Brother S-7200C User manual

S-7200C
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-7200C
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-7200C 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 will 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-7200C
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 cover 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 45 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.
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.
Secure the table so that it will not move when tilting
back the machine head. If the table moves, it may
crush your feet or cause other injuries.
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-7200C 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.
yWhen threading the needle
yWhen replacing the bobbin and needle
yWhen 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.
Secure the table so that it will not move when tilting
back the machine head. If the table moves, it may
crush your feet or cause other injuries.
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 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.
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.
Secure the table so that it will not move when tilting
back the machine head. If the table moves, it may
crush your feet or cause other injuries.
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.
yWhen carrying out inspection, adjustment and
maintenance
yWhen 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.
Secure the table so that it will not move when tilting
back the machine head. If the table moves, it may
crush your feet or cause other injuries.
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-7200C
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 Touching areas where high voltages are present can
result in severe injury. Turn off the power before
opening the cover.
4 Be careful not to get your hands
caught when returning the
machine head to its original
position after it has been tilted.
3
5
Be careful to avoid injury from
the moving thread take-up.
6Be 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.
7Direction of operation
* Safety devices: (A) Finger guard
(B) Thread take-up cover
Control box
Oil pan
4123M
Transformer box
(100 V/400 V system only)

S-7200C
CONTENTS
1. MACHINE SPECIFICATIONS................ 1
2. NAMES OF MAJOR PARTS .................. 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) ........... 14
4. PREPARATION BEFORE SEWING .... 15
4-1. Installing the needle........................................ 15
4-2. Removing the bobbin case............................. 15
4-3. Winding the lower thread................................ 16
4-4. Installing the bobbin case............................... 16
4-5. Threading the upper thread............................ 17
4-6. Adjusting the stitch length............................... 18
4-7. Using the thread wiper (-4[][] specifications)... 18
4-8. Using the knee lifter........................................ 18
5. USING THE G50 OPERATION PANEL
(BASIC OPERATIONS)............................ 19
5-1. Names and functions...................................... 19
5-2. Sewing start and end backtack stitches ......... 21
5-3. Sewing continuous backtack stitches............. 22
5-4. Sewing fixed stitches ...................................... 23
5-5. Sewing name labels ....................................... 24
5-6. Sewing pleat presser stitches......................... 25
5-7. Using the lower thread counter ...................... 26
6. USING THE G50 OPERATION PANEL
(ADVANCED OPERATIONS) ................ 27
6-1. Names and functions...................................... 27
6-2. Adjusting the needle up stop position............. 28
6-3. LOCK key ....................................................... 29
6-4. Resetting all settings to their defaults............. 30
7. USING THE G10 OPERATION PANEL
(BASIC OPERATIONS)............................ 31
7-1. Names and functions...................................... 31
7-2. Sewing start and end backtack stitches ......... 32
7-3. Sewing continuous backtack stitches............. 33
8. USING THE G10 OPERATION PANEL
(ADVANCED OPERATIONS) ................ 34
8-1. Changing the needle stop position ................. 34
8-2. Slow start........................................................ 35
8-3. Correction sewing........................................... 36
8-4. Thread trimming lock ...................................... 37
8-5. Setting the maximum sewing speed ...............38
8-6. Adjusting the needle up stop position .............39
8-7. Lock function...................................................40
8-8. Resetting all settings to their defaults .............40
9. SEWING.........................................................41
9-1. Sewing ...............................................................41
9-2. Backtacking.....................................................41
9-3. Sewing condensed stitches ............................42
10. THREAD TENSION....................................43
10-1. Adjusting the thread tension ........................43
10-2. Adjusting the presser foot pressure .............44
10-3. Adjusting the trailing length after thread
trimming .......................................................44
10-4. Adjusting the thread take-up amount
(-[][]3 specifications).....................................45
11. CLEANING....................................................46
11-1. Daily cleaning procedures............................46
11-2. Applying grease (-[]3[], []5[] specifications*)
[When "GrEASEUP" appears…When using
the G50 operation panel] .............................49
11-3. Applying grease (-[]3[], []5[] specifications*)
[When "GrUP" appears ... When using
the G10 operation panel] .............................51
12. ADJUSTING THE ROTARY HOOK
LUBRICATION AMOUNT
(-[]0[], []3[] specifications).....................53
13. STANDARD ADJUSTMENTS ................54
13-1. Adjusting the actuator switch position..........54
13-2. Adjusting the safety switch position .............55
13-3. Adjusting the thread take-up spring .............56
13-4. Adjusting arm thread guide R ......................57
13-5. Adjusting the presser foot height .................57
13-6. Adjusting of the feed dog height ..................58
13-7. Adjusting the feed dog angle .......................59
13-8. Adjusting the needle bar height ...................60
13-9. Adjusting the needle and feed
mechanism timing ........................................60
13-10. Adjusting the needle and rotary hook
timing...........................................................61
13-11. Adjusting the treadle ...................................62
13-12. Adjusting the presser foot floating amount
(minute lifting amount) ................................62
14. TROUBLESHOOTING ..............................63
14-1. Sewing ..........................................................63
14-2. Error code displays .......................................68
15. 7-SEGMENT DISPLAY .............................72

S-7200C
1. MACHINE SPECIFICATIONS
1
1. 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-7200C
2. NAMES OF MAJOR PARTS
2
2. NAMES OF MAJOR PARTS
(1) Bobbin winder (2) Thread wiper (-4[][] specifications)
(3) Lifting lever (4) Actuator switch
(5) Presser foot (6) Knee lifter assembly
(7) Power switch (8) Oil gauge window (-[]0[], []3[] specifications)
(9) Reverse lever (10) Stitch length dial
(11) Oil feeding pocket (-[]0[]・[]3[]specifications) (12) Machine pulley
(13) Operation panel (14) Cotton stand
(15) Control box
Safety devices
(16) Thread take-up cover (17) Finger guard
4124M
G10 operation panel (basic function LED)
G50 operation panel (advanced function LCD)

S-7200C
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 45 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.
Secure the table so that it will not move when tilting
back the machine head. If the table moves, it may
crush your feet or cause other injuries.
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
4125M

S-7200C
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
4126M
Cotton stand hole
Cord hole
Head rest hole
Control box mounting hole
4127M

S-7200C
3. INSTALLATION
5
3. Oil pan
(1) Head cushions (left) [2 pcs]
(2) Head cushions (right) [2 pcs]
(3) Oil pan
4. Rubber cushions
(1) Rubber cushions [2 pcs]
(2) Nails [4 pcs]
5. Knee lifter complying bar
(3) Knee lifter complying bar
6. 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.
2094M
4128M
4129M

S-7200C
3. INSTALLATION
6
7. Operation panel
(1) Operation panel
(2) Screws [2 pcs]
(Use for tightening rear cover)
8. Sticker (Remove)
(1) Sticker
9. 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.
4131M
3636M
4306M

S-7200C
3. INSTALLATION
7
10. Knee lifter plate
(1) Knee lifter plate
(2) Bolt
* Loosen the bolt (3) and the bolt (4),
and then adjust the position of the
knee lifter plate (1) so that 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 (6) by using the lifting lever (5).
3. Loosen the nut (7).
4. Turn the screw (9) to adjust so that the amount of play in
the knee lifter (8) is approximately 2 mm when the knee
lifter plate (1) is gently pressed.
5. Securely tighten the nut (7).
6. Loosen the nut (10).
7. Turn the screw (11) until the distance between the end of
the screw (11) and the knee lifter (12) is approximately 3
mm.
8. Turn the adjusting screw (11) to adjust so that the presser
foot (6) 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
(10).
4132M
4133M
4134M
4135M
Within 16 mm

S-7200C
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 <Nippon Oil Corporation
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 of the accessory oil tank (1),
and use scissors to cut about half-way along the straight
section (A) of the nozzle.
2. Loosen and remove the nozzle, and then remove the seal
(2).
3. Tighten the nozzle.
4. Open the oil feeding pocket cover (3).
5. Insert the nozzle of the oil tank (1) deeply into the oil
feeding pocket (4), and then add about 120 ml of
lubricating oil.
6. Check that the oil gauge (6) comes to the upper reference
line in the oil gauge window (5).
7. Close the oil feeding pocket cover (3).
<Lubrication oil replenishment interval>
Be sure to add more oil if the oil gauge (6) is below the lower
reference line.
Upper reference
line
Lower reference
line
4136M

S-7200C
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 cover 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.
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.
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
4137M
4138M

S-7200C
3. INSTALLATION
10
(1) 6-pin head detector unit connector
(2) 12-pin operation panel connector
(3) 10-pin resolver connector
(4) 14-pin machine connector
(5) 4-pin motor connector
2. Binding the cords
(1) Repeat cable tie
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 (2) 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.
4139M
Push in securely until the tabs (6) engage.
<Closing the cover>
4141M
<Removal>
<Securing>
Press
the tab.
Cords
4140M
Lower the tab (6). Raise the tab (6).

S-7200C
3. INSTALLATION
11
3. Ground wire
(1) Ground wire
(2) Washer
(3) Spring washer
(4) Screw
4. Other cords
Connect cords that match the voltage
specifications.
< Europe specifications >
(1) Filter box
(2) Screws [4 pcs.]
(3) Staples [7 pcs.]
(4) Power cord
1. Attach an appropriate plug to the
power cord (4). (The green and
yellow wire is the ground wire.)
2. Insert the power plug into a
properly-grounded electrical outlet.
NOTE:
Take care when tapping in the
staples (3) to make sure that they do
not pierce the cords.
Do not use extension cords,
otherwise machine operation
problems may result.
4143M
Green and yellow wire (ground wire)
Ground symbol
Oil pan
4142M
<Seen from underneath table>
Control box
Leg
4144M
Ground symbol

S-7200C
3. INSTALLATION
12
<200 V system >
(1) Power switch
(2) Screws [2 pcs]
(3) 3-pin power supply connector
(4) Power cord
(5) Staples [5 pcs.]
1. Attach an appropriate plug to the
power cord (4). (The green and
yellow wire is the ground wire.)
2. Insert the power plug into a
properly-grounded electrical outlet.
NOTE:
Take care when tapping in the
staples (5) to make sure that they do
not pierce the cords.
Do not use extension cords,
otherwise machine operation
problems may result.
4145M
Green and yellow wire
(ground wire)
Operator
4147M
4146M

S-7200C
3. INSTALLATION
13
<100 V/400 V system >
(1) Power switch
(2) Screws [2 pcs]
(3) Transformer box
(4) Transformer box plates [2 pcs.]
(5) Screw [with washer]
(6) 3-pin power supply connector
(7) Staples [6 pcs.]
(8) Cord clamps [2 pcs.]
(9) Power cord
1. Attach an appropriate plug to the
power cord (9). (The green and
yellow wire is the ground wire.)
2. Insert the power plug into a
properly-grounded electrical outlet.
NOTE:
Take care when tapping in the
staples (7) to make sure that they do
not pierce the cords.
Do not use extension cords,
otherwise machine operation
problems may result.
Operator
4145M
4148M
Green and yellow wire
(ground wire)
4150M