Brother DH4-B981 User Manual

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

Brother DH4-B981 Specifications

General

Brand	Brother
Model	DH4-B981
Category	Sewing Machine
Language	English

Summary

DH4-B981 Instruction Manual

Introduction and Safety Precautions

Please read this manual before using the machine for quick reference.

SAFETY INSTRUCTIONS

Safety Indications and Their Meanings

Explains DANGER, CAUTION terms and warning symbols used in the manual and on the machine.

Notes on Safety

Environmental Requirements

Details ambient temperature, humidity, sunlight, and electrical noise considerations for operation.

Installation Safety Precautions

Covers qualified technician, securing cords, grounding, and electrical work for safe installation.

CAUTION

Sewing Safety Precautions

Advice for operators, protective gear, turning off power during specific tasks like threading or needle replacement.

Cleaning Safety Precautions

Safety during cleaning, handling oil and grease, and keeping oil out of reach of children.

Maintenance and Inspection Safety

Procedures for maintenance, using qualified technicians, and ensuring safety devices are installed.

Warning Labels

Hazardous Voltage Warning

Instructs to turn off power and wait before opening covers to prevent severe injury.

Moving Parts Warning

Warns about moving parts and advises using safety devices to prevent injury.

Ground Connection Warning

Emphasizes secure ground connection for safety and correct machine operation.

NAMES OF EACH PART

Machine Components Identification

Lists and labels major parts of the sewing machine for operational reference.

SPECIFICATIONS

Model Specifications

Details specifications for different DH4-B981 models like speed, stitch length, and dimensions.

Fly Indexer Specifications (-52)

Specifics for fly indexer models including max. hole spacing and vertical/horizontal margins.

SPECIFICATIONS

Optional Parts

Lists available optional parts for the DH4-B981 machine, such as select switch and foot switch.

BAS-PC/300 Software

Describes programming software for pattern sewer and its system requirements.

SPECIFICATIONS

Replacement Parts List for Specification Changes

Lists parts needed to change between L1-L7 specifications for -02 and -52 models.

INSTALLATION

Table Processing Diagram

Shows dimensions and hole placements for the work table required for machine installation.

INSTALLATION

Installing the Motor

Step-by-step guide for mounting the motor onto the work table with cushions and plates.

INSTALLATION

Installing the Motor Pulley

Instructions for mounting the motor pulley onto the motor shaft, aligning key grooves.

Installing the Control Box

Steps for securing the control box to the work table using nuts, washers, and bolts.

INSTALLATION

Installing the Machine Head

Procedures for placing and securing the machine head onto the work table with base cushions.

Raising and Lowering the Machine Head

Steps to safely adjust the machine head position during installation using support levers.

INSTALLATION

Installing the Oil Container

Steps to mount the oil container to the dust oiler support on the bed base.

Tightening the V-belt

Instructions for V-belt tension adjustment and checks for proper deflection.

INSTALLATION

Installing the Spool Stand

Steps for assembling and attaching the spool stand to the rear right corner of the work table.

Installing the Hand Switch

Guide for mounting the hand switch onto the work table using screws.

Installing the Air Unit and Valve Unit

Instructions for connecting air units and valve assemblies to the work table.

INSTALLATION

Connecting the Wiring

Routing and connecting electrical cables and air tubes from machine to control box via cable holes.

INSTALLATION

Connections Inside the Control Box

Detailed wiring connections and connector assignments within the control box for machine head and panel.

INSTALLATION

Connecting the Motor Cables

Steps for connecting motor power and ground cables to the terminal block.

Connecting the Air Tubes

Guide for connecting air hoses to specific solenoid valves based on machine specification.

INSTALLATION

Securing the Cables

Procedures for routing and securing various cables using cable holders and screws.

INSTALLATION

Installing the Air Tubes

Connecting air tubes from the compressor to the air unit under the work table.

Adjusting the Air Pressure

Steps to set main regulator and knife pressure regulators for optimal cutting performance.

INSTALLATION

Connecting the Power Cord

Instructions for attaching the plug and connecting the main power cord to the supply.

INSTALLATION

Installing the Select Switch (Option)

Steps for installing the optional select switch for program selection on the control box.

Installing the Foot Switch (Option)

Guide for connecting the optional foot switch to the control box connector.

INSTALLATION

Installing the Indexer (Option) - Main Unit

Detailed steps for installing the indexer main unit, connecting air tubes and parts.

INSTALLATION

Installing the Upper Thread Presser

Instructions for mounting the upper thread presser component and adjusting its height.

Replacing the Plate Presser and Presser Plate

Steps for replacing presser components for different settings or specifications.

Installing the Valve Unit

Guide for mounting the valve unit and connecting air tubes to the unit.

INSTALLATION

Connecting the Connectors

Detailed steps for connecting various electrical connectors, limit switches, and sensors.

INSTALLATION

Connecting the Air Tubes

Connecting specific air tubes to solenoid valve types for proper pneumatic operation.

Securing the Air Tubes and Cables

Routing and securing air tubes and cables with necessary slack to allow for movement.

INSTALLATION

Installing the Hand Start Switch

Steps for mounting the hand start switch support plate and the hand start switch.

LUBRICATION

Adding Oil

Instructions for filling arm and bed base oil tanks to the correct level using sight glass.

LUBRICATION

Oiling the Looper, Spreader and Looper Base

Detailed steps for oiling various moving parts for proper function and preventing wear.

CORRECT USE

Initializing Settings

Procedure to reset all machine settings to their default factory values after power on.

Changing Lower Thread and Gimp Thread Trimming

How to enable or disable thread trimming functions via DIP switch C No. 4.

CORRECT USE

Installing the Needle

Step-by-step guide for correctly installing a new needle, ensuring proper orientation.

Threading the Upper Thread

Instructions for properly threading the upper thread through the machine guides and tension discs.

CORRECT USE

Threading the Lower Thread

Instructions for properly threading the lower thread through the machine components.

CORRECT USE

Threading the Gimp

Instructions for properly threading the gimp thread through the machine components.

Setting the Material

How to position material and adjust cloth guides for the sewing margin.

CORRECT USE

Setting Material (Fly) Position

Adjusting cloth guides for precise placement of fly material according to specifications.

Cloth Setting Position

Details on setting the left and horizontal cloth positions for proper operation.

CORRECT USE

Setting Cloth Feed Plate (L) Position (-52 specs)

Adjusting feed plate position based on buttonhole spacing and number of holes.

CORRECT USE

Replacing the PROMs

Guide for replacing machine PROMs, ensuring correct orientation and matching numbers.

USING THE OPERATION PANEL

Panel Switch and Indicator Names

Identifies and describes controls and indicators on the operation panel and select switch.

USING THE OPERATION PANEL

Setting the Buttonhole Length

How to set the desired buttonhole length using the panel's up/down switches.

Turning Cutting On and Off

Controls for activating or deactivating the knife cutting function via the KNIFE switch.

USING THE OPERATION PANEL

Setting Stitch Pitch

Adjusting stitch pitch from 0.9-1.8mm using Panel DIP switch A.

Setting Number of Eyelet Stitches

Setting stitch count for eyelets via Panel DIP switch A, based on standard stitch count.

USING THE OPERATION PANEL

Setting Taper Bar Tacking Length

Adjusting tacking length from 4-10mm via Panel DIP switch A.

Setting Eyelet Shape

Choosing eyelet cutting patterns (hole, straight) via Panel DIP switch B.

USING THE OPERATION PANEL

Setting Sewing Speed

Adjusting machine sewing speed from 1,400-2,000 rpm via Panel DIP switch B.

USING THE OPERATION PANEL

Setting the Mode

Selecting feed, manual, or automatic sewing modes via Panel DIP switch C.

Setting Panel Protection

Enabling or disabling parameter changes and cutting settings via Panel DIP switch C.

Setting Cloth Position (-52 specs)

Adjusting cloth setting positions (left/horizontal) via Panel DIP switch C.

USING THE OPERATION PANEL

Setting Number of Eyelet Buttonholes (-52 specs)

Setting buttonhole count (3-6) via Panel DIP switch C for -52 specifications.

Setting Home Position Start Cycles

Reducing cycle time by setting home position start cycles (0-9, A) via panel controls.

USING THE OPERATION PANEL

Using the Select Switch (Option)

Selecting programs and changing settings like stitch length and cutting with the optional select switch.

USING THE OPERATION PANEL

Using the Memory Switch

Storing and recalling settings using the memory switch function for various parameters.

USING THE OPERATION PANEL

List of Error Codes

Explains error codes appearing on the display and their resetting methods for troubleshooting.

USING THE OPERATION PANEL

List of Error Codes (Continued)

Continues the list of error codes for machine operation and hardware errors.

SEWING

Using the EMERGENCY STOP Switch

How to operate the emergency stop switch to halt machine operations and clear errors.

SEWING

Performing Sewing Operations

General steps for automatic sewing, including test sewing, setting stitch length, and using controls.

SEWING

Adjusting Thread Tension

Instructions for adjusting upper, lower, and spring thread tensions for optimal stitch quality.

SEWING

Needle and Knife Position

Relationship between knife position and eyelet shape for different cutting modes (before/after sewing).

Cutting Space Function

Explanation of the cutting space feature to prevent the seam from being cut by the knife.

SEWING

Single-pedal vs. Dual-pedal Operation

Switching between pedal operation modes for starting sewing and work clamp control.

SEWING

Using Feed Mode

Moving feed bracket and work clamp without sewing for checking relative positions.

Using Manual Mode

Moving needle/feed bracket one stitch at a time by hand for timing adjustments.

CLEANING AND MAINTENANCE

Cleaning Procedures

Daily cleaning steps for thread paths, feed bar, and checking the oil level.

CLEANING AND MAINTENANCE

Draining the Oil

Procedure for draining oil from the oil container when it is full.

Checking the Air Filter

How to check and drain air and water from the air filter.

STANDARD ADJUSTMENTS

Spreader and Looper Height Adjustment

Adjusting the height of spreaders and loopers for correct clearance and alignment.

STANDARD ADJUSTMENTS

Needle and Looper Timing Adjustment

Crucial timing adjustment for needle and looper alignment to ensure correct stitch formation.

STANDARD ADJUSTMENTS

Loop Stroke Adjustment

Adjusting the loop stroke distance based on material and thread used.

STANDARD ADJUSTMENTS

Needle Bar Height Adjustment

Setting the correct height for the needle bar relative to the looper.

Looper and Needle Clearance Adjustment

Setting the optimal gap between the looper tip and the needle.

STANDARD ADJUSTMENTS

Needle Guard Adjustment

Adjusting the needle guard position relative to the needle and looper.

Spreader Mounting Position Adjustment

Adjusting spreader mounting positions for proper alignment with the eye looper.

STANDARD ADJUSTMENTS

Spreader Timing Adjustment

Adjusting the timing of the spreaders relative to the needle bar position.

Needle Racking Width (Stitch Width) Adjustment

Adjusting the stitch width by sliding the adjustment screw vertically.

STANDARD ADJUSTMENTS

Changing Knife Cutting Length (Hammer Replacement)

How to change cutting length by replacing or grinding the hammer.

STANDARD ADJUSTMENTS

Adjusting Knife and Hammer Contact

Ensuring proper contact between knife and hammer for clean cutting by grinding.

STANDARD ADJUSTMENTS

Replacing the Knife

Steps for replacing the knife, ensuring correct number matching with eyelet shape.

Adjusting Cutting Pressure

Setting the correct air pressure for the knife pressure adjustment regulator.

STANDARD ADJUSTMENTS

Adjusting Cloth Opening Amount

Adjusting opening amount of work clamp plates for equal opening via feed bracket adjustment.

Measuring Opening Amount

Method to measure the work clamp plate opening amount using feed mode.

STANDARD ADJUSTMENTS

Adjusting Upper Thread Trimming

Adjusting the upper movable knife for proper thread trimming, cutting one thread strand.

Adjusting Lower Thread and Gimp Trimming

Adjusting lower thread and gimp trimming mechanisms for correct timing.

STANDARD ADJUSTMENTS

Adjusting Gimp Length After Trimming (-02, -52)

Setting gimp thread length after trimming via gimp thread guide adjustment.

Lower Thread Presser (-02, -52)

Function of the lower thread presser during upper thread trimming to hold thread end.

STANDARD ADJUSTMENTS

Auxiliary Clamp Arm (-02, -52)

Function of the auxiliary clamp arm for stable thread length after trimming.

Adjusting Cloth Feeding Speed (-52 specs)

Adjusting the speed of cloth feeding using A-side or B-side needle valves.

STANDARD ADJUSTMENTS

Adjusting Cloth Feed Bar Home Position (-52 specs)

Setting the home position for the cloth feed bar using the adjustment bolt.

STANDARD ADJUSTMENTS

Adjusting Indexer Hole Spacing (-52 specs)

Setting spacing for indexer holes using the feed movable block and stopper block.

Using the Set Screw Collar

Using set screw collars for easier switching of hole spacing settings between standard and large sizes.

STANDARD ADJUSTMENTS

Adjusting Limit Switch L Position (-52 specs)

Setting the position for limit switch L to turn on when the feed movable block touches the stopper.

Adjusting Limit Switch R Position (-52 specs)

Setting the position for limit switch R to turn on when the cloth feed bar is at the left position.

SUMMARY OF DIP SWITCHES

Front Panel DIP Switches

Overview and default settings of DIP switches located on the front panel.

SUMMARY OF DIP SWITCHES

Panel DIP Switch A Functions

Details on settings for Panel DIP Switch A, including stitch pitch and eyelet stitch counts.

Panel DIP Switch B Functions

Details on settings for Panel DIP Switch B, including cutting, offset, and sewing speed.

SUMMARY OF DIP SWITCHES

Panel DIP Switch C Functions

Details on settings for Panel DIP Switch C, including mode, cloth position, and number of holes.

SUMMARY OF DIP SWITCHES

Circuit Board DIP Switches C

Configuration and functions of DIP switches on the circuit board, controlling pedal and material type.

SUMMARY OF DIP SWITCHES

Circuit Board DIP Switch D

Details on settings for Circuit Board DIP Switch D, which are designated as spares.

TROUBLESHOOTING

Machine Head - Thread Breaks

Troubleshooting common causes and remedies for thread breakage issues in the machine head.

TROUBLESHOOTING

Machine Head - Skipped Stitches

Troubleshooting causes and remedies for skipped stitches in the machine head.

Machine Head - Needle Breaks

Troubleshooting causes and remedies for needle breakage issues in the machine head.

TROUBLESHOOTING

Knife Issues

Troubleshooting issues related to the knife not cutting or cutting improperly.