Brother S-7200B User manual

S-7200B
Please read this manual before using the machine.
Please keep this manual within easy reach for quick reference.
SINGLE NEEDLE DIRECT DRIVE STRAIGHT LOCK STITCHER
WITH THREAD TRIMMER
INSTRUCTION MANUAL

S-7200B
Thank you very much for buying a BROTHER sewing machine. Before using your new machine,
please read the safety instructions 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, 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.

S-7200B i
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
DANGER The instructions which follow this term indicate situations where failure to follow the
instructions may result in death or serious 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 damage to
equipment and surroundings.
Symbols
· · · · · This symbol ( ) indicates something that you should be careful of. The picture inside the triangle
indicates 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”.)

S-7200B
ii
[2] Notes on safety
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. Touching areas where high voltages are present can result in
severe injury.
CAUTION
Environmental requirements
Use the sewing machine in an area which is free
from sources of strong electrical noise such as
electrical line noise or static electric noise.
Sources of strong electrical noise may cause
problems 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 power
consumption.
Insufficient power supply capacity may cause
problems with correct operation.
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
formation 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 dealer or a qualified
electrician for any electrical work that may need to
be done.
The sewing machine weighs more than 44 kg. The
installation should be carried out by two or more
people.
Do not connent the power cord until installation is
complete. The machine may operate if the treadle
is depressed by mistake, which could result in
injury.
Turn off the power switch before inserting or
removing the plug, otherwise damage to the
control box could result.
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.
When securing the cords, do not bend the cords
excessively or fasten them too hard with staples,
otherwise there is the danger that fire or electric
shocks could occur.
If using a work table which has casters, the casters
should be secured in such a way so that they
cannot move.
Use both hands to hold the machine head when
tilting it back or returning it to its original position. If
only one hand is used, the weight of the machine
head may cause 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.

S-7200B iii
CAUTION
Sewing
This sewing machine should only be used by
operators 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.
The machine may operate if the treadle is
depressed by mistake, which could result in injury.
 When threading the needle
 When replacing the bobbin and 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.
Use both hands to hold the machine head when
tilting it back or returning it to its original position. If
only one hand is used, the weight of the machine
head may cause your hand to slip, and your hand
may get caught.
If an error occurs in machine, 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.
Cleaning
Turn off the power switch before carrying out
cleaning. The machine may operate if the treadle is
depressed by mistake, which could result in injury.
Use both hands to hold the machine head when
tilting it back or returning it to its original position. If
only one hand is used, the weight of the machine
head may cause 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 the proper replacement parts as specified
by Brother.
Maintenance and inspection
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 treadle is
depressed by mistake, which could result in injury.
 When carrying out inspection, adjustment and
maintenance
 When replacing consumable parts such as the
rotary hook
If the power switch needs to be left on when
carrying out some adjustment, be extremely careful
to observe all safety precautions.
Use both hands to hold the machine head when
tilting it back or returning it to its original position.
If only one hand is used, the weight of the machine
head may cause your hand to slip, and your hand
may get caught.
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 covered by the warranty.

S-7200B
iv
[3] Warning labels
The following warning labels appear on the sewing machine.
Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are
difficult to read, please contact your nearest Brother dealer.
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
3629M
Control box
Oil pan

S-7200B
CONTENTS
1. NAMES OF MAJOR PARTS................ 1
2. MACHINE SPECIFICATIONS.............. 2
3. INSTALLATION.................................... 3
3-1. Table processing diagram................................ 4
3-2. Installation ........................................................ 4
3-3. Lubrication (-[]0[], []3[] specifications) .............. 8
3-4. Connecting the cords ....................................... 9
3-4-1. Opening the control box cover............. 9
3-4-2. Connecting the cords .......................... 9
3-5. Test operation (Operating the treadle) ............. 12
4. PREPARATION BEFORE SEWING .... 13
4-1. Installing the needle ......................................... 13
4-2. Removing the bobbin case............................... 13
4-3. Winding the lower thread ................................. 14
4-4. Installing the bobbin case................................. 14
4-5. Threading the upper thread.............................. 15
4-6. Adjusting the stitch length ................................ 15
4-7. Using the thread wiper (-4[][] specifications) .... 16
4-8. Using the knee lifter ......................................... 16
5. USING THE OPERATION PANEL
(BASIC OPERATIONS)....................... 17
5-1. Names and functions ....................................... 17
5-2. Sewing start and end backtack stitches ........... 19
5-3. Sewing continuous backtack stitches............... 20
5-4. Sewing fixed stitches........................................ 21
5-5. Sewing name labels ......................................... 22
5-6. Sewing pleat presser stitches .......................... 23
5-7. Using the lower thread counter ........................ 24
6. USING THE OPERATION PANEL
(ADVANCED OPERATIONS).............. 25
6-1. Names and functions ....................................... 25
6-2. Adjusting the needle up stop position............... 26
6-3. LOCK key......................................................... 26
6-4. Resetting all settings to their defaults............... 26
7. USING THE CONTROL BOX PANEL
(BASIC OPERATIONS)....................... 27
7-1. Names and functions ....................................... 27
7-2. Sewing start and end backtacking and
continuous backtacking and locking thread
trimming ........................................................... 28
8. USING THE CONTROL BOX PANEL
(ADVANCED OPERATIONS).............. 32
8-1. Before setting any functions............................. 32
8-2. Changing the needle stop position ................... 32
8-3. Slow start ......................................................... 33
8-4. Correction sewing.............................................33
8-5. Initialization method..........................................33
8-6. Setting the needle up stop position and
needle down stop position ................................34
9. SEWING ............................................... 35
9-1. Sewing..............................................................35
9-2. Backtacking ......................................................35
9-3. Sewing condensed stitches ..............................36
10. THREAD TENSION ............................ 37
10-1. Adjusting the thread tension ...........................37
10-2. Adjusting the presser foot pressure ................38
10-3. Adjusting the trailing length after thread
trimming..........................................................38
10-4. Adjusting the thread take-up amount
(-[][]3 specifications) .......................................39
11. CLEANING ......................................... 40
11-1. Daily cleaning procedures ..............................40
11-2. Applying grease (-[]3[], []5[] specifications)
[When “GrEASEUP” appears…
when using the operation panel].....................43
11-3. Applying grease (-[]3[], []5[] specifications)
[When “GU” appears ...
when using the control box panel] ..................45
12. ADJUSTING THE ROTARY HOOK
LUBRICATION AMOUNT
(-[]0[], []3[] specifications) ............... 47
13. STANDARD ADJUSTMENTS............ 48
13-1. Adjusting the actuator position........................48
13-2. Adjusting the safety switch position ................49
13-3. Adjusting the thread take-up spring ................50
13-4. Adjusting arm thread guide R .........................51
13-5. Adjusting the presser foot height ....................51
13-6. Adjusting of the feed dog height .....................52
13-7. Adjusting the feed dog angle ..........................53
13-8. Adjusting the needle bar height ......................54
13-9. Adjusting the needle and
feed mechanism timing...................................54
13-10. Adjusting the needle and rotary hook timing.55
13-11. Adjusting the treadle .....................................56
13-12. Adjusting the presser foot floating amount
(minute lifting amount) ..................................56
14. TROUBLESHOOTING ....................... 57
14-1. Sewing............................................................57
14-2. Error code displays .........................................62

S-7200B
1. NAMES OF MAJOR PARTS
1
1. NAMES OF MAJOR PARTS
(1) Bobbin winder (2) Thread wiper (-4[][] specifications)
(3) Lifting lever (4) Quick reverse (Actuator)
(5) Presser foot (6) Control box
(7) Control box panel (8) Knee lifter assembly
(9) Power switch (10) Oil gauge window (-[]0[], []3[] specifications)
(11) Reverse lever (12) Stitch length dial
(13) Machine pulley (14) Operation panel (Models with operation panel)
(15) Cotton stand
Safety devices
(16) Thread take-up cover (17) Finger guard
3630M

S-7200B
2. MACHINE SPECIFICATIONS
2
2. MACHINE SPECIFICATIONS
3 4
Quick reverse O O
Thread wiper - O
0 3 5
Lubrication type Minimum lubrication Semi dry Complete dry
S 3 5
Use For light-weight
and difficult-to-sew
materials
For medium-
weight materials
For heavy-weight
materials
-33S, -43S
-45S
-453 -303, -403
-333, -433
-305
-405
Max. sewing speed 4,000 rpm 5,000 rpm* 4,500 rpm*
Start backtacking and continuous
backtacking speed
220 - 3,000 rpm
End backtacking speed 1,800 rpm
Max. stitch length 4.2 mm 5 mm
Lifting lever 6 mmPresser foot
height Knee lifter 16 mm
Feed dog height 0.8 mm 1.2 mm
Needle (DB×1, DP×5) NS #9 - #11 #11 - #18 #19 - #22
Motor AC servo motor (4-pole, 450W)
Control circuit Microprocessor
*…When sewing at speeds of 4,000 rpm or higher, set the stitch length to 4.2 mm or less.
Rotary hook
-33S
-43S
-303, -403
-333, -433
-305
-405
-45S
-453
Lubricated /
for light materials
Lubricated /
for medium materials
Lubricated /
for heavy materials
Rotary hook RP
(lubrication-free rotary hook)
Lubricating oil
-30[], -40[] -33[], -43[] -45[]
Rotary hook High-speed spindle -
Needle bar High-speed spindle Special Brother grease Special Brother grease

S-7200B
3. INSTALLATION
3
3. INSTALLATION
CAUTION
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 44 kg. The
installation should be carried out by two or more
people.
Do not connect the power cord until installation is
complete. The machine may operate if the treadle is
depressed by mistake, which could result in injury.
Use both hands to hold the machine head when
tilting it back or returning it to its original position. If
only one hand is used, the weight of the machine
head may cause your hand to slip, and your hand
may get caught.
About the machine set-up location
 Do not set up this sewing machine near other equipment such as
televisions, radios or cordless telephones, otherwise such
equipment may be affected by electronic interference from the
sewing machine.
 The sewing machine should be plugged directly into an AC wall
outlet. Operation problems may result if extension cords are
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 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.
2086M
2088M
2089M
3631M

S-7200B
3. INSTALLATION
4
3-1. Table processing diagram
 The top of the table should be 40 mm in thickness and should be strong enough to hold the weight and with-stand the
vibration of the sewing machine.
 Drill holes as indicated in the illustration below.
3-2. Installation
1. Control box
(1) Control box
(2) Bolts [3 pcs]
(3) Nuts [3 pcs]
(4) Spring washers [3 pcs]
(5) Washers [3 pcs]
2. Connecting rod
(6) Connecting rod
(7) Nut
2090M
Cotton stand hole
Cord hole
Head rest hole
Control box mounting hole
2091M

S-7200B
3. INSTALLATION
5
3. Power switch
(1) Power switch
(2) Screws [2 pcs]
4. Oil pan
(1) Head cushions (left) [2 pcs]
(2) Head cushions (right) [2 pcs]
(3) Oil pan
5. Rubber cushions
(1) Rubber cushions [2 pcs]
(2) Nails [4 pcs]
6. Knee lifter complying bar
(3) Knee lifter complying bar
2092M
Operato
r
2094M
3632M

S-7200B
3. INSTALLATION
6
7. Machine head
(1) Hinges [2 pcs]
(2) Machine head
(3) Head rest
NOTE:
Tap the head rest (3) securely into
the table hole. If the head rest (3) is
not pushed in as far as it will go, the
machine head will not be sufficiently
stable when it is tilted back.
8. Operation panel
(Models with operation
panel)
(1) Operation panel
(2) Screws [2 pcs]
(Use for tightening rear cover)
9. Sticker (Remove)
(1) Sticker
10. Cotton stand
(1) Cotton stand
NOTE:
Securely tighten the nut (4) so that
the two rubber cushions (2) and the
washer (3) are securely clamped and
so that the cotton stand (1) does not
move.
2097M
3636M
3633M
3634M

S-7200B
3. INSTALLATION
7
11. Knee lifter plate
(1) Knee lifter plate
(2) Bolt
* Loosen the bolt (3) and move the
knee lifter plate (1) to a position
where it is easy to use.
<Knee lifter adjustment>
1. Turn the machine pulley so that the feed dog is below the
top of the needle plate.
2. Lower the presser foot (5) by using the lifting lever (4).
3. Loosen the nut (6).
4. Turn the screw (8) to adjust so that the amount of play in
the knee lifter (7) is approximately 2 mm when the knee
lifter plate (1) is gently pressed.
5. Securely tighten the nut (6).
6. Loosen the nut (9).
7. Turn the screw (10) until the distance between the end of
the screw (10) and the knee lifter (11) is approximately 3
mm.
8. Turn the adjusting screw (10) to adjust so that the presser
foot (5) is at the desired position within a distance of 16
mm of the needle plate when the knee liter plate (1) is
fully pressed.
9. After adjustment is completed, securely tighten the nut
(9).
3637M
3638M
3644M
3639M
Within 16 mm

S-7200B
3. INSTALLATION
8
3-3. Lubrication (-[]0[],[]3[] specifications)
* If the sewing machine is -[]5[] specifications, it is a
complete dry type machine, and so no lubrication is
necessary.
CAUTION
Do not connect the power cord until lubrication has been completed, otherwise the machine may operate if the
treadle is depressed 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
diarrhea.
Keep the oil out of the reach of children.
When cutting the nozzle of the oil tank, hold the base of the nozzle securely.
If you hold the end of the nozzle, injury from the scissors may result.
 The sewing machine should always be lubricated and the
oil supply replenished before it is used for the first time,
and also after long periods of non-use.
 Use only the lubricating oil (Nisseki Mitsubishi Sewing
Lube 10N; VG10) specified by Brother.
* If this type of lubricating oil is difficult to obtain, the
recommended oil to use is <Exxon Mobil Essotex SM10;
VG10>.
1. Hold the base of the nozzle on the accessory oil tank (1),
and then use scissors to cut 3 - 5 mm off the end of the
nozzle.
2. Tilt back the machine head.
3. Remove the rubber cap (2), and pour 120ml of lubricating
oil into the oil tank (3).
(Use the upper reference line (4) as a guide when
pouring.)
4. Replace the rubber cap (1).
5. Return the machine head to its original position.
6. Check that the oil gauge (6) comes to the upper reference
line in the oil gauge window (5).
<Lubrication oil replenishment interval>
If the oil gauge (6) drops below the lower reference line (or if
the oil level drops below the lower reference line (7) on the oil
tank (3)), be sure to replenish the oil.
3640M
Upper reference
line
Lower reference
line
3641M

S-7200B
3. INSTALLATION
9
3-4. Connecting the cords
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. Touching areas where high voltages are present can result in
severe injury.
CAUTION
Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done.
Do not connect the power cord until all cords have been connected.
The machine may operate if the treadle is depressed 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.
3-4-1. Opening the control box cover
(1) Screw
(2) Cover
3-4-2. Connecting the cords
1. Sewing machine cords
3642M
3643M

S-7200B
3. INSTALLATION
10
(1) 7-pin head detector unit connector
(2) 10-pin operating panel connector
(Models with operation panel)
(3) 14-pin encoder connector
(4) 14-pin machine connector
Refer to the following page for the 4-pin
motor connector.
2. Binding the cords
(1) Repeat cable tie
(2) Wire clip
NOTE:
 Bind the cords in such a way that the
connector does not get pulled out.
 All cords that come out from the
control box should be secured to the
cord holder (3) using the repeat
cable tie (1), otherwise vibration from
the sewing machine may cause the
cords to become disconnected,
which can cause problems with the
operation of the control box.
3131M
Push in securely until
the tabs
(
5
)
en
g
a
g
e.
<Closing the cover>
3645M
<Removal>
<Securing>
Press
the tab.
Cords
3132M

S-7200B
3. INSTALLATION
11
3. Other cords
(1) 6-pin power supply connector
(2) 4-pin motor connector
(3) Wire clip
(4) Power cord
<For single-phase specifications>
Insert the power cord plug (5) into a
wall outlet.
<For three-phase specifications>
1. Attach an appropriate plug to the
power cord (4). (The green and
yellow wire is the ground wire.)
2. Insert the plug into a
properly-grounded AC power supply.
NOTE:
Do not use extension cords,
otherwise machine operation
problems may result.
4. Ground wire
(1) Ground wire
(2) Screw [With washer]
(3) Screw
2111M
<Single-phase> <Three-phase>
Green and yellow wire
(ground wire)
2112M
Ground symbol
Oil pan
2113M

S-7200B
3. INSTALLATION
12
3-5. Test operation (Operating the treadle)
CAUTION
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.
1. Turning on the power
<Models with operation panel>
Press the ON power switch (1).
The power indicators (2) and (3) will illuminate.
NOTE: When turning the power switch on for the first
time
The treadle and the operation panel will not operate for
approximately four seconds after the power switch is
turned on.
After approximately 4 seconds, “iniT rPM” (speed
initialization) or “iniT ALL” (full initialization) will be
displayed on the operation panel. After “iniT rPM” or “iniT
ALL” is displayed, the treadle can be operated. (The
operation panel will change to the stitch number display.)
This message will not appear the second and subsequent
times that the power switch is turned on.
<Models without operation panel>
Press the ON power switch (1).
The power indicators (3) and (4) will illuminate.
NOTE: When turning the power switch on for the first
time
The treadle and control box panel cannot be operated for
approximately 4 seconds after the power switch has been
turned on.
After approximately 4 seconds, “Ar (All reset)” may
appear in the stitch number display (5).
If this happens, turn the power switch off and then back
on again. After that, normal treadle operation will then be
possible.
2. Test operation
1. Check that the machine sews at low speed when the
treadle (1) is gently pressed to position (B).
2. Then check that it sews at high speed when the treadle
(1) is gently pressed to position (C).
3. After pressing the treadle (1) forward, check that the
needle is lowered to the top of the needle plate when the
treadle (1) is returned to the neutral position (A). (when
needle down stopping has been set.)
4. If the treadle (1) is pressed to position (D), thread
trimming is carried out and the needle then rises above
the needle plate and stops.
2114M
3648M
2117M
3646M
3647M

S-7200B
4. PREPARATION BEFORE SEWING
13
4. PREPARATION BEFORE SEWING
4-1. Installing the needle
CAUTION
Turn off the power switch before installing the needle.
The machine may operate if the treadle is depressed by mistake, which could result in injury.
1. Turn the machine pulley to move the needle bar to its
highest position.
2. Loosen the screw (1).
3. Insert the needle (2) in a straight line as far as it will go,
making sure that the long groove on the needle is at the
left, and then securely tighten the screw (1).
4-2. Removing the bobbin case
CAUTION
Turn off the power switch before removing the bobbin case.
The machine may operate if the treadle is depressed by mistake, which could result in injury.
1. Turn the machine pulley to raise the needle until it is
above the needle plate.
2. Pull the latch (1) of the bobbin case upward and then
remove the bobbin case.
3. The bobbin (2) will come out when the latch (1) is
released.
* There is an anti-spin spring (3) inside the bobbin case.
The anti-spin spring (3) prevents the bobbin from racing at
times such as during thread trimming.
* Use bobbins (2) made of light alloy as specified by
BROTHER.
3649M 0795M
Front
Long
groove
2119M
2120M
For thick materials
0798M 2121M