 4 3776Q ...

Page 60: ...r setting plate 3 in the direction of the arrow 6 Return the machine head to its original position Repeat the above steps from 1 The X axis home position can be adjusted in increments of 0 05 mm 4 6 Adjusting the Y axis home position The clearance from the rear end surface of the feed bracket to the bed should be 2 mm 0 2 mm 1 After detecting the home position measure the clearance from the rear e...

Page 61: ... inside needle forward cloth penetration points are not identical with that of the returning ones for the straight portion remove the face plate and loosen the bolt 1 5 Insert a screwdriver into the arm from the left and turn the zigzag eccentric pin 2 to adjust 4 8 Adjusting the home position of the looper base The match mark in the looper base must be aligned with that on the bed 1 After detecti...

Page 62: ...sure that the portion where the needle penetrates for the eyelet button hole uniformly overlaps the knife cutting positions For easier checking change the value for cutting space by the parameter settings 6 If it is not turn off the power and adjust the position of the knife Back and forth movement adjustment Loosen the bolt 2 and adjust the position of the knife by following the block stopper pla...

Page 63: ...e cutter lever 3 has no end play and it can operate easily Too much end play may damage the knife 4 11 Adjusting the height of the throat plate To prevent material from being pressed down by the needle which penetrates the material the top surface of the throat plate 1 should be flush with the top surface of the needle plate 2 Loosen the screw 3 turn the set screw 4 and adjust the height of the th...

Page 64: ...preaders move smoothly between the right spreader stopper 4 the left spreader stopper 5 and the LS holder bracket 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 Looper height 1 Set the clearance between the eye looper 8 and the left spreader 2 to the same distance as the thickness of the lower loo...

Page 65: ...ame measurement 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 measurements 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 whe...

Page 66: ...es the edge of the calipers B Check that the tip of the eye looper is aligned 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 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 Lo...

Page 67: ...le 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 4 16 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 Loosen the looper screw 1 and then adjust th...

Page 68: ...ust so that the looper clasps the upper thread securely 4 18 Adjusting the spreader mounting positions 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 adjust the position of the right spreader stopper 8 so that the tip of the right spreader 5 ...

Page 69: ...amount to pull the upper thread and tension release The amount to pull the upper thread should be sufficiently maintained to form the correct stitches at the start of sewing The upper thread take up lever operates as soon as sewing is completed and is released when the start switch is pressed to move the feed bracket with the needle stopped Loosen the screw 1 and move the upper thread take up leve...

Page 70: ...ance between the needle and the point of the upper movable knife 1 to appox 0 5 mm 2 The height of the upper movable knife 1 should be between the bottom of the throat plate 4 and spreader R 5 02 52 The mounting position of upper movable knife 1 is determined by the position of the lower thread presser 2 1 Loosen the screw 3 and position upper movable knife 1 between the projection of the throat p...

Page 71: ...djusting the thread trimmer which can cut the lower thread and gimp leaving them longer The thread trimmer is operated by means of an air cylinder when the feed bracket is returned to the home position 4 22 1 Adjusting the knife pressure Adjust the knife pressure so that the thread can be cut neatly Note Do not subject the knife to excessive pressure It may cause the knife to wear quickly or damag...

Page 72: ...he position of the thread trimmer arm 4 and determine the engagement between the movable knife 5 and the fixed knife 6 The above figure shows standard adjustment Note When tightening the bolt 3 make sure that the thread trimmer lever arm 7 and the thread trimmer arm 4 can move smoothly without any end play Too little engagement may cause the lower thread not to be hooked leading to thread cast off...

Page 73: ...gle thread clamp D 1 may not open because it makes contact with the throat plate and fail to hook the lower thread leading to thread cast off at the start of sewing The lower thread must pass over the projection of thread clamp M 8 and be securely held by thread clamp D 1 1 Make sure that thread clamp D 1 is opened at least 0 3 mm when the thread nipper opener 9 presses the opener pin 10 down 2 Ma...

Page 74: ...hich the thread handler 1 moves to separate the lower thread and the gimp 1 Set the stitch pitch to 2 0 mm by the parameter settings to decrease the total number of stitches 2 Press the start switch in the MANUAL mode and turn the pulley manually until the last stitch 3 When the pulley is stopped with its match mark aligned with that in the arm after a series of operations is completed press the s...

Page 75: ...s the lower thread to guide it to the fixed knife the lower thread should be pulled sufficiently to prevent the thread snapping and deviation from stitching path To cut the lower thread when the feed bracket is at the home position the thread trimmer lever bracket will continue to operate just before the looper turns 45o and the lower thread will be pulled Loosen the screw 1 turn the tension relea...

Page 76: ...eturns to the home position after thread trimming is completed When the stitch length is greatly changed it is necessary to adjust the amount of lower thread to be pulled 1 Turn off the power 2 Turn the looper base 3 manually to check the angle of the tension release lever 1 3 Loosen the screw 4 turn the tension release claw 5 regarding the pivot 6 as the center to adjust the angle of the tension ...

Page 77: ...ached to movable knives L 1 and R 2 align the end of thread trimmer link lever J assembly 6 with the match mark on the rear of the link fulcrum plate assembly 7 and tighten the screw 3 Note Make sure that the movable knife driving cam 8 and thread trimmer lever arm B 9 rotate smoothly without any gap 3 Move thread trimmer link lever J assembly 6 to check engagement between movable knives L 1 and R...

Page 78: ...rns to 0 o from 180 o after the gimp is trimmed The gimp is trimmed when the feed bracket is at the home position When the stitch length is changed dimensions B and A will change It is necessary to adjust the force to pull the gimp Also dimension A differs according to the gimp type and the gimp tension so it is necessary to adjust the force to pull the gimp Loosen the screw 3 and adjust so that t...

Page 79: ...y the tension should be weak so that the gimp can be sewn under the stitches 1 During sewing gimp thread take up guide J 3 moves toward the front in accordance with the movement of the feed bracket and the gimp thread release plate 4 releases the thread tension disc 5 2 After sewing is completed the feed bracket moves to the home position to trim the gimp 1 gimp thread take up guide J 3 pushes the...

Page 80: ...ength from the throat plate may vary In this case pass the gimp through gimp thread work clamp 2 attached to gimp guide C J 1 Note When thick and soft gimp is passed through gimp thread work clamp 2 the gimp tension may be too great during sewing 3823Q 3822Q The gimp is slack Threading route maintained ...

Page 81: ...material next to work clamp Note Be sure that the auxiliary clamp arm 2 does not make contact with clamp arm L J 3 2 Turn on the power to set the home position 3 Turn off the air and loosen the two screws 4 4 With the rod of the auxiliary clamp arm cylinder 5 fully extended adjust so that the auxiliary clamp arm 2 can be stationary to the needle plate without subjecting it to any pressure Note If ...

Page 82: ...mmer lever bracket B is operating just before the lower thread is trimmed when the feed bracket is at the home position and that causes the lower thread to be pulled 1 After automatic sewing is completed switch to the MANUAL mode and press the start switch 2 Turn the pulley manually to check the condition of the lower thread 3 If adjustment is necessary loosen the screw 1 and turn the tension rele...

Page 83: ...e lower thread presser 1 does not fill the front groove of the throat plate If it does loosen the nut 3 and adjust the screw 4 Note Set the height from the stopper portion of thread trimmer lever bracket B 5 to the top of the looper base to 11 mm at maximum 3 Make sure that the front of the throat plate overlaps with the lower thread presser 1 by 0 5 1 0 mm when thread trimmer lever bracket B 5 op...

Page 84: ...e smoothly without gap 3 Loosen the two bolts 4 and adjust needle bar gear support B 5 in the same manner as above Note When needle bar gear support A 2 or needle bar gear support B 5 is raised excessively the looper base may be in an inappropriate position When the looper base is at 360 o where the needle bar can move lightly up and down adjust the position of needle bar bush U 7 Loosen the three...

Page 85: ... rises from the lowest point at the outside sewing position Loosen the screw 3 and align the notch 1 of belt cover F with the timing mark 2 on the pulley Note When the stop position is changed the operation range of spreader R will change Reconfirm the mounting position of the upper movable knife 3832Q ...

Page 86: ...es to control machine operation Power supply circuit board The power supply circuit board is fixed at the bottom of the control box Four fuses are mounted on this PCB Refer to 5 2 Fuse explanation PMD PCB for θ axis shaft The PMD PCB for θ axis shaft is fixed to the board on the top of the control box This is used to run the θ axis pulse motor DC fan motor large Cools the heat sink on the PCB DC f...

Page 87: ...POWER SUPPLY EQUIPMENT RH 981A 79 3518Q DC fan motor large PMD PCB for θ axis shaft Conversion transformer DC fan motor small Power supply circuit board 3519Q Rear of the control box Control circuit board ...

Page 88: ...use has blown 1 G fuse 5AFB quick melting type 5A 250V S08030 000 Toyo Fuse Company TOYO5A The feed mechanism does not operate 2 G fuse 5AFB quick melting type 5A 250V S08030 000 Toyo Fuse Company TOYO5A The machine motor does not turn 3 Fuse 6A glass tube fuse 6A 250V 153242 000 Fuji Tanshi Company FGB0 The power indicator is not lit and nothing operates 4 Fuse 6A glass tube fuse 6A 250V 153242 0...

Page 89: ...e the power supply circuit board If fuse No 2 is blown Separate connectors P15 DC300 on the control circuit board and measure the resistance between pins 1 and 2 on the board with the polarities as shown in the figure If the resistance is 0 ohms it means a short circuit replace the power supply circuit board If fuse No 3 or 4 is blown Separate connectors P1 ACIN on the power supply circuit board a...

Page 90: ...refore be sure to check if each connector is correctly inserted and that there is no contact failure between pins and wires before starting troubleshooting procedures 5 3 1 Connector positions Head harness relay 3526Q For θ axis pulse motor red For θ axis home position sensor 3527Q For X axis pulse motor white For Y axis pulse motor blue For θ axis pulse motor red ...

Page 91: ...de of the control box 3528Q For specification harness For hand switch for foot switch Note This type harness B is only for 12 specifications If this harness is not connected you will not be able to run programs for 12 specification sewing machines 3529Q Type harness B ...

Page 92: ...5 POWER SUPPLY EQUIPMENT RH 981A 84 Control circuit board Power supply circuit board 3530Q 3531Q ...

Page 93: ...er mechanism optional 3532Q 3533Q 3534Q Indexer sensor harness is inserted into the relay connector for θ axis home position sensor Relays the valve harness of the indexer The harness which relays the valve of the indexer is inserted into connector P21 EXOUT of the control circuit board ...

Page 94: ...or MOLEX 5557 06R blue 5559 06P blue Pin no Signal name Probable symptoms due to poor contact 1 Y axis PM driving current YA 2 Y axis PM driving current YB 3 Y axis PM driving current YC 4 Y axis PM driving current YD 5 Y axis PM driving current YE 6 Back and forth movement of feed bracket is not correct Y axis home position can not be found Error code E81 appears For θ axis pulse motor MOLEX 5557...

Page 95: ...position sensor when special lapel cutting device is attached 11 0V for θ axis home position sensor 12 0V for feed plate home position sensor when indexer is attached 13 0V 14 0V for right driving sensor when indexer is attached 15 0V for left driving sensor when indexer is attached θ axis home position can not be found Error code E52 or E82 appears Indexer does not work properly Special lapel cut...

Page 96: ... 2 Open and close 4 Feed plate fixing valve motion signal 5 Chuck valve motion signal Special lapel cutting valve motion signal 6 24V 7 24V 8 24V 9 24V for feed plate fixing valve 10 24V for chuck valve 11 Feed plate driving valve signal 12 24V for feed plate driving valve 13 14 15 Indexer does not work properly Upper thread nipper does not work properly Special lapel cutting device does not work ...

Page 97: ...al 5 Cloth opener valve signal 6 7 8 Work clamp valve 9 10 24V for work clamp cloth opener and lower thread trimmer 11 24V for upper thread adjuster upper thread trimmer and knife driving 12 Upper thread adjuster does not work Upper thread can not be trimmed Lower thread can not be trimmed Knife does not work Cloth opener does not work Work clamp does not work One of error codes E12 E15 E42 E45 E7...

Page 98: ...riving sensor when indexer is attached 2 Left driving sensor signal when indexer is attached 3 24V for left driving sensor when indexer is attached 4 0V for right driving sensor when indexer is attached 5 Right driving sensor signal when indexer is attached 6 24V for right driving sensor when indexer is attached 7 8 9 10 0V for feed plate home position sensor when indexer is attached 11 Feed plate...

Page 99: ...to poor contact 1 5V 2 24V 3 0V 4 55V 5 55V 6 0V P0V 7 0V P0V Power does not come on Feed bracket does not move Machine operation becomes unstable Home position can not be found Error code E80 appears P13 DC55 JAPAN SOLDERLESS TERMINAL MFG CO LTD VHR 2N Pin no Signal name Probable symptoms due to poor contact 1 55V 2 0V P0V Feed bracket does not move Home position can not be found Error code E80 a...

Page 100: ...11V 8 11V 9 5V 10 5V No keys on panel are activated P19 FOOT JAPAN SOLDERLESS TERMINAL MFG CO LTD PHR 6 Pin no Signal name Probable symptoms due to poor contact 1 Start switch signal common side 2 Start switch signal 3 Work clamp switch signal common side 4 Work clamp switch signal 5 Reserved common side 6 Reserved Work clamp does not move when work clamp switch is pressed Machine does not start H...

Page 101: ... 9 24V 10 24V Indexer does not work properly One of error codes E07 E37 E38 E66 E67 and E68 appears P24 OPTION not attached P25 FAN L JAPAN SOLDERLESS TERMINAL MFG CO LTD PHR 3 Pin no Signal name Probable symptoms due to poor contact 1 24V 2 Fan lock error signal 3 0V Error code E94 appears P26 SELECT MOLEX 5566 10A Pin no Signal name Probable symptoms due to poor contact 1 TYPE 1 2 TYPE 2 3 TYPE ...

Page 102: ... 5 0V One of error codes E26 E92 E98 and E99 appears P3 DC18 JAPAN SOLDERLESS TERMINAL MFG CO LTD PHR 11 Pin no Signal name Probable symptoms due to poor contact 1 18V A18V 2 0V A0V 3 4 18V B18V 5 0V B0V 6 7 18V C18V 8 0V C0V 9 10 18V D18V 11 0V D0V Machine motor does not run Rotation of machine motor is not correct Error code E70 or E91 appears P4 ACIN JAPAN SOLDERLESS TERMINAL MFG CO LTD LP 04 2...

Page 103: ...o poor contact 1 0V 2 0V 3 0V 4 0V 5 T x D 6 DTR 7 R x D 8 DSR 9 EMLED 10 12V 11 12V 12 12V 13 12V 14 5V 15 5V 16 5V No keys on the operation panel are activated Programmer does not work P3 PRG JAPAN SOLDERLESS TERMINAL MFG CO LTD PHR 10 Pin no Signal name Probable symptoms due to poor contact 1 0V 2 0V 3 T x D 4 DTR 5 R x D 6 DSR 7 12V 8 12V 9 5V 10 5V Programmer does not work ...

Page 104: ...tion can not be found Error code E52 or E82 appears P2 DC55 JAPAN SOLDERLESS TERMINAL MFG CO LTD VHR 2N Pin no Signal name Probable symptoms due to poor contact 1 55V 2 0V P0V Feed bracket does not move Home position can not be found Error code E80 appears P3 CONTROL JAPAN SOLDERLESS TERMINAL MFG CO LTD H8P SHF AA Pin no Signal name Probable symptoms due to poor contact 1 θ axis PM clock signal 2 ...

Page 105: ... 97 5 4 Specification harness connections 02 12 52 specifications L1 L2 L3 L4 02 12 52 specifications 00 01 specifications L5 L6 L7 The dotted lines indicate 12 specifications and the broken lines indicate 52 specifications only 3535Q ...

Page 106: ...d bracket to the back position OFF ON 4 OFF OFF ON Single pedal operation 5 OFF Dual pedal operation OFF ON 6 OFF OFF ON 7 OFF OFF ON Maximum stitch width correction amount 2 0 mm 8 OFF Maximum stitch width correction amount 1 0 mm OFF 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...

Page 107: ...ng device enabled 1 OFF Special lapel cutting device disabled OFF ON Button hole sensor of special lapel cutting device enabled 2 OFF Button hole sensor of special lapel cutting device disabled OFF ON With pressure sensor 3 OFF Without pressure sensor OFF ON 4 OFF OFF ON Upper thread nipper enabled 5 OFF Upper thread nipper disabled OFF ON Lower thread trimming enabled 6 OFF Lower thread trimming ...

Page 108: ...POWER SUPPLY EQUIPMENT RH 981A 100 Circuit board DIP switch D No ON OFF Setting items Default ON 1 OFF OFF ON 2 OFF OFF ON 3 OFF OFF ON 4 OFF OFF ON 5 OFF OFF ON 6 OFF OFF ON 7 OFF OFF ON 8 OFF OFF 1001Q ...

Page 109: ... will appear in the program number display 5 and the memory switch setting 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 Re...

Page 110: ...peed 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 used OFF Fly indexer is not used 1 9 1 1 12 Cloth setting position when fly indexer is used 1 Left setting position 2 Horizontal ...

Page 111: ...nstions 3536Q 3537Q Y axis home position sensor magnetic sensor Knife ON sensor photo sensor X axis home position sensor magnetic sensor Lower thread trimmer OFF sensor cylinder sensor Looper base θ axis home position sensor magnetic sensor Safety sensor limit sensor ...

Page 112: ...is home position sensor is out of order its connectors are not attached correctly or the cord does not flow electricity error code E 50 or E 80 will appear Y axis home position sensor The Y axis home position sensor determines the home position of the feed bracket in the Y direction The Y axis home position sensor is set to on only when the feed bracket is at the home position If the Y axis home p...

Page 113: ... base home position sensor is out of order its connectors are not attached correctly or the cord does not supply electricity error code E 52 or E 82 will appear Knife ON sensor The knife ON sensor is intended to sense that the operation of the cutter lever 1 has been completed and to know the cutter lever 1 lift stroke The cutter sensor partition plate slit 3 is attached to link C 2 which moves th...

Page 114: ...the cord does not supply electricity error code E 15 E 45 or E 75 will appear Safety sensor The limit switch is attached to the front of the bed The safety sensor is intended to check that the machine head is positioned correctly for safe operation The safety sensor will be activated to stop all motions when the machine head is raised during sewing If the machine head is kept raised the safety sen...

Page 115: ...ons 6 1 Solenoid valves and air tubes 6 1 1 Adjusting the solenoid valve speed controllers There are 3 speed controllers No 3 for lower thread trimming No 5 for upper thread trimming and one for the knife 1 As for the No 3 and No 5 speed controllers adjust their heights to 10 mm Note If the speed controllers are excessively throttled error codes including E 75 lower thread and operations are incor...

Page 116: ...oth opener 2 Cylinder assembly A 16X15 3 Cylinder assembly B 16X15 Lower thread trimming 4 Cylinder assembly B 16X30 B Auxiliary clamp 5 Cylinder assembly 10X15J C Upper thread tightening 6 Cylinder assembly 10X15 Upper thread trimming 7 Cylinder assembly 10X15 D Knife 8 Cylinder assembly 63X100 02 12 52 specifications only ...

Page 117: ...09 6 2 Air tube layout Reference Dimensions for cylinder rod assembly 1 Upper thread release cylinder and sub presser cylinder 3549Q Work clamp cylinder For cloth opener For work clamp For lower thread trimming Work clamp cylinder 3550Q ...

Page 118: ...6 AIR PRESSURE MECHANISM RH 981A 110 2 Upper thread trimming cylinder 3 Cutter cylinder 4 Work clamp cylinder 3553Q 3552Q 3551Q ...

Page 119: ...6 AIR PRESSURE MECHANISM RH 981A 111 5 Cloth opener cylinder 6 Lower thread trimming cylinder 3554Q 3555Q ...

Page 120: ... released X and Y axes start to return to their home positions X and Y axes start to return to their home positions Upper thread is trimmed Upper thread is trimmed X and Y axes finish returning to their home positions X and Y axes finish returning to their home positions Hammer operates Work clamp rises Work clamp rises and cloth opener is closed Cloth opener is closed and lower thread is trimmed ...

Page 121: ...ogram number display 1 and the check result will appear in the detail display 2 3 Press the and keys to select a desired check mode F1 or F2 4 When the switch or sensor is turned on the corresponding segment on the detail display 2 or indicators on the operation panel will react Turn the switch on and off to check it and move the object by hand to check the sensor 5 When returning to normal operat...

Page 122: ...y stop connecting signal Segment 2 A 19 Head sensor Segment 2 B 20 Knife ON sensor Segment 2 C 21 Lower thread trimming OFF sensor Segment 2 D 22 Feed plate home position sensor Button hole cloth sensor Segment 1 A 23 Left driving sensor Hammer home position sensor Segment 1 B 24 Right driving sensor Button hole position sensor Segment 1 C 25 F1 Pressure sensor Segment 1 D 26 Specification harness...

Page 123: ... 46 Circuit board DIP switch C No 5 Segment 2 D 47 Circuit board DIP switch C No 6 Segment 2 C 48 Circuit board DIP switch C No 7 Segment 2 B 49 Circuit board DIP switch C No 8 Segment 2 A 50 Circuit board DIP switch D No 1 Segment 1 D P 51 Circuit board DIP switch D No 2 Segment 1 G 52 Circuit board DIP switch D No 3 Segment 1 F 53 Circuit board DIP switch D No 4 Segment 1 E 54 Circuit board DIP ...

Page 124: ...off the power 2 Turn on the power while pressing the key 3 Press the start switch 1 The machine will start to detect the home position The check code will appear in the detail display 2 4 Press the and keys to select the desired check code 5 Press the start switch 1 While the start switch is kept pressed the machine will work as it is specified by each check code 6 When returning to normal operati...

Page 125: ...ote Be sure to remove the work clamp and check the motion of the X feed mechanism C 12 After activating the buzzer for a second the Y feed mechanism will reciprocate in the range of 1 mm to 65 mm Note Be sure to remove the work clamp and check the motion of the Y feed mechanism C 13 After activating the buzzer for a second the θ feed mechanism will reciprocate in the range of 2 7 362 7 Note Be sur...

Page 126: ...ighest position I 11 E 12 Cutter sensor is ON Turn off the power I 20 O C 06 E 15 Lower thread trimming OFF sensor is OFF Turn off the power I 21 O C 04 E 26 PER terminal connection error Turn off the power E 27 External RAM error Turn off the power E 28 Panel communication start error Turn off the power E 29 Machine motor communication start error Turn off the power 2 Errors before operation Code...

Page 127: ... off the power I 23 O C 18 E 68 Feed plate right range sensor is not activated within a specified time Turn off the power I 24 O C 18 E 70 Needle up sensor is not activated within a specified time Turn off the power I 11 O C 07 E 71 Needle down sensor is not activated within a specified time Turn off the power I 12 O C 07 E 72 Cutter sensor is not activated within a specified time Turn off the pow...

Page 128: ...ror Turn off the power E 98 Power supply relay error Turn off the power E 99 Power supply circuit board overcurrent error Turn off the power 5 Errors when the special lapel cutting device is attached Code Explanation Resetting method I Input check No O Output check code E200 Hammer position sensor does not turn ON when changing to the straight buttonhole hammer Turn off the power I 24 I C 19 E201 ...

Page 129: ...ead safety switch replace the control circuit board E 03 1 Release the cloth presser switch Turn it off 2 Check if hand switch foot switch connector which is outside the control box is securely inserted 3 Check if connector P19 FOOT on the control circuit board is securely inserted and if any harness is broken or short circuited 4 With the power turned off separate connectors P19 FOOT and check if...

Page 130: ... relay connector replace the control circuit board E 07 E 37 E 67 1 Make sure that the valve unit of the indexer is supplied with air or wiring is correct 2 Check and adjust the position of the left driving sensor limit switch L of the indexer Refer to the instruction manual 3 Of connectors relayed to head harness check if the harness for the feed plate home position sensor is correctly attached t...

Page 131: ...ted 3 Replace the power supply circuit board with a new one 4 Replace the control circuit board with a new one E 27 1 Check if ROM chips of the control circuit board or panel circuit board are correctly inserted Check position orientation lead clinching etc 2 Replace the panel circuit board with a new one 3 Replace the control circuit board with a new one E 28 1 Check if ROM chips of the control c...

Page 132: ...Replace the θ axis home position sensor and its harness with a new one 7 Replace the control circuit board with a new one E 59 1 Turn on the power again 2 Make sure that ROM chips of the panel circuit board are correctly inserted Check position orientation lead clinching etc 3 Initialize memory 4 Replace the panel circuit board with a new one E 60 1 This is not an error This code indicates machine...

Page 133: ...f connector P12 POWER on the control circuit board without removing P12 from the harness as follows Considering pin 7 as 0V standard measure the voltage of pin 5 It is normal if the voltage is 55V Be careful not to touch any other place when measuring voltage If the voltage is 55V the cause of the error is the Y axis pulse motor or its harness is broken If the voltage is not 55V turn off the power...

Page 134: ...one E 95 1 With the power turned off check if the feed bracket moves to the left and right 2 Of the connectors relayed to the head harness check if the connector for the X axis pulse motor is securely inserted and if any harness is broken or short circuited 3 Check if connector P7 XPM on the control circuit board is securely inserted and if any harness is broken or short circuited 4 Replace the X ...

Page 135: ... air is supplied to valve unit of the special lapel cutting device or wiring is correct 2 Of connectors relayed to head harness check if the harness for the hammer home position sensor is correctly attached to the connector for the hammer home position sensor Check if there is no harness in the control box that is broken or short circuited 3 Check if connectors P9 EXINB and P21 EXOUT on the contro...

Page 136: ...7 SOFTWARE RH 981A 128 7 6 Control circuit block diagram 1 3842Q ...

Page 137: ...7 SOFTWARE RH 981A 129 7 7 Control circuit block diagram 2 3843Q ...

Page 138: ...SERVICE MANUAL Printed in Japan RH 981A I3080846H 2003 10 H 1 http www brother com ...