Brother DH4-B981 User manual

DH4-B981
Please read this manual before using the machine.
Please keep this manual within easy reach for quick reference.
ELECTRONIC EYELET BUTTON HOLER
INSTRUCTION MANUAL

iDH4-B981
Thank you very much for buying a BROTHER sewing machine. Before using your new machine, please read the safety instruc-
tions below and the explanations given in the instruction manual.
With industrial sewing machines, it is normal to carry out work while positioned directly in front of moving parts such as the
needle and thread take-up lever, and consequently there is always a danger of injury that can be caused by these parts. Follow
the instructions from training personnel and instructors regarding safe and correct operation before operating the machine so
that you will know how to use it correctly.
SAFETY INSTRUCTIONS
1. Safety indications and their meanings
This instruction manual and the indications and symbols that are used on the machine itself are provided in order to ensure safe
operation of this machine and to prevent accidents and injury to yourself or other people.
The meanings of these indications and symbols are given below.
Indications
The instructions which follow this term indicate situations where failure to follow the instruc-
tions could cause injury when using the machine or physical damage to equipment and sur-
roundings.
Symbols
................ This symbol ( ) indicates something that you should be careful of. The picture inside the triangle indi-
cates the nature of the caution that must be taken.
(For example, the symbol at left means “beware of injury”.)
................ This symbol ( ) indicates something that you must not do.
................ This symbol ( ) indicates something that you must do. The picture inside the circle indicates the nature
of the thing that must be done.
(For example, the symbol at left means “you must make the ground connection”.)
The instructions which follow this term indicate situations where failure to follow the instructions
will almost certainly result in death or severe injury.
DANGER
CAUTION

DH4-B981 ii
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. Touching areas where high voltages are present can result in severe injury.
All cords should be secured at least 25 mm away from
any moving parts. Furthermore, do not excessively
bend the cords or secure them too firmly with staples,
otherwise there is the danger that fire or electric shocks
could occur.
Install the belt covers to the machine head and motor.
If using a work table which has casters, the casters
should be secured in such a way so that they cannot
move.
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 in-
flammation can result.
Furthermore, do not drink the oil or eat the grease un-
der any circumstances, as they can cause vomiting
and diarrhoea.
Keep the oil out of the reach of children.
The ambient temperature should be within the range
of 5°C to 35°C during use.
Temperatures which are lower or higher than this may
cause problems with correct operation.
The relative humidity should be within the range of 45%
to 85% during use, and no dew formation should occur
in any devices.
Excessively dry or humid environments and dew for-
mation may cause problems with 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.
Use the sewing machine in an area which is free from
sources of strong electrical noise such as high-
frequency welders.
Sources of strong electrical noise may cause prob-
lems with correct operation.
Any fluctuations in the power supply voltage should
be within ±10% of the rated voltage for the machine.
Voltage fluctuations which are greater than this may
cause problems with correct operation.
The power supply capacity should be greater than the
requirements for the sewing machine's electrical
consumption.
Insufficient power supply capacity may cause prob-
lems with correct operation.
The pneumatic delivery capability should be greater
than the requirements for the sewing machine's total
airconsumption.
Insufficient pneumatic delivery capability may cause
problems with correct operation.
DANGER
CAUTION
Environmental requirements
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 87 kg. The
installation should be carried out by two or more people.
Do not connect the power cord until installation is
complete, otherwise the machine may operate if the
start switch is pressed by mistake, which could result
in injury.
Be sure to connect the ground. If the ground connec-
tion is not secure, you run a high risk of receiving a
serious electric shock, and problems with correct
operation may also occur.
Installation
2. Notes on safety

iii DH4-B981
Maintenance and inspection of the sewing machine
should only be carried out by a qualified technician.
Ask your Brother dealer or a qualified electrician to
carry out any maintenance and inspection of the
electrical system.
Turn off the power switch and disconnect the power
cord from the wall outlet at the following times,
otherwise the machine may operate if the start switch
is pressed by mistake, which could result in injury.
•When carrying out inspection, adjustment and main-
tenance
•When replacing consumable parts such as the
loopers and knife
Disconnect the air hoses from the air supply and wait
for the needle on the pressure gauge to drop to “0”
before carrying out inspection, adjustment and repair
of any parts which use the pneumatic equipment.
CAUTION
Turn off the power switch before carrying out cleaning,
otherwise the machine may operate if the start 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 in-
flammation can result.
Furthermore, do not drink the oil or eat the grease un-
der any circumstances, as they can cause vomiting
and diarrhoea.
Keep the oil out of the reach of children.
This sewing machine should only be used by opera-
tors who have received the necessary training in safe
use beforehand.
The sewing machine should not be used for any
applications other than sewing.
Be sure to wear protective goggles when using the
machine.
If goggles are not worn, there is the danger that if a
needle breaks, parts of the broken needle may enter
your eyes and injury may result.
Turn off the power switch at the following times,
otherwise the machine may operate if the start switch
is pressed by mistake, which could result in injury.
• When threading the needle
• When replacing the needle
• When not using the machine and when leaving the
machine unattended
If using a work table which has casters, the casters
should be secured in such a way so that they cannot
move.
Attach all safety devices before using the sewing
machine. If the machine is used without these devices
attached, injury may result.
Do not touch any of the moving parts or press any
objects against the machine while sewing, as this may
result in personal injury or damage to the machine.
If an error occurs in machine operation, or if abnormal
noises or smells are noticed, immediately turn off the
power switch. Then contact your nearest Brother dealer
or a qualified technician.
If the machine develops a problem, contact your
nearest Brother dealer or a qualified technician.
Sewing
Cleaning
If the power switch and air need to 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 abso-
lutely sure to re-install them to their original positions
and check that they operate correctly before using the
machine.
Any problems in machine operation which result from
unauthorized modifications to the machine will not be
covered by the warranty.
Maintenance and inspection

DH4-B981 iv
Moving parts
may cause injury.
Operatewithsafetydevices.
Turn off main switch before
threading, changing bobbin
and needle, cleaning etc.
Safety devices
Eye guard
Finger guard
Needle bar guard
Belt cover, etc.
2
4Be sure to connect the ground. If the ground connection is
not secure, you run a high risk of receiving a serious elec-
tric shock, and problems with correct operation may also
occur.
The following warning labels appear on the sewing machine.
Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are
difficult to read, please contact your nearest Brother dealer.
3. Warning labels
1
3Do not touch the cutter and hammer or press any
objects against the machine while sewing, as this
may result in personal injury or damage to the ma-
chine.
5Direction of operation
5
3
3
2
1
4
Finger guard
Belt cover
Needle bar guard
Eye guard
Belt cover
(Rear)
Hazardous voltage
will cause injury.
Turn off main
switch and wait 5
minutes before
opening this cover.
Un voltage non adapt
provoque des blessures.
Eteindrel’interrupteur et
attendre 5 minutes
avantd’ouvrir le capot
Hochspannung
verletzungsgefahr!
Bitte schalten sie den
hauptschalter aus und
warten sie 5 minuten,
bevor sie diese
abdeckung ffnen.
Un voltaje inadecuado
puede provocar las
heridas.
Apagar el interruptor
principal y esperar 5
minutos antes de abrir
esta cubierta.
0789Q

DH4-B981
H. Setting the sewing speed ................................ 36
I . Setting the mode ............................................ 37
J . Setting panel protection ................................. 37
K. Setting the cloth setting position (-52 specifications) ... 37
L . Setting the number of eyelet buttonholes (-52 specifications) ... 38
6-5. Setting the number of home position start cycles ... 38
6-6. Using the select switch (option) ........................ 39
6-7. Moving the cloth feed bar (-52 specifications) ....40
6-8. Using the memory switch.................................... 40
6-9. List of error codes ............................................. 41
7. SEWING................................................................ 43
7-1. Using the EMERGENCY STOP switch............. 43
7-2. Sewing .............................................................. 44
7-3. Adjusting the thread tension ............................. 45
7-4. Needle and knife position ................................. 46
7-5. Setting the feed bracket to the front position .... 47
7-6. Switching between single-pedal and dual-pedal operation .... 47
7-7. Using feed mode............................................... 48
7-8. Using manual mode .......................................... 49
8. CLEANING AND MAINTENANCE................... 50
8-1. Cleaning............................................................ 50
8-2. Draining the oil.................................................. 51
8-3. Checking the air filter ........................................ 51
9. STANDARD ADJUSTMENTS........................... 52
9-1. Adjusting the height of the spreader and looper ... 52
9-2. Adjusting the needle and looper timing............. 53
9-3. Adjusting the loop stroke .................................. 54
9-4. Adjusting the height of the needle bar .............. 55
9-5. Adjusting the clearance between the looper and needle ... 55
9-6. Adjusting the needle guard ............................... 56
9-7. Adjusting the spreader mounting positions....... 56
9-8. Adjusting the spreader timing ........................... 57
9-9. Adjusting the needle racking width (stitch width) ... 57
9-10. Changing the knife cutting length (Replacing the hammer)..... 58
9-11. Adjusting the contact between the knife and the hammer ....... 59
9-12. Replacing the knife ......................................... 60
9-13. Adjusting the cutting pressure ........................ 60
9-14. Adjusting the cloth opening amount................ 61
9-15. Adjusting the trimming of the upper thread..... 62
9-16. Adjusting the trimming of the lower thread and gimp ........... 62
9-17. Adjusting the gimp length after trimming (-02, -52) .. 63
9-18. Lower thread presser ...................................... 63
9-19. Auxiliary clamp arm ........................................ 64
9-20. Adjusting the cloth feeding speed (-52 specifications) ... 64
9-21. Adjusting the cloth feed bar home position (-52 specifications) ... 65
9-22. Adjusting the indexer hole spacing (-52 specifications) ... 66
9-23. Adjusting the position of limit switch L (-52 specifications) ... 67
9-24. Adjusting the position of limit switch R (-52 specifications) .. 67
10. SUMMARY OF DIP SWITCHES..................... 68
10-1. Front panel DIP switches................................ 68
10-2. Circuit board DIP switches.............................. 70
11. TROUBLESHOOTING ..................................... 72
1. NAMES OF EACH PART................................... 1
2. SPECIFICATIONS............................................... 2
2-1. Specifications.................................................... 2
2-2. Optional parts.................................................... 3
2-3. BAS-PC/300, Programming Software for Electronic Pattern sewer (peripheral device) ... 3
2-4. Replacement parts list for specification changes ... 4
3. INSTALLATION................................................... 5
3-1. Table processing diagram................................. 5
3-2. Installing the motor............................................ 6
3-3. Installing the motor pulley ................................. 7
3-4. Installing the control box ................................... 7
3-5. Installing the machine head .............................. 8
3-6. Installing the oil container ................................. 9
3-7. Tightening the V-belt......................................... 9
3-8. Installing the spool stand .................................. 10
3-9. Installing the hand switch..................................10
3-10. Installing the air unit and the valve unit........... 10
3-11. Connecting the wiring ..................................... 11
3-12. Connections inside the control box .................12
3-13. Connecting the motor cables .......................... 13
3-14. Connecting the air tubes .................................13
3-15. Securing the cables ........................................ 14
3-16. Installing the air tubes .....................................15
3-17. Connecting the power cord ............................. 16
3-18. Installing the select switch (option) ................. 17
3-19. Installing the foot switch (option).....................17
3-20. Installing the indexer (option).......................... 18
4. LUBRICATION ....................................................23
4-1. Adding oil .......................................................... 23
4-2. Lubrication ........................................................ 23
5. CORRECT USE ................................................... 25
5-1. Initializing settings............................................. 25
5-2. Changing the lower thread and gimp thread trimming ... 25
5-3. Installing the needle ..........................................26
5-4. Threading the upper thread .............................. 26
5-5. Threading the lower thread ...............................27
5-6. Threading the gimp ...........................................28
5-7. Setting the material ...........................................28
5-8. Setting the installation position for cloth feed plate (L) (-52 specifications) ... 30
5-9. Replacing the PROMs ...................................... 31
6. USING THE OPERATION PANEL ................... 32
6-1. Panel switch and indicator names .................... 32
6-2. Setting the buttonhole length ............................ 33
6-3. Turning cutting on and off ................................. 33
6-4. Setting by changing the panel DIP switches.....34
A. Setting the stitch pitch .................................... 34
B. Setting the number of eyelet stitches ............. 34
C. Setting the taper bar tacking length................35
D. Setting the knife operation method ................35
E. Setting the eyelet shape................................. 35
F. Setting the offset (setting the taper bar tacking overlap) ... 36
G. Setting the cutting space ................................36
CONTENTS

1
DH4-B981
1. NAMES OF EACH PART
Fly indexer (-52 specifications)
qFront cover
tEMERGENCY STOP switch
oPower switch
wHand switch
yUpper shaft pulley
!0 Motor
eCloth presser switch
uFeed bracket
!1 Operation panel
rStart switch
iSpool stand
!2 Control box
w
e
r
t
q
!2
!1
y
u
i
o
!0
1. NAMES OF EACH PART
Fly indexer
0790Q
0791Q

2DH4-B981
MADE IN JAPAN
BROTHER INDUSTRIES, LTD.
DH4-B981-
2. SPECIFICATIONS
* -02 and -52 specifications are further divided into L1 - L7 specifications
* in accordance with the stitch length. Please be sure to specify the
* stitch length when ordering.
2-1. Specifications
2. SPECIFICATIONS
-00
-01
-02
-52
Upper thread trimmer Long type
Lower thread trimmer Fly indexer
Short type
Specification
Application
Sewing speed
Stitch length
Stitch width
Needle racking width
Tacking length
Work clamp height
Stitch shape changing
Cut timing selection
Starting method
Feed method
Needle
Safety equipment
Motor
Air pressure
Air consumption
Noise level
Dimensions
Work table legs
Power supply
Weight
1,400 - 2,000 rpm (200-rpm steps)
0.9 - 1.8 mm
1.5 - 3.2 mm
4 - 10 mm or none
Single-phase 110, 200, 220, 230, 240 V
3-phase 220, 380, 415 V
Maximum electric power consumption : 1 kVA
DH4-B981-02, DH4-B981-52
Jeans and work clothes
16 mm12 mm
L1 14 - 18 mm
L2 18 - 22 mm
L3 22 - 26 mm
L4 26 - 30 mm
L5 28 - 32 mm
L6 32 - 36 mm
L7 36 - 40 mm
Main regulator: 0.5 MPa
Knife pressure regulator: 0.3 MPa
DH4-B981-00 DH4-B981-01
10 - 50 mm 10 - 38 mm
Men's clothes and ladies' clothes
Selected by DIP switch setting
Selected by DIP switch setting
Dual switch (cloth presser switch and start switch) or single switch
Intermittent feed by three pulse motors (X, Y, )
DO x 558 Nm80 - Nm120 (Schmetz 558)
Built-in emergency stop function and automatic stopping device which stops the machine when the safety circuit is activated
Inverter-type induction motor
43.2 R/min. (8 cycles/min.)
81 dB at max. speed of 2,000 rpm, measured according to ISO 10821
1,200 mm (W) x 590 mm (D) x 1,120 mm (H)
T-shaped height-adjustable type
163.5 kg
Fly indexer specifications (-52 specifications)
Max. hole spacing
Max. overall feed amount
No. of holes
Horizontal sewing margin
Vertical sewing margin
Standard
50.8 mm
(2 inch)
152.4 mm
(2 inch x 3)
3 - 4
9 - 21 mm (*9 - 11 mm)
30 - 40 mm
Large size
57.15 mm
(2 1/4 inch)
285.75 mm
(2 1/4 inch x 5)
3 - 6
Overall feed amount
No. of holes
Vertical sewing
margin
Hole spacing Horizontal
sewing
margin
* L5 -L7 specifications
0792Q

3
DH4-B981
○○○○○○○○○○○○○○○○○○○○○○○○○○
2. SPECIFICATIONS
Sewing shape
Eyelet buttonhole Straight buttonhole
The following optional parts are available for the DH4-B981.
2-2. Optional parts
™Select switch
(S45043-009) This switch is used to select one program from a choice
of three. This conveniently-located switch makes
program selection easier, so that work efficiency can
be increased.
™Two-pedal foot switch
(S42838-101)
™Waist belt presser
• Cloth presser (L3W) set
(S43701-001)
• Cloth presser (L4W) set
(S43704-001)
This allows the work clamp to raised and lowered and
the sewing machine to be started by pedal operation.
When sewing eyelet buttonholes into waist belts with
which have differences in thickness, this presser
provides secure clamping for the different thicknesses.
It prevents any slippage of the material during sewing.
™Fly indexer
• Fly indexer assembly for L1,L2 and L5 specifications
(S44279-001)
• Fly indexer aseembly for L3,L4,L6 and L7 specifications
(S44281-001)
This is an indexer which is specially for use when sewing
flys. It allows from one to nine buttonholes to be set,
and automatically feeds the material. Using this device
makes the sewing of buttonholes for flys much quicker.
○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○
Eyelet buttonhole
without taper Eyelet buttonhole with taper Straight buttonhole without taper Straight buttonhole with taper
General sewing conditions can be set by means of the operation panel, the operation panel DIP switches and the
circuit board DIP switches.
The BAS-PC/300 can store up to a maximum of 10 sets of sewing conditions in its "data ROM", and these sets of
sewing conditions can be selected and displayed by means of the operation panel.
The data-ROM which is created by the BAS-PC/300 can be used to set the knife position compensation and angle
compensation functions, which cannot otherwise be set by means of switches.
However, the BAS-PC/300 requires a system of Version 3.0 or later.
The BAS-PC/300 requires the following system components which are commercially available.
• Personal computer
• Operating system
• ROM writer
For details, please consult the place of purchase.
2-3. BAS-PC/300, Programming Software for Electronic Pattern sewer (peripheral device)
0793Q 0795Q0794Q 0796Q

4DH4-B981
Specifications
(buttonhole length)
L1
(14 - 18 mm)
L2
(18 - 22 mm)
L3
(22 - 26 mm)
L4
(26 - 30 mm)
L5
(28 - 32 mm)
L6
(32 - 36 mm)
L7
(36 - 40 mm)
Plate R assembly
Plate L assembly
S38576-301
S38577-201
S38578-301
S38579-201
S38580-301
S38581-201
S38582-301
S38583-201
S41470-101
S41471-101
S41472-101
S41473-101
S41474-101
S41475-101
S37702-001 (S12)
S37704-001 (S16)
S37704-001 (S16)
S37706-001 (S20)
S37706-001 (S20)
S37708-001 (S24)
S37708-001 (S24)
S42053-001 (S28)
S37197-001 (26)
S37199-001 (30)
S37199-001 (30)
S37201-001 (34)
S37201-001 (34)
S35093-001 (38)
Replacement parts set
S44238-001
S44239-001
S44240-001
S44271-001
S44272-001
S44273-001
S44274-001
Specification harness
S43337-000
S43338-000
S43339-000
S43340-000
S43341-000
S43342-000
S43343-000
Hammer
NOTE: There is 10 mm of difference in the knife cuttin
g
position between L1 - L4 and L5 - L7 specifications. (Refer to pa
g
e 60.)
2. SPECIFICATIONS
2-4. Replacement parts list for specification changes
The sewing machine can be changed to any one of L1 - L7 for -02 and -52 specifications by replacing the specified
parts with the appropriate parts given below.
# -02 specifications
# -52 specifications
L
R
NOTE: There is 10 mm of difference in the knife cutting position between L1 - L4 and L5 - L7 specifications. (Refer to page 60.)
Specifications
(buttonhole length)
L1
(14 - 18 mm)
L2
(18 - 22 mm)
L3
(22 - 26 mm)
L4
(26 - 30 mm)
L5
(28 - 32 mm)
L6
(32 - 36 mm)
L7
(36 - 40 mm)
Plate R assembly
Plate L assembly
S38576-301
S38577-201
S38578-301
S38579-201
S38580-301
S38581-201
S38582-301
S38583-201
S41470-101
S41471-101
S41472-101
S41473-101
S41474-101
S41475-101
S37702-001 (S12)
S37704-001 (S16)
S37704-001 (S16)
S37706-001 (S20)
S37706-001 (S20)
S37708-001 (S24)
S37708-001 (S24)
S42053-001 (S28)
S37197-001 (26)
S37199-001 (30)
S37199-001 (30)
S37201-001 (34)
S37201-001 (34)
S35093-001 (38)
Specification harness
S43360-000
S43361-000
S43362-000
S43363-000
S43364-000
S43365-000
S43366-000
Cloth feed plate R
S43809-001
S43809-001
S42139-101
S42139-101
S43809-001
S42139-101
S42139-101
Hammer
0797Q 0798Q 0799Q

5
DH4-B981
3. INSTALLATION
3-1. Table processing diagram
The top of the table should be 50 mm in thickness and should be strong enough to hold the weight and withstand the
vibration of the sewing machine. Drill holes in the table as shown in the diagram below.
3. INSTALLATION
CAUTION
Machine installation should only be carried out
by a qualified technician.
All cords should be secured at least 25 mm away
from any moving parts.
Furthermore, do not excessively bend the cable
or secure it too firmly staples, otherwise there is
the danger that fire or electric shocks could occur.
The sewing machine head weighs more than 87
kg. The installation should be carried out by two
or more people.
Do not connect the power cord until installa-tion
is complete, otherwise the machine may
operate if the start switch is pressed by mistake,
which could result in injury.
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.
Contact your Brother dealer or a qualified
electrician for any electrical work that may need
to be done.
Install the belt covers to the machine head and
motor.
590
175
411
165
105
65
70
184.3
36056
115
30
263 78.5
100
30
201
1200
200
34
10
Motor
Valve unit
Air unit
Power switch
145.5
R17
R17
21
223 15
462
284 30
338
38
51
50
200124
(499)
74
ø20
ø50
2-ø4 depth 20
(from underside)
2-ø4 depth 20
(from underside)
2-ø2 depth 10
(from underside)
4-ø8.5 26 counterbore depth 7
(from underside)
186
116
35 306
51
4-R10
4-ø8.5
0.3
ø50
ø100
4-ø8.5
0.3
Control box
Teble/legs assembly
Model
127-981-04902
0800Q
* There is the special B981 work table indicated below.

6DH4-B981
3. INSTALLATION
3-2. Installing the motor
1. Insert the four bolts qinto the work table.
2. Turn the work table upside down to make it easier to
2. install the motor w.
3. Align the holder plate eand the motor plate rwith
the bolts q, and then install them with the four washers
tand the four bolts y.
4. Place the eight accessory cushions uand the four
4. accessory cushion collars ionto the motor base
plate o, and then install the motor as shown in the
illustration.
y
t
e
r
q
u
u
o
w
q
i
0803Q
0801Q

7
DH4-B981
3. INSTALLATION
3-3. Installing the motor pulley
3-4. Installing the control box
1. Insert the four nuts q into the work table.
2. Open the front and rear covers of the control box w .
3. Align the control box w with the nuts q , and then
install it with the four flat washers e , spring washers
3. r and bolts t .
3. NOTE:
3. Be careful not to drop any small parts such as washers
3. onto the circuit board when installing the bolts.
1. Place the motor pulley qonto the shaft of the motor w
1. so that the key grooves are aligned, and then tighten
1. the set screws eso that the center of the V groove in
1. the motor pulley qis aligned as closely as possible
1. with the center of the belt hole in the power table.
2. Install the motor rear cover support r with the two flat
2. washers t and the two screws y .
2. NOTE:
2. Check that the motor rear cover support r does not
2. touch the motor pulley q or the edge of the motor.
e
q
w
t
y
r
t
r
e
w
q
0804Q
0805Q
0806Q

8DH4-B981
3. INSTALLATION
3-5. Installing the machine head
1. Insert the accessory bed base cushions A qinto the bed base, and then place the machine head on top of the
1. work table.
1. NOTE: When placing the machine head on top of the work table, have two or more people there to hold the handles
1. Note: and the rear of the head as indicated in the illustration.
2. Open the front cover w, and then use the bolt e, washer r, rubber sheet t, bed base cushion A q, large
washer yand nut uto attach the front right corner of the bed base to the work table.
3. Open the rear cover i, and then attach the bed base to the work table in two places inside the base in the same
way as in step 2. above.
4. Remove the bolt oand the washer.
4. NOTE: The bolt oand washer should be kept, as they will be needed again if the machine head is moved.
5. Raise the machine head, and then attach the front left corner of the bed base to the work table in the same way as
in the steps above.
5. NOTE: Make sure that steps 2. to 4. above have been completed before raising the machine head.
Raising the machine head
1. While holding the handles of the machine head qwith both hands, gently raise the machine head.
1. NOTE: Be sure to turn the power supply off before raising the machine head.
2. If you wish to keep the machine head in the raised position, insert the head support lever wsecurely into the hinge
2. lever support shaft e.
2. NOTE: Always check that the head support lever wand the hinge lever support shaft eare meshed.
Lowering the machine head
2. Pull the machine head down toward you gently, remove the head support lever wfrom the hinge lever support
2. shaft e, and then gently lower the machine head.
2 . NOTE: Do not hold the machine head by the feed bracket ror X feed shaft A twhen it is being raised and lowered.
t
r
q
qWhen machine head is lowered
When machine head is raised
w
e
w
e
o
q
t
w
e
r
0808Q
0807Q
0810Q0809Q
i
e
r
t
q
y
u
y
u

9
DH4-B981
3. INSTALLATION
1. Open the rear cover.
2. Pass the V-belt qthrough the base of the bed base and through the hole in the work table.
3. Place the V-belt qonto the motor pulley w.
4. Check that there is approximately 10 mm of deflection in the V-belt qwhen it is pushed in the middle with a load
of 10 N.
If the tightness needs adjusting, loosen the two nuts eand move the motor up or down. After adjustind, tighten
the nuts e.
4. NOTE: Check that the motor rear cover support rdoes not touch the motor pulley qor the edge of the motor.
5. Install the motor cover twith the three screws y.
NOTE: After a long period of use, the V-belt will become run in and will loosen around the motor pulley. When
this happens, turn off the power and adjust by the procedure given in step 4. above.
3-6. Installing the oil container
1. Install the dust oiler support wto the base of the bed
base qwith the two screws e.
2. Screw the oil container rinto the dust oiler support
w.
3. Push the pin tinto the bed base quntil the pin is
flush with the surface of the base.
4. Lower the machine head. (Refer to "Lowering the
machine head" on prefer page.)
3-7. Tightening the V-belt
t
q
w
e
r
e
q
t
y
tr
10 N Approx.
10 mm
q
e
w
0812Q
0813Q 0814Q
0811Q

10 DH4-B981
3. INSTALLATION
3-8. Installing the spool stand
1. To assemble the spool stand q, follow the instructions
1. in the manual that came with the spool stand q.
2. Secure the spool stand qto the rear right corner of
2. the work table with the washer and nut w.
3-10. Installing the air unit and the valve unit
3-9. Installing the hand switch
1. Install the hand switch qwith the two screws w.
q
w
w
q
1. Install the air unit qto the underside of the work table with the two screws w.
2. Install the valve unit ewith the two screws r.
3. Connect air tube ⁄5 to the intermediate joint tof the air unit qand to the joint yof the valve assembly, and
3. connect air tube ⁄6 to joints uand i.
Connecting the valve cables
3. Insert the cable owhich is coming out of the valve unit to the 2-pin connector !0 of the valve cable assembly.
Valve unit
Air unit
50
51
115
360
Installation position
16
16
15
w
u
q
t
!0 o
e
y
r
i
0815Q
0816Q
0818Q
0817Q

11
DH4-B981
3. INSTALLATION
3-11. Connecting the wiring
1. Pass the cable and air tube which are coming out of
1. the belt cover qand the machine head wthrough the
1. cable hole ein the work table.
2. Pass the cables and air tube which are coming out of
the feed bracket r and the left side of the bed base
t and the cable for the hand switch y through the
2. cable hole u in the work table.
NOTE:
2. Leave enough looseness in the cables so that they will
2. not be pulled when the machine head is tilted back.
2. Adjust the looseness after all connections to the control
2. box are complete.
w
q
e
y
r
t
u
3. Connect the hand switch connector i to the control
3. box connector.
4. Install the power switch o to the underside of the work
4. table with the two screws !0 .
4. Secure the cables using staples !1 (in four locations).
o
i
!1
!0
0820Q
0821Q
0819Q

12 DH4-B981
3. INSTALLATION
P1 ORGP2
SYNCHRO
P3 HEADP4 AIR
P6P7
YPM (BLUE)XPM
P9 EXINB P8 EXINA
5. Insert the connector !4 (6-pin with z‰mark) to the
5. connector !5.
6. Loosen the middle screw !6 and then install the ground
5. cable !7.
7. Secure the cables with the cable clamp as shown in
6. the illustration.
NOTE:
6. When securing the cables, do not let any of the cables
6. touch the components on the circuit board or the heat
6. sink. Furthermore, adjust the lengths of the cables from
6. outside the control box so that there is no looseness in
6. the cables inside the control box.
1. Open the rear cover qof the control box.
2. Pass the cables through the holes wand ein the
2. side of the control box.
3. Loosen the screw t, and then connect the three ground
3. cables r that are coming from the machine head.
4. Securely insert each of the connectors y- !3 as
3. indicated below.
e
r
o
t
i
y
u
!0
q
!3
!2
w
i
o
!2
!3
!1 !0
y
u
!1
Connector y
(12-pin with zmark)
Connector u
(5-pin with xmark)
Connector i
(9-pin with cmark)
Connector o
(12-pin with vmark)
Connector !0
(5-pin with nmark)
Connector !1
(5-pin with mmark)
Connector !2
(16-pin with ,mark)
Connector !3
(18-pin with .mark)
(Connection indications)
* This is indicated on the P.C. board.
P1 (ORG)
P2 (SYNCHRO)
P3 (HEAD)
P4 (AIR)
P6 (YPM) (BLUE)
P7 (XPM)
P8 (EXINA)
P9 (EXINB)
Machine head connectors
!6
!7
!4
!5
PMD circuit
board
3-12. Connections inside the control box
0823Q
0822Q
0824Q

13
DH4-B981
3. INSTALLATION
1
3
5
7
8
6
4
9
5
4
3
2
1
10
3. Connect the cables so that the cable marks (U, V, W)
3. match the symbols on the screw terminals.
4. Close the cover w.
NOTE:
4. Be careful not to clamp the cables when closing the
4. cover.
3-14. Connecting the air tubes
1. Remove the screws q, and then open the terminal
1. block cover wof the motor.
2. Loosen the screw r, and then connect the ground
2. cables e.
Connect the air tubes to the joints of the solenoid valve assembly, using the illustration below as a reference.
Numbers are marked on each of the air hoses which come out of the sewing machine.
Plug 4
r
e
q
w
3-13. Connecting the motor cables
*1 If the lower thread trimmer is not installed,
solenoid valve [3] is not used.
*2 The auxiliary clamp arm can only be used
for machines with -02 specification.
Label No.
5
4
3
2
1
Solenoid valve
Upper thread trimming
Upper thread tightening
Lower thread trimming *1
Cloth spreading
(Auxiliary clamp arm)
Work clamp
< -00, -01 >
< -02 >
9
10
17
14
22
7
8
5
6
3
4
9
10
7
8
5
6
3
4
1
22
18
11
0825Q
0826Q
0828Q 0829Q
0827Q

14 DH4-B981
3. INSTALLATION
3-15. Securing the cables
1. Pass the cable through the cable holder q, and then
1. secure the cable holder qto the underside of the work
1. table with the screw.
2. Pass the air tube and the hand switch cable through
2. the cable holder w, and then secure the cable holder
2. wto the underside of the work table with the screw.
3. Place the machine head cable together with the valve
3. cable assembly and motor cable, pass them all through
3. the cable holder e , and then secure the cable holder
3. e to the underside of the work table with the screw.
Insert the specification harness qinto the control box con-
nector w.
NOTE:
Check that the label number on the specification
harness qmatches the movable knife (R) e,
movable knife (L) r, thread handler t, work clamp
(R) y, work clamp (L) uand movable knife driving
cam inumbers before inserting the specification
harness q. (If a connector with an incorrect label
number is connected, it may cause problems such as
damage to the sewing machine or thread trimming
errors.)
No.
No.
u
i
r
e
y
qw
e
No.
wq
t
< -02 >
* There is 10 mm of difference in the knife installation positions
between L1 - L4 and L5- L7.
Specification
-00, -01
-02
L1
L2
L3
L4
L5
L6
L7
Label No. of
harness
0
1
2
3
4
5
6
7
Right/left work clamp No.
Right/left movable knife No.
Thread handler No.
1
2
3
4
5
6
7
0831Q
0830Q
0832Q
0833Q