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Brother S-7200A Service Manual
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Brother S-7200A Service Manual

Brother S-7200A Service Manual

Single needle direct drive straight lock stitcher with thread trimmer
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See also: Basic Operation Manual , Instruction Manual
S-7200A
SERVICE MANUAL
Please read this manual before making any adjustments.
SINGLE NEEDLE DIRECT DRIVE STRAIGHT LOCK STITCHER
WITH THREAD TRIMMER

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

  • Page 2: Safety Instructions

    This service manual is intended for S-7200A; be sure to read the S-7200A instruction manual before this manual. Carefully read the “SAFETY INSTRUCTIONS” below and the whole of this manual to understand this product before you start maintenance. As a result of research and improvements regarding this product, some details of this manual may not be the same as those for the product you purchased.

  • Page 3: Notes On Safety

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

  • Page 4: Maintenance And Inspection

    When threading the needle switch. Then contact your nearest Brother dealer or a When replacing the bobbin and needle qualified technician. When not using the machine and when leaving...

  • Page 5: Warning Labels

    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. Be sure to connect the ground. If the ground connection is not...

  • Page 6: Table Of Contents

    12-2. Error code displays .........57 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 S-7200A...

  • Page 7: Machine Specifications

    Lubricated / Lubricated / Rotary hook RP for light materials for medium materials for heavy materials (lubrication-free rotary hook) Lubricating oil -40[] -43[] -45[] Rotary hook High-speed spindle – High-speed spindle Needle bar Special Brother grease Special Brother grease S-7200A...

  • Page 8: Optional Parts

    (Two pedals +kick pedal) 0772M Standing operation 3 pedal #40 J80380-040 (Three pedals) Standing operation 3 pedal two-speed J80630-001 (Three pedals) 0773M Foot plug set, NDD J04099-001 (for control box) 1144M Spacer set 183504-009 0527M Caster set 183501-001 0528M S-7200A...

  • Page 9: Notes On Handling

    Returning the machine head to the upright position 1. Clear away any tools, etc. which may be near the table holes. 2. While holding the face plate with your left hand, gently return the machine head to the upright position with your right hand. 2089M S-7200A...

  • Page 10: Function Settings

    When the main display is green, normal key operations such as the start backtack key and the fixed stitch key cannot be used. Press the MAX key once more to clear the sewing speed display and return to the orange display. Normal key operations can then be carried out. S-7200A...

  • Page 11: Using The Lock Key

    (NOTE 2) The treadle unit should also be adjusted when using this function. (Refer to page 47.) (NOTE 3) When set to ON, treadle operation is disabled, so it should always be left at OFF. If set to ON, the messages “ 「 “ (green) and “ “ (orange) will flash alternately in the display. S-7200A...

  • Page 12: Setting Functions

    ・ If you change the function number after changing the setting value but before pressing the ENTER key, the setting value will not be changed. You need to press the ENTER key for each function number for the setting to be accepted. S-7200A...

  • Page 13: Function List

    0: Slow stop control without step operation 1: Above control is not used (NOTE 1) If function No. 69 is set to "3", operation is enabled. (NOTE 2) Presser foot will not drop if DIP switch 1 is set to OFF. S-7200A...
  • Page 14 (NOTE 5) Stitch number setting is enabled when Function No. 118 is set to "2" or "3". (NOTE 6) Stitch number setting is enabled when Function No. 118 is set to "3". (NOTE 7) Operates when treadle is lightly pressed when Function No. 31 is set to "0". S-7200A...
  • Page 15 (NOTE 12) Only enabled when Function No. 35 is set to "1". (NOTE 13) Only enabled when Function No. 35 is set to "0". If set to "10", response is fastest and operating noise is greatest. (NOTE 14) Setting is only enabled when DIP switch 1 is set to OFF. S-7200A...
  • Page 16 (NOTE 16) Setting is only enabled when DIP switch 1 is set to ON. (NOTE 17) Setting is only enabled when DIP switch 2 is set to ON. *… Settings indicated with " * " are enabled when the power is turned off and then back on. S-7200A...
  • Page 17 (NOTE 19) Operation is disabled when Function No. 62 is set to "1". Presser foot is raised after needle bar is raised. (NOTE 20) Used when you would like to match the seam accurately during automatic backtacking. Use Function No. 78 to set the stop position and Function No. 79 to change the time before restarting. S-7200A...
  • Page 18 ・ When the high speed switch is pressed, the sewing speed returns to the maximum sewing speed that has been set using the MAX key. <When set as an option actuator> Connect to connector CN9 on the control circuit board. Option Actuator 2251M ・ Set the operation using Function No. 11. S-7200A...
  • Page 19 ・ The delay time after thread trimming until output turns off is set using Function No. 112. If the needle stops in the down position after the edge of the material is detected, output turns off when the needle stops. Motor Option Needle up signal Fixed stitch number E Material edge sensor signal 2253M S-7200A...
  • Page 20 ・ 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. Needle up stop Motor Presser foot lifting Option 2256M S-7200A...
  • Page 21 ・ If the values are set to values that are greater than the initial value (+ direction), the quick reverse solenoid on/off timing becomes slower. If the seam length immediately after switching occurs is short, change the setting to a value in the + direction. S-7200A...
  • Page 22 (ex. 1) Setting for Function No. 80 Speed Neutral Treadle backward stroke Depression stroke 2258M (ex. 2) Setting for Function No. 83 Speed Neutral Treadle backward stroke Depression stroke 2259M (ex. 3) Setting for Function No. 85 Speed Neutral Treadle backward stroke Depression stroke 2260M S-7200A...
  • Page 23 (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 detector unit. (NOTE 29) This is the upper limit for the maximum sewing speed setting. Refer to page 4 for details on maximum sewing speed settings. S-7200A...
  • Page 24 External output; signal is open collector output within maximum 10 mA 2262M Motor Needle up signal Variable input signal Output signal 2263M NOTE: If Function No. 112 and No. 113 are set to "0", output is synchronized with the variable input signal. S-7200A...
  • Page 25 When set to "2", stitch number G is set for function No. 23 and stitch number H is set for Function No. 24. When set to "3", stitch number G is set for function No. 23, stitch number H is set for Function No. 24 and stitch number I is set for Function No. 25. S-7200A...
  • Page 26 Settings indicated with " * " are enabled when the power is turned off and then back on. Function No.132−135 The following function numbers show maintenance information. Description of displays Cumulative power on time (Actual time = Displayed time x 10) Cumulative operating time (Actual time = Displayed time xxxx x 10) ROM version (x.xxx) S-7200A...

  • Page 27: Clearing Saved Data (Initialization)

    When initialization is complete, the main display will change to green and "init rPM" will be displayed. After this, the operation panel and the treadle can be operated. When an operation is carried out, the display will return to the normal display. S-7200A...

  • Page 28: Adjustments

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

  • Page 29: Adjusting The Thread Take-Up Spring

    (1). Scale NOTE: If using the tension gauge (7) (sold separately) to measure the tension, take the reading from the scale on the side of the red line. <-4[ ]S> <-4[ ]3> <-4[ ]5> 0.1–0.2N 0.25–0.35N 0.3–0.5N 2276M S-7200A...

  • Page 30: Adjusting Arm Thread Guide R

    (1) is at the standard height of 6 mm. 5. Tighten the bolt (6). 6. Replace the oil cap (5). 7. Adjust the presser foot pressure using the adjustment screw (4), and then tighten the nut (3). 2278M S-7200A...

  • Page 31: Adjusting Of The Feed Dog Height

    (Figure (B)) lower (Refer to "5-6. Adjusting the feed dog angle" on the next page for details of this operation.) 2280M Becomes higher Needle plate Standard Becomes lower 2281M Becomes higher Becomes higher Standard Standard Becomes lower Becomes lower 2282M S-7200A...

  • Page 32: Adjusting The Feed Dog Angle

    Needle has been adjusted, so it will be necessary to re-adjust the plate height of the feed dog (1). Standard Lower the front 2284M Back is lowered Raise the front Standard Standard Back is raised Lower the front 2285M S-7200A...

  • Page 33: Adjusting The Needle Bar Height

    NOTE: Do not turn the vertical cam (3) too far in the direction of (C), otherwise it could cause the needle to break. Needle timing is (Standard) Needle timing 3. After adjustment is completed, securely tighten the two advanced is retarded screws (5). 2289M S-7200A...

  • Page 34: Adjusting The Needle And Rotary Hook Timing

    (7) is enough to allow the thread being used to pass through smoothly. The clearance should be 0.4–0.7 mm for -4[]S / 4[]3 models, and 0.6–0.9 mm for -4[]5 models. <-4[]S / 4[]3> 0.4–0.7mm <-4[]5> 0.6–0.9mm 2293M 2294M S-7200A...

  • Page 35: Quick Reverse Mechanism

    (3) operates smoothly. If the solenoid lever (3) does not operate smoothly, retighten the eccentric pin (2) while referring to step 4 above. Normal feed length Normal feed length becomes smaller becomes longer 2297M S-7200A...

  • Page 36: Adjusting The Tension Release Wire

    1. Check that the solenoid lever (6) has returned fully. 2. Check that the tension release wire (7) is not stretched. 3. Adjust using nuts (4) and (5) as described above. * If adjustment is not possible, adjust the tension of the tension release wire (7). 0.5–1mm 2300M S-7200A...

  • Page 37: Adjusting The Needle Up Stop Position

    (6) from the position in figure A to the position in figure B. The treadle stroke will then be increased by approximately 27 %. At this time, the treadle forward and backward depression sensitivity will change, so readjust if necessary. 2302M S-7200A...

  • Page 38: Adjusting The Rotary Hook Lubrication Amount (-40[] / 43[])

    “Checking the lubrication amount” above. 2305M * Turn the adjusting screw (3) and check the lubrication amount repeatedly until the lubrication amount is correct. 4. Check the lubrication amount again after the sewing machine has been used for approximately two hours. S-7200A...

  • Page 39: Selecting Tension Release

    Turn the adjusting screw (5) clockwise. ・ To lower the presser foot (1) ... Turn the adjusting screw (5) counterclockwise. 5. Tighten the nut (4). * After making the adjustment, sew a piece of material to check the floating amount. Raise Lower 2308M S-7200A...

  • Page 40: Replacing Parts

    Use only the proper replacement parts as specified head may cause your hand to slip, and your hand by Brother. may get caught. Turn off the power switch and disconnect the power Be sure to wear protective goggles and gloves when cord before replacing any parts.

  • Page 41: Rotary Hook Rp

    (B) of the bed.) NOTE: If the sewing machine is used while the adjusting screw (5) is in the fully-tightened position, it will cause oil to leak out through the gap between the rotary hook shaft (6)and the bracket (7). 2315M S-7200A...

  • Page 42: Feed Bar Shaft, Lifting Feed Shaft, Needle Bar Connecting Rod Unit

    6-4. Feed bar shaft, Lifting feed shaft, Needle bar connecting rod unit When changing over these parts, apply grease as described below and then install the parts to the sewing machine. * Use Brother-specified grease (SA2355-001). 1. Apply grease to the holes of each part as shown in the...

  • Page 43: Applying Grease

    “Err100” will appear after a certain period of time and the sewing machine will be forcibly prevented from operating for safety reasons. If this happens, apply grease and carry out the reset procedure. <Applying grease> Use Brother-specified grease (SA2355-001). Using the tube 2216M S-7200A...
  • Page 44 5. Press and hold the ENTER key (6) for two seconds or more. The buzzer will make a long beep, and then the main display (1) will change to stitch number display mode. (This completes the reset procedure.) 2139M S-7200A...

  • Page 45: Control System

    (6) that is attached to the DD motor (5). The thread trimming operation is carried out immediately before the sewing machine stops at the needle up stop position. S-7200A...

  • Page 46: Control Box And Motor

    4. Loosen the nuts (11) and (12) (without removing them). 5. Remove the bolt (13) and nut (14). 2323M 6. Pivot the control box around the bolt (15) and pull it out to remove it from the table. <Installation> Install by following the removal procedure in reverse. 2324M S-7200A...

  • Page 47: Control Box And Motor Rating Plate

    USA/Mexico Canada Destination Oceania (C-TICK) Turkey/ North Africa China Europe/Greece (CE) 100V 110V 200V Power supply voltage 220–240V 380–415V 1 forward 1 backward step type Treadle unit 2 forward 2 backward step type Operation panel External Sewing machine S-7200A S-7200A...
  • Page 48 9. CONTROL BOX AND MOTOR <Motor> Serial No. 2326M 2327M S-7200A...

  • Page 49: Control Circuit Board

    For input/output signals used by external devices (22) Option connector 3 Connect to stitch counter actuator. Cooling fan power supply connector Only used for three-phase high-voltage specifications. (23) Thermistor connector Connect to shorted connector when not using three-phase high-voltage specifications. S-7200A...
  • Page 50 Remarks DC +5V Variable signal input For stitch counting SPSP Speed command input [Not used by the S-7200A] STOP Operation prevention input L level: Operation prevented Needle down signal output (*) L level: Needle down stop position Needle up signal output (*)

  • Page 51: Checking The Motor And Power Supply

    Measure the AC voltage between terminals 2–3. 200 V type (200–240 V) [A] For three-phase <200 V type> Measure the AC voltage between terminals 4–5, 5–6 and 6–4. [B] For single-phase Measure the AC voltage between terminals 4–6. 1884M S-7200A...

  • Page 52: Checking The Solenoids

    If the values are as shown in the table below, the Knee switch connector is normal. Between 3–6 Presser lifter solenoid: Approx. 9.6 Ω Between 4–5 When knee switch is pressed: 0 Ω Presser lifter solenoid When knee switch is released: ∞ Ω 2331M S-7200A...

  • Page 53: Treadle Unit Assembly

    OFF, the presser foot lifter control signal is not output when the treadle is depressed backward after the knee switch has been used to raise the presser foot. Furthermore, if Function No. 41 is set to "1", the presser foot lifter control signal is not output when the treadle is depressed backward. S-7200A...

  • Page 54: Standard Setting Values

    ・ For treadle unit -H, the point of change (F) in the forward depression force is between S1 and S2, and the point of change (R) in the backward depression force is between S6 and S7. Speed Backward depression Neutral Forward depression 1841M S-7200A...

  • Page 55: Setting Method For Standard Depression Strokes

    "PdFF x.xxx" will appear in the main display (3). (x.xxx indicates the depression voltage.) 2333M 2) Memorizing the maximum forward position With the treadle depressed forward to the maximum forward position, press the thread trimming key (2). "Pdnn x.xxx" will appear in the main display (3). 2334M S-7200A...
  • Page 56 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. 2337M 2. Turn off the power switch (1). 3. Set DIP switch No.4 to OFF. 2338M S-7200A...

  • Page 57: Standing Operation Pedal

    2339M Connect the foot plug (1) to connector CN3 on the control circuit board. Connect the standing pedal connector (2) to the foot plug (1). Secure the standing pedal cord (3) with a repeat cable tie (4). S-7200A...

  • Page 58: Connectors

    High-speed switch Thread trimmer switch Spare Low-speed switch Presser foot switch Variable speed input Ground 2340M <At pedal> NOTE: Connector types Manufacturer Connector No. Connector terminal MOLEX 1292 P 1380 TL 1867M <A> Two-step pedal <B> Variable speed pedal 1868M S-7200A...

  • Page 59: Troubleshooting

    12. TROUBLESHOOTING 12. TROUBLESHOOTING ・ Please check the following points before calling for repairs or service. ・ If the following suggestions do not solve the problem, turn off the machine power supply and contact your nearest Brother service center. DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box.
  • Page 60 Is the sewing speed too fast? Use the sewing speed control keys to gradually reduce the Instruction sewing speed. manual 0978M Material slippage Is the presser foot pressure too strong? Instruction Adjust the presser foot pressure. manual 0750M S-7200A...
  • Page 61 Attach the anti-spin spring. manual Is the bobbin turning smoothly? If the bobbin is not turning smoothly, replace the bobbin. Is a bobbin other that the light-alloy bobbins specified by Brother being used? Instruction Use only bobbins which are specified by Brother.
  • Page 62 Nothing appears on the Is the power supply connector operation panel display. disconnected from the control box? Insert connector securely. 2196M operation panel connector inside the control box disconnected? Insert connector securely. 2197M S-7200A...

  • Page 63: Error Code Displays

    Voltage rating label Problem with control box. Replace the control box. 2199M Is connector CN7 or CN8 inside the control box disconnected? Insert the connector securely. 2200M Is connector CN4 inside the control box disconnected? Insert the connector securely. 2201M S-7200A...
  • Page 64 Replace the motor. This is displayed when abnormal current is flowing in a solenoid (thread trimming, thread wiping, quick reverse or presser foot lifter). Check the resistances of each solenoid. Problem with control circuit board. Replace the control box. S-7200A...
  • Page 65 Check that there is no problem with the cooling fan. If there is a problem, replace the cooling fan. Has the setting for standard depression strokes been set correctly? Repeat the setting for standard depression strokes. Treadle unit malfunction. Replace the treadle unit. S-7200A...
  • Page 66 Apply grease and then carry out the reset procedure. Err 101 Is DIP switch No.4 inside the control box set to ON? (diP SW 4) Set DIP switch No.4 to OFF. 2205M If an error code that is not listed above appears, contact the place of purchase. S-7200A...
  • Page 67 SERVICE MANUAL 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177 Printed in Japan S-7200A I30508-38B 2003. 05. B (1)

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