Brother S-7200A, Service Manual

Page 1: ...S 7200A Please read this manual before making any adjustments SINGLE NEEDLE DIRECT DRIVE STRAIGHT LOCK STITCHER WITH THREAD TRIMMER SERVICE MANUAL ...

Page 2: ... prevent accidents and injury to yourself or other people Indications DANGER 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 when using the machine or physical dama...

Page 3: ...ect 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 dealer or a qualified electrician for any electrical work that may need to be done The sewing machine weighs more than 48 kg The installation should be carried out by two or more people Do not connent...

Page 4: ...se 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 Use only th...

Page 5: ...ave been removed or are difficult to read please contact your nearest Brother dealer 1 2 3 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 Safety devices A Finger guard B Thread take up cover 4 Direction of operation 2084M Control box 2082M 2083M Oil pan ...

Page 6: ...erse feed 29 5 12 Adjusting the tension release wire 30 5 13 Adjusting the needle up stop position 31 5 14 Adjusting the treadle 31 5 15 Adjusting the rotary hook lubrication amount 40 43 32 5 16 Selecting tension release 33 5 17 Adjusting the presser foot floating amount minute lifting amount 33 6 REPLACING PARTS 34 6 1 Fixed knife 34 6 2 Movable knife 34 6 3 Rotary hook RP 35 6 4 Feed bar shaft ...

Page 7: ... presser foot lifter 10 mm Option Feed dog 4 row Feed dog height 0 8 mm 1 2 mm Bed size 517 5 mm 178 mm Arm pocket size Arm pocket width 300 mm Arm height 137 mm Needle DB 1 DP 5 NS 9 11 11 18 19 22 Motor AC servo motor 4 pole 450W Control circuit Microprocessor Power requirement Power consumption Single phase 100 120V 200 240V 3 phase 200 240V 380 415V Power rating 400VA Weight 48kg When sewing a...

Page 8: ...set SA2407 001 Tension gauge set 183922 101 Material edge sensor S2 SENSOR S7200A J80975 001 Table parts Part name Part code Standing operation 2 pedal 6 Two pedals kick pedal J80081 040 Standing operation 3 pedal 40 Three pedals J80380 040 Standing operation 3 pedal two speed Three pedals J80630 001 Foot plug set NDD for control box J04099 001 Spacer set 183504 009 Caster set 183501 001 0772M 077...

Page 9: ... used Carrying the machine The machine should be carried by the arm by two people as shown in the illustration Hold the motor cover A by hand also so that the pulley does not rotate Tilting back the machine head Hold section B 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...

Page 10: ... that is set here when the treadle is fully depressed 3 The start backtack sewing speed can be set to a speed from 220 rpm to 3 000 rpm The factory default setting is 1 800 rpm 4 When sewing starts the sewing speed display disappears and returns to the orange display NOTE When the main display is green normal key operations such as the start backtack key and the fixed stitch key cannot be used Pre...

Page 11: ...late of the control box Touching areas where high voltages are present can result in severe injury ON Presser foot is lowered Export specification 1 Presser foot position when the treadle is returned to the neutral position after thread trimming OFF Presser foot is kept raised Japanese specification only See NOTE 1 ON Enabled 2 Presser foot lowering when the treadle is depressed to step 1 See NOTE...

Page 12: ...ing range 4 The buzzer will sound for approximately 1 second and then the setting will be accepted The main display will return to the stitch number display orange Press for 2 seconds or more NOTE If you depress the treadle before pressing the ENTER key the main display will return to orange and the setting value will not be changed If you change the function number after changing the setting valu...

Page 13: ...ntrol key 9 0 0 1 End backtack sewing speed 0 Separate setting from start backtack sewing speed is possible 1 Setting for start backtack sewing is used 11 NOTE 1 0 0 4 Option actuator operation setting 0 Half stitch correction sewing 1 Single stitch correction sewing 2 Single reverse stitch correction sewing reverse feed 3 Thread trimming 4 Single end backtack cycle cancel 12 0 0 1 Presser foot st...

Page 14: ...then end backtacking starts 1 Decelerates to end backtacking speed then end backtacking starts Cycle time can be shortened 27 0 0 1 Continuous backtacking operation 0 Stitch number A B C D 1 Stitch number A B x D times 28 0 0 1 Feed direction when stopping immediately after start backtacking 0 Quick reverse solenoid turns off and stops in normal feed direction 1 After stopping quick reverse soleno...

Page 15: ...sser foot See NOTE 14 0 Presser foot cannot be raised and lowered by depressing the treadle backward 1 Above operation is possible 41 0 0 1 Presser foot lifting when treadle is depressed backward to 1st step after returning to neutral 0 Possible 1 Not possible 42 0 0 1 Operation when treadle is depressed backward 0 Thread trimming operation 1 Thread trimming operation disabled presser foot is rais...

Page 16: ... as normal 1 Starting using treadle is disabled thread trimming by depressing treadle backward is possible 2 Starting using treadle is completely disabled once treadle is returned to neutral and operation stops 55 NOTE 16 0 0 1 Operation after treadle is depressed backward or knee switch is operated when presser foot is raised 0 When treadle is returned to neutral presser foot is raised 1 When tre...

Page 17: ... stop operation 66 NOTE 18 0 0 1 Presser foot lift timing during highest needle position stop operation 0 Presser foot is raised after needle bar is raised 1 Presser foot is raised before needle bar lift operation starts See NOTE 19 67 NOTE 18 0 degrees 20 20 degrees Highest needle position stop position setting 68 NOTE 20 0 0 1 Seam matching function during automatic backtacking 0 Operation does ...

Page 18: ...T key on the operation panel When set as a sewing speed actuator Connect the switches to connector CN11 on the control circuit board When the low speed switch is pressed the sewing speed becomes 1 000 rpm The speed can be changed by setting Function No 122 When the medium speed switch is pressed the sewing speed becomes 3 000 rpm The speed can be changed by setting Function No 121 When the high sp...

Page 19: ...ime of 10 seconds can be changed by setting Function No 72 Function No 71 can be used to set the number of stitches until the puller is lowered after sewing starts If the puller is raised in synchronization with the automatic presser foot lifter while the sewing machine is stopped after thread trimming this operation occurs When set to needle cooler synchronized output during operation Output is s...

Page 20: ...titch thread trimming thread wiping After thread trimming the thread wiper signal is output Use Function No 109 and No 110 to set the timer operation When set to pneumatic wiper After thread trimming output is synchronized with the automatic presser foot lifter Use Function No 111 and No 112 to set the timer operation When the presser foot is lowered option output turns off Motor Option Needle up ...

Page 21: ...ion No 63 is set to 1 NOTE 24 Setting is enabled when Function No 22 or No 26 is set to 1 NOTE 25 Setting is enabled when Function No 68 is set to 1 The stopping position is the angle after the need up signal turns on NOTE 26 Setting is enabled when Function No 68 is set to 1 The reverse feed mechanism switches at the stopping position When the stopping time has elapsed the sewing machine restarts...

Page 22: ...anding operation variable speed pedal 88 0 0 2 Treadle speed curve 0 Constant 1 Curves downward 2 Curves upward Settings indicated with are enabled when the power is turned off and then back on With the treadle neutral position as the 0 point the values in the forward direction are plus values and those in the backward direction are minus values so that the speeds accelerate or decelerate around t...

Page 23: ...rt backtacking limit speed SBL See NOTE 27 96 1 800 rpm INCH 3 000 rpm End backtacking speed EBT 98 HIL rpm INCH HIL rpm Automatic speed AUTO 99 NOTE 28 INCH 5 000 rpm Maximum sewing speed limit speed HIL See NOTE 29 NOTE 27 This is the upper limit for the start backtacking speed setting Refer to page 4 for details on start backtacking speed settings NOTE 28 This setting is read from the head dete...

Page 24: ...on output C7 NOTE 30 Setting is enabled when Function No 70 is set to 2 NOTE 31 Setting is enabled when Function No 70 is set to 4 NOTE 32 Setting is enabled when Function No 70 is set to 5 NOTE 33 Setting is enabled when Function No 70 is set to 2 or 5 NOTE 34 The stitch number control output signal can be set in accordance with the variable input signal Stitch number control output signal The va...

Page 25: ...F E F Name label attaching 1 E F E F G 2 E F G H H G F E Pocket sewing 1 3 E F G H I H G F E Pocket sewing 2 NOTE 35 Setting is enabled when Function No 37 is set to 0 NOTE 36 Setting is enabled when Function No 37 is set to 1 NOTE 37 When set to 1 stitch number G is set for function No 23 When set to 2 stitch number G is set for function No 23 and stitch number H is set for Function No 24 When se...

Page 26: ...ion 1 120 Timer operates 1 120 seconds 128 0 0 3 Flicker reduction function when flickering occurs from fluorescent light 0 None 1 Medium flicker reduction 2 Low flicker reduction 3 High flicker reduction 4 Do not use this setting otherwise the motor will overheat 129 0 2 2 Motor acceleration gain Do not change this setting 130 0 2 2 Motor deceleration gain Do not change this setting NOTE 38 Setti...

Page 27: ... pressing the FUNC key on the operation panel turn on the power switch The main display will change to orange and iniT FUnC will be displayed 2 Press the ENTER key Initialization of the function setting data will be carried out and the iniT FUnC display will change to green 3 After this the operation panel and the treadle can be operated When an operation is carried out the display will return to ...

Page 28: ...placing consumable parts such as the rotary hook and knife If the power switch needs to be left on when carrying out some adjustment be extremely careful to observe all safety precautions 5 1 Adjusting the safety switch position The safety switch 1 is normally installed as shown in figure A However if the processing method used for the table leaves too much space between the machine head and the t...

Page 29: ...4 S specifications 0 1 0 2N 4 3 specifications 0 25 0 35N 4 5 specifications 0 30 0 5N 1 Push the needle thread with your finger until it is slightly higher than the thread tension bracket 5 and so that the upper thread is not pulled out 2 Pull the upper thread down until the thread take up spring 1 is at the same height as the base of the thread guide 3 and then measure the tension of the thread ...

Page 30: ... become less 5 4 Adjusting the presser foot height The standard height of the presser foot 1 is 6 mm when the presser foot 1 is raised by means of the lifting lever 2 1 Loosen the nut 3 of the adjustment screw 4 and then turn the adjustment screw 4 so that there is no pressure applied to the presser foot 2 Raise the lifting lever 2 The presser foot 1 will also rise 3 Remove the oil cap 5 4 Loosen ...

Page 31: ...eed lifting rock bracket stud 3 within a range of 90 from the reference line 4 to adjust the vertical height of the feed bar 5 Fig A 5 Tighten the screw 2 If you are worried about the angle of the feed dog 1 turn the shaft 6 while carrying out the above adjustment Figure B Refer to 5 6 Adjusting the feed dog angle on the next page for details of this operation 2279M 4 S 4 3 0 8mm 4 5 1 2mm Becomes...

Page 32: ...n Fig C In order to prevent puckering lower the front of the feed dog 1 In order to prevent the material from slipping raise the front of the feed dog 1 5 Securely tighten the set screws 4 If you would like to tilt the feed dog 1 further turn the feed lifting rock bracket stud 5 while carrying out the above adjustment Figure D Refer to 5 5 Adjusting the feed dog height on the previous page for det...

Page 33: ...op of the feed dog 1 and the top of the needle plate 2 should be aligned and the point of the needle should be approximately 1 mm below the needle plate 2 4 5 The top of the feed dog 1 and the top of the needle plate 2 should be aligned and there should be a clearance of approximately 3 mm between the point of the needle and the needle plate 2 1 Tilt back the machine head 2 Loosen the two set scre...

Page 34: ...The needle should rise by 1 8 mm 2 2 mm for 5 specifications and the distance from the needle hole to the tip of the rotary hook should be 0 0 5 mm 2 Loosen the set screws 5 and then align the tip of the rotary hook 3 with the center of the needle 4 The distance between the tip of the rotary hook 3 and the needle 4 should be approximately 0 0 05 mm 3 Securely tighten the set screws 5 Checking the ...

Page 35: ...3 If adjustment is required carry out the following 1 Tilt back the machine head 2 Loosen the screw 1 3 Adjust by turning the eccentric pin 2 within a range of 90 If the eccentric pin 2 is turned more than 90 the adjustment will be reversed If the stitch length is larger for normal feed than for reverse feed Turn the eccentric pin 2 clockwise If the stitch length is smaller for normal feed than fo...

Page 36: ... by 0 5 1 mm at this time When the solenoid plunger 2 is released the tension disc presser 1 tension disc 3 closes 1 Loosen the nuts 4 and 5 and then push the solenoid plunger 2 by 2 3 mm 2 Tighten the left side nut 4 until the tension disc presser 1 starts to open 3 Check that the tension disc presser 1 opens fully when the solenoid plunger 2 is pushed all the way and that the tension disc presse...

Page 37: ...on of approximately 10 for the upper shaft 5 14 Adjusting the treadle Forward depression sensitivity adjustment 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 heaviest and the setting becomes progressively...

Page 38: ...inute without sewing any material following the same start stop pattern as when actually sewing 4 Place the lubrication amount check sheet 1 underneath the rotary hook 2 and hold it there Then run the sewing machine at the normal sewing speed for 8 seconds Any type of paper can be used as the lubrication amount check sheet 1 5 Check the amount of oil which has spattered onto the sheet Adjusting th...

Page 39: ...e screw 2 5 Replace the rubber cap 1 5 17 Adjusting the presser foot floating amount minute lifting amount When sewing stretch materials and materials with long pile you can make minute adjustments to the floating amount for the presser foot 1 in accordance with the material 1 Turn the sewing machine pulley by hand to move the feed dog 2 below the needle plate 3 2 Use the lifting lever to lower th...

Page 40: ...at the grease under any circumstances as they can cause vomiting and diarrhea Keep the oil out of the reach of children 6 1 Fixed knife 1 Tilt back the machine head 2 Remove the screw 1 and then remove the rotary hook stopper 2 3 Remove the screw 3 and then remove the fixed knife 4 Carry out the above steps in reverse to install the fixed knife 4 Sharpening the fixed knife If the cutting performan...

Page 41: ...hook RP 4 and the needle After installing the rotary hook RP adjust the needle and rotary hook timing Refer to page 28 6 Install the feed dog 2 7 Install the needle plate 1 Adjust the installation position of the feed dog 2 so that it is in the middle of the needle plate 1 groove 8 Install the presser foot Adjusting the adjusting screw Tighten the adjusting screw 5 as far as it will go and then tu...

Page 42: ...part as shown in the arrow until a small amount of grease overflows 2 Tighten the screws to force the grease in 3 Wipe away any excess grease from around the screws 4 Apply grease to the meshing areas areas of each part 5 Install each part to the sewing machine Feed bar shaft unit Grease Grease 2317M Grease Grease 43 45 specifications Grease 2318M Grease Grease Be particularly sure to apply grease...

Page 43: ...treadle is depressed The power indicator 3 will flash NOTE If you do not apply grease when the GREASEUP notification appears the notification will continue to appear and the power indicator 3 will flash each time the power is turned on until you reset the notification by carrying out the procedure on the following page If you continue to use the sewing machine after the GREASEUP notification appea...

Page 44: ...ter the grease has been applied carry out the following procedure to reset the cumulative time between grease applications 1 Turn the power switch to ON GREASEUP will flash in the main display 1 and the buzzer will sound 2 Press the RESET key 2 The main display 1 will change to stitch number display mode 3 Press the FUNC Function key 4 n 134 xxx will appear in green in the main display 1 xxx repre...

Page 45: ... the control box 4 and the electrical brake is then applied to slow the DD motor 5 2 The encoder circuit board that is installed to the DD motor 5 sends a signal to the control box 4 so that the electrical brake is applied in order to stop the sewing machine at the stopping position needle up or needle down set by the pulley 6 that is attached to the DD motor 5 C When the treadle is depressed back...

Page 46: ...evere injury Removal 1 Remove the repeat cable tie 1 and then disconnect the connectors 2 to 7 from the sewing machine Be careful not to break the pawls of connectors 5 6 and 7 2 Disconnect the power supply connector 8 and the motor connector 9 3 Disconnect the ground wire 10 4 Loosen the nuts 11 and 12 without removing them 5 Remove the bolt 13 and nut 14 6 Pivot the control box around the bolt 1...

Page 47: ...late Model MD 7410 Single phase MD 7510 Three phase Serial No 1 4 4 5 2 1 Japan 2 Asia Middle East 3 USA Mexico 4 Canada 5 Oceania C TICK 7 Turkey North Africa 9 China Destination L Europe Greece CE 1 100V 2 110V 3 200V 5 220 240V Power supply voltage 8 380 415V 4 1 forward 1 backward step type Treadle unit 6 2 forward 2 backward step type Operation panel 4 External Sewing machine 1 S 7200A Phase ...

Page 48: ...S 7200A 9 CONTROL BOX AND MOTOR 42 Motor Serial No 2326M 2327M ...

Page 49: ...lay connector 6 Coupler connector Connect to power supply circuit board connectors 10 Control power supply connector Connect to transformer connectors 1 Treadle connector Connect to treadle unit connector 20 Standing operation connector Connect to plug sold separately for standing operation 13 Puller connector Connect to solenoid for puller or other device 3 Option connector 1 Connect to sewing sp...

Page 50: ...p stop position 7 ENG Machine shaft sync signal 45 pulses stitch 8 STBY Operation signal output H level Operation in progress 9 S0V 0V GND 10 ENC A A phase signal output Encoder A phase 180 pulses stitch 11 ENC B B phase signal output Encoder B phase 180 pulses stitch Open collector output 22 Connector CN9 Signal name Remarks 1 5V DC 5V 2 UNTH_LED Stitch counter LED signal output Stitch counter wa...

Page 51: ... an ohmmeter in the x 1 range If the value is as shown in the table below the connector is normal Between 2 3 Between 3 4 Between 4 2 Approx 1 6Ω Power switch 1 Disconnect the power supply connector 6P 2 from the control box 2 Turn on the power switch 3 Measure the voltage at the power supply connector 2 using the AC voltage range of a multimeter and check that the voltage is within the allowable ...

Page 52: ...Quick reverse solenoid Approx 4 8Ω When actuator is pressed 0Ω Between 6 13 When actuator is released Ω When machine head is upright switch ON 0 Ω Between 7 14 When machine head is tilted back switch OFF Ω Solenoid type presser lifter connector 1 Disconnect the solenoid type presser lifter connector 6P 2 from the control circuit board 2 Measure the resistance of the solenoid type presser lifter co...

Page 53: ...rd depression strokes on page 49 Set the neutral position maximum forward position and maximum backward position The first modulation position for the treadle depression force is set automatically D Depression force When depressed forward and depressed backward The depression force hardly changes at all from the start of depression until full depression When depressed forward and depressed backwar...

Page 54: ...um speed reaching point S5 1 S5 1 S5 Maximum forward depression point 14 5 12 14 5 32 81 S6 Back automatic presser lifter operating point 2 NOTE 2 14 80 S7 Thread trimmer operating point 5 22 5 35 S8 Maximum back depression point 8 28 8 43 NOTE 1 Setting is enabled when DIP switch 1 is set to ON and Function No 13 is set to 1 NOTE 2 Setting is enabled when Function No 12 is set to 0 When the conne...

Page 55: ...it board are replaced it will be necessary to make new settings according to the procedure described below Use the following procedure to set the operating positions for the depression stroke 1 Signal setting entry 1 Turn off the power switch 1 2 Set DIP switch No 4 to ON 3 While pressing the thread trimming key 2 turn on the power switch 1 PdFF x xxx will appear in the main display 3 x xxx indica...

Page 56: ...d position With the treadle depressed backward to the maximum backward position press the thread trimming key 2 Pd x xxx will appear in the main display 3 5 Completion of setting 1 Press the ENTER key 4 The buzzer will sound and the main display 3 will switch off NOTE If you do not press the ENTER key 4 the settings will not be memorized 2 Turn off the power switch 1 3 Set DIP switch No 4 to OFF 2...

Page 57: ...r turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box Touching areas where high voltages are present can result in severe injury 1 Connect the foot plug 1 to connector CN3 on the control circuit board 2 Connect the standing pedal connector 2 to the foot plug 1 3 Secure the standing pedal cord 3 with a repeat cable tie ...

Page 58: ...nnector 1 DC 8 V 2 High speed switch 3 Thread trimmer switch 4 SOV 5 Spare 6 Low speed switch 7 Presser foot switch 8 Variable speed input 9 Ground NOTE Connector types Manufacturer Connector No Connector terminal MOLEX 1292 P 1380 TL 2340M 1868M 1867M High speed Thread trimming Low speed Presser foot High speed Thread trimming Low speed Presser foot ...

Page 59: ...ght Is the lower thread tension too weak or is the upper thread tension too strong Adjust the lower thread tension or upper thread tension Instruction manual 3 Loops appear in seam Is the thread path not smooth enough Use a file with a fine grain or sandpaper to polish smooth the thread path Is the bobbin not turning smoothly Pull out the lower thread to check that there is no slackness in the thr...

Page 60: ...nual Instruction manual 6 Uneven seam Is the presser foot pressure too weak Adjust the presser foot pressure Is the feed dog too low Adjust the feed dog height Is the bobbin scratched If the bobbin is damaged smooth it with an oiled grindstone or replace it Instruction manual 25 7 Large degree of puckering excess tension Is the upper thread tension too strong Make the upper thread tension as weak ...

Page 61: ... thread correctly Is the rotary hook sufficiently lubricated 40 43 specifications If the oil gauge is down to the lower reference line in the oil gauge window add more oil Is the upper or lower thread tension too weak or too strong Adjust the upper thread or lower thread tension Is the upper thread may be loose because the thread take up spring operating range is too small Adjust the position of t...

Page 62: ... turned on and treadle is pressed Is the power supply connector disconnected from the control box Insert the connector securely 45 16 Machine does not operate at high speed Is the sewing speed setting or backtack speed setting incorrect Use the sewing speed control keys to set the high speed Instruction manual 17 Machine stops during sewing Is the fixed stitch key turned on Press the fixed stitch ...

Page 63: ...then turn off the power 2 After the operation panel display has turned off eliminate the cause of the error and then turn the power back on Error code Possible cause Page Err 1 Is the power supply voltage abnormally high Check the voltage Problem with control box Replace the control box 41 Err 2 Is connector CN7 or CN8 inside the control box disconnected Insert the connector securely 43 Err 3 Is c...

Page 64: ...is a problem in communication with the operation panel CPU Is connector CN5 inside the control box disconnected Insert the connector securely Problem with operation panel or control box Replace the operation panel or control box 43 40 Err 8 This appears on the display when the sewing machine has been operating continuously for 3 minutes or more Turn the power switch off and then back on again and ...

Page 65: ...motor driver Replace the control box 40 Err 16 This is displayed when the sewing machine motor locks during thread trimming Remove any thread that is tangled Check that there are no problems with the thread trimming mechanism Err 18 This is displayed when data could not be written correctly into the memory element of the control circuit board Replace the control box 40 Err 19 This is displayed whe...

Page 66: ...rEASEUP This appears on the display when the sewing machine has continued to be used for a certain period after the GREASEUP notification appears without the grease being applied without the reset procedure being carried out Apply grease and then carry out the reset procedure 37 Err 101 diP SW 4 Is DIP switch No 4 inside the control box set to ON Set DIP switch No 4 to OFF 44 If an error code that...

Page 67: ...SERVICE MANUAL S 7200A I30508 38B 2003 05 B 1 15 1 Naeshiro cho Mizuho ku Nagoya 467 8561 Japan Phone 81 52 824 2177 Printed in Japan ...