ACE&EASTMAN Rh 981A Service I3080846H User Manual

2016-09-25

User Manual: ACE&EASTMAN Rh-981A Service

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RH-981A SERVICE MANUAL
SAFETY INSTRUCTIONS
CONTENTS
1. MECHANICAL DESCRIPTIONS
2. DISASSEMBLY
3. ASSEMBLY
4. ADJUSTMENT
5. POWER SUPPLY EQUIPMENT
6. AIR PRESSURE MECHANISM
- 6-1. Solenoid valves and air tubes
  - 6-1-1. Adjusting the solenoid valve speed controllers
  - 6-1-2. Air tubes
- 6-2. Air tube layout
7. SOFTWARE
COVER

RH-981A

Please read this manual before using the machine.

Please keep this manual within easy reach for quick reference.

ELECTRONIC EYELET BUTTON HOLER

SERVICE MANUAL

RH-981A

This service manual is intended for RH-981A; be sure to read the RH-981A 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.

If you have any questions regarding this product, please contact a Brother dealer.

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 almost certainly result in death or severe injury.

CAUTION The instructions which follow this term indicate situations where failure to follow the

instructions could cause injury when using the machine or physical 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”.)

RH-981A ii

2. Notes on safety

DANGER

Wait at least 5 minutes after turnin

off the

ower switch and disconnectin

the

ower cord from the wall outlet

before o

enin

the face

late of the control box. Touchin

areas where hi

h volta

es are

resent can result in

severe injury.

CAUTION

Environmental requirements

Use the sewin

machine in an area which is free

from sources of stron

electrical noise such as

high-frequency welders.

Sources of stron

electrical noise ma

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

ower su

acit

should be

reater than

the re

uirements for the sewin

machine’s

electrical consumption.

Insufficient

ower su

acit

cause

problems with correct operation.

The

neumatic deliver

abilit

should be

reater than the re

uirements for the sewin

machine's total air consumption.

Insufficient

neumatic deliver

abilit

cause problems with correct operation.

The ambient tem

erature should be within the

range of 5 to 35 during use.

Tem

eratures which are lower or hi

her than this

may cause problems with correct operation.

The relative humidit

should be within the ran

e of

45% to 85% durin

use, and no dew formation

should occur in any devices.

Excessivel

or humid environments and dew

formation ma

cause

roblems with correct

operation.

Avoid exposure to direct sunlight during use.

osure to direct sunli

ht ma

cause

roblems

with correct operation.

In the event of an electrical storm, turn off the

ower and disconnect the

ower cord from the

wall outlet.

htnin

cause

roblems with correct

operation.

Installation

Machine installation should onl

be carried out b

a qualified technician.

Contact your Brother dealer or a qualified electrician

for any electrical work that may need to be done.

The sewin

machine wei

hs more than 87 k

The installation should be carried out b

two or

more people.

Do not connect the

ower cord until installation is

com

lete, otherwise the machine ma

erate if

the start switch is

ressed b

mistake, which could

result in injury.

Be sure to connect the

round. If the

round

connection is not secure,

ou run a hi

h risk of

receivin

a serious electric shock, and

roblems

with correct operation may also occur.

All cords should be secured at least 25 mm awa

from an

movin

arts. Furthermore, do not

excessivel

bend the cords or secure them too

firml

with sta

les, otherwise there is the dan

that fire or electric shocks could occur.

Install the belt covers to the machine head and

motor.

If usin

a work table which has casters, the

casters should be secured in such a wa

so that

they cannot move.

Be sure to wear

rotective

les and

loves

when handlin

the lubricatin

oil and

rease, so

that the

do not

et into

our e

es or onto

our

skin, otherwise inflammation can result.

Furthermore, do not drink the oil or eat the

rease

under an

circumstances, as the

can cause

vomiting and diarrhoea.

Keep the oil out of the reach of children.

RH-981A

iii

CAUTION

Sewing

This sewing machine should only be used by

operators who have received the necessary

training in safe use beforehand.

The sewin

machine should not be used for an

applications other than sewing.

Be sure to wear

rotective

les when usin

the

machine.

les are not worn, there is the dan

er that if

a needle breaks,

arts of the broken needle ma

enter your eyes and injury may result.

Turn off the

ower switch at the followin

times,

otherwise the machine ma

erate if the start

switch is

ressed b

mistake, which could result in

injury.

When threading the needle

When replacing the needle

When not usin

the machine and when leavin

the machine unattended

If usin

a work table which has casters, the

casters should be secured in such a wa

so that

they cannot move.

Attach all safet

devices before usin

the sewin

machine. If the machine is used without these

devices attached, injury may result.

Do not touch an

of the movin

arts or

ress an

ects a

ainst the machine while sewin

, as this

result in

ersonal in

or dama

e to the

machine.

If an error occurs in machine o

eration, or if abnormal

noises or smells are noticed, immediatel

turn off the

ower switch. Then contact

our nearest Brother

dealer or a qualified technician.

If the machine develo

s a

roblem, contact

our

nearest Brother dealer or a qualified technician.

Cleaning

Turn off the

ower switch before carr

out

cleanin

, otherwise the machine ma

erate if

the start switch is

ressed b

mistake, which could

result in injury.

Be sure to wear

rotective

les and

loves

when handlin

the lubricatin

oil and

rease, so

that the

do not

et into

our e

es or onto

our

skin, otherwise inflammation can result.

Furthermore, do not drink the oil or eat the

rease

under an

circumstances, as the

can cause

vomiting and diarrhoea.

Keep the oil out of the reach of children.

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

start switch is pressed by mistake, which could

result in injury.

When carrying out inspection, adjustment and

maintenance

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.

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

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.

RH-981A iv

Finger guard

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.

Safety devices

Eye guard

Finger guard

Needle bar guard

Belt cover, etc.

3Do not touch the knife or press any objects

against the machine while sewing, as this

may result in personal injury or damage to

the machine.

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.

6Direction of operation

3122Q

Belt cover

Needle bar guard

Eye guard

Belt cover

(Rear)

4Be careful not to clamp your fingers when

closing the front cover.

RH-981A

CONTENTS

1. MECHANICAL DESCRIPTIONS ...................1

1-1. Upper and lower shaft mechanisms ..................1

1-2. Needle bar mechanism ......................................2

1-3. Thread take-up mechanism ...............................2

1-4. Zigzag mechanism .............................................3

1-5. Needle bar rocking mechanism .........................3

1-6. Feed mechanism ................................................4

1-7. Work clamp mechanism.....................................5

1-8. Cloth opener mechanism ...................................6

1-9. Cutter mechanism...............................................7

1-10.Looper mechanism.............................................7

1-11.Spreader mechanism .........................................8

1-12.Double chain stitch looper mechanism..............9

2. DISASSEMBLY ...................................................10

2-1. Covers and work clamp mechanism ...............10

2-2. Feed mechanism ..............................................11

2-3. Lubrication mechanism ....................................11

2-4. Looper and spreader mechanisms..................12

2-5. Needle bar rotating mechanism.......................13

2-6. Looper base mechanism..................................14

2-7. Needle bar, thread take-up, and zigzag

mechanisms......................................................15

2-8. Knife pipe assembly..........................................17

2-9. Lower shaft mechanism ...................................17

2-10.Synchronizer mechanism.................................18

2-11.Upper shaft mechanism ...................................18

2-12.Cutter mechanism.............................................19

2-13.Zigzag fork mechanism ....................................19

3. ASSEMBLY...........................................................20

3-1. Zigzag fork mechanism ....................................20

3-2. Cutter mechanism.............................................21

3-3. Upper shaft mechanism ...................................22

3-4. Lower shaft mechanism ...................................23

3-4-1. Adjusting the timing belt..............................23

3-5. Upper thread trimmer mechanism ...................24

3-5-1.

Adjusting the thread trimmer lever

hammer stroke ....................................................24

3-6. Knife pipe and the knife bracket.......................25

3-7. Driving gear shaft mechanism .........................26

3-8. Needle bar, thread take-up, and zigzag

mechanisms......................................................27

3-8-1. Eliminating end play of the thread take-up

on the arm ...................................................27

3-8-2. Applying grease to the ends of the thread

take-up spring..............................................27

3-8-3.Eliminating end play of the needle bar

driving lever...................................................27

3-8-4.Eliminating end play of the driving rod ........28

3-8-5.The strength to tighten the set screw

of ball bearing 25/20.....................................28

3-8-6.

Eliminating end play of the zigzag rock shaft

.....

3-8-7.Eliminating end play of the zigzag lever......29

3-8-8.Attaching the needle bar yoke and

the needle bar level feed link .......................29

3-8-9.Attaching the needle bar bush U and the

needle bar.....................................................30

3-8-10. Eliminating end play of

the needle bar block..................................31

3-8-11. Adjusting the needle bar

in the radial direction ...................................... 31

3-8-12.

Attaching the needle bar block assembly

....32

3-8-13. Adjusting the height of the needle bar .....32

3-9. Looper base.......................................................33

3-10.Needle bar rocking mechanism........................34

3-10-1. Driving looper shaft ...................................34

3-10-2. Needle bar rocking mechanism ...............35

3-11.Looper and spreader machanisms ..................37

3-12.Lubrication mechanism.....................................40

3-12-1. Machine head ...........................................40

3-12-2. Driving gear shaft.......................................41

3-13.Feed mechanism ..............................................42

3-13-1. X direction...............................................42

3-13-2. Y direction...............................................43

3-13-3. Attaching the X-feed guide shaft ...........45

3-14.Synchronizer......................................................46

3-15.Covers and work clamp mechanism................47

3-16.Safety switch......................................................47

4. ADJUSTMENT.....................................................48

4-1. Adjusting the work clamp lift height..................48

4-2.

Adjusting the position of the work clamp plate ....

4-3. Adjusting the cloth opening amount.................50

4-4. Adjusting the position of the work clamp..........51

4-5. Adjusting the X-axis home position..................52

4-6. Adjusting the Y-axis home position..................52

4-7. Adjusting 0 position (reference line)

of the needle......................................................53

4-8. Adjusting the home position of the

looper base........................................................53

4-9. Fine adjustment of knife position......................54

4-10.Adjusting the sideways movement

of the cutter lever...............................................55

4-11.Adjusting the height of the throat plate.............55

RH-981A

4-12.Adjusting the height of the spreader

and looper..........................................................56

4-13.Adjusting the needle and looper timing............57

4-14.Adjusting the loop stroke ..................................58

4-15.Adjusting the height of the needle bar .............59

4-16.Adjusting the clearance between

the looper and needle .......................................59

4-17.Adjusting the needle guard...............................60

4-18.Adjusting the spreader mounting positions .....60

4-19.Adjusting the spreader timing...........................61

4-20.Adjusting the amount to pull

the upper thread and tension release..............61

4-21.Adjusting upper thread trimming ......................62

4-21-1. Adjusting the upper movable

knife mounting position..............................62

4-21-2. Adjusting the position of the thread

trimmer lever bracket.................................63

4-22.Adjusting the lower thread trimmer

(-01 specification).............................................63

4-22-1.Adjusting the knife pressure......................63

4-22-2.Adjusting the position of the

thread trimmer arm ....................................64

4-22-3.Adjusting the thread clamp assembly

and thread clamp opener...........................65

4-22-4.Adjusting the thread handler .....................66

4-22-5.Adjusting the thread guide plate................67

4-22-6.Adjusting the amount to pull the lower

thread required for thread trimming ..........67

4-22-7.Adjusting the amount to pull the lower

thread for safety stitching...........................68

4-22-8.Adjusting the amount to pull the gimp.......68

4-23.Adjusting the lower thread trimmer

(-02, -52 specifications).....................................69

4-23-1. Adjusting the knife engagement...............69

4-23-2. Adjusting the knife pressure......................70

4-23-3. Adjusting the gimp pull force.....................70

4-23-4. Adjusting the gimp tension ........................71

4-23-5. Using gimp thread work clamp .................72

4-23-6. Adjusting the auxiliary clamp arm.............73

4-23-7. Adjusting the length of the lower thread

to be pulled for a safe sewing start...........74

4-24.

Adjusting the position of the lower thread presser

(-02, -52 specifications)

.....................................75

4-25.Adjusting the rotating centers

of the needle bar and the looper base.............76

4-26.Adjusting the needle bar stop position.............77

5. POWER SUPPLY EQUIPMENT .................. 78

5-1. Components inside the control box................. 78

5-2. Fuse explanation .............................................. 80

5-2-1.Before replacing a fuse ............................... 81

5-3. Connectors........................................................ 82

5-3-1.Connector positions..................................... 82

5-3-2.Signal names for connectors and probable

symptoms due to poor contact ................... 86

5-4. Specification harness connections .................. 97

5-5. Summary of DIP switches................................ 98

5-5-1.Panel DIP switches ..................................... 98

5-5-2. Circuit board DIP switches ......................... 99

5-6. CHANGING FUNCTIONS USING

THE MEMORY SWITCHES.......................... 101

5-6-1. Memory switch table................................. 102

5-7. Sensors positions and funstions.................... 103

6. AIR PRESSURE MECHANISM.................. 107

6-1. Solenoid valves and air tubes........................ 107

6-1-1.Adjusting the solenoid valve speed

controllers....................................................

107

6-1-2.Air tubes..................................................... 108

6-2. Air tube layout................................................. 109

7. SOFTWARE.........................................................112

7-1. Motion flowchart.............................................. 112

7-2. Input check list ................................................ 113

7-3. Output check list ............................................. 116

7-4. List of error codes........................................... 118

7-5. Troubleshooting.............................................. 121

7-6. Control circuit block diagram (1).................... 128

7-7. Control circuit block diagram (2).................... 129

RH-981A

1. MECHANICAL DESCRIPTIONS

RH-981A

1. MECHANICAL DESCRIPTIONS

1-1. Upper and lower shaft mechanisms

1. When the motor pulley (1) rotates, its motion is transmitted to the V belt (2), the idler pulley (3), and the V belt (4),

and finally to the pulley (5).

2. When the pulley (5) rotates in the direction of the arrow, its motion is transmitted to the upper shaft timing pulley

(6), the timing belt (7), and the lower shaft tension pulley (8), and the lower shaft (9), causing the lower shaft cam

(10) to turn in the direction of the arrow.

3679Q

1. MECHANICAL DESCRIPTIONS

RH-981A 2

1-2. Needle bar mechanism

1. When the pulley rotates in the direction of the arrow (towards you), its rotation is transmitted to the upper shaft (2),

the needle bar gear (3), and the driving gear (4), that makes the eccentric rod (5) rotate.

2. The driving rod (6), which is engaged with the eccentric rod (5), rocks the needle bar driving lever (7).

3. The rocking motion of the needle bar driving lever (7) is transmitted to the needle bar york (8), the needle bar level

feed link (9), and the needle bar clamp (10), and then the needle bar (11) moves up and down.

4. The needle bar (11) is guided by needle bar bush U (12) and the needle bar block (13).

1-3. Thread take-up mechanism

1. When the pulley (1) rotates in the direction of the arrow, the needle bar gear (3) rotates via the upper shaft (2).

2. The thread take-up cam (4), which is attached to the needle bar gear (3), moves the thread take-up (6) via the

thread take-up cam roller (5).

3. The thread take-up cam roller (5) is always kept in contact with the cam (4) by the thread take-up spring (7)

attached to the thread take-up (6).

3681Q

3682Q

1. MECHANICAL DESCRIPTIONS

RH-981A

1-4. Zigzag mechanism

1. When the pulley (1) is turned in the direction of the arrow, its motion is transmitted to the upper shaft (2) that

rotates the zigzag cam (3), and the zigzag fork (4) rocks.

2. The zigzag rock shaft (7) is rocked by the zigzag fork (4), via the zigzag connecting rod (5), and the zigzag crank

(6).

3. The rocking motion of the zigzag rock shaft (7) is transmitted to the zigzag lever (8), the needle bar lever feed link

(9), and the needle bar block clamp (10), those move the needle bar block (11) up and down.

4. The needle bar (12) is fitted on the needle bar block (11), and the needle bar guide (14) is fitted in the notch of the

needle bar block (11). When the needle bar block (11) moves up and down, the needle bar (12) oscillates.

1-5. Needle bar rocking mechanism

1. When pulse motor R (1) operates, the motion is transmitted to the driving needle pulley assembly (2), timing belt

D (3), and the looper pulley assembly (4), which then moves the driving looper shaft assembly (5).

2. The looper base (6) is rotated by the looper pulley assembly (4).

3. When the vertical shaft T pulley U assembly (7), which is attached to the driving looper shaft assembly (5), rotates,

the motion is transmitted to timing belt U (8), and the needle bar block assembly (9) that rotates the needle bar (10).

3683Q

3684Q

1. MECHANICAL DESCRIPTIONS

RH-981A 4

1-6. Feed mechanism

[X-direction feeding]

1. When pulse motor X (1) operates, its motion is transmitted to the actuating gear (2), the idle gears (3) and (4), and

the X racks (5) and (6), that finally moves X-feed shaft holder L (7).

2. The X-feed guide shafts A (8) and B (9), which are connected to X-feed shaft holder L (7), move X-feed shaft

holder R (10).

3. The Y-feed guide shafts (11) and (12), which are attached to X-feed shaft holders L (7) and R (10), move the feed

bar (13) in the X direction.

[Y-direction feeding]

1. When pulse motor Y (14) rotates, its motion is transmitted to the actuating gear (15), the idle gear (16), timing

pulley A (17), that finally moves the Y-timing belt (18).

2. The Y-timing belt (18) is secured by the Y-driving shaft holder (19) and the belt holder (20), and that moves the Y

shaft (21).

3. The linear bush (23), which is fitted in the ball bearing (22), is fitted in the Y-guide shaft (24) to move the feed bar

(13) in the Y direction.

X direction

3685Q

Y direction

1. MECHANICAL DESCRIPTIONS

RH-981A

1-7. Work clamp mechanism

1. Cylinder 16 X 10 (1) moves clamp lever B (6) in the direction of the arrow according to the cylinder’s motion, via

the presser cylinder rod (2), the cylinder rod pin (3), the presser driving lever (4), and the clamp lever shaft (5).

2. The end of clamp lever B (6) is fitted on clamp lever L (7), and the work clamp (9) attached to clamp arm L (8)

lowers.

3. When the cylinder (1) is returned by the presser spring (10), the work clamp (9) rises. The speed controller (11)

attached to the cylinder (1) controls the rising speed of the work clamp (9).

* The work clamp mechanism is activated by independently-operated left and right cylinders, that can equalize the

pressure of the work clamp.

The pressure of the work clamp is always applied to the material equally even when the material thickness

changes.

3686Q

1. MECHANICAL DESCRIPTIONS

RH-981A 6

1-8. Cloth opener mechanism

1. The feed bracket (1) carries the cylinder 16 X 15 assembly (2), whose end is connected to the opening cylinder

rod (3), cylinder rod pin B (4), and the opening driving lever (5).

2. The opening connecting rod (6) attached to the opening driving lever (5) is connected to the fulcrum lever plate

(8) and the lever (9) via the slide block (7).

3. The projection (10) of the fulcrum lever plate (8) and the pin (11) of the lever (9) are fitted on the hole of the work

clamp plate (12) and the slide block on it.

4. When the cylinder 16 X 15 assembly (2) operates, and the stopper (13) of the opening driving lever (5) and the

bolt (14) make contact, the work clamp plate (12) moves in the direction of a, consequently opening a button

eyelet on the material.

5. At this time, there should be at least 1.3 mm clearance between the throat plate (15) and the needle plate (16).

Adjust the clearance using the bolt (14).

6. When the cylinder 16 X 15 assembly (2) is not pressurized, the work clamp plate (12) is moved in the direction of

b by the opening spring (17). At this time, the stopper (13) of the work clamp plate (12) makes contact with the

stopper plate (18).

* The c indicates the movement of the work clamp plate (12).

3687Q

3688Q

1.3 mm or more

1. MECHANICAL DESCRIPTIONS

RH-981A

1-9. Cutter mechanism

1. When cylinder 63 X 100 (1) operates, the motion is transmitted to the cylinder rod (2), link C (3), and link A (4),

which then activates the cutter lever assembly (5).

2. The cutter sensor partition plate (6) attached to link C (3), and the cutter sensor assembly (7) monitor the motion

of the cutter sensor assembly (5).

3. Engagement of the hammer (8) attached to the end of the cutter sensor assembly (5) and the cutter (9) attached

to the bed, cuts the material requiring button eyelets.

1-10. Looper mechanism

1. At the end of the looper link assembly (2) which has the looper link support shaft (1) as the pivot of the rocking

motion, the looper cam roller (3) is fitted in the groove in the lower shaft cam (4). The two looper link springs (5)

are attached to the other end.

2. The looper link springs (5) are secured by the looper driving plate (7) through which the looper driving shaft (6)

passes.

3. When the lower shaft cam (4) rotates in the direction of the arrow, the looper link assembly (2) is rocked via the

looper cam roller (3).

4. The looper driving shaft (6) moves up and down due to the motion of the looper link assembly (2).

3689Q

3690Q

1. MECHANICAL DESCRIPTIONS

RH-981A 8

1-11. Spreader mechanism

1. At the end of the spreader cam lever (2) which has the looper link support shaft (1) as the pivot of the rocking

motion, the spreader cam roller (3) makes contact with the circumference of the lower shaft cam (4), and the

spreader driving lever (5) is attached to the other end using the screw (6). The forked part of the spreader driving

lever (5) is fitted in the groove (8) of the spreader link shaft (7).

2. When the lower shaft cam (4) rotates in the direction of the arrow, the spreader cam lever (2) is rocked via the

spreader cam roller (3).

3. The spreader link shaft (7) moves up and down due to the motion of the spreader cam lever (2).

3691Q

1. MECHANICAL DESCRIPTIONS

RH-981A

1-12. Double chain stitch looper mechanism

1. When the looper driving shaft (1) moves up and down,

the motion is transmitted to the looper link clamp (2),

and the looper link (3), which rocks LS-holder bracket

(6) with the holder support shaft (5) secured to the

loop base (4) regarded as the pivot.

2. When the spreader link shaft (7) moves up and down,

the motion is transmitted to the spreader link base (8)

and the spreader cam link (9), which then rocks the

spreader differential cam (10) with the holder support

shaft (5) secured to the loop base (4) regarded as the

pivot.

3. The rocking motions of the LS-holder bracket (6) and the spreader differential cam (10) cause spreader L (11) to

rock.

4. In the same way, spreader R (12) is rocked.

3692Q

3693Q

2. DISASSEMBLY

RH-981A 10

2. DISASSEMBLY

CAUTION

Disassembly should only be carried out by a

qualified technician.

Turn off the power switch before disassembly,

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 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.

Disconnect the air hoses from the air supply and

wait for the needle on the pressure gauge to drop

to “0” before disassembly of any parts which use

the pneumatic equipment.

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.

If disassembly is not performed in the correct order, it may be hard to remove parts. Disassemble as follows.

The following is the main points of disassembly.

2-1. Covers and work clamp mechanism

1. Remove the needle (1).

2. Remove the face plate (2), the belt cover F (3), the belt cover R (4), the top cover (5), the zigzag window cover (6),

and the driving needle guard cover (7).

3. Remove the work clamp plates R (8) and L (9).

3694Q 3695Q

3696Q

2. DISASSEMBLY

RH-981A

2-2. Feed mechanism

[Feed bracket]

Remove the two Y-feed guide shafts (1) toward you. The feed bracket (2) unit will come off.

[X motor unit]

Remove the motor support (3), which includes the X motor unit.

[Y motor unit]

Loosen the screw (4) of the Y driving shaft holder, pull out the Y-shaft (5) toward you, and remove the Y-feed base

(6), including the Y motor unit.

2-3. Lubrication mechanism

1. Remove the wick supports (1) and (2).

2. Remove the wicks (3) and (4) from the hole.

3. Remove the two screws (5) and wick support L (6).

3697Q 3698Q

3699Q

Hole

Oil tank

2. DISASSEMBLY

RH-981A 12

2-4. Looper and spreader mechanisms

1. Loosen the two set screws (2) of the set collar (1), and the two set screws (3), and remove the looper link support

shaft (4).

2. Position the needle at its lower position. Pull the spreader link shaft (5) downward, and remove the spreader cam

lever (6).

3. Remove the two bolts (7) and the looper link springs (8).

4. Loosen the two set screws (10) of the set collar (9) and the two set screws (11), and remove the looper link

support shaft (12).

5. Slide the lower shaft cam (13) in the direction of the arrow, and remove the looper link (14).

3700Q

3701Q

2. DISASSEMBLY

RH-981A

2-5. Needle bar rotating mechanism

1. Remove the two bolts (1), then remove the tension pulley U assembly (2) and timing belt U (3).

2. Remove the two bolts (4), then remove the tension pulley D assembly (5) and timing belt D (6).

3. Remove the two screws (7) and the R-sensor setting plate (8).

4. Remove the four bolts (9) and the motor base (10).

5. Loosen the bolt (12) of the vertical shaft T-pulley U assembly (11) and the two set screws (14) of the set collar

(13).

6. Remove the driving looper shaft assembly (15) downward.

3703Q

3702Q

3704Q

3706Q

3705Q

2. DISASSEMBLY

RH-981A 14

2-6. Looper base mechanism

1. Loosen the screw (1), and remove the spreader link shaft (2) in the direction of the arrow.

2. Loosen the screw (3), and remove the looper driving shaft (4) in the direction of the arrow.

3. Remove the tension nut (5), pre-tension spring B (6), the thread guide discs (7), and the L-tension stud (8).

Loosen the screw (10) of the looper pulley assembly (9), and remove the looper base (11) in the direction of the

arrow.

* Be careful not to drop the two ball bearings (12) when removing the looper pulley assembly (9).

3707Q

2. DISASSEMBLY

RH-981A

2-7. Needle bar, thread take-up, and zigzag mechanisms

3710Q 3711Q

3709Q3708Q

2. DISASSEMBLY

RH-981A 16

[Needle bar mechanism]

1. Remove the two screws (1), the needle bar guide support plate (2), the two springs (3), the two needle bar guides

(4), and the two washers (5).

2. Loosen the two set screws (6), and remove the two needle bar guide collars (7).

3. Remove the set screw (8), the stud screw (9), the tension spring (10), the needle thread holder plate A (11), and

the guide A (12). Loosen the two bolts (13), and remove the needle bar assembly (14) in the direction of the

arrow.

4. Remove the rubber caps (15) and (16).

5. Loosen the set screw (17), and remove the driving rod pin (18).

6. Loosen the two set screws (19) and the two set screws (21) of the set collar (20), and then pull out the driving

lever shaft (22) in the direction of the arrow.

7. Remove the needle bar driving lever assembly (23).

[Zigzag mechanism]

1. Loosen the bolt (25) of the needle bar block clamp (24), and remove the needle bar block (26) in the direction of

the arrow.

2. Remove the needle bar block clamp (24), the needle bar level feed links (27) and (28), and the needle bar block

collar (29).

3. Remove the rubber cap (30). Loosen the bolt (32) of the needle bar clamp (31), and remove the zigzag lever (33)

in the direction of the arrow.

4. Loosen the bolt (35) of the needle bar block clamp (34), and the bolt (37) of the zigzag crank (36), and remove the

zigzag rock shaft (38) in the direction of the arrow.

[Thread take-up mechanism]

1. Remove the spring (39) and the two rubber caps (40).

2. Loosen the two set screws (41) and the two set screws (43) of the set collar (42), and remove the support shaft

(44).

3. Remove the thread take-up lever assembly (45).

2. DISASSEMBLY

RH-981A

2-8. Knife pipe assembly

1. Remove the two screws (1).

2. Remove the knife pipe assembly (2).

2-9. Lower shaft mechanism

Before removing the cam shaft, loosen the timing belt, referring to “3-4-1. Adjusting the timing belt”.

1. Loosen the two set screws (2) of the lower shaft tension pulley assembly (1).

2. Loosen the two set screws (4) of the lower shaft cam (3).

3. Loosen the two set screws (6) of the set collar (5).

4. Remove the cam shaft (7) in the direction of the arrow.

3712Q

3713Q

2. DISASSEMBLY

RH-981A 18

2-10. Synchronizer mechanism

1. Loosen the two set screws (1) and (2), and remove the pulley assembly (3).

2. Loosen the two screws (4), and remove the synchronizer assembly B (5).

3. Remove the two screws (6), and the NP support bracket B (7).

2-11. Upper shaft mechanism

1. Remove ball bearing cap S (1) and the retaining ring (2).

2. Loosen each set screw (2 each) of the needle bar gear (3), the zigzag cam (4), and the upper shaft tension pulley

assembly (5).

3. Pull the upper shaft (6) in the direction of the pulley to remove it. The upper shaft unit will come off.

3714Q

3715Q

2. DISASSEMBLY

RH-981A

2-12. Cutter mechanism

1. Remove the extension spring (1), loosen the set screw (2), and remove the link shaft B (3) in the direction of the

arrow.

2. Remove the two nuts (4) and the two support screws (5).

3. Loosen the set screw (6), and remove the cutter lever shaft (7) in the direction of the arrow, and the cutter lever

(8) along with the knife lever cover (9).

4. Remove the wick (10), and loosen the set screw (11). Remove the cylinder rod shaft (12).

5. Loosen the set screw (13), and remove the link shaft A (14), and the combination of link A (15), link C (16), and

link shaft C (17) downward.

6. Remove the two air tubes (18).

7. Loosen the two set screws (19), and remove the cylinder support shaft (20) and the cutter cylinder (21).

2-13. Zigzag fork mechanism

1. Remove the two nuts (1), and the zigzag connection rod assembly (2).

2. Remove the nut (3), the zigzag fork support pin (4), and the zigzag fork (5).

3716Q

Seen from below

3717Q

3. ASSEMBLY

RH-981A 20

3. ASSEMBLY

CAUTION

Assembly should only be carried out by a

qualified technician.

Turn off the power switch before assembly,

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 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.

Disconnect the air hoses from the air supply

and wait for the needle on the pressure gauge

to drop to “0” before disassembly of any parts

which use the pneumatic equipment.

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.

If assembly is not performed in the correct order, it may be hard to attach parts. Assemble as follows.

The following is the main points of assembly.

3-1. Zigzag fork mechanism

1. Combine the zigzag fork (1) and the zigzag connecting rod assembly (2) using the two nuts (3). Insert the zigzag

fork support pin (4) into the hole in the zigzag fork (1), and put them into the arm from above.

2. Insert the zigzag fork support pin (4) into the hole in the side of the arm, and secure it using the nut (5).

3718Q

3. ASSEMBLY

RH-981A

3-2. Cutter mechanism

1. Put the cutter cylinder (1) into the arm with the joints facing the front. Insert the cylinder support shaft (2) into the

hole in the cutter cylinder (1), and secure it using the two set screws (3).

2. Attach No.18 air tube to the upper tube, and No.19 air tube to the lower tube of the cutter cylinder (1).

3. Combine link C (4), link A (5), and link shaft C (6). Position them in the bed from below, and attach link shaft A (7)

to them using the set screw (8).

4. Attach the cylinder rod shaft (9) with the lubrication hole facing the left to the link C (4) and the cylinder rod, and

secure it using the set screw (10).

5. Insert the cutter lever shaft (11) with its slit facing the right, into the hole in the bed, the cutter lever (12), and the

hole in the bed, and tighten the set screw (13) on the screw flat of the cutter lever shaft (11).

6. Tighten the two support screws (14) on each end of the cutter lever shaft (11), and secure it using the two nuts

(15).

7. Hook the extension spring (16) over the cutter lever (12) and the tab of the bed.

8. Pass link shaft B (17) with its slit facing the right, through the slot of link A (5), and the hole in the cutter lever (12),

and tighten the set screw (18).

9. Wind the wick (19) around the right of link C (4), and insert the end of the wick into the lubrication hole in the

cylinder rod shaft (9).

3719Q

Seen from below

3. ASSEMBLY

RH-981A 22

3-3. Upper shaft mechanism

1. Insert the upper shaft (1) into the arm from the right, and place the upper shaft collar (2), the needle bar gear (3),

the zigzag cam (4), the thrust washer (5), the upper shaft tension pulley assembly (6), and the timing belt on it.

* The emergency stop switch cord should be routed above the upper shaft.

2. Position the zigzag fork so that the zigzag cam (4) is between the arms.

3. Attach the ball bearing cap S (7) using the three flat screws (8).

4. Place the ball bearing (9) on the upper shaft, and secure it using the retaining ring (10).

5. Lightly press the needle bar gear (3) and the zigzag cam (4) toward the pulley so that the ball bearing (12) is

pressed between the retaining ring (11) and the upper shaft collar (2).

Tighten the set screw which comes first when the shaft is rotated in the rotation direction, against the screw flat.

6. Position the zigzag fork between the zigzag cam (4) and the thrust washer (5) so that there is no play between

them, face the screw flat to the front, and secure the upper shaft tension pulley assembly (6) by tightening the set

screw which comes first when rotated in the rotation direction, against the screw flat. Then tighten the other set

screw.

7. Temporarily tighten the pulley with its screw flat facing the front.

3720Q

3. ASSEMBLY

RH-981A

3-4. Lower shaft mechanism

1. Fit the two ball bearings into the holes in the bed, insert the lower shaft (1) from the left.

2. Put the timing belt (2), the lower shaft tension pulley assembly (3), the lower shaft cam (4), and the set collar (5),

in this order, on the lower shaft (1), and tighten the two set screws (6) of the set collar (5) so that there is no play

between the parts on the lower shaft (1).

3. Lightly press the lower shaft tension pulley assembly (3) and the lower shaft cam (4) against the left ball bearing,

and tighten the two set screws (7) of the lower shaft cam (4).

* The screw flat should align with the set screw which comes first when the lower shaft is rotated in the rotation

direction.

4. When the screw flat of the upper shaft is at the top, and the two set screws (8) of the lower shaft tension pulley

assembly (3) are as shown in figure 1, loop the timing belt over the lower shaft tension pulley assembly (3).

3-4-1. Adjusting the timing belt

Use a screwdriver or similar tool to press the notch of

the tension pulley arm assembly (1) with a force of 39.2

N, and attach the tension pulley assembly.

3722Q

3723Q

3721Q

3. ASSEMBLY

RH-981A 24

3-5. Upper thread trimmer mechanism

1. Assemble the thread trimmer lever (2), the adjust screw (3), and the nut (4), and attach them to the cylinder 10 X

15 assembly (1). Insert them into the tubular part of the bed, and temporarily tighten the two bolts (5).

2. Insert the thread trimmer lever shaft (6) into the hole in the bed, and pass it through the thread trimmer lever (2)

and the set screw collar (7).

3. Secure the thread trimmer lever (2) using the retaining ring (8) and the set screw collar (7), and tighten the set

screw (9).

4. Insert the thread trimmer lever hammer (10) into the hole in the bed, and tighten the adjusting screw (3) and the

nut (4), until there is 2.7 mm between the nut and the head of the adjusting screw (3).

5. Manually move the thread trimmer lever hammer (10) up and down, and tighten the two set screws (11) where the

thread trimmer lever hammer (10) motion is the smoothest.

6. In the same way, move the thread trimmer lever hammer (10) up and down manually, and tighten the two bolts (5)

where the thread trimmer lever hammer (10) motion is the smoothest.

3-5-1. Adjusting the thread trimmer lever hammer stroke

1. Raise the thread trimmer lever hammer (1), and

adjust the set screw (2) so that the clearance with the

bed is 11 mm.

2. Lower the thread trimmer lever hammer (1), and

adjust the set screw (3) so that the clearance with the

bed is 6 mm.

3724Q 3725Q

3726Q

3. ASSEMBLY

RH-981A

3-6. Knife pipe and the knife bracket

Knife pipe

Insert the knife pipe assembly (1) into the bed from

below, and secure it using the two screws (2).

Knife bracket

Insert a bar with a diameter of 4 mm into the hole (1) in

the knife bracket to fix the knife bracket position, and

tighten the bolts (2) to (6).

3727Q

3728Q

3. ASSEMBLY

RH-981A 26

3-7. Driving gear shaft mechanism

Assembling the needle bar gear and the driving rod gear

Engage the needle bar gear (1) with the driving rod gear (3) by matching their identification holes (2) and (4).

Note: Do not mistake the hole (4) for the hole in which the dowel pin is inserted.

Adjusting the set screw collar of the needle bar gear

Tighten the two set screws (3) of the set screw collar (2) with either set screw at the center of the screw flat on the

driving gear shaft (1).

Adjusting the backlash between the needle bar gear and the driving gear

1. The driving gear shaft (1) is eccentric. Turn it to adjust the backlash.

* The driving gear shaft (1) should be turned in the direction where its lubrication hole is moving upward.

2. While pressing the set screw collar (2) toward the pulley so that the driving gear shaft (1) has no end play, tighten

the two set screws (4).

3729Q

Dowel pin

3730Q

3. ASSEMBLY

RH-981A

3-8. Needle bar, thread take-up, and zigzag mechanisms

3-8-1. Eliminating end play of the thread take-up on the arm

Eliminate end play of the thread take-up lever (1) on the arm by placing it between the end of the arm and the set

screw collar (2).

3-8-2. Applying grease to the ends of the thread take-up spring

1. Apply grease to the ends (2) of the thread take-up

spring (1).

2. Apply grease to the ends of the thread take-up lever

(3) and the spring hook (4).

3-8-3. Eliminating end play of the needle bar driving lever

Adjust the position of the set screw collar (2) to

eliminate end play of the needle bar driving lever

assembly (1).

3731Q

3732Q

3733Q

3. ASSEMBLY

RH-981A 28

3-8-4. Eliminating end play of the driving rod

The driving rod assembly (1) is attached to the needle

bar driving lever assembly (2) and the pin (3). The

eccentric wheel of the driving rod assembly (1) is free in

the thrust direction.

Place the driving rod assembly (1) between the edge of

the needle bar driving lever assembly (2) and the head

of the pin (3) to eliminate end play of the driving rod

assembly (1).

3-8-5. The strength to tighten the set screw of ball bearing 25/20

The set screw (3) of ball bearing 25/20 (2) for the needle

bar gear (1) should be tightened as little as possible. If it

is tightened excessively, unnecessary load may be

applied to the needle bar gear (1), causing pulse motor

R to go out of control.

* Be sure to apply the screw lock to the circumference

of ball bearing 25/20 (2) before press fitting it.

3-8-6. Eliminating end play of the zigzag rock shaft

Insert the zigzag eccentric pin (2) into the zigzag crank (1), attach the washer (3) and the needle position control

plate assembly (4) as shown in the above figure, and pass the zigzag rock shaft (5) through the arm from the right.

At this time, insert a wedge or similar tool into the split of the zigzag crank (1) for easier adjustment.

Note: Do not fail to attach the washer (3).

3734Q

3735Q

3736Q

3. ASSEMBLY

RH-981A

3-8-7. Eliminating end play of the zigzag lever

1. Adjust the needle bar clamp (3) so that there is no

end play of the zigzag lever (2) which is connected to

the zigzag rock shaft (1).

The zigzag lever (2) should rotate easily in the

rotation direction.

2. Pass the wick (4) through the zigzag lever (2), and fit

the cap (5).

3. Attach the needle bar level feed link (6) to the zigzag

lever (2) vertically, and turn it 90°.

3-8-8. Attaching the needle bar yoke and the needle bar level feed link

1. Combine the needle bar driving lever assembly (1)

and the needle bar yoke (2), pass the wick (3)

through the needle bar driving lever assembly (1),

and fit the cap (4).

2. Attach the needle bar level feed link (5) to the needle

bar yoke (2) vertically, and turn it 90°.

3737Q

3738Q

3. ASSEMBLY

RH-981A 30

3-8-9. Attaching the needle bar bush U and the needle bar

1. Put the thrust bearing (2) and the thrust washer (3) on

the needle bar gear (1). Attach them to bearing 25/20

(4), and secure them using gear supports A (5) and B

(6) and the screws (7) so that the needle bar gear (1)

can turn easily but without any end play.

* Do not forget to attach timing belt U.

2. Insert the plate spring (8) into the hole in the arm, and

bind it using needle bar bush U (9) and the needle

bar bush nut U (10).

3. Temporarily attach holder base B (11) using the three

bolts (12).

4. Pass the needle bar assembly (13) through the arm

from above.

5. Insert the needle bar felt (14), the needle bar clamp

(5), the needle bar level feed link (16), the needle bar

block clamp (17), the needle bar level feed link (18),

and the needle bar block collar (19), through the

needle bar assembly (13) in this order.

3739Q

3740Q

3. ASSEMBLY

RH-981A

3-8-10.Eliminating end play of the needle bar block

Adjust the positions of the needle bar level feed link (1) and the needle bar block collar (2) using the flange (4) of the

needle bar block (3) and the needle bar block clamp (5), so that there is no end play.

Note: Be sure to insert the needle bar block felt (6).

3-8-11.Adjusting the needle bar in the radial direction

Insert the two needle bar guide collars (2) into the

needle bar block (1), and adjust the position of the

needle bar assembly (4) using the two set screws (3) so

that the needle bar can move smoothly.

Note: Position the needle bar assembly (4) so that the

holder plate A (5) will face the front when the set

screws (3) are facing the front.

When assembling the needle bar block and

the needle bar gear, align their white paint

marks with each other.

3741Q 3742Q

White paint marks

3743Q

3. ASSEMBLY

RH-981A 32

3-8-12.Attaching the needle bar block assembly

The needle bar block assembly is a set of the needle bar gear, the needle bar block, and the washers.

When disassembling and then reassembling the needle bar block assembly, align the white marks of the needle bar

gear, the needle bar block, and the collars with each other.

1. Insert the two needle bar guides (2) into the hole in the needle bar block (3) on each side, taking care of the white

paint mark of the washer (1).

2. Attach the two spring (4) using the needle bar guide support plate (5), and tighten the two screws (6).

3-8-13.Adjusting the height of the needle bar

1. Turn the pulley to set the needle bar level feed link (1)

at its highest position.

2. Set the height of the needle bar (2) to approx. 62 mm,

eliminate end play between the two needle bar

clamps (3) and the needle bar level feed link (1), and

tighten the two screws (4).

3745Q

3744Q

White paint marks

Approx. 62 mm

3746Q

3. ASSEMBLY

RH-981A

3-9. Looper base

1. Insert the shaft of the looper base (1) through the hole in the bed, attach the two ball bearings (2) and the looper

pulley (3) to the shaft of the looper base (1) so that there is no end play, and tighten the screw (4).

2. Insert the looper driving shaft (5) into the shaft of the looper base (1), then the looper link clamp (6) into the looper

driving shaft (5), and tighten the screw (7).

3. Insert the spreader link shaft (8) into the hole in the looper driving shaft (5), then the spreader link base (9) into the

spreader link shaft (8). Align the reference line (10) with the top surface of the spreader link base (9), and tighten

the screw (11).

4. Attach the L-tension stud (12), the thread guide discs (13), pre-tension spring B (14), and the tension nut (15) to

the looper base (1).

3747Q

3. ASSEMBLY

RH-981A 34

3-10. Needle bar rocking mechanism

3-10-1.Driving looper shaft

1. Insert the driving looper shaft assembly (1) through

the hole in the bed from below, place the ball bearing

(2), the set screw collar (3), the vertical shaft T-pulley

U assembly (4), the washer (5), and finally the ball

bearing (6) on the driving looper shaft assembly (1).

2. Set the clearance between the set screw collar (3)

and the bed (7) to 0.02 – 0.03 mm in the thrust

direction, and tighten the two set screws (8).

3. Press the vertical shaft T-pulley U assembly (4) and

the washer (5) against the ball bearing (6), and

tighten the screw (9).

* Be sure to pass the driving looper shaft assembly

(1) through timing belt U (10).

4. Attach the tension pulley arm U assembly (11) while it

is being pulled by a force of 19.6 N.

* Deflection in the center of span: 3 ± 0.5 mm when

4.9 N is applied.

3749Q

3748Q

3. ASSEMBLY

RH-981A

3-10-2. Needle bar rocking mechanism

Adjusting the positional relationship between the needle rotation pulley assembly M and the

looper base

1. Align the match mark in the looper base (1) with that in the bed, as shown in the figure.

2. Turn the needle rotation pulley assembly M (2) until the pin (3) makes contact with the motor base.

3. Attach the timing belt.

4. Make sure that the looper base (1) can rotate through 360° easily.

* Tighten the screw of the looper pulley at the front.

Adjusting the timing belt tension

Attach the timing belt D while the tension pulley arm D assembly is being pulled by a force of 68.6 N.

* Deflection in the center of span: 6 ± 0.5 mm when 4.9 N is applied.

3751Q

3750Q

3. ASSEMBLY

RH-981A 36

Adjusting the positional relationship between the looper base and the needle bar gear

1. Loosen the bolt (2) of the vertical shaft T-pulley U assembly (1).

2. Align the match mark in the looper base (3) with that in the bed, as shown in the figure.

3. Orient the needle bar gear (4) in the direction shown in the figure, and align it with gear support B (5).

4. Tighten the bolt (2) of the vertical shaft T-pulley U assembly (1).

3752Q 3754Q

Align

3753Q

3. ASSEMBLY

RH-981A

3-11. Looper and spreader machanisms

1. Attach the looper oil guide (1) using the screw (2).

2. Wind the wick (4) around the boss of the looper link (3). Be sure to pass the two wicks (5) under the wick (4).

3. Wind the wick (6) around the spreader driving lever (7), as shown in the figure.

3755Q

3. ASSEMBLY

RH-981A 38

4. Place the looper link (3) and the set screw collar (9) on the looper link shaft (8), and secure the latter using the two

set screws (10).

5. Tighten the two set screws (11) of the set screw collar (9) to eliminate end play.

6. Position the lower shaft cam (12) and the lower shaft tension pulley assembly (13) so that they lightly make

contact, then tighten the screw (14) on the screw flat at the front and another screw (15).

7. Insert an allen wrench (2.5 mm across flats) into the hole in the bed and the hole (16) in the lower shaft cam (12).

Position the screw flat of the upper shaft at the top (where the needle is at its lowest position), and tighten the two

set screws (17) of the lower shaft tension pulley assembly (13).

8. Attach the two plate springs (18) to the looper link (3) using the two spring washers (19) and the two bolts (20).

3757Q

3756Q

3. ASSEMBLY

RH-981A

9. Turn the pulley until it comes to its stop position, and attach the spreader link shaft (21) to the forked portion of the

spreader driving lever (22) while pulling the former downward.

10.Pass the looper link support shaft (24) through the spreader driving lever (22) and the set screw collar (23), and

secure them using the two set screws (25). (The split in the shaft should be facing the right.)

11. Tighten the two set screws (26) of the set screw collar (23) to eliminate the end play.

3758Q

3. ASSEMBLY

RH-981A 40

3-12. Lubrication mechanism

3-12-1.Machine head

1. Hold the wick (2) using the cord holder (1).

2. Hold the wick (3) using the cord holder (4).

3. Insert the wicks (2) and (5) into the hole (6).

4. Attach wick support L (7) using the two screws (8).

* At this time, the emergency stop switch cord should be routed above wick support L (7).

5. Using a pair of tweezers, insert the wick (9) into the hole in the oil tank. At this time, insert the oil tube into the hole,

as shown in the figure.

6. Pass the wick (4) under the felt (10).

7. Push the felt (10) into the lubrication hole in the thread take-up lever (11).

3759Q

Oil tank

3. ASSEMBLY

RH-981A

3-12-2. Driving gear shaft

1. Oil is supplied to the driving gear shaft (2) through the wick (1).

2. The wick (4), which is wound around the boss of the pin (3), makes contact with the felt (5), and oil is supplied to

the pin (3), the eccentric wheel (6) and the driving rod (7).

3760Q

3. ASSEMBLY

RH-981A 42

3-13. Feed mechanism

3-13-1.X direction

Adjusting the backlash between the driving gear and the idle gear

Note: Be sure to remove the motor support. Adjustment should be carried out with the driving gear and the idle

gear treated as a unit.

Adjust the backlash between the driving gear (1) and the idle gear (2) when they are engaged, using the weight of

pulse motor X (3) (as shown in the figure above).

Tighten the four bolts (4).

Adjusting the idle gear

Adjust the positions of the X racks and the idle gear

1. Loosen the two set screws (5) of the idle gear (2) to adjust the engagement between the X rack (3) and the idle

gear (4) based on the engagement between the X rack (1) and the idle gear (2).

2. Engage the idle gears (2) and (4) with the X racks (1) and (3), respectively, and attach the motor support (6) while

pressing it.

3. Tighten the two set screws (5) so that there is no end play of the idle gear (4).

3761Q

3762Q

3. ASSEMBLY

RH-981A

3-13-2. Y direction

Adjusting the tension of the Y-timing belt

Secure Y-pulley support L (1) while pulling it with a force of 117.6 N.

When the belt deflection is used instead to determine Y-pulley support L (1) position, the deflection will be 1 ± 0.5

mm when the belt is pressed at the center with a force of 4.9 N.

* The belt tension can be adjusted when the Y-feed base is still attached to the bed.

Loosen the two bolts (2) of Y-support L (1), and use the bolt (3) to adjust the belt tension.

The tension in this case should be the same value as that above.

3763Q

3764Q

3. ASSEMBLY

RH-981A 44

Adjusting the position of the Y-driving shaft holder

Align the left end of the Y-driving shaft holder (2) with the reference line A of the Y-shaft (1).

* When tightening the bolt (3), the sensor partition plate assembly (4) should face the top.

Adjusting the backlash between the driving gear and the idle gear

Remove the Y-feed base (1). Adjustment should be carried out with the driving gear and the idle gear treated as a

unit.

Adjust the backlash between the driving gear (2) and the idle gear (3) when they are engaged under the weight of

pulse motor Y (4) (as shown in the figure above).

Tighten the four bolts (5).

3766Q

3765Q

3. ASSEMBLY

RH-981A

3-13-3.Attaching the X-feed guide shaft

1. Loosen the four bolts (2) and the two set screws (3) of the X-feed guide shaft (1) so that the shaft is still

temporarily held in place.

2. Insert the Y-feed guide shafts (4) into the X-feed shaft holder R (5) and the X-feed shaft holder L assembly (6)

and the feed bracket (7), and tighten the four set screws (8).

3. Move the feed bracket (7) in the X direction a few times.

4. Tighten the four bolts (2) and the two set screws (3).

3767Q

3. ASSEMBLY

RH-981A 46

3-14. Synchronizer

1. Attach the NP support bracket B (1) with its notched portion facing the rear, using the two screws (2).

2. Secure the synchronizer assembly B (3) using the two screws (4).

3. Tighten the set screw (5) in the V-groove in the upper shaft, and attach the pulley assembly (6). Then tighten

another set screw (7).

* The set screw (5) should be tightened in the front hole which comes first when the pulley is rotated in the

rotation direction.

4. After attaching the synchronizer, check the machine torque.

3768Q

3. ASSEMBLY

RH-981A

3-15. Covers and work clamp mechanism

1. Attach the work clamp plates R (1) and L (2).

2. Attach the driving needle guard cover (3), the zigzag window cover (4), the top cover (5), the belt cover F (6), the

belt cover R (7), and the face plate (8).

3. Attach the needle (9).

3-16. Safety switch

1. Switch to the input check mode.

2. Adjust the height of the safety switch (1) using the two screws (2) so that the LED does not go off even if the

machine head is lowered and the bed is shaken up and down.

3771Q 3770Q

3769Q

3772Q 3773Q

LED is lit.

4. ADJUSTMENT

RH-981A 48

4. ADJUSTMENT

CAUTION

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 maintenance

• 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.

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

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.

4-1. Adjusting the work clamp lift height

The work clamp lift height is adjusted to 16 mm.

(The lift height includes the clearance between clamp lever B (1) and clamp lever L (R) (2).)

1. Insert the block or the thickness gage (5) between the work clamp L (R) (3) and the needle plate (4).

2. Loosen the screw (7) of the driving lever (6), and put the end (8) of clamp lever B (1) on the end of clamp lever L

(R) (2). Then re-tighten the screw (7).

Note: Make sure that work clamp L (R) (3) securely holds the block or the thickness gage (5).

Make sure that work clamp cylinder is fully extended.

3774Q 3775Q

Clamp arm

4. ADJUSTMENT

RH-981A

4-2. Adjusting the position of the work clamp plate

Before this adjustment, make sure that adjustment in “4-5. Adjusting the X-axis home position” has been completed.

Adjust so that the throat plate (1) and the needle plate R (2) do not make contact during sewing.

The standard clearance between the throat plate (1) and the needle plate R (2) is 1.3 mm (when the cutting space is

set to 0).

1. Use the parameter settings to set the cutting space to "0".

2. Select the test feed mode, and press the start switch.

3. Keep pressing the start switch, and make sure that the clearance between the throat plate (1) and the needle

plate R (2) is 1.3 mm.

4. If the clearance is not 1.3 mm, loosen the nut (3), and turn the bolt (4) to adjust the clearance.

Note: Adjust the clearance between the throat plate (1) and the needle plate L in the same manner.

* If the maximum stitch width correction amount is set to 2.0 mm, adjust the distance between the throat plate and

the needle plate to more than 2.0 mm.

1.3 mm

3094Q 3095Q

Increase

Decrease

4. ADJUSTMENT

RH-981A 50

4-3. Adjusting the cloth opening amount

1. Loosen the screw (1), and then insert a screwdriver into the notch in the side of the feed bracket and turn the

adjusting screw (2) to adjust the opening amount.

2. After tightening the screw (1), measure the opening amount.

Note: Adjust so that the opening amounts for the left and right work clamp plates are equal.

* It is usually sufficient for one work clamp plate to open by 0.8 mm.

Measuring the opening amount

1. Switch the mode to test feed mode.

2. Lower the work clamp and then use calipers to measure the distance a.

3. Press the start switch. The feed bracket will move and then the left and right work clamp plates will open.

4. Use calipers to measure the distance b.

5. The difference between a and b is the opening amount. (Opening amount = a - b)

3098Q 3099Q

3096Q 3097Q

4. ADJUSTMENT

RH-981A

4-4. Adjusting the position of the work clamp

The back and forth and sideways movement of the work clamp can be respectively adjusted.

The work clamp should be centrally positioned as to the needle movement.

[Back and forth movement]

Loosen the bolt (1), and adjust the position of the clamp arm (2).

[Sideways movement]

Loosen the two screws (3), and adjust the position of the clamp lever (4).

3776Q

4. ADJUSTMENT

RH-981A 52

4-5. Adjusting the X-axis home position

Dimension a (when the looper base is at 0°) and dimension b (when the looper base is at 180°) from the stepped

portion of the throat plate to both edges of the feed bracket must be equal.

1. Set the tacking length to 0 by the parameter settings, and switch to the test feed mode.

2. Remove the work clamp plate, and press the start switch.

3. Move the feed bracket, and measure dimensions a and b.

4. If dimensions a and b are not equal, turn off the power.

5. Raise the machine head, secure it using the head support lever (1), loosen the two screws (2), and adjust the

position of the X-sensor setting plate (3) in the direction of the arrow.

6. Return the machine head to its original position. Repeat the above steps from 1.

* The X-axis home position can be adjusted in increments of 0.05 mm.

4-6. Adjusting the Y-axis home position

The clearance from the rear end surface of the feed bracket to the bed should be 2 mm ± 0.2 mm.

1. After detecting the home position, measure the clearance from the rear end surface of the feed bracket to the

bed.

2. If it is not 2 mm ± 0.2 mm, turn off the power.

3. Loosen the two screws (1), and move the Y-sensor setting plate (2) in the direction of the arrow.

4. Repeat the above steps from 1.

* The Y-axis home position can be adjusted in increments of 0.05 mm.

Note: If the clearance is too great, the movable knife and the throat plate may hit each other.

3779Q3777Q 3778Q

Looper base at 180°

Looper base at 0°

3780Q

4. ADJUSTMENT

RH-981A

4-7. Adjusting 0 position (reference line) of the needle

The 0 position (reference line) of the needle is at the inside needle penetration points.

If the needle gage is changed, the 0 position (reference line) of the needle is not changed, only the outer needle

cloth penetrations are changed.

1. Insert a short needle (for adjustment).

2. Press the OFF key on the operation panel to set no cutting.

3. Place a sheet of paper under the work clamp, and turn the pulley to trace where the needle will penetrate for an

eyelet button hole on the paper.

At this time, adjust the height of the short needle so that it can pebetrate the paper with as small holes as

possible.

4. When the inside needle forward cloth penetration points are not identical with that of the returning ones for the

straight portion, remove the face plate, and loosen the bolt (1).

5. Insert a screwdriver into the arm from the left, and turn the zigzag eccentric pin (2) to adjust.

4-8. Adjusting the home position of the looper base

The match mark in the looper base must be aligned with that on the bed.

1. After detecting the home position, make sure that the match mark (1) in the looper base is aligned with the match

mark (2) in the bed.

2. If it is not, turn off the power.

3. Raise the machine head, secure it using the head support lever (3), loosen the two screws (4), and move the R-

sensor setting plate (5) in the direction of the arrow.

4. Return the machine head to its original position. Repeat above steps from 1.

* The home position of the looper base can be adjusted in increments of 0.45°

3781Q 3782Q

3783Q 3788Q

4. ADJUSTMENT

RH-981A 54

4-9. Fine adjustment of knife position

Before this adjustment, make sure that adjustment in “4-7. Adjusting 0 position (reference line) of the needle” has

been completed.

The knife position should be adjusted so that it can correctly cut the eyelet button hole which is formed by the portion

where the needle will penetrate at the inside position and round the eyelet.

The back and forth and sideways movement, and inclination of the knife position can be independently adjusted.

1. Use a short needle (for adjustment).

2. Set the air pressure of the regulator under the table to 0.2 – 0.3 MPa.

* This is to protect the hammer from being damaged by the knife after the knife position is adjusted.

3. Press the AFTER key on the operation panel to set cutting after sewing.

4. Place a sheet of paper under the work clamp, and turn the pulley to trace where the needle will penetrate for an

eyelet button hole on the paper.

5. Make sure that the portion where the needle penetrates for the eyelet button hole uniformly overlaps the knife

cutting positions.

* For easier checking, change the value for cutting space by the parameter settings.

6. If it is not, turn off the power, and adjust the position of the knife.

[Back and forth movement adjustment]

Loosen the bolt (2), and adjust the position of the knife

by following the block stopper plate (1) as a guide.

After adjustment, loosen the screw (3), and press the

block stopper plate (1) against the knife.

[Sideways movement adjustment]

1. Loosen the bolts (1), (2), and (3), of the knife bracket.

2. Loosen the bolts (4) and (5) of the knife bracket

guide.

3. Turn the adjusting screw (6). Fine adjustment for

sideways movement of the knife can be performed

without removing the knife bracket and the knife

bracket guide.

[Inclination adjustment]

1. Loosen the bolts (1), (2), and (3), of the knife bracket.

2. Loosen the bolt (7), which secures the knife bracket

and the knife bracket guide.

3. Turn the adjusting screw (6). Inclination of the knife

can be adjusted by rotating the knife bracket and the

knife bracket guide, regarding the pivot (8) as the

center.

3790Q

3789Q

4. ADJUSTMENT

RH-981A

4-10. Adjusting the sideways movement of the cutter lever

The cutter lever should be positioned so that the knife can make contact with the center of the hammer.

1. Loosen the two nuts (1).

2. Turn the two support screws (2) to adjust the sideways position of the cutter lever (3).

3. Tighten the two nuts (1).

Note: Adjust the two support screws (2) so that the cutter lever (3) has no end play, and it can operate easily. Too

much end play may damage the knife.

4-11. Adjusting the height of the throat plate

To prevent material from being pressed down by the needle which penetrates the material, the top surface of the

throat plate (1) should be flush with the top surface of the needle plate (2).

Loosen the screw (3), turn the set screw (4), and adjust the height of the throat plate (1).

Note: The set screw (4) is adjusted to maintain the height of the throat plate when it is removed and re-installed.

Hammer

Knife

3791Q 3792Q

3794Q

Align

3793Q

4. ADJUSTMENT

RH-981A 56

4-12. Adjusting the height of the spreader and looper

Spreader height

The clearance between the left spreader (forked spreader) and the eye looper must be set to match the thickness of

the lower thread. The clearance between the right spreader and the right looper should be as small as possible while

still letting the parts slide.

1. The right spreader (1) and left spreader (2) move by means of springs (3). Adjust so that the spreaders move

smoothly between the right spreader stopper (4), the left spreader stopper (5) and the LS-holder bracket (6), with

no looseness.

2. If adjustment is necessary, loosen the screw (7) and then move the right spreader stopper (4) or left spreader

stopper (5) up or down.

Looper height

1. Set the clearance between the eye looper (8) and the left spreader (2) to the same distance as the thickness of

the lower (looper) thread.

2. The clearance between the right looper (9) and the right spreader (1) should be as small as possible.

3. If adjustment is necessary, loosen the screw (10) and then move the eye looper (8) and right looper (9) up or

down.

3072Q

3071Q

3073Q 3074Q

4. ADJUSTMENT

RH-981A

4-13. Adjusting the needle and looper timing

The distance by which the needle bar rises from its lowest position to the position where the tip of the eye looper and

the center of the needle are aligned should be the same as the distance from its lowest position to the position where

the tip of the right looper and the center of the needle are aligned.

Before adjusting the looper timing, first adjust the stitch width (needle racking width). (The standard width is 3 mm.)

1. Move the needle bar to its lowest position.

2. Use calipers to measure the distance between the end of the needle bar (1) and the top of the holder base (2)

when the needle bar is at its lowest position.

3. Turn the upper shaft pulley until the tip of the eye looper (4) and the center of the needle (3) are aligned when the

needle (3) is at the inside sewing position, and then use the calipers to take the same measurement as taken in

step 2. Find the difference between the measurements taken in this step and in step 2.

4. Follow the same procedure as in step 3. above to find the difference between the two measurements when the

needle (3) is at the outside sewing position.

* When the needle (3) is at the inside sewing position, the tip of the eye looper (4) should be aligned with the center

of the needle (3), and when the needle (3) is at the outside sewing position, the tip of the right looper (5) should be

aligned with the center of the needle (3).

* The distance from the end of the needle bar (1) and the top of the holder base (2) should be the same when the

needle (3) is at both the inside sewing position and the outside sewing position.

5. If adjustment is necessary, turn the looper base (6) in the direction indicated by the arrow in the illustration, loosen

the screw (7), and then move the looper link clamp (8) up or down to tilt the LS-holder bracket (9) to the left or

right (in the direction of the arrow).

3077Q

3075

3076

Lowest position

of needle bar When center of needle and

looper tip are aligned

0952

3841Q

4. ADJUSTMENT

RH-981A 58

4-14. Adjusting the loop stroke

The loop stroke is the distance the needle bar rises from its lowest position to the position where the tips of the eye

looper and right looper are aligned with the center of the needle. The standard loop stroke is 2.7 mm. (The loop

stroke may need changing depending on the material and thread being used.)

* Carry out the adjustment in "4-13. Adjusting the needle and looper timing" before making this adjustment.

1. In the same way as in "4-13. Adjusting the needle and looper timing", move the needle bar to its lowest position

with the needle at the inside sewing position, and then use calipers to measure the distance between the end of

the needle bar (1) and the top of the holder base (2).

2. Add 2.7 mm to the value obtained in step 1. above.

3. Touch the end of the calipers (A) against the top of holder base (2), and then turn the upper shaft pulley until the

end of the needle bar (1) touches the edge of the calipers (B). Check that the tip of the eye looper is aligned with

the center of the needle at this time.

4. In the same way, check that the tip of the right looper is aligned with the center of the needle when the needle is at

the outside sewing position.

5. If the tips of the loopers are not aligned with the center of the needle, carry out the adjustment below.

• Raise the machine head.

• Loosen the two screws (3) of the lower shaft timing pulley, hold the upper shaft pulley so that it doesn't move,

and then turn the lower shaft cam (4) in the direction indicated by the arrow until the tip of the eye looper (5) is

aligned with the center of the needle (6). Once they are aligned, tighten the two screws (3).

• After adjusting, check that the screws have been adequately tightened.

• Once this adjustment has been carried out, repeat the procedure given in "4-13. Adjusting the needle and

looper timing".

* Basically, the machine is assembled so that the hole (7) of the lower shaft cam (4) is aligned with the hole (9) of

the lower shaft base (8) when the needle bar is at its lowest position and at the inside sewing position.

3079Q

3081Q

3080Q 3795Q

4. ADJUSTMENT

RH-981A

4-15. Adjusting the height of the needle bar

The standard height for the needle bar is 2.5 mm. (The needle bar height may need changing depending on the

material and thread being used.)

1. Align the tip of the eye looper (1) with the center of the needle (2) when the needle (2) is at the inside sewing

position.

2. Remove the face plate.

3. Loosen the screw (3) of the needle bar clamp (5) and adjust the height of the needle bar (4).

* After aligning the tip of the eye looper (1) with the top edge of the needle hole, lower the needle bar (4) 2.5 mm.

4. Adjust so that there is as little play as possible, and so that the needle bar clamp (5) and the needle bar level feed

link (6) can maintain their oil films. This will help to ensure that the needle bar turns smoothly.

4-16. Adjusting the clearance between the looper and needle

Be sure to carry out this adjustment after changing the size of the needle.

The clearance between the tip of the looper and the needle should be 0.05 - 0.2 mm.

Loosen the looper screw (1) and then adjust the clearance.

* This clearance must be uniform while the looper base is rotating (through 360o ).

If the clearance is not uniform, adjust the turning center for the needle bar. (This adjustment is made at the time of

shipment from the factory.)

* After making the adjustment in step 1. above, carry out the adjustment procedure given in "4-18. Adjusting the

spreader mounting positions".

3082Q 3083Q 0961Q

2.5 mm

3084Q 0963Q

0.05 - 0.2 mm

2.5 mm

4. ADJUSTMENT

RH-981A 60

4-17. Adjusting the needle guard

Be sure to carry out this adjustment after changing the size of the needle.

The needle must remain stationary with respect to the needle guard until the tip of the looper reaches the needle.

Loosen the screw (1) and then move the needle guard

(3) in the directions indicated by the arrows by an

appropriate amount in accordance with the thickness of

the needle (2).

Note: Adjust so that the looper clasps the upper

thread securely.

4-18. Adjusting the spreader mounting positions

1. Loosen the screw (3) and adjust the position of the left spreader stopper (4) so that the fork of the left spreader (1)

is aligned with the lower thread guide hole of the eye looper (2).

2. Loosen the screw (7) and adjust the position of the right spreader stopper (8) so that the tip of the right spreader

(5) is aligned with the tip of the right looper (6).

Note: Both the left spreader (1) and right spreader (5) should be installed so that they do not project past the tips

of the eye looper (2) and right looper (6) respectively.

3085Q

3086Q

4. ADJUSTMENT

RH-981A

4-19. Adjusting the spreader timing

When the needle is at the inside sewing position, the left spreader should touch the left spreader stopper and stop

immediately before the needle bar reaches its lowest position.

When the needle is at the outside sewing position, the right stopper should touch the right spreader stopper and stop

immediately before the needle bar reaches its lowest position.

1. Raise the machine head.

2. Loosen the screw (1) and the nut (2), and then turn the adjusting screw (3) to adjust the spreader timing.

3. After adjusting, tighten the nut (2) and the screw (1).

Note: Make sure that the LS-holder bracket (4) does not touch the spreader cam link (5). If it does, return to “4-13.

Adjusting the needle and looper timing”.

4-20. Adjusting the amount to pull the upper thread and tension release

The amount to pull the upper thread should be sufficiently maintained to form the correct stitches at the start of sewing.

The upper thread take-up lever operates as soon as sewing is completed, and is released when the start switch is

pressed to move the feed bracket with the needle stopped.

Loosen the screw (1), and move the upper thread take-up lever guide (2) up and down to adjust the amount to pull

the upper thread.

• The upper thread tension mechanism has double tension mechanisms. The main tension disc (3) is open after sewing

is completed, and closed when the start switch is pressed to move the feed bracket with the needle stopped.

• The upper thread tension plate (4) and the upper thread take-up lever are interlocked.

• The sub tension disc (5) is always kept closed to give the upper thread tension. The tension will change the

thread end length at the start of sewing.

3087Q 3796Q

Becomes greater

Becomes

less

3797Q

4. ADJUSTMENT

RH-981A 62

4-21. Adjusting upper thread trimming

Upper thread trimming will be performed on the correct time after sewing is completed.

4-21-1.Adjusting the upper movable knife mounting position

[-00, -01]

The upper movable knife (1) must cut the upper loop which is caught by looper R (2), in one place (front). If the

upper loop is cut at 2 places (front and rear), the thread end length from the needle will be shorter, causing skipped

stitches at the start of sewing.

1. Loosen the screw (3), and adjust the clearance between the needle and the point of the upper movable knife (1),

to appox. 0.5 mm.

2. The height of the upper movable knife (1) should be between the bottom of the throat plate (4) and spreader R

(5).

[-02, -52]

The mounting position of upper movable knife (1) is determined by the position of the lower thread presser (2).

1. Loosen the screw (3), and position upper movable knife (1) between the projection of the throat plate (4) and

spreader R (5).

2. Adjust the clearance between the needle and the point of upper movable knife (1) to 0.5 – 1.0 mm.

* If adjustment can not be performed, reconfirm “4-11. Adjusting the height of the throat plate” and “4-23.

Adjusting the position of the lower thread presser”.

Approx. 0.5 mm 3799Q

3798Q

3800Q 3801Q

4. ADJUSTMENT

RH-981A

4-21-2. Adjusting the position of the thread trimmer lever bracket

When the needle is swinging to the right with the maximum stitch width, the needle should be able to pass the upper

movable knife sufficiently.

Loosen the nut (1), and turn the screw (2) to adjust the

position of the thread trimmer lever bracket.

At this time, dimension a to the shoulder of the thread

trimmer lever bracket should be 10 mm.

Note: Turn the looper base, and make sure that the

thread trimmer lever bracket can smoothly go in

under the thread trimmer lever hammer. The

height of the thread trimmer lever hammer is

adjusted to 11 mm.

4-22. Adjusting the lower thread trimmer (-01 specification)

[Adjusting the thread trimmer which can cut the lower thread and gimp, leaving them longer]

The thread trimmer is operated by means of an air cylinder when the feed bracket is returned to the home position.

4-22-1. Adjusting the knife pressure

Adjust the knife pressure so that the thread can be cut neatly.

Note: Do not subject the knife to excessive pressure. It may cause the knife to wear quickly or damage it.

Loosen the two screws (1), and move the fixed knife setting bracket (2) along the slot which the screws (1) are in, in

the direction of the arrow.

* The standard adjustment is done as shown in the above enlarged view, which indicates the first point to make contact

with the point of the fixed knife (4) and the pin of the movable knife (5) when the thread trimmer arm (3) operates.

3802Q

3804Q

3803Q

Match mark

Align the pin with the point

of the fixed knife (4).

Decrease

pressure.

Increase

pressure.

4. ADJUSTMENT

RH-981A 64

4-22-2.Adjusting the position of the thread trimmer arm

The rocking stroke of the thread trimmer arm is fixed to the drive cylinders.

1. Turn the thread trimmer link lever (1) in the direction of the arrow until it touches the stopper screw (2).

2. Loosen the bolt (3), adjust the position of the thread trimmer arm (4), and determine the engagement between the

movable knife (5) and the fixed knife (6). The above figure shows standard adjustment.

Note: When tightening the bolt (3), make sure that the thread trimmer lever arm (7) and the thread trimmer arm

(4) can move smoothly without any end play.

Too little engagement may cause the lower thread not to be hooked, leading to thread cast-off at the start

of sewing.

3805Q

Align the tip of the fixed knife

with the match mark.

Match mark

4. ADJUSTMENT

RH-981A

4-22-3.Adjusting the thread clamp assembly and thread clamp opener

The lower thread should go under thread clamp D (1); the gimp should go under thread clamp U (2). Install the

thread clamp assembly correctly, and make sure that the thread clamp opener operates correctly.

Loosen the two screws (3), and move the thread clamp assembly (5) along the fixed knife setting bracket (4) in the

direction of the arrow. Decrease clearance a to as narrow as possible so that the thread clamp assembly (5) and the

thread handler (7) do not make contact with each other when the thread trimmer arm (6) rotates.

Note : If clearance a is too great, the lower thread may not be hooked correctly, leading to thread cast-off at the

start of sewing.

If the thread clamp assembly (5) is installed on an angle, thread clamp D (1) may not open because it makes

contact with the throat plate, and fail to hook the lower thread, leading to thread cast-off at the start of

sewing.

The lower thread must pass over the projection of thread clamp M (8), and be securely held by thread clamp D (1).

1. Make sure that thread clamp D (1) is opened at least 0.3 mm when the thread nipper opener (9) presses the

opener pin (10) down.

2. Make sure that thread clamp D (1) is closed just before the thread is trimmed.

3. When the thread trimmer arm (6) returns to its original position after thread trimming, the thread nipper opener (9)

should travel around the opener pin (10). Make sure that thread clamp D (1) should not be open.

Note: When the start switch is pressed and the feed bracket moves to the sewing start point, the lower thread

should be securely hooked by thread clamp D (1).

On the contrary, the gimp should be just released from thread clamp U (2) to prevent double cutting it.

3807Q

3806Q

Movable knife

Fixed knife

Movable knife

4. ADJUSTMENT

RH-981A 66

4-22-4.Adjusting the thread handler

• The thread handler (1) separates the lower thread and the gimp, and guides them to their respective threading

routes. The lower thread is guided into thread handler D; the gimp is guided into thread handler U.

• When the thread trimmer arm operates, the throat plate (2) turns 45 o.

Then, the gimp moves onto the projection on the throat plate (2), and this creates the height difference between

the lower thread and the gimp. A triangle is formed by the lower thread and the gimp at the last stitch, into which

the thread handler (1) moves to separate the lower thread and the gimp.

1. Set the stitch pitch to 2.0 mm by the parameter settings to decrease the total number of stitches.

2. Press the start switch in the MANUAL mode, and turn the pulley manually until the last stitch.

3. When the pulley is stopped with its match mark aligned with that in the arm after a series of operations is

completed, press the start switch again and again to check each thread trimming operation.

4. Loosen the screws (3) and (4). Adjust the thread handler (1) by turning it while pivoting on the screw (3).

Note: When changing the height of the throat plate (2), be sure to adjust the thread handler (1) because the

triangle formed by the lower thread and the gimp will change.

3808Q

Thread clamp

4. ADJUSTMENT

RH-981A

4-22-5.Adjusting the thread guide plate

When the movable knife (1) moves, the lower thread

and the gimp should be guided to the notches in the

movable knife (1). Adjust the position of the thread

guide plate (2) so that the end of the movable knife (1)

aligns with the end of the thread guide plate (2).

4-22-6.Adjusting the amount to pull the lower thread required for thread trimming

When the thread handler catches the lower thread to guide it to the fixed knife, the lower thread should be pulled

sufficiently to prevent the thread snapping and deviation from stitching path.

To cut the lower thread when the feed bracket is at the home position, the thread trimmer lever bracket will continue

to operate just before the looper turns 45o, and the lower thread will be pulled.

Loosen the screw (1), turn the tension release plate (2)

to adjust clearance a between the tension release plate

(2) and thread trimmer lever bracket (3).

Note: If the lower thread has snapped, reconfirm “6-1-1.

Adjusting the solenoid valve speed controllers”.

3809Q

Should

align

3810Q

4. ADJUSTMENT

RH-981A 68

4-22-7.Adjusting the amount to pull the lower thread for safety stitching

To secure the first stitch, while looper L is catching the first upper loop, the lower thread should be taut between

looper L and the throat plate, and not be pulled off thread clamp D.

1. After automatic sewing is completed, switch to the MANUAL mode, and press the start switch.

2. Turn the pulley manually to check the condition of the lower thread.

To prevent the lower thread from being pulled off thread clamp D while the feed bracket is moving to the sewing start

position, the pressure of thread clamp D should be sufficiently strong enough, and the tension release lever (1)

should be oscillated by the tension release claw (2) to pull the lower thread appropriately while the looper base

returns to the home position after thread trimming is completed.

When the stitch length is greatly changed, it is necessary to adjust the amount of lower thread to be pulled.

1. Turn off the power.

2. Turn the looper base (3) manually to check the angle

of the tension release lever (1).

3. Loosen the screw (4), turn the tension release claw

(5) regarding the pivot (6) as the center to adjust the

angle of the tension release lever (1).

Note: When the tension release lever (1) oscillates

with its maximum stroke, make sure that it

does not make contact with the looper link

(7).

4-22-8.Adjusting the amount to pull the gimp

The amount of the gimp required for thread trimming is

pulled by the thread trimmer that cuts the lower thread

and the gimp, leaving them longer.

If adjustment is not correct, the gimp sewn in stitches

may be pulled, and stitch formation around the button

eyelet may be distorted.

Loosen the two screws (1), and set the distance from

the bed to the upper end of the roller to 11 mm.

3811Q

3812Q

4. ADJUSTMENT

RH-981A

4-23. Adjusting the lower thread trimmer (-02, -52 specifications)

[Adjusting the thread trimmer which can cut the lower thread and gimp, leaving them shorter]

The thread trimmer operates by means of an air cylinder when the feed bracket is at the home position.

4-23-1. Adjusting the knife engagement

Movable knives L (1) and R (2) should overlap each other by approx. 1 mm.

1. Loosen the screw (3).

2. With springs L (4) and R (5) attached to movable knives L (1) and R (2), align the end of thread trimmer link lever

J assembly (6) with the match mark on the rear of the link fulcrum plate assembly (7), and tighten the screw (3).

Note: Make sure that the movable knife driving cam (8) and thread trimmer lever arm B (9) rotate smoothly without

any gap.

3. Move thread trimmer link lever J assembly (6) to check engagement between movable knives L (1) and R (2).

4. If the engagement is insufficient, return to step 2 to perform fine adjustment so that the end of thread trimmer link

lever J assembly (6) overlaps with the match mark on the rear of the link fulcrum plate assembly (7).

3815Q3813Q

3814Q

4. ADJUSTMENT

RH-981A 70

4-23-2.Adjusting the knife pressure

Adjust the knife pressure to the lowest where the knife can still cut the material.

1. Loosen the nut (1).

2. Turn the shoulder screw (2) to adjust the knife

pressure.

Note: When the shoulder screw (2) is fully tightened,

the movable knife will not operate. Tighten the

shoulder screw (2) slowly while checking that

the movable knife can operate smoothly.

4-23-3.Adjusting the gimp pull force

• The gimp should be completely sewn in a few stitches at the start of sewing, and the gimp end length from the

stitches should be as small as possible.

• The gimp is pulled by utilizing the difference in distance between gimp thread guide J (1) and gimp thread guide

C-J (2) when the looper base returns to 0 o from 180 o after the gimp is trimmed.

• The gimp is trimmed when the feed bracket is at the home position. When the stitch length is changed,

dimensions B and A will change. It is necessary to adjust the force to pull the gimp.

Also, dimension A differs according to the gimp type and the gimp tension, so it is necessary to adjust the force to

pull the gimp.

Loosen the screw (3), and adjust so that the gimp appears about 2 mm from the first covering stitch at the start of

sewing.

Note: The tip of the gimp is pressed down on the material by a few stitches at the start of sewing, and pulled by the

movement of the feed bracket. If the gimp is excessively taut when the feed bracket is at the sewing start

position, or dimension A is too small, the gimp may come out from under the stitches.

3816Q

3818Q

3817Q

The gimp is trimmed.

Looper base at 0 o

The gimp end length at the end

of sewing is fixed.

Looper base at 180 o

Smaller

Larger

4. ADJUSTMENT

RH-981A

4-23-4.Adjusting the gimp tension

When the looper base rotates and the gimp (1) is pulled, the gimp tension at the side of the spool stand should be

stronger than that close to throat plate, regarding gimp thread guide J (2) as the center.

During sewing, on the contrary, the tension should be weak so that the gimp can be sewn under the stitches.

1. During sewing, gimp thread take-up guide J (3) moves toward the front in accordance with the movement of the

feed bracket, and the gimp thread release plate (4) releases the thread tension disc (5).

2. After sewing is completed, the feed bracket moves to the home position to trim the gimp (1), gimp thread take-up

guide J (3) pushes the gimp thread release plate (4), and the thread tension disc (5) is closed.

3821Q3820Q

3819Q

4. ADJUSTMENT

RH-981A 72

4-23-5.Using gimp thread work clamp

When the gimp is stiff, dimension A (gimp length from the throat plate) may vary.

In this case, pass the gimp through gimp thread work clamp (2) attached to gimp guide C-J (1).

Note: When thick and soft gimp is passed through gimp thread work clamp (2), the gimp tension may be too great

during sewing.

3823Q

3822Q

The gimp is slack. Threading route maintained.

4. ADJUSTMENT

RH-981A

4-23-6.Adjusting the auxiliary clamp arm

The auxiliary clamp arm holds the material until the lower thread and the gimp are trimmed after the work clamp

rises.

The auxiliary clamp arm should be adjusted so that it can operate when the feed bracket is at the home position, and

will be stationary on the needle plate without subjecting it to any pressure.

1. Loosen the bolt (1), and position the auxiliary clamp arm (2) on the needle plate so that the auxiliary clamp arm

(2) can hold the material next to work clamp.

Note: Be sure that the auxiliary clamp arm (2) does not make contact with clamp arm L-J (3).

2. Turn on the power to set the home position.

3. Turn off the air, and loosen the two screws (4).

4. With the rod of the auxiliary clamp arm cylinder (5) fully extended, adjust so that the auxiliary clamp arm (2) can

be stationary to the needle plate without subjecting it to any pressure.

Note: If excessive pressure is applied to the auxiliary clamp arm when the feed bracket is at the home position,

the feed bracket may be in an inappropriate position in the Y direction.

The lift height of the auxiliary clamp arm is set to 16 mm.

Loosen the nut (6), and turn the screw (7) to adjust the

height.

3824Q

3825Q

4. ADJUSTMENT

RH-981A 74

4-23-7.Adjusting the length of the lower thread to be pulled for a safe sewing start

To secure the first stitch, while looper L is holding the first upper loop, the lower thread should be taut between

looper L and the throat plate, and not be pulled off the lower thread presser.

Thread trimmer lever bracket B is operating just before the lower thread is trimmed when the feed bracket is at the

home position, and that causes the lower thread to be pulled.

1. After automatic sewing is completed, switch to the

MANUAL mode, and press the start switch.

2. Turn the pulley manually to check the condition of the

lower thread.

3. If adjustment is necessary, loosen the screw (1), and

turn the tension release plate (2) to adjust distance a

between the tension release plate (2) and thread

trimmer lever bracket B (3).

3810Q

4. ADJUSTMENT

RH-981A

4-24.

Adjusting the position of the lower thread presser (-02, -52 specifications)

The lower thread presser (1) should be adjusted so that it can securely clamp the lower thread.

1. Loosen the screw (2), and move the lower thread presser (1) up and down so that its top surface is flush with the

groove in the throat plate.

2. Make sure that the lower thread presser (1) does not fill the front groove of the throat plate.

If it does, loosen the nut (3), and adjust the screw (4).

Note: Set the height from the stopper portion of thread trimmer lever bracket B (5) to the top of the looper base,

to 11 mm at maximum.

3. Make sure that the front of the throat plate overlaps with the lower thread presser (1) by 0.5 – 1.0 mm when

thread trimmer lever bracket B (5) operates.

4. If adjustment is necessary, remove the lower thread presser bracket (6), loosen the nut (7), and adjust the screw

(8).

3826Q 3827Q

3828Q 3829Q

Lap amount

4. ADJUSTMENT

RH-981A 76

4-25. Adjusting the rotating centers of the needle bar and the looper base

The rotating centers of the needle bar and the looper base are adjusted before shipment from the factory.

When disassembling the machine or exchanging parts such as the needle bar gear assembly, the needle bar, and

looper base, adjust the clearance between the needle and the point of the looper so that it does not change through

360 o.

Before adjusting the position of needle bar bush U, be sure to check there is no gap between the needle bar gear (1)

and needle bar gear support A (2).

1. Raise the needle bar gear (1) using your fingers to

check the loseness.

Note: If the looseness is great, the center of

rotation can not be adjusted.

2. Loosen the two bolts (3), and adjust needle bar gear

support A (2) so that the needle bar gear assembly

can rotate smoothly without gap.

3. Loosen the two bolts (4), and adjust needle bar gear

support B (5) in the same manner as above.

Note: When needle bar gear support A (2) or

needle bar gear support B (5) is raised

excessively, the looper base may be in an

inappropriate position.

When the looper base is at 360 o where the needle bar can move lightly up and down, adjust the position of needle

bar bush U (7).

Loosen the three bolts (6) a little, and tap on the needle

bar to adjust the position of needle bar bush U (7).

* Adjust the back and forth movement of needle bar

bush U (7) so that the clearance between the needle

and the point of the looper is not changed when the

looper base is at 0 o and 180 o.

Adjust the sideways movement of needle bar bush U

(7) so that the clearance between the needle and the

point of the looper is not changed when the looper

base is at 90 o and 270 o.

Note: If the needle penetration movement is

adjusted to one point, the clearance between

the needle and the point of the looper will not

be fixed.

No looseness

Press manually.

3830Q

3831Q

4. ADJUSTMENT

RH-981A

4-26. Adjusting the needle bar stop position

The needle bar should stop when it rises from the lowest point at the outside sewing position.

Loosen the screw (3), and align the notch (1) of belt

cover F with the timing mark (2) on the pulley.

Note: When the stop position is changed, the

operation range of spreader R will change.

Reconfirm the mounting position of the upper

movable knife.

3832Q

5. POWER SUPPLY EQUIPMENT

RH-981A

5. POWER SUPPLY EQUIPMENT

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.

Be sure to turn off the power and disconnect the plug before replacing and adjusting the parts associated with the

power supply equipment.

5-1. Components inside the control box

The following are brief explanations of components inside the control box. See control circuit block diagram at the

end of this manual for the details of the connections.

Control circuit board

The control circuit board is fixed to the rear panel of the control box.

This PCB serves to control machine operation.

Power supply circuit board

The power supply circuit board is fixed at the bottom of the control box.

Four fuses are mounted on this PCB. (Refer to “5-2. Fuse explanation”.)

PMD PCB for θ-axis shaft

The PMD PCB for θ-axis shaft is fixed to the board on the top of the control box.

This is used to run the θ-axis pulse motor.

DC fan motor (large)

Cools the heat sink on the PCB.

DC fan motor (small)

Discharges air in the control box. Clean the inlet filter monthly.

Conversion transformer (depending on power supply voltage specification)

Adjust the power voltage so that it is that required for the PCB.

* There are two types of transformers: a high voltage transformer is equipped with 240V, 380V, 400V, and 415V

specifications; a low voltage transformer is equipped with 100V and 110V specifications.

Transformer connections

1145S

Input side

1144S

Power supply

circuit board side

<415V, 400V, 380V, 240V> <100V,110V>

Power supply

circuit board side

Input side

5. POWER SUPPLY EQUIPMENT

RH-981A

3518Q

DC fan motor (large)

PMD PCB for

θ-axis shaft

Conversion

transformer DC fan motor (small)

Power supply

circuit board

3519Q

Control circuit board

5. POWER SUPPLY EQUIPMENT

RH-981A

5-2. Fuse explanation

Before replacing a fuse, be sure to read “5-2-1. Before replacing a fuse”.

If a component on a PCB is damaged, a fuse may blow again immediately even when it has been replaced.

When replacing a fuse, be sure to use the specified ones listed below.

No. Part name Part code Manufacturer When a fuse has blown

1G fuse (5AFB)

(quick melting type, 5A-250V) S08030-000 Toyo Fuse Company

TOYO5A

The feed mechanism does not

operate.

2G fuse (5AFB)

(quick melting type, 5A-250V) S08030-000 Toyo Fuse Company

TOYO5A

The machine motor does not

turn.

3Fuse 6A

(glass tube fuse, 6A-250V) 153242-000 Fuji Tanshi Company

FGB0

The power indicator is not lit, and

nothing operates.

4Fuse 6A

(glass tube fuse, 6A-250V) 153242-000 Fuji Tanshi Company

FGB0

The power indicator is not lit, and

nothing operates.

3521Q3520Q

Front Rear

Fuse

No.2 Fuse

No.3

Fuse

No.4

Fuse

No.1

5. POWER SUPPLY EQUIPMENT

RH-981A

5-2-1. Before replacing a fuse

If fuse No.1 is blown

1. Separate connectors P5 (DC300) on the power

supply circuit board, and measure the resistance with

the polarities as shown in the figure.

If the resistance is 0 ohms (it means a short-circuit),

replace the power supply circuit board.

2. Separate connectors P1 (POWER) on the power

supply circuit board, and measure the resistance

between pins 4 and 7 on the board with the polarities

as shown in the figure.

If the resistance is 0 ohms (it means a short-circuit),

replace the power supply circuit board.

If fuse No.2 is blown

Separate connectors P15 (DC300) on the control circuit

board, and measure the resistance between pins 1 and

2 on the board with the polarities as shown in the figure.

If the resistance is 0 ohms (it means a short-circuit),

replace the power supply circuit board.

If fuse No.3 or 4 is blown

Separate connectors P1 (ACIN) on the power supply

circuit board, and measure the resistance of the three

places between A and B, A and C, and B and C on the

board with the polarities as shown in the figure.

If the resistance is 0 ohms (it means a short-circuit), or

the resistance between A and C or B and C is not infinity,

replace the power supply circuit board.

3522Q

BLACK

RED

3523Q

3524Q

RED BLACK

3525Q

RED

5. POWER SUPPLY EQUIPMENT

RH-981A

5-3. Connectors

Most of the machine trouble is due to connector problems including improper connection or insufficient contact.

Therefore, be sure to check if each connector is correctly inserted and that there is no contact failure between pins

and wires before starting troubleshooting procedures.

5-3-1. Connector positions

Head harness relay

3526Q

For θ–axis pulse motor (red)

For θ–axis home position sensor

3527Q

For X–axis pulse motor

(white)

For Y–axis pulse motor

(blue)

For θ–axis pulse motor (red)

5. POWER SUPPLY EQUIPMENT

RH-981A

Outside of the control box

Inside of the control box

3528Q

For specification harness

For hand switch (for foot switch)

Note: This type-harness B is only for -12

specifications. If this harness is no

connected, you will not be able to run

programs for -12 specification sewing

machines.

3529Q

Type harness B

5. POWER SUPPLY EQUIPMENT

RH-981A

Control circuit board

Power supply circuit board

3530Q

3531Q

5. POWER SUPPLY EQUIPMENT

RH-981A

Panel circuit board

PMD PCB for θ-axis shaft

Indexer mechanism (optional)

3532Q

3533Q

3534Q

Indexer sensor harness

is inserted into the relay

connector for θ–axis

home position sensor.

Relays the valve harness

of the indexer.

The harness which relays the

valve of the indexer is inserted

into connector P21 (EXOUT)

of the control circuit board.

5. POWER SUPPLY EQUIPMENT

RH-981A

5-3-2. Signal names for connectors and probable symptoms due to poor contact

1. Relay connectors

For X-axis pulse motor (MOLEX 5557-06R, 5559-06P)

Pin no. Signal name Probable symptoms due to poor contact

1 X-axis PM driving current (XA)

2 X-axis PM driving current (XB)

3 X-axis PM driving current (XC)

4 X-axis PM driving current (XD)

5 X-axis PM driving current (XE)

• Left and right movement of feed bracket is not

correct.

• X-axis home position can not be found.

• Error code E80 appears.

For Y-axis pulse motor (MOLEX 5557-06R, [blue], 5559-06P [blue])

Pin no. Signal name Probable symptoms due to poor contact

1 Y-axis PM driving current (YA)

2 Y-axis PM driving current (YB)

3 Y-axis PM driving current (YC)

4 Y-axis PM driving current (YD)

5 Y-axis PM driving current (YE)

• Back and forth movement of feed bracket is not

correct.

• Y-axis home position can not be found.

• Error code E81 appears.

For θ-axis pulse motor (MOLEX 5557-06R [red], 5559-06P [red])

Pin no. Signal name Probable symptoms due to poor contact

1θ-axis PM driving current (RA)

2θ-axis PM driving current (RB)

3θ-axis PM driving current (RC)

4θ-axis PM driving current (RD)

5θ-axis PM driving current (RE)

• Needle bar motion is not correct.

•θ-axis home position can not be found.

• Error code E82 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

For θ-axis home position sensor (AMP 172163-1, 172171-1)

Pin no. Signal name Probable symptoms due to poor contact

1+5V (for θ-axis home position sensor)

2+5V

3+24V

4+24V (for right cylinder driving sensor)

(when indexer is attached)

6θ-axis home position sensor signal

Feed plate home position sensor signal

(when indexer is attached) /

Button hole cloth sensor (when special

lapel cutting device is attached)

8Reserved

Right driving sensor (when indexer is

attached) /

Button hole position sensor (when special

lapel cutting device is attached)

Left driving sensor (when indexer is

attached) /

Hammer home position sensor (when

special lapel cutting device is attached)

11 0V (for θ-axis home position sensor)

12 0V (for feed plate home position sensor)

(when indexer is attached)

13 0V

14 0V (for right driving sensor)

(when indexer is attached)

15 0V (for left driving sensor)

(when indexer is attached)

• θ-axis home position can not be found.

• Error code E52 or E82 appears.

• Indexer does not work properly.

• Special lapel cutting device does not work properly.

• One of error codes E06, E07, E36, E37, E38, E66,

E67, E68, E200, E201, E202 and E203 appears.

For specification harness (MOLEX 5557-16R, 5559-16P)

Pin no. Signal name Probable symptoms due to poor contact

1 TYPE 1 (COM)

2 TYPE 2 (COM)

3 TYPE 3 (COM)

4 TYPE 4 (COM)

5 TYPE 5 (COM)

6 TYPE 6 (COM)

7 TYPE 7 (COM)

8 TYPE 8 (COM)

9 TYPE 1

10 TYPE 2

11 TYPE 3

12 TYPE 4

13 TYPE 5

14 TYPE 6

15 TYPE 7

16 TYPE 8

• Error code E09 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

For hand switch (foot switch) (AMP 172161-1, 172169-1)

Pin no. Signal name Probable symptoms due to poor contact

1Work clamp switch signal (common

side)

2 Work clamp switch signal

3 Reserved (common side)

4Reserved

5Ground

7 Start switch signal (common side)

8 Start switch signal

• Work clamp does not work when work clamp switch is

pressed.

• Machine does not start.

• Home position detection is not possible immediately after

the power is turned on.

For indexer valve (MOLEX 5025-15P1, 5025-15R1) (when indexer is attached) /

For upper thread nipper (MOLEX 5025-15P1, 5025-15R1) (when upper thread nipper is attached) /

For special lapel cutting valve (MOLEX 5025-15P1, 5025-15R1) (when special lapel cutting device is attached)

Pin no. Signal name Probable symptoms due to poor contact

1Reserved

2Upper thread nipper [1] (upper and

lower)

3Upper thread nipper [2] (Open and

close)

4Feed plate fixing valve motion

signal

Chuck valve motion signal /

Special lapel cutting valve motion

signal

6+24V

7+24V

8+24V

9 +24V (for feed plate fixing valve)

10 +24V (for chuck valve)

11 Feed plate driving valve signal

12 +24V (for feed plate driving valve)

13 -

14 -

15 -

• Indexer does not work properly.

• Upper thread nipper does not work properly.

• Special lapel cutting device does not work properly.

• One of error codes E07, E37, E38, E66, E67 and E68

appears.

2. Connectors to be attached to control circuit board

P1 [ORG] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. XHR-12)

Pin no. Signal name Probable symptoms due to poor contact

2 X-axis home position sensor signal

30V (for X-axis home position

sensor)

4+5V (for X-axis home position

sensor)

6 Y-axis home position sensor signal

70V (for Y-axis home position

sensor)

8+5V (for Y-axis home position

sensor)

10 Pressure sensor signal

11 0V (for pressure sensor)

12 -

• X-axis or Y-axis home position can not be found.

• One of error codes E50, E51, E80 and E81 appears.

• Error codes E05 or E35 appears. (when pressure sensor is

attached)

5. POWER SUPPLY EQUIPMENT

RH-981A

P2 [SYNCHRO] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. XHR-5)

Pin no. Signal name Probable symptoms due to poor contact

1+5V

2 Encoder timing signal

3 Needle down signal

4 Needle up signal

50V

• Machine motor does not run.

• Sewing machine motor is running unevenly.

• One of error codes E10, E40, E70, E71, E76, E77,

and E91 appears.

P3 [HEAD] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. XHR-9)

Pin no. Signal name Probable symptoms due to poor contact

1Emergency stop switch normal close

signal

2 0V (for emergency stop switch)

3 Emergency stop switch normal open signal

• Error code E60 appears and machine stops.

• One of error codes E00, E12, E30, E42, and E72

appears.

7 +5V (for knife ON sensor)

8 Knife ON sensor signal

9 Knife ON sensor cathode

P4 [AIR] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. H12P-SHF-AA)

Pin no. Signal name Probable symptoms due to poor contact

1 Upper thread adjuster valve signal

2 Upper thread trimmer valve signal

3 Lower thread trimmer valve signal

4 Knife driving valve signal

5 Cloth opener valve signal

8 Work clamp valve

10 +24V (for work clamp, cloth opener, and

lower thread trimmer)

11 +24V (for upper thread adjuster, upper

thread trimmer, and knife driving)

12 -

• Upper thread adjuster does not work.

• Upper thread can not be trimmed.

• Lower thread can not be trimmed.

• Knife does not work.

• Cloth opener does not work.

• Work clamp does not work.

• One of error codes E12, E15, E42, E45, E72, and

E75 appears.

P5 [SOL] (not connected)

P6 [YPM] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-5N [blue])

Pin no. Signal name Probable symptoms due to poor contact

1 Y-axis PM driving current (YA)

2 Y-axis PM driving current (YB)

3 Y-axis PM driving current (YC)

4 Y-axis PM driving current (YD)

5 Y-axis PM driving current (YE)

• Back and forth motion of feed bracket is not correct.

• Y-axis home position can not be found.

• Error code E81 appears.

P7 [XPM] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-5N)

Pin no. Signal name Probable symptoms due to poor contact

1 X-axis PM driving current (XA)

2 X-axis PM driving current (XB)

3 X-axis PM driving current (XC)

4 X-axis PM driving current (XD)

5 X-axis PM driving current (XE)

• Left and right motion of feed bracket is not correct.

• X-axis home position can not be found.

• Error code E80 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

P8 [EXINA] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHDR-16VS)

Pin no. Signal name Probable symptoms due to poor contact

1 0V (for head safety switch)

2 Head safety switch signal

4 0V (for lower thread trimming OFF sensor)

5 Lower thread trimming OFF sensor signal

6+24V

(for lower thread trimming OFF sensor)

7 0 V (for TYPE 5)

8 TYPE 5

10 0 V (for TYPE 6)

11 TYPE 6

12 -

13 0 V (for TYPE 7)

14 TYPE 7

15 -

16 -

• One of error codes E02, E09, E15, E32, E45, E62,

and E75 appears.

P9 [EXINB] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHDR-18VS)

Pin no. Signal name Probable symptoms due to poor contact

10V (for left driving sensor)

(when indexer is attached)

2Left driving sensor signal

(when indexer is attached)

3+24V (for left driving sensor)

(when indexer is attached)

40V (for right driving sensor)

(when indexer is attached)

5Right driving sensor signal

(when indexer is attached)

6+24V (for right driving sensor)

(when indexer is attached)

10 0V (for feed plate home position sensor)

(when indexer is attached)

11 Feed plate home position sensor signal

(when indexer is attached)

12 +24V (for feed plate home position sensor)

(when indexer is attached)

13 0V (for θ-axis home position sensor)

14 θ-axis home position sensor signal

15 -24V

16 +5V

17 +5V

18 +5V (for θ-axis home position sensor)

•θ-axis home position can not be found.

• Error code E52 or E82 appears.

• Indexer does not work properly.

• One of error codes E06, E07, E36, E37, E38, E66,

E67, and E68 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

P10 [FAN-R] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-3)

Pin no. Signal name Probable symptoms due to poor contact

1+24V

2 Fan lock error signal

30V

• Error code E93 appears.

P11 [HATOME] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHDR-12VS)

Pin no. Signal name Probable symptoms due to poor contact

5θ-axis PM clock signal

6θ-axis PM direction signal

7θ-axis PM save signal

8θ-axis PM excitation signal

9+5V

10 +5V

11 0V

12 0V

• Rotation motion of feed mechanism is not correct.

•θ-axis position can not be found.

• Error code E52 or E82 appears.

P12 [POWER] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-7N)

Pin no. Signal name Probable symptoms due to poor contact

1+5V

2+24V

30V

4+55V

5+55V

60V (P0V)

70V (P0V)

• Power does not come on.

• Feed bracket does not move.

• Machine operation becomes unstable.

• Home position can not be found.

• Error code E80 appears.

P13 [DC55] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-2N)

Pin no. Signal name Probable symptoms due to poor contact

1+55V

20V (P0V)

• Feed bracket does not move.

• Home position can not be found.

• Error code E80 appears.

P14 [UVW] (MOLEX3191-03R1)

Pin no. Signal name Probable symptoms due to poor contact

1 Machine motor U phase

2 Machine motor V phase

3 Machine motor W phase

• Machine motor does not run.

• Rotation of machine motor is not correct.

• Error code E70 or E91 appears.

P15 [DC300] (MOLEX3191-02R1)

Pin no. Signal name Probable symptoms due to poor contact

10V (for machine motor)

2 +300V

• Machine motor does not run.

• Rotation of machine motor is not correct.

• Error code E70 or E91 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

P16 [DC18] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-11)

Pin no. Signal name Probable symptoms due to poor contact

1 +18V (A18V)

20V (A0V)

4 +18V (B18V)

50V (B0V)

7 +18V (C18V)

80V (C0V)

10 +18V (D18V)

11 0V (D0V)

• Machine motor does not run.

• Rotation of machine motor is not correct.

• Error code E70 or E91 appears.

P17 [EXPM] (not attached)

P18 [PANEL] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. XHR-10)

Pin no. Signal name Probable symptoms due to poor contact

10V

20V

3 Send (CHO)

4 DTR (CHO)

5Receive (CHO)

6 DSR (CHO)

7+11V

8-11V

9+5V

10 +5V

• No keys on panel are activated.

P19 [FOOT] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-6)

Pin no. Signal name Probable symptoms due to poor contact

1 Start switch signal (common side)

2 Start switch signal

3 Work clamp switch signal (common side)

4 Work clamp switch signal

5 Reserved (common side)

6Reserved

• Work clamp does not move when work clamp switch

is pressed.

• Machine does not start.

• Home position detection is not possible immediately

after the power is turned on.

P20 [PER] (JAPAN SOLDERLESS TERMINAL MFG.CO., LTD PHR-5)

Pin no. Signal name Probable symptoms due to poor contact

1 Relay condition input

2 Primary voltage detect

3 Relay OFF output

4 +55V OFF output

50V

• One of error codes E26, E92, E98, and E99 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

P21 [EXOUT] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. H10P-SHF-AA) (when indexer is attached)

Pin no. Signal name Probable symptoms due to poor contact

1 Feed plate driving valve motion signal

2 Chuck valve motion signal

3 Feed plate fixing valve motion signal

4Reserved

5Reserved

6Reserved

9+24V

10 +24V

• Indexer does not work properly.

• One of error codes E07, E37, E38, E66, E67 and E68

appears.

P24 [OPTION] (not attached)

P25 [FAN-L] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-3)

Pin no. Signal name Probable symptoms due to poor contact

1+24V

2 Fan lock error signal

30V

• Error code E94 appears.

P26 [SELECT] (MOLEX 5566-10A)

Pin no. Signal name Probable symptoms due to poor contact

1 TYPE 1

2 TYPE 2

3 TYPE 3

4 TYPE 4

5 TYPE 8

6 0V (for TYPE 1)

7 0V (for TYPE 2)

8 0V (for TYPE 3)

9 0V (for TYPE 4)

10 0V (for TYPE 8)

• Error code E09 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

3. Connectors to be attached to power supply circuit board

P1 [POWER] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-7N)

Pin no. Signal name Probable symptoms due to poor contact

1+5V

2+24V

30V

4+55V

5+55V

6 0V(P0V)

7 0V(P0V)

• Power does not come on.

• Feed bracket does not move.

• Machine operation becomes unstable.

• Home position can not be found.

• Error code E80 appears.

P2 [PER] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-5)

Pin no. Signal name Probable symptoms due to poor contact

1 Relay condition input

2 Primary voltage detect

3 Relay OFF output

4 +55V OFF output

50V

• One of error codes E26, E92, E98, and E99 appears.

P3 [DC18] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-11)

Pin no. Signal name Probable symptoms due to poor contact

1 +18V (A18V)

20V (A0V)

4 +18V (B18V)

50V (B0V)

7 +18V (C18V)

80V (C0V)

10 +18V (D18V)

11 0V (D0V)

• Machine motor does not run.

• Rotation of machine motor is not correct.

• Error code E70 or E91 appears.

P4 [ACIN] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. LP-04-2V)

Pin no. Signal name Probable symptoms due to poor contact

1 AC input

2 AC input

4Ground

• Power does not come on.

• Machine operation becomes unstable.

• Error code E92 appears.

P5 [DC300] (MOLEX3191-02R1)

Pin no. Signal name Probable symptoms due to poor contact

10V (for machine motor)

2 +300V

• Machine motor does not run.

• Rotation of machine motor is not correct.

• Error code E70 or E91 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

4. Connectors to be attached to panel circuit board

P1 [EXT-PNL] (not attached)

P2 [MAIN] (OMRON XG4M-1630-U)

Pin no. Signal name Probable symptoms due to poor contact

10V

20V

30V

40V

5T x D

6DTR

7R x D

8DSR

9EMLED

10 +12V

11 +12V

12 +12V

13 -12V

14 +5V

15 +5V

16 +5V

• No keys on the operation panel are activated.

• Programmer does not work.

P3 [PRG] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-10)

Pin no. Signal name Probable symptoms due to poor contact

10V

20V

3T x D

4DTR

5R x D

6DSR

7+12V

8-12V

9+5V

10 +5V

• Programmer does not work.

5. POWER SUPPLY EQUIPMENT

RH-981A

5. Connectors to be attached to PMD PCB for θ axis

P1 [RPM] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-6N)

Pin no. Signal name Probable symptoms due to poor contact

1θ-axis PM driving current (RA)

2θ-axis PM driving current (RB)

3θ-axis PM driving current (RC)

4θ-axis PM driving current (RD)

5θ-axis PM driving current (RE)

• Needle bar motion is not correct.

•θ-axis home position can not be found.

• Error code E52 or E82 appears.

P2 [DC55] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-2N)

Pin no. Signal name Probable symptoms due to poor contact

1+55V

20V (P0V)

• Feed bracket does not move.

• Home position can not be found.

• Error code E80 appears.

P3 [CONTROL] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. H8P-SHF-AA)

Pin no. Signal name Probable symptoms due to poor contact

1θ-axis PM clock signal

2θ-axis PM direction signal

3θ-axis PM save signal

4θ-axis PM excitation signal

5+5V

6+5V

70V

80V

• Needle bar motion is not correct.

•θ-axis home position can not be found.

• Error code E52 or E82 appears.

5. POWER SUPPLY EQUIPMENT

RH-981A

5-4. Specification harness connections

-02, -12, -52 specifications

-02, -12, -52 specifications -00, -01 specifications

* The dotted lines indicate -12 specifications and the broken lines indicate -52 specifications only.

3535Q

5. POWER SUPPLY EQUIPMENT

RH-981A

5-5. Summary of DIP switches

Always turn off the power supply before changing any of the DIP switch settings.

5-5-1. Panel DIP switches

The ON/OFF positions of the DIP switches inside the operation panel are checked only once when the power is

turned on.

Any changes to the DIP switch positions will not be effective until the power is switched off and back on again.

No. ON/OFF Setting items Default

ON Program mode disabled

1* OFF Program mode enabled OFF

ON Switches between taper bar ←→ straight bar tacking

2OFF Normal OFF

ON Set the feed bracket to the front position

3OFF Set the feed bracket to the back position OFF

ON -

4OFF -OFF

ON Single-pedal operation

5OFF Dual-pedal operation OFF

ON -

6OFF - OFF

ON -

7OFF -OFF

ON Maximum stitch width correction amount = 2.0 mm

8** OFF Maximum stitch width correction amount = 1.0 mm OFF

* If program mode is disabled, operation becomes as follows.

• Program numbers, knife operations and the production counter cannot be changed.

• The modes change in the order Automatic → Test feed → Manual → Automatic.

** If the maximum stitch width correction amount is set to 2.0 mm, carry out the adjustment in "9-14. Adjusting the

position of the work clamp plate". If this adjustment is not carried out, the throat plate and needle plate may

interfere with each other.

If the stitch width correction amount is set to more than 1.0 mm, the sewing speed will be limited in accordance

with the value set.

2425Q

5. POWER SUPPLY EQUIPMENT

RH-981A

5-5-2. Circuit board DIP switches

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.

The ON/OFF positions of the DIP switches inside the control box are checked only once when the power is turned

on.

Any changes to the DIP switch positions will not be effective until the power is switched off and back on again.

Circuit board DIP switch C

No. ON/OFF Setting items Default

ON Special lapel cutting device enabled

1OFF Special lapel cutting device disabled OFF

ON Button hole sensor of special lapel cutting device enabled

2OFF Button hole sensor of special lapel cutting device disabled OFF

ON With pressure sensor

3OFF Without pressure sensor OFF

ON -

4OFF - OFF

ON Upper thread nipper enabled

5OFF Upper thread nipper disabled OFF

ON Lower thread trimming enabled

6OFF Lower thread trimming disabled ON

ON -

7OFF - OFF

ON Maximum straight bar tacking length = 9.0 mm

8* OFF Maximum straight bar tacking length = 6.0 mm OFF

* If the maximum straight bar tacking length is set to 9.0 mm, it will be necessary to process the work clamp plate.

Consult with your local Brother sales office for further details. If the work clamp plate is not processed, the throat

plate may interfere with the needle plate and work clamp plate.

2426Q

5. POWER SUPPLY EQUIPMENT

RH-981A

100

Circuit board DIP switch D

No. ON/OFF Setting items Default

ON -

1OFF - OFF

ON -

2OFF - OFF

ON -

3OFF - OFF

ON -

4OFF - OFF

ON -

5OFF - OFF

ON -

6OFF - OFF

ON -

7OFF - OFF

ON -

8OFF - OFF

1001Q

5. POWER SUPPLY EQUIPMENT

RH-981A

101

5-6. CHANGING FUNCTIONS USING THE MEMORY SWITCHES

The memory switches are valid for all programs.

1. Press the SELECT key (1) to change the mode to program or cycle program mode.

2. While pressing the ENTER key (2), press the key.

* The program mode indicator (3) and the cycle program mode indicator (4) will illuminate.

* The memory switch number "00" will appear in the program number display (5), and the memory switch setting

will appear in the detail display (6).

3. Press the keys to select the number for the memory switch to be changed.

4. Press the keys to change the memory switch setting.

* The memory switch setting will flash while it is being changed.

5. Press the ENTER key (2) to accept the new setting.

* The memory switch setting will stop flashing.

6. Repeat steps 3 to 5 to change other memory switch settings.

7. Press the SELECT key (1) to change the mode to automatic mode.

* The memory switch settings will be memorized.

3118Q

5. POWER SUPPLY EQUIPMENT

RH-981A

102

5-6-1. Memory switch table

The memory switch settings are applied immediately to all programs once the settings have been changed.

However, memory switches marked with * are only applied after the power is turned on.

No. Setting items Setting range Unit Default

00. Work clamp down operation when feed bracket is

forward

OFF, ON - OFF

01. Work clamp stays down after sewing OFF, ON - OFF

02. Number of home position start cycles (Note 1) OFF, 1 - 9 1 1

03. Cutting block ON time 25 - 200 ms 25 ms 25 ms

04. Timer for checking raising of hammer

(Timer for determining if the cutting block has been

raised to a position where it will not touch the next

feed bracket to operate)

OFF (Determined

from number of slit

signals),

200 - 500 ms

50 ms OFF

05. Feed operation timing correction after hammer is

raised

(After checking that the hammer is raised, the timer

interval is added so that the hammer and feed

bracket do not touch.)

0 - 150 ms 25 ms 0

06. Test feeding deceleration speed OFF, 1 - 4 1 OFF

07. Increased amount of upper thread remaining OFF, 1 - 3 1 OFF

08. Stitch length display in automatic mode OFF, ON - OFF

09.* Max. stitch length of L7 40 mm, 42 mm 2 mm 40 mm

10. Feed timing correction -10 - 10 1 0

11.* Number of eyelet buttonholes when fly indexer is

used

OFF (Fly indexer is

not used),1 - 9

12.* Cloth setting position when fly indexer is used 1: Left setting

position

2: Horizontal setting

position

13. Program number selected when buttonhole sensor

is ON when using the special lapel cutting device

OFF, 1 - 9 1 OFF

14. Program number for operating the straight

buttonhole hammer regardless of eyelet shape

setting (parameter No. 01) and whether the

buttonhole sensor is ON or OFF (Note 2)

OFF, 1 - 9 1 OFF

(Note 1) If home position starting is not carried out for each piece of material, there is the danger that the feed

bracket may become overloaded for some reason and come off, which will affect the next piece to be sewn.

Accordingly it is recommended that you set home position starting to be carried out each time (setting "1").

(Note 2) If a program number has been set for memory switch No. 13, it will be ignored if a program number has

been set for memory switch No. 14.

5. POWER SUPPLY EQUIPMENT

RH-981A

103

5-7. Sensors positions and funstions

3536Q

3537Q

Y-axis home position sensor

(magnetic sensor)

Knife ON sensor

(photo sensor)

X-axis home position sensor

(magnetic sensor)

Lower thread trimmer OFF sensor

(cylinder sensor)

Looper base (θ-axis) home position sensor

(magnetic sensor)

Safety sensor

(limit sensor)

5. POWER SUPPLY EQUIPMENT

RH-981A

104

X-axis home position sensor

• The X-axis home position sensor determines the

home position of the feed bracket in the X direction.

• When the feed bracket is on the left of the head, the

X-axis home position sensor is set to off, and when

right, set to on.

• When the home position is detected, the X-axis home

position sensor is turned on.

• If the X-axis home position sensor is out of order, its

connectors are not attached correctly, or the cord

does not flow electricity, error code E-50 or E-80 will

appear.

Y-axis home position sensor

• The Y-axis home position sensor determines the

home position of the feed bracket in the Y direction.

• The Y-axis home position sensor is set to on only

when the feed bracket is at the home position.

• If the Y-axis home position sensor is out of order, its

connectors are not attached correctly, or the cord

does not supply electricity, error code E-51 or E-81

will appear.

3538Q

3539Q

Y-sensor

X-sensor

5. POWER SUPPLY EQUIPMENT

RH-981A

105

Looper base home position sensor (θ-axis home position sensor)

• The looper base home position sensor determines

the home position of the looper base (when it is at 0°)

• The looper base home position sensor is set to on

only when the looper base is at the home position.

• If the looper base home position sensor is out of

order, its connectors are not attached correctly, or the

cord does not supply electricity, error code E-52 or E-

82 will appear.

Knife ON sensor

• The knife ON sensor is intended to sense that the operation of the cutter lever (1) has been completed, and to

know the cutter lever (1) lift stroke.

• The cutter sensor partition plate (slit) (3) is attached to link C (2) which moves the cutter lever (1). The signal is

sent from the cutter sensor (4) mounted on the bed.

3540Q

R-sensor

3541Q

Cutter sensor

5. POWER SUPPLY EQUIPMENT

RH-981A

106

Lower thread trimmer OFF sensor

• The lower thread trimmer OFF sensor is attached to

the cylinder which drives the lower thread trimmer.

• The lower thread trimmer OFF sensor is intended to

make the lower thread trimmer securely set to off.

• If the lower thread trimmer OFF sensor is out of

control or attached incorrectly, its connectors are not

attached correctly, or the cord does not supply

electricity, error code E-15, E-45, or E-75 will appear.

Safety sensor

• The limit switch is attached to the front of the bed.

• The safety sensor is intended to check that the

machine head is positioned correctly for safe

operation.

• The safety sensor will be activated to stop all motions

when the machine head is raised during sewing.

• If the machine head is kept raised, the safety sensor

is out of control, its connectors are not attached

securely, or the cord does not flow electricity, error

code E-02, E-32, or E-62 will appear.

3542Q

Lower thread trimmer

OFF sensor

3543Q

Safet

switch

6. AIR PRESSURE MECHANISM

RH-981A

107

6. AIR PRESSURE MECHANISM

CAUTION

Maintenance and inspection of the sewing

machine should only be carried out by a

qualified technician.

Disconnect the air hoses from the air supply and

wait for the needle on the pressure gauge to drop

to “0” before disassembly of any parts which use

the pneumatic equipment.

Turn off the power switch before

disassembly, otherwise the machine may

operate if the start switch is pressed by

mistake, which could result in injury.

If the power switch and air need to be left on when

carrying out some adjustment, be extremely

careful to observe all safety precautions.

6-1. Solenoid valves and air tubes

6-1-1. Adjusting the solenoid valve speed controllers

There are 3 speed controllers: No.3 (for lower thread trimming), No.5 (for upper thread trimming), and one for the knife.

1. As for the No.3 and No.5 speed controllers, adjust their heights to 10 mm.

Note: If the speed controllers are excessively throttled, error codes including E-75 (lower thread and operations

are incorrect) and E-76 (upper thread operation is incorrect), may appears.

2. The exhaust throttle valve is only attached to the OFF side of the knife valve. Adjust the protrusion of the speed

controller to 7.2 mm.

Note: If the speed controllers are excessively throttled, error codes including E-72 (cutting block operation is

incorrect), may appear. If excessively opened, abnormal noise may be emitted when the knife cylinder

returns.

3545Q

3544Q

6. AIR PRESSURE MECHANISM

RH-981A 108

6-1-2. Air tubes

3546Q 3547Q

3548Q

Air tubes Cylinders

[A] Work clamp (1) Cylinder, 16X10

Cloth opener (2) Cylinder assembly, A 16X15

(3) Cylinder assembly, B 16X15

Lower thread trimming (4) Cylinder assembly, B 16X30

[B]* Auxiliary clamp (5)* Cylinder assembly, 10X15J

[C] Upper thread tightening (6) Cylinder assembly, 10X15

Upper thread trimming (7) Cylinder assembly, 10X15

[D] Knife (8) Cylinder assembly, 63X100

* -02, -12, -52 specifications only

6. AIR PRESSURE MECHANISM

RH-981A

109

6-2. Air tube layout

[Reference] Dimensions for cylinder rod assembly

1. Upper thread release cylinder and sub presser cylinder

3549Q

Work clamp cylinder

For cloth

opener

For work

clam

For lower

thread

trimming

Work clamp cylinder

3550Q

6. AIR PRESSURE MECHANISM

RH-981A 110

2. Upper thread trimming cylinder

3. Cutter cylinder

4. Work clamp cylinder

3553Q

3552Q

3551Q

6. AIR PRESSURE MECHANISM

RH-981A

111

5. Cloth opener cylinder

6. Lower thread trimming cylinder

3554Q

3555Q

7. SOFTWARE

RH-981A

112

7. SOFTWARE

7-1. Motion flowchart

Cutting before sewing, back position Cutting after sewing, back position

Start switch ON Start switch ON

↓↓

Hammer operates. Cloth opener operates, and the

upper thread is tightened.

↓↓

Cloth opener operates, and the

upper thread is tightened.

Feed bracket moves to sewing start

position.

↓↓

Feed bracket moves to sewing start

position. Sewing

↓↓

Sewing Upper thread tension is released.

↓↓

Upper thread tension is released. X and Y axes start to return to their

home positions.

↓↓

X and Y axes start to return to their

home positions. Upper thread is trimmed.

↓↓

Upper thread is trimmed. X and Y axes finish returning to their

home positions.

↓↓

X and Y axes finish returning to their

home positions. Hammer operates.

↓↓

Work clamp rises. Work clamp rises and cloth opener

is closed.

↓↓

Cloth opener is closed and lower

thread is trimmed. Lower thread is trimmed.

↓↓

θ axis is returned to home position. θ axis is returned to home position.

↓↓

X, Y, and θ axes each return to

home position (by means of

respective sensors).

X, Y, and θ axes each return to

home position (by means of

respective sensors).

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7-2. Input check list

Use the following procedure when checking for switch and sensor breakdown, cord breakage, and adjusting the

sensor positions.

The CPU can be checked as to whether it has correctly interpreted signals from switches and sensors.

1. Turn off the power.

2. Turn on the power while pressing the key.

* The check mode will appear in the program number display (1), and the check result will appear in the detail

display (2).

3. Press the and keys to select a desired check mode (F1 or F2).

4. When the switch or sensor is turned on, the corresponding segment on the detail display (2) or indicators on the

operation panel will react.

* Turn the switch on and off to check it, and move the object by hand to check the sensor.

5. When returning to normal operation, turn power off and then on again.

<Example> When checking the cloth presser switch

Check whether a response occurs here

3558Q

3557Q

3556Q

Segment

Segment meanings

3559Q

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No. Check mode Check items Indicator / Segment

1 Detail UP key ( key) Automatic mode indicator

2 Detail DOWN key ( key) Test feed mode indicator

3 ENTER key Manual mode indicator

4 SELECT key Program mode indicator

5 RESET key Cycle program mode indicator

6 BEFORE key BEFORE indicator

7 OFF key OFF indicator

8 AFTER key AFTER indicator

9 Cloth presser switch Segment 4-A

10 Start switch Segment 4-D

11 Needle up signal Segment 4-E

12 Needle down signal Segment 4-F

13 Speed detecting sensor Segment 4-G

14 X-axis home position sensor Segment 3-A

15 Y-axis home position sensor Segment 3-B

16 θ-axis home position sensor Segment 3-C

17 EMERGENCY STOP switch Warning indicator

18 Emergency stop connecting signal Segment 2-A

19 Head sensor Segment 2-B

20 Knife ON sensor Segment 2-C

21 Lower thread trimming OFF sensor Segment 2-D

22 Feed plate home position sensor

(Button hole cloth sensor) Segment 1-A

23 Left driving sensor

(Hammer home position sensor) Segment 1-B

24 Right driving sensor

(Button hole position sensor) Segment 1-C

Pressure sensor Segment 1-D

26 Specification harness No.1 Segment 4-D.P

27 Specification harness No.2 Segment 4-G

28 Specification harness No.3 Segment 4-F

29 Specification harness No.4 Segment 4-E

30 Specification harness No.5 Segment 4-D

31 Specification harness No.6 Segment 4-C

32 Specification harness No.7 Segment 4-B

33 Specification harness No.8 Segment 4-A

34 Panel DIP switch No.1 Segment 3-D.P

35 Panel DIP switch No.2 Segment 3-G

36 Panel DIP switch No.3 Segment 3-F

37 Panel DIP switch No.4 Segment 3-E

Panel DIP switch No.5 Segment 3-D

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No. Check mode Check items Indicator / Segment

39 Panel DIP switch No.6 Segment 3-C

40 Panel DIP switch No.7 Segment 3-B

41 Panel DIP switch No.8 Segment 3-A

42 Circuit board DIP switch C No.1 Segment 2-D.P

43 Circuit board DIP switch C No.2 Segment 2-G

44 Circuit board DIP switch C No.3 Segment 2-F

45 Circuit board DIP switch C No.4 Segment 2-E

46 Circuit board DIP switch C No.5 Segment 2-D

47 Circuit board DIP switch C No.6 Segment 2-C

48 Circuit board DIP switch C No.7 Segment 2-B

49 Circuit board DIP switch C No.8 Segment 2-A

50 Circuit board DIP switch D No.1 Segment 1-D.P

51 Circuit board DIP switch D No.2 Segment 1-G

52 Circuit board DIP switch D No.3 Segment 1-F

53 Circuit board DIP switch D No.4 Segment 1-E

54 Circuit board DIP switch D No.5 Segment 1-D

55 Circuit board DIP switch D No.6 Segment 1-C

56 Circuit board DIP switch D No.7 Segment 1-B

Circuit board DIP switch D No.8 Segment 1-A

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7-3. Output check list

Use the following procedure when checking for PCB-related failures, mechanism breakdown, and cord breakage.

It can be checked as to whether signals that the CPU correctly output have been received.

1. Turn off the power.

2. Turn on the power while pressing the key.

3. Press the start switch (1).

* The machine will start to detect the home position.

* The check code will appear in the detail display (2).

4. Press the and keys to select the desired check code.

5. Press the start switch (1).

* While the start switch is kept pressed, the machine will work as it is specified by each check code.

6. When returning to normal operation, turn power off and then on again.

3560Q 3141Q

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Check code Function

C-01

After activating the buzzer for a second, X-, Y-, and θ-home positions are detected when the

machine stops with the needle at its upper limit.

(Head sensor will not conduct any error check.)

C-02 The machine will hold the material.

C-03 The machine will open the material.

C-04 After activating the buzzer for a second, the machine opens the material, turns 180˚ (θ), and

activates lower thread and lower gimp trimmers.

C-05 After activating the buzzer for a second, turns 180˚ (θ), and the upper thread trimmer will be

activated.

C-06 After activating the buzzer for a second, the machine will hold the material and activate the

hammer.

C-07

After activating the buzzer for a second, the machine will hold the material, and operate the

machine motor at 700rpm.

Turn off the start switch to stop the machine.

C-10 Upper thread will be tightened.

C-11

After activating the buzzer for a second, the X feed mechanism will reciprocate in the range of

–6 mm to + 6 mm.

Note: Be sure to remove the work clamp and check the motion of the X feed mechanism.

C-12

After activating the buzzer for a second, the Y feed mechanism will reciprocate in the range of

–1 mm to + 65 mm.

Note: Be sure to remove the work clamp and check the motion of the Y feed mechanism.

C-13

After activating the buzzer for a second, the θ feed mechanism will reciprocate in the range of

–2.7˚ + 362.7˚.

Note: Be sure to remove the work clamp and check the motion of the θ-axis feed mechanism.

C-16 *1 Feed plate is temporarily fixed. (Fixing cylinder on)

C-17 *1 Feed plate is fixed. (Chuck cylinder on)

C-18 *1 Feed plate is moved to the right. (Cloth feed driving cylinder on)

C-19 *2

After the feed bracket moves forward, the hammer plate of the hammer selector assembly

drops.

Note: Be sure to remove the work clamp and check the motion of the hammer plate.

C-20 *3 Upper thread nipper [1] (up/down) turns on.

C-21 *3 Upper thread nipper [2] (open/close) turns on.

C-31 The buzzer sounds.

C-32 All indicators on the operation panel will be lit.

*1 Available only when indexer is attached.

*2 Available only when special lapel cutting device (optional) is attached.

*3 Available only when upper thread nipper (optional) is attached.

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7-4. List of error codes

When an error occurs, the warning indicator and the error code display flash and the buzzer sounds.

1. Errors after power is turned on

Code Explanation Resetting method [ I ] Input check No.

[O] Output check code

E-00 EMERGENCY STOP switch was

pressed.

Release the EMERGENCY STOP

switch, and then press the RESET key. [ I ] 17,18

E-02 Machine head is tilted back. Turn off the power. [ I ] 19

E-03 Cloth presser switch was pressed. Release the cloth presser switch, and

press the RESET key. [ I ] 9

E-04 Start switch was pressed. Release the start switch, and press

the RESET key. [ I ] 10

E-05 Air pressure is insufficient. Turn off the power. -

E-06 Feed plate home position sensor is

OFF. Set it to ON. [ I ] 22

E-07 Feed plate left range sensor is OFF. Turn off the power. [ I ] 23

[O]C-18

E-09 Specification that machine does not

support is set. Turn off the power. [ I ] 26 - 33

E-10 Needle bar is not at the highest

position.

Turn the pulley by hand to raise the

needle bar to its highest position. [ I ]11

E-12 Cutter sensor is ON. Turn off the power. [ I ] 20

[O] C-06

E-15 Lower thread trimming OFF sensor is

OFF. Turn off the power. [ I ] 21

[O] C-04

E-26 PER terminal connection error Turn off the power. -

E-27 External RAM error Turn off the power. -

E-28 Panel communication start error Turn off the power. -

E-29 Machine motor communication start

error Turn off the power. -

2. Errors before operation

Code Explanation Resetting method [ I ] Input check No.

[O] Output check code

E-30 EMERGENCY STOP switch was

pressed.

Release the EMERGENCY STOP

switch, and then press the RESET key. [ I ] 17,18

E-32 Machine head is tilted back. Turn off the power. [ I ] 19

E-35 Air pressure is insufficient. Turn off the power. -

E-36 Feed plate home position sensor is

OFF when it should be ON. Turn off the power. [ I ] 22

E-37 Feed plate left range sensor is OFF

when it should be ON. Turn off the power. [ I ] 23

[O] C-18

E-38 Feed plate right range sensor is OFF

when it should be ON. Turn off the power. [ I ] 24

[O] C-18

E-40 Needle up sensor is OFF when it

should be ON.

Turn the pulley by hand to raise the

needle bar to its highest position, and

then press the RESET key.

[ I ] 11

E-42 Cutter sensor is ON. Turn off the power. [ I ] 20

[O] C-06

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Code Explanation Resetting method [ I ] Input check No.

[O] Output check code

E-45 Lower thread trimming OFF sensor is

OFF. Turn off the power. [ I ] 21

[O] C-04

E-50 X home position sensor is OFF when

it should be ON. Turn off the power. [ I ] 14

E-51 Y home position sensor is OFF when

it should be ON. Turn off the power. [ I ] 15

E-52 θ home position sensor is OFF when it

should be ON. Turn off the power. [ I ] 16

E-59 Sewing data error Turn off the power. -

3. Errors during operation

Code Explanation Resetting method [ I ] Input check No.

[O] Output check code

E-60 EMERGENCY STOP switch was

pressed.

Release the EMERGENCY STOP

switch, and then press the RESET

key.

E-62 Machine head is tilted back. (Head

sensor is OFF.) Turn off the power. [ I ] 19

E-66 Feed plate home position sensor is

not activated within a specified time. Turn off the power. [ I ] 22

E-67 Feed plate left range sensor is not

activated within a specified time. Turn off the power. [ I ] 23

[O] C-18

E-68 Feed plate right range sensor is not

activated within a specified time. Turn off the power. [ I ] 24

[O] C-18

E-70 Needle up sensor is not activated

within a specified time. Turn off the power. [ I ] 11

[O] C-07

E-71 Needle down sensor is not activated

within a specified time. Turn off the power. [ I ] 12

[O] C-07

E-72 Cutter sensor is not activated within a

specified time. Turn off the power. [ I ] 20

[O] C-06

E-75 Lower thread trimming OFF sensor is

not activated within a specified time. Turn off the power. [ I ] 21

[O] C-04

E-76 Needle up sensor is OFF during test

feeding. Turn off the power. [ I ] 11

E-77 Synch signal is not activated within a

specified time. Turn off the power. [ I ] 13

E-80

X home position sensor is not set to

ON within a specified time of

searching home position.

Turn off the power. [ I ] 14

E-81

Y home position sensor is not set to

ON within a specified time of

searching home position.

Turn off the power. [ I ] 15

E-82

θ home position sensor is not set to

ON within a specified time of

searching home position.

Turn off the power. [ I ] 16

E-89 Machine motor reverse operation error Turn off the power. [O] C-07

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4. Hardware errors

Code Explanation Resetting method [ I ] Input check No.

[O] Output check code

E-90 Communication error (against

machine motor CPU) Turn off the power. -

E-91 Machine motor running error Turn off the power. [ I ] 11 - 13

[O] C-07

E-92 Abnormal voltage error Turn off the power. -

E-93 Fan (large) lock error Turn off the power. -

E-94 Fan (small) lock error Turn off the power. -

E-95 X motor overcurrent error Turn off the power. -

E-96 Y motor overcurrent error Turn off the power. -

E-97 Control circuit board temperature rise

error Turn off the power. -

E-98 Power supply relay error Turn off the power. -

E-99 Power supply circuit board overcurrent

error Turn off the power. -

5. Errors when the special lapel cutting device is attached

Code Explanation Resetting method [ I ] Input check No.

[O] Output check code

E200

Hammer position sensor does not turn

ON when changing to the straight

buttonhole hammer.

Turn off the power. [ I ] 24

[ I ] C-19

E201

Hammer home position sensor does

not turn ON when changing to the

eyelet buttonhole hammer.

Turn off the power. [ I ] 23

[O] C-19

E202

Buttonhole sensor does not turn ON

when using a straight buttonhole

program.

Press the RESET key. [ I ] 22

E203

Buttonhole sensor does not turn OFF

when using an eyelet buttonhole

program.

Press the RESET key. [ I ] 22

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7-5. Troubleshooting

Code Countermeasure

E-00

E-30

1. Release the EMERGECY STOP switch.

2. Check if connector P3 (HEAD) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

3. With the power turned off, separate connectors P3 (HEAD), and check if continuity between the

following pairs of pins 1 to 3 in the connector on the harness is as follows:

• When the EMERGECY STOP switch is activated, between pins 1 and 2 is opened, and between

pins 2 and 3 is short-circuited.

• When the EMERGECY STOP switch is not activated, between pins 1 and 2 is short-circuited, and

between pins 2 and 3 is opened.

* If the result of continuity test is not acceptable in either case, replace the EMERGECY STOP

switch and its harness.

* Even if the result of continuity test is acceptable, harness may be broken or short-circuited. It may

appear when oscillation occurs.

4. If there is still an error even after replacing the EMERGECY STOP switch, replace the control circuit

board.

E-02

E-32

E-62

1. Return machine head to original position.

2. Adjust safety switch so that it is turned on when machine head is returned to its original position.

3. Check if connector P8 (EXINA) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

4. With the power turned off, separate connectors P8 (EXINA), and check if continuity between pins 1

and 2 in the connector on the harness is as follows:

• When machine head is raised, between pins 1 and 2 is opened.

• When machine head is in position, between pins 1 and 2 is short-circuited.

* If the result of continuity test is not acceptable in either case, replace the head safety switch and

its harness.

* Even if the result of continuity test is acceptable, harness may be broken or short-circuited. It may

appear when oscillation occurs.

5. If there is still an error even after replacing the head safety switch, replace the control circuit board.

E-03

1. Release the cloth presser switch. (Turn it off.)

2. Check if hand switch (foot switch) connector which is outside the control box is securely inserted.

3. Check if connector P19 (FOOT) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

4. With the power turned off, separate connectors P19 (FOOT), and check if continuity between pins 3

and 4 in the connector on the harness is as follows:

• When the cloth presser switch is activated, between pins 3 and 4 is short-circuited.

• When the cloth presser switch is not activated, between pins 3 and 4 is opened.

* If the result of continuity test is not acceptable in either case, replace the hand switch (or foot

switch) and its harness.

* Even if the result of continuity test is acceptable, harness may be broken or short-circuited. It may

appear when oscillation occurs.

5. If there is still an error even after replacing the hand switch (foot switch) harness (which is connected

to control circuit board and control box), replace the control circuit board.

E-04

1. Release the start switch. (Turn it off.)

2. Check if hand switch (foot switch) connector which is outside the control box is securely inserted.

3. Check if connector P19 (FOOT) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

4. With the power turned off, separate connectors P19 (FOOT), and check if continuity between pins 1

and 2 in the connector on the harness is as follows:

• When the start switch is activated, between pins 1 and 2 is short-circuited.

• When the start switch is not activated, between pins 1 and 2 is opened.

* If the result of continuity test is not acceptable in either case, replace the hand switch (or foot

switch) and its harness.

* Even if the result of continuity test is acceptable, harness may be broken or short-circuited. It may

appear when oscillation occurs.

5. If there is still an error even after replacing the hand switch (foot switch) harness (which is connected

to control circuit board and control box), replace the control circuit board.

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Code Countermeasure

E-05

E-35

1. Check whether the air pressure is insufficient.

2. Check if the circuit board DIP switch No.3 is set to ON.

* If you are not using the pressure sensor, an error will occur if this DIP switch is set to ON.

3. Check if pins 10 and 11 of the connector P1 (ORG) on the control circuit board is securely inserted.

E-06

E-36

E-66

1. Turn on the feed plate home position sensor (limit switch R) of the indexer. (Place the cloth feed bar

at the left position.)

2. Check and adjust the position of the feed plate home position sensor of the indexer. (Refer to the

instruction manual.)

3. Of connectors relayed to head harness, check if the harness for the feed plate home position sensor

is correctly attached to the connector for the θ-axis home position sensor. (The white harness should

be attached to pin 7, and the black one to pin 12. Refer to the instruction manual.)

* Check if there is a harness in the control box that is broken or short-circuited.

4. Check if connector P9 (EXINB) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

5. With the power turned off, separate connectors P9 (EXINB), and check if continuity between pins 10

and 11 in the connector on the harnesses is as follows:

• When feed plate home position sensor is activated, between pins 10 and 11 is short-circuited.

• When feed plate home position sensor is not activated, between pins 10 and 11 is opened.

* If the result of continuity test is not acceptable in either case, replace the feed plate home position

sensor and its harness.

* Even if the result of continuity test is acceptable, harness may be broken or short-circuited. It may

appear when oscillation occurs.

6. If there is still an error even after replacing the feed plate home position sensor and the sensor relay

cord (attached to the control circuit board and the relay connector), replace the control circuit board.

E-07

E-37

E-67

1. Make sure that the valve unit of the indexer is supplied with air or wiring is correct.

2. Check and adjust the position of the left driving sensor (limit switch L) of the indexer. (Refer to the

instruction manual.)

3. Of connectors relayed to head harness, check if the harness for the feed plate home position sensor

is correctly attached to the connector for the θ-axis home position sensor. (The white harness should

be attached to pin 10, and the black one to pin 15. Refer to the instruction manual.)

* Check if there is a harness in the control box that is broken or short-circuited.

4. Check if connector P9 (EXINB) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

5. With the power turned off, separate connectors P9 (EXINB), and check if continuity between pins 1

and 2 in the connector on the harnesses is as follows:

• When left driving sensor is activated, between pins 1 and 2 is short-circuited.

• When left driving sensor is not activated, between pins 1 and 2 is opened.

* If the result of continuity test is not acceptable in either case, replace the left driving sensor and its

harness.

* Even if the result of continuity test is acceptable, harness may be broken or short-circuited. It may

appear when oscillation occurs.

6. If there is still an error even after replacing the left driving sensor and the sensor relay cord (attached

to the control circuit board and the relay connector), replace the control circuit board.

E-09

1. Connect the specification harness that conforms to machine’s specification.

2. Check if all pins are inserted into the connector of the specification harness.

3. Check if the connector for the specification harness which is outside the control box is securely

inserted.

4. Check if connector P4 (TYPE) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

5. Replace the type cord (harness connected to control circuit board and the control box).

6. Replace the control circuit board with a new one.

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Code Countermeasure

E-10

E-40

E-76

1. Turn the pulley manually to set the needle to its highest position. (“UP” will appear on the display.)

2. Check if connector P2 (SYNCHRO) on the control circuit board is securely inserted and if any

harness is broken or short-circuited.

3. With connector P2(SYNCHRO) inserted into the PCB in the input check mode, check the voltage

across pins 4 and 5 from the harness as follows:

• Considering pin 5 as 0V (standard), measure the voltage of pin 4 while turning the pulley

manually. It is normal if the voltage is 0V with the needle at its highest position, and 4 – 5V

everywhere but that position.

* If the result is not acceptable, check how the magnet of the pulley is attached, and if it is correct,

replace the synchronizer.

* Even if the result is acceptable, the harness may be broken or short-circuited. It may appear when

oscillation occurs.

4. When there is no problem with the above, replace the control circuit board.

E-12

E-42

1. Position knife correctly.

2. Make sure that knife driving valve is supplied with air and wiring is correct.

3. Make sure that knife ON sensor and neighboring parts are attached correctly.

4. Check if connector P3 (HEAD) of the control circuit board is inserted and if any harness is broken or

short-circuited.

5. Replace knife ON sensor and its harness.

6. Replace the control circuit board with a new one.

E-15

E-45

E-75

1. Check if cylinder is in place. (Check if air is supplied normally, position is correct, nothing caught on

the cylinder, and so on.)

2. Check if connector P8 (EXINA) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

3. Replace lower thread trimming OFF sensor and its harness.

4. Replace the control circuit board with a new one.

E-26

1. Check if connector P20 (PER) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

2. Check if connector P2 (PER) on the power supply circuit board is securely inserted and if any

harness is broken or short-circuited.

3. Replace the power supply circuit board with a new one.

4. Replace the control circuit board with a new one.

E-27

1. Check if ROM chips of the control circuit board or panel circuit board are correctly inserted.

(Check position, orientation, lead clinching, etc.)

2. Replace the panel circuit board with a new one.

3. Replace the control circuit board with a new one.

E-28

1. Check if ROM chips of the control circuit board or panel circuit board are correctly inserted.

(Check position, orientation, lead clinching, etc.)

2. Check if connector P2 (MAIN) on the panel circuit board is securely inserted and if any harness is

broken or short-circuited.

3. Check if connector P18 (PANEL) on the control circuit board is securely inserted and if any harness

is broken or short-circuited.

4. Replace the panel circuit board with a new one.

5. Replace the control circuit board with a new one.

E-29

1. Make sure that ROM chips of the control circuit board are correctly inserted. (Check position,

orientation, lead clinching, etc.)

2. Replace the control circuit board with a new one.

E-38

E-68

1. Check if air is supplied to valve unit of the indexer or wiring is correct.

2. If the cloth feed bar of the indexer works correctly, skip to step 5 below. (This is because the place to

be checked is different if the failure is with the sensor or driving system.)

3. Check if the valve harness of the indexer is connected to the indexer relay cord and connector P21

(EXOUT) on the control circuit board.

* Check if there is no pin that is out of place in either of indexer relay connector and P21.

4. Check if feed plate works in output check.

5. Of connectors relayed to head harness, check if the harness for the right driving sensor (cylinder

sensor) is correctly attached to the connector for the θ-axis home position sensor. (The brown

harness should be attached to pin 4, the black one to pin 9, and the blue one to pin 14. Refer to the

instruction manual.)

* Check if there is no harness in the control box that is broken or short-circuited.

6. Check if connector P9 (EXINB) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

7. Replace the right driving sensor and its harness.

8. Replace the control circuit board with a new one.

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Code Countermeasure

E-50

1. Turn power off and then on again. Press start switch to search home position again.

2. Make sure that X-axis home position sensor and X-axis home position sensor magnet are correctly

attached.

3. Check if connector P1 (ORG) on the control circuit board is correctly inserted and if any harness is

broken or short-circuited.

4. Replace X-axis home position sensor and its harness.

5. Replace the control circuit board with a new one.

E-51

1. Turn power off and then on again. Press start switch to search home position again.

2. Make sure that Y-axis home position sensor and Y-axis home position sensor magnet are correctly

attached.

3. Check if connector P1 (ORG) on the control circuit board is correctly inserted and if any harness is

broken or short-circuited.

4. Replace Y-axis home position sensor and its harness.

5. Replace the control circuit board with a new one.

E-52

1. Turn power off and then on again. Press start switch to search home position again.

2. Make sure that θ-axis home position sensor and θ-axis home position sensor magnet are correctly

attached.

3. Check if the θ-axis home position sensor pulley is loosened.

4. Of connectors relayed to head harness, check if the harness for the θ-axis home position sensor is

correctly attached to the connector for the θ-axis home position sensor. (The brown harness should

be attached to pin 1, the black one to pin 6, and the blue one to pin 11. Refer to the instruction

manual.)

* Check if there is a harness in the control box that is broken or short-circuited.

5. Check if connector P9 (EXINB) on the control circuit board is correctly inserted and if any harness is

broken or short-circuited.

6. Replace the θ-axis home position sensor and its harness with a new one.

7. Replace the control circuit board with a new one.

E-59

1. Turn on the power again.

2. Make sure that ROM chips of the panel circuit board are correctly inserted. (Check position,

orientation, lead clinching, etc.)

3. Initialize memory.

4. Replace the panel circuit board with a new one.

E-60

1. This is not an error. This code indicates machine operation is being suspended due to emergency

stop.

2. Refer to the instruction manual, “Using the EMERGENCY STOP switch.” (Press the RESET switch

to return to home position, and the start switch to resume sewing.)

E-70

1. Turn the pulley manually to see if the upper shaft is not locked.

2. In input mode, turning the pulley manually, check the machine detects needle up signal. If not, refer

to E10. Even if it does, synchronizer harness may be broken or short-circuited. It may appear when

oscillation occurs.

3. With the power turned off, separate connectors P15 (DC300) on the control circuit board, and check

if between pins 1 and 2 in the connector on the board is short-circuited. If it is short-circuited, replace

the control circuit board. At this time, if fuse No.2 on the power supply circuit board has been blown,

replace it.

E-71 Refer to E70. (In input mode, check if the machine detects needle down signal.)

E-72

1. If the knife works correctly, refer to E12. If not, proceed the following steps to check the knife driving

system. (This is because the place to be checked is different if the failure is with the sensor or driving

system.)

2. Make sure that air is supplied to knife valve unit.

3. Check if there is a broken valve cord around valve unit.

4. Check if connector P4 (AIR) of the control circuit board is correctly inserted and if valve cord is

broken or short-circuited.

5. Replace valve cord with a new one.

6. Replace valve unit with a new one.

7. Replace the control circuit board with a new one.

7. SOFTWARE

RH-981A

125

Code Countermeasure

E-77 Refer to E70. (In input mode, check if the machine detects synchronizer signal.)

E-80

1. If X-axis pulse motor works, refer to E50. If not, proceed with the following steps to examine the

driving system of the X-axis pulse motor. (This is because the place to be checked is different if the

failure is with the sensor or driving system.)

2. With the power turned off, check if there is a loose screw in a belt or gear around the X-axis pulse

motor and that the feed bracket can move to the left and right.

3. Of the connectors relayed to the head harness, check if the connector for the X-axis pulse motor is

securely inserted and if any harness is broken or short-circuited.

4. Check if connector P7 (XPM) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

5. While E80 is displayed, measure the voltage across pins 5 and 7 of connector P12 (POWER)

without removing P12, from the harness, as follows:

• Considering pin 7 as 0V (standard), measure the voltage of pin 5. It is normal if the voltage is +

55V. (Be careful not to touch any other place when measuring voltage.)

* If the voltage is + 55V, the cause of the error is the X-axis pulse motor or its harness is broken.

* If the voltage is not + 55V, turn off the power, remove connector P12 (POWER), and then turn on

the power again, measure the voltage across pins 5 and 7 in the harness with connector P1

(POWER) inserted in the power supply circuit board in the same manner as above.

• If the voltage is not + 55V, replace the power supply circuit board.

* If the voltage is + 55V, the control circuit board or PMD circuit board for θ-axis may be damaged

or X-, Y-, or θ-axis pulse motor or its harness may be short-circuited.

E-81

1. If the Y-axis pulse motor works refer to E51. If not, proceed the following steps to examine the

driving system of Y-axis pulse motor. (This is because the place to be checked is different if the

failure is with the sensor or driving system.)

2. With the power turned off, check if there is a loose screw in a belt or gear around Y-axis pulse motor

and if the feed bracket can move back and forth.

3. Of the connectors relayed to the head harness, check if the connector for the Y-axis pulse motor is

securely inserted and if any harness is broken or short-circuited.

4. Check if connector P6 (YPM) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

5. While E81 is displayed, measure the voltage across pins 5 and 7 of connector P12 (POWER) on the

control circuit board without removing P12, from the harness, as follows:

• Considering pin 7 as 0V (standard), measure the voltage of pin 5. It is normal if the voltage is +

55V, (Be careful not to touch any other place when measuring voltage.)

* If the voltage is + 55V, the cause of the error is the Y-axis pulse motor or its harness is broken.

* If the voltage is not + 55V, turn off the power, remove connector P12 (POWER) from the control

circuit board, and then turn on the power again, and measure the voltage across pins 5 and 7 in

the harness with connector P1 (POWER) inserted in the power supply circuit board in the same

manner as above.

• If the voltage is not + 55V, replace the power supply circuit board.

* If the result is acceptable, the control circuit board or PMD circuit board for θ-axis may be

damaged or X-, Y-, or θ-axis pulse motor or its harness may be short-circuited.

E-82

1. If the θ-axis pulse motor works, refer to E52. If not, proceed the following steps to examine the

driving system of θ-axis pulse motor. (This is because the place to be checked is different if the

failure is with the sensor or driving system.)

2. With the power turned off, check if there is a loose screw in a belt or gear around θ-axis pulse motor

and if the feed bracket can move back and forth.

3. Of the connectors relayed to the head harness, check if the connector for the θ-axis pulse motor is

securely inserted and if any harness is broken or short-circuited.

4. Check if connectors P1 (RPM), P2 (DC55), and P3 (CONTROL) on the PMD circuit board for the θ-

axis are securely inserted and if any harness is broken or short-circuited.

5. Check if connectors P11 (HATOME) and P13 (DC55) on the control circuit board are securely

inserted and if any harness is broken or short-circuited.

6. While E82 is displayed, measure the voltage across pins 5 and 7 of connector P12 (POWER) on the

control circuit board without removing P12, from the harness, as follows:

• Considering pin 7 as 0V (standard), measure the voltage of pin 5. It is normal if the voltage is +

55V. (Be careful not to touch any other place when measuring voltage.)

* If the voltage is + 55V, the cause of the error is the θ-axis pulse motor or its harness is broken.

* If the voltage is not + 55V, turn off the power, remove connector P12 (POWER), and then turn on

the power again, and measure the voltage across pins 5 and 7 in the harness with connector P1

(POWER) inserted in the power supply circuit board in the same manner as above.

• If the voltage is not + 55V, replace the power supply circuit board.

* If the result is acceptable, the control circuit board or PMD circuit board for θ-axis may be

damaged or X-, Y-, or θ-axis pulse motor or its harness may be short-circuited.

7. SOFTWARE

RH-981A

126

Code Countermeasure

E-89

1. Check if the upper shaft motor wiring (U/V/W) is correct.

2. Check if connector P14 (UVW) on the control circuit board is inserted and that the harness-side

wiring is correct.

E-90

1. Check if connector P2 (MAIN) on the panel circuit board is securely inserted and if any connector is

broken or short-circuited.

2. Check if connector P18 (PANEL) on the control circuit board is securely inserted and if any

connector is broken or short-circuited.

3. Replace the panel circuit board with a new one.

4. Replace the control circuit board with a new one.

E-91 Refer to E70. (In input mode, check if the machine detects synchronizer signal.)

E-92

1. Make sure that power supply voltage is the same as the specification voltage.

2. If the conversion transformer is installed, check if terminals connections are correct.

3. Check if connector P20 (PER) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

4. Check if connector P2 (PER) on the power supply circuit board is securely inserted and if any

harness is broken or short-circuited.

5. Replace the power supply circuit board with a new one.

6. Replace the control circuit board with a new one.

E-93

1. Make sure that the large cooling fan is normally running.

2. Clean the large cooling fan. (Remove dust.)

3. Check if connector P10 (FAN-R) on the control circuit board is securely inserted and if any harness

is broken or short-circuited.

4. Replace the large cooling fan with a new one.

5. Replace the control circuit board with a new one.

E-94

1. Make sure that the small cooling fan is normally running.

2. Clean the small cooling fan. (Remove dust.)

3. Check if connector P25 (FAN-L) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

4. Replace the small cooling fan.

5. Replace the control circuit board with a new one.

E-95

1. With the power turned off, check if the feed bracket moves to the left and right.

2. Of the connectors relayed to the head harness, check if the connector for the X-axis pulse motor is

securely inserted and if any harness is broken or short-circuited.

3. Check if connector P7 (XPM) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

4. Replace the X-axis pulse motor with a new one.

5. Replace the control circuit board with new one.

E-96

1. With the power turned off, check if the feed bracket moves back and forth smoothly.

2. Of the connectors relayed to the head harness, check if the connector for the Y-axis pulse motor is

securely inserted and if any harness is broken or short-circuited.

3. Check if connector P6 (YPM) on the control circuit board is securely inserted and if any harness is

broken or short-circuited.

4. Replace the Y-axis pulse motor with a new one.

5. Replace the control circuit board with new one.

E-97

1. Make sure that the control box is normally ventilated.

2. Clean the filter of the air intake. (Remove dust.)

3. Clean the small and large cooling fans (Remove dust.)

4. Make sure that cooling fans are attached correctly.

• Large cooling fan: The wind blows toward the control circuit board and the PMD circuit board for

θ-axis.

• Small cooling fan: The wind blows in the direction that it can discharge the air in the control box.

E-98

1. Check if connectors P12 (POWER) and P13 (DC55) on the control circuit board are securely

inserted and if any harness is broken and short-circuited.

2. Check if connector P1 (POWER) on the power supply circuit board is securely inserted and if any

harness is broken or short-circuited.

3. Check if connector P2 (DC55) on the PMD circuit board for θ-axis is securely inserted and if any

harness is broken or short-circuited.

4. Replace the power supply circuited board with a new one.

5. Replace the PMD circuit board for θ-axis with a new one.

6. Replace the control circuit board with a new one.

E-99 1. Refer to E95, E96 and E98.

2. Replace the power supply circuit board with a new one.

7. SOFTWARE

RH-981A

127

Code Countermeasure

E-200

1. Check if air is supplied to valve unit of the special lapel cutting device or wiring is correct.

2. Of connectors relayed to head harness, check if the harness for the hammer position sensor is

correctly attached to the connector for the hammer position sensor.

* Check if there is no harness in the control box that is broken or short-circuited.

3. Check if connectors P9 (EXINB) and P21 (EXOUT) on the control circuit board are securely

inserted and if any harness is broken or short-circuited.

E-201

1. Check if air is supplied to valve unit of the special lapel cutting device or wiring is correct.

2. Of connectors relayed to head harness, check if the harness for the hammer home position sensor

is correctly attached to the connector for the hammer home position sensor.

* Check if there is no harness in the control box that is broken or short-circuited.

3. Check if connectors P9 (EXINB) and P21 (EXOUT) on the control circuit board are securely

inserted and if any harness is broken or short-circuited.

E-202

E-203

1. Press the RESET key.

2. Of connectors relayed to head harness, check if the harness for the buttonhole sensor is correctly

attached to the connector for the buttonhole sensor.

* Check if there is no harness in the control box that is broken or short-circuited.

7. SOFTWARE

RH-981A 128

7-6. Control circuit block diagram (1)

3842Q

7. SOFTWARE

RH-981A 129

7-7. Control circuit block diagram (2)

3843Q

SERVICE MANUAL

Printed in Japan RH-981

I3080846H

2003.10. H (1)

http://www.brother.com/

ACE&EASTMAN Rh 981A Service I3080846H User Manual

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