Brother Innovis 4500 D Manual

							ADJUSTING THE SCREEN
Appendix
239
8
c
cc cUsing the included touch pen, lightly touch 
the center of each +, in order from 1 to 5. 
* If the buzzer sounds one time after you press 
number 5, the operation is finished. If the buzzer 
sounds twice, there was an error. In this case, repeat 
the steps above. 
d
dd dTurn the main power to OFF, then turn it 
back to ON.  Note

Only use the included touch pen to touch the 
screen. Do not use a mechanical pencil, pin, 
or other sharp object. Do not press strongly 
on the screen. Otherwise, damage may 
result. 
Note
If you finish the screen adjustment and the 
screen still does not respond, or if you can-
not do the adjustment, contact your autho-
rized dealer. 
+1 +4
+2 +5
+3 
						

							TROUBLESHOOTING
240
TROUBLESHOOTING
If you have a minor problem with your sewing machine, check the following solutions. If the solutions 
suggested do not correct the problem, contact your authorized dealer. You can also press   then  for advice about minor sewing problems during sewing. Press   at any time to return to 
the original screen. 
ProblemCauseSolutionPage
Upper thread breaks Machine is not threaded correctly (used the  wrong spool cap, spool cap is loose, the thread 
did not catch the needle bar threader, etc.) Rethread the machine correctly.
29
Thread is knotted or tangled. Rethread upper and lower thread. 26, 29
Thread is too thick for the needle. Check needle and thread combinations. 41
Upper thread tension is too strong. Adjust the thread tension. 50, 174
Thread is twisted. Use scissors, etc., to cut the twisted thread 
and remove it from the race, etc. —
Needle is turned, bent or the point is dull. Replace the needle. 39
Needle is installed incorrectly. Reinstall the needle correctly. 39
There are scratches near the hole of the needle 
plate. Replace the needle plate, or consult your 
authorized dealer. 65
There are scratches near the hole in the presser 
foot. Replace the presser foot, or consult your 
authorized dealer. 37
There are scratches on the race. Replace the race, or consult your authorized 
dealer. 236
Bobbin thread breaks Bobbin is set incorrectly. Reset the bobbin thread correctly.26
There are scratches on the bobbin or it doesn ’t 
rotate properly. Replace the bobbin.
26
Thread is twisted. Use scissors, etc. to cut the twisted thread 
and remove it from the race, etc. —
Skipped stitches Machine is threaded incorrectly. Check the steps for threading the machine 
and rethread it correctly. 29
Using improper needle or thread for the 
selected fabric. Check the 
“Fabric/Thread/Needle 
Combination ” chart. 41
Needle is turned, bent or the point is dull. Replace the needle. 39
Needle is installed incorrectly. Reinstall the needle correctly. 39
Needle is defective. Replace the needle. 39
Dust or lint has collected under the needle plate. Remove the dust or lint with the brush. 236
Fabric puckers  There is a mistake in the upper or bobbin  threading.  Check the steps for threading the machine 
and rethread it correctly. 26, 29
Spool cap is set incorrectly.  Check the method for attaching the spool cap, 
then reattach the spool cap.  29
Using improper needle or thread for the 
selected fabric.  Check the 
“Fabric/Thread/Needle 
Combination ” chart.  41
Needle is turned, bent or the point is dull.  Replace the needle. 39
Stitches are too long when sewing thin fabrics.  Shorten the stitch length.  49
Thread tension is set incorrectly.  Adjust the thread tension.  50, 174
Wrong presser foot.  Use the correct presser foot. “STITCH SETTING 
CHART ”
High-pitched sound 
while sewing  Dust or lint is caught in the feed dogs.  Remove the dust or lint. 
236
Pieces of thread are caught in the race.  Clean the race.  236
Upper threading is incorrect.  Check the steps for threading the machine 
and rethread the machine.  29
There are scratches on the race.  Replace the race, or consult your authorized 
dealer.  236
Cannot thread the 
needle  Needle is not in the correct position. 
Press the “Needle Position”  button to raise the 
needle.  3
Threading hook does not pass through the eye 
of the needle.  Press the 
“Needle Position”  button to raise the 
needle.  3
Needle is installed incorrectly.  Reinstall the needle correctly.  39 
						

							TROUBLESHOOTING
Appendix
241
8
Cannot lower the 
presser foot with the 
presser foot leverPresser foot was raised using the “Presser Foot 
Lifter” button.
Press the “Presser Foot Lifter” button to lower 
the presser foot. 3
Thread tension is 
incorrect  Upper threading is incorrect. 
Check the steps for threading the machine 
and rethread the machine.  29
Bobbin is set incorrectly.  Reset the bobbin. (If needle plate was 
removed. reinstall needle plate and tighten 
screws prior to installing bobbin case.) 26
Using improper needle or thread for the 
selected fabric.  Check the “Fabric/Thread/Needle 
Combination” chart.  41
Presser foot holder is not attached correctly.  Reattach the presser foot holder correctly.  38
Thread tension is set incorrectly.  Adjust the thread tension.  50, 174
Character pattern 
does not turn out  Wrong presser foot was used.
Attach the correct presser foot. “STITCH SETTING 
CHART”
Pattern adjustment settings were set incorrectly.  Revise the pattern adjustment settings.  121
Did not use a stabilizer material on thin fabrics 
or stretch fabrics.  Attach a stabilizer material. 
120
Thread tension is set incorrectly.  Adjust the thread tension.  50, 174
Embroidery pattern 
does not sew out 
correctly  Thread is twisted. 
Use scissors, etc., to cut the twisted thread 
and remove it from the race, etc.  —
Fabric was not inserted into the frame correctly 
(fabric was loose, etc.).  If the fabric is not stretched tight in the frame, 
the pattern may turn out poorly or there may 
be shrinkage of the pattern. Set the fabric into 
the frame correctly.  159
Stabilizing material was not attached.  Always use stabilizing material, especially  with stretch fabrics, lightweight fabrics, fabrics 
with a coarse weave, or fabrics that often 
cause pattern shrinkage. See your authorized 
dealer for the proper stabilizer. 157
There was an object placed near the machine, 
and the carriage or embroidery frame hit the 
object during sewing.  If the frame bumps something during sewing, 
the pattern will turn out poorly. Do not place 
anything in the area where the frame may 
bump it during sewing.  165
Fabric outside the frame edges interferes with 
the sewing arm, so the embroidery unit cannot 
move.  Reinsert the fabric in the embroidery frame so 
that the excess fabric is away from the sewing 
arm, and rotate the pattern 180 degrees. 159
Fabric is too heavy, so the embroidery unit 
cannot move freely.  Place a large thick book or similar object 
under the arm head to lightly lift the heavy 
side and keep it level. —
Fabric is hanging off the table.  If the fabric is hanging off the table during 
embroidery, the embroidery unit will not move 
freely. Place the fabric so that it does not hang 
off the table or hold the fabric to keep it from 
dragging.  165
Fabric is snagged or caught on something.  Stop  the machine and place the fabric so that 
it does not get caught or snagged.  —
Embroidery frame was removed during sewing 
(for example, to reset the bobbin). The presser 
foot was bumped or moved while removing or 
attaching the embroidery frame, or the 
embroidery unit was moved.  If the presser foot is bumped or the 
embroidery unit is moved during sewing, the 
pattern will not turn out. Be careful when 
removing or reattaching the embroidery frame 
during sewing.  170
Loops appear on the 
surface of the fabric 
when embroidering The thread tension is incorrectly set.
Adjust the thread tension. 174
The tension of the upper thread is incorrectly set 
for the combination of the fabric, thread and 
pattern being used. Use the embroidery needle plate cover.
165
The combination of the bobbin case and bobbin 
thread is incorrect. Change the bobbin case or bobbin thread so 
that the correct combination is used. 165
ProblemCauseSolutionPage 
						

							TROUBLESHOOTING
242
Needle breaks  Needle is installed incorrectly. Reinstall the needle correctly.39
Needle clamp screw is not tightened.  Tighten the needle clamp screw. 40
Needle is turned or bent.  Replace the needle.  39
Using improper needle or thread for the 
selected fabric.  Check the 
“Fabric/Thread/Needle 
Combination ” chart.  41
Wrong presser foot was used.  Use the recommended presser foot. 
“STITCH SETTING 
CHART ”
Upper thread tension is too strong.  Adjust the thread tension setting. 50, 174
Fabric is pulled during sewing.  Do not pull the fabric during sewing.  —
Spool cap is set incorrectly.  Check the method for attaching the spool cap, 
then reattach the spool cap.  29
There are scratches around the holes in the 
needle plate.  Replace the needle plate, or consult your 
authorized dealer.  65
There are scratches around the hole(s) in the 
presser foot.  Replace the presser foot, or consult your 
authorized dealer.  37
There are scratches on the race.  Replace the race, or consult your authorized 
dealer.  236
Needle is defective.  Replace the needle.  39
Fabric does not feed 
through the machine  Feed dogs are set in the down position.  Use the feed dog position lever to raise the 
feed dogs.  85
Stitches are too close together.  Lengthen the stitch length setting. 49
Wrong presser foot was used.  Use the correct presser foot.
“STITCH SETTING 
CHART ”
Needle is turned, bent or the point is dull.  Replace the needle.  39
Thread is entangled.  Cut the entangled thread and remove it from 
the race.  —
Machine does not 
operate  There is no pattern selected. 
Select a pattern. 59, 116, 149, 199
“ Start/Stop”  button was not pushed.  Press the “Start/Stop”  button.  3
Main power switch is not turned on.  Turn the main power to ON.  10
Presser foot is not lowered.  Lower the presser foot.  3
“ Start/Stop”  button was pushed with the foot 
controller attached.  Remove the foot controller, or use the foot 
controller to operate the machine.  45
Speed control lever is set to control the zigzag 
stitch width.  Use the foot controller instead of the 
“Start/
Stop”  button to operate the machine.  45
All keys and buttons have been locked by  . Press 
 to unlock all keys and 
buttons. 37, 39
Embroidery unit does 
not operate  There is no pattern selected. 
Select a pattern.  149, 199
Main power switch is not turned on.  Turn the main power to ON.  10
Embroidery unit is not attached correctly.  Reattach the embroidery unit correctly.  146
Embroidery frame was attached before the unit 
was initialized.  Perform the initialization process correctly. 
146
LCD display is difficult 
to see  LCD contrast is not properly adjusted.  Adjust the LCD contrast. 
19, 238
Nothing happens, 
even if the LCD 
display is pressed  The  screen  has  been  locked. 
Press either of the following keys to unlock the 
screen.   —
ProblemCauseSolutionPage
 CAUTION

This machine is equipped with a thread detection device. If the  “Start/Stop” button is pushed before the 
upper threading is done, the machine will not operate properly. Also, depending on the pattern selected, 
the machine may feed the fabric even if the needle is raised. This is due to the needle bar release 
mechanism. At these times, the machine will make a sound different from that made during normal 
sewing. This is not the sign of a malfunction. 
 If the power is disconnected during sewing:
Turn the main power to OFF and unplug the machine. 
If you restart the machine, follow the instructions for operating the machine correctly.  
						

							ERROR MESSAGES
Appendix
243
8
ERROR MESSAGES
If the machine is not properly set and the “Start/Stop” button or the “Reverse/Reinforcement Stitch” button 
is pressed, or if the operation procedure is incorrect, the machine does not start. An alarm sounds and an 
error message is displayed on the LCD. If an error message displays, follow the instructions in the 
message. 
Below is an explanation of 55 error messages. Refer to these when necess\
ary (if you press   or do 
the operation correctly while the error message is displayed, the message disappears). 
 CAUTION
Be sure to rethread the machine. If you press the  “Start/Stop” button without rethreading the machine, 
the thread tension may be wrong or the needle may break and cause injury. 
This message is displayed when 
the motor locks due to tangled 
thread or for other reasons 
related to thread delivery.  This message is displayed if the 
 is touched when 
an unusable embroidery card is 
inserted. 
This message is displayed when 
a button, such as the  “Start/Stop”  
button, is pushed while the 
presser foot is raised. This message is displayed when 
there is no stitch or embroidery 
pattern selected and the 
“Start/
Stop”  button or the  “Reverse/
Reinforcement Stitch ” button is 
pressed. 
This message is displayed when 
the upper thread is broken or not 
threaded correctly, and the 
“ Start/Stop”  button or the 
“ Reverse/ Reinforcement Stitch ” 
button is pressed.  This message is displayed when 
the “
Reverse/Reinforcement 
Stitch ” button is pushed while the 
embroidery unit is attached.
This message is displayed when 
the   is touched 
without an embroidery card 
inserted.  This message is displayed when 
you try to combine more than 71 
patterns.  
						

							ERROR MESSAGES
244
This message is displayed when 
the patterns you are editing take 
up too much memory, or if you 
are editing too many patterns for 
the memory. This message is displayed when 
the embroidery unit is attached 
and the power is turned on with 
the needle in the down position. 
This message is displayed when 
the  “Start/Stop ” button is pushed 
to sew Utility stitches or 
Character/Decorative stitches 
while the foot controller is 
connected. (This message does 
not appear when embroidering.) This message is displayed when 
the buttonhole lever is up, a 
buttonhole stitch is selected, and 
the “
Start/ Stop”  button or 
“ Reverse/Reinforcement Stitch ” 
button is pushed. 
This message is displayed when 
the  “Start/ Stop”  button is pushed 
while the machine is in 
embroidery edit mode and a 
pattern is being edited.  This message is displayed when 
there are too many characters 
and the curved character 
configuration is impossible. 
This message is displayed when 
a key on the LCD display is 
touched while the needle is in 
the down position.  This message is displayed when 
the machine is in embroidery 
mode and the combined 
character pattern is too large for 
the embroidery frame. You can 
rotate the pattern 90 degrees 
and continue combining 
characters. 
This message is displayed when 
the buttonhole lever is down, a 
stitch other than a buttonhole is 
selected, and the  “Start/ Stop”  
button or the “ Reverse/
Reinforcement Stitch ” button is 
pushed.  This message is displayed when 
the machine is in embroidery 
mode, and the character pattern 
combination is too large to fit in 
the embroidery frame.  
						

							ERROR MESSAGES
Appendix
245
8
This message is displayed when 
the machine is in embroidery 
mode and the small frame is 
attached, and the selected 
pattern does not fit in the small 
frame. This message is displayed when 
the bobbin is being wound, and 
the motor locks because the 
thread is tangled, etc. 
This message is displayed when, 
with the machine in embroidery 
mode and the small embroidery 
frame or medium embroidery 
frame attached, the selected 
pattern is larger than the 
embroidery area of the medium 
embroidery frame.  This message is displayed when 
the bobbin thread is running out. 
This message is displayed when, 
with the machine in embroidery 
mode and the small embroidery 
frame, medium embroidery 
frame or large embroidery frame 
attached, the selected pattern is 
larger than the embroidery area 
of the large embroidery frame.  This message is displayed when 
the embroidery unit is initializing. 
This message is displayed when 
the machine is in embroidery 
mode and the embroidery unit 
tries to initialize while the 
embroidery frame is attached.  This message is displayed when 
the memory is full and the stitch 
or pattern cannot be saved. 
This message is displayed when 
the machine is ready to sew an 
embroidery pattern, and the 
“ Start/Stop”  button is pushed 
while the embroidery frame is 
not attached.  This message is displayed when 
the machine is retrieving a 
previously saved pattern while in 
embroidery edit mode.  
						

							ERROR MESSAGES
246
This message is displayed when, 
after selecting a pattern, , , , 
or   is pressed and the 
pattern is about to be deleted.  This message is displayed when 
the foot controller is pressed 
while the embroidery unit is 
attached and machine is set up 
for embroidering.
This message is displayed when 
the speed control lever is set to 
control the zigzag stitch width, 
and the “ Start/ Stop ” button is 
pushed. Use the foot controller 
to operate the machine.  This message is displayed when 
there is a possibility that the data 
for the selected pattern is 
corrupted.
This message is displayed when 
the machine is in embroidery edit 
mode, and you try to use an 
editing function when the pattern 
is not completely within the red 
outline.  This message is displayed when 
 is pressed when 
changing thread colors.
This message is displayed when 
you try to save a copyright 
protected pattern to USB media/
Computer. According to 
copyright laws, patterns that are 
illegal to reproduce or edit 
cannot be saved to USB media 
or computer. If this message 
displays, save the pattern in the 
machine ’s memory.  This message is displayed when 
the feed dogs are raised while 
the Embroidery or Embroidery 
Edit screen is displayed.
This message is displayed when 
the machine is in twin needle 
mode and a pattern that cannot 
be sewn with the twin needle is 
selected. This message is displayed when 
either   or   is 
pressed when the feed dogs are 
lowered. 
						

							ERROR MESSAGES
Appendix
247
8
This message is displayed when 
the “Start/Stop”  button is pushed 
and the machine is in 
embroidery mode, but the 
embroidery unit is not attached. This message is displayed while 
the USB media is transmitting.
This message is displayed when 
you try to recall or save a pattern 
while no USB media is loaded. This message is displayed when 
the memory is full and a pattern 
must be deleted.
This message is displayed when 
you try to use incompatible 
media. This message is displayed when 
the 
“Presser Foot Lifter ” button is 
pushed while the presser foot 
lever is raised/the needle is 
lowered.
This message is displayed when 
you attempt to select a pattern 
after the USB media in which the 
pattern is saved has been 
changed. This message is displayed if 
some malfunction occurs.
This message is displayed when 
an error occurs with the USB 
media. This message is displayed when 
you try to sew with a stitch other 
than a middle needle position 
stitch while the single-hole 
needle plate is installed.
This message is displayed when 
the needle plate is removed with 
the machine on or when the 
machine is turned on in the 
embroidery or embroidery edit 
mode. 
						

							ERROR MESSAGES
248

Alarm Sounds 
If the operation procedure was correct, the machine 
will beep once. If the operation procedure was 
incorrect, the machine will beep twice or four times. 
This message is displayed when 
replacing the embroidering 
bobbin thread.
This message is displayed when 
rotating a saved combined 
pattern in the Embroidery 
screen.
This message is displayed when 
you try to use incompatible USB 
media.
This message is displayed when 
it seems that the upper thread 
has not been threaded correctly.
This message is displayed when 
 is pressed (the 
presser foot is raised).This message is displayed when 
the automatic needle threading 
button is pushed while twin 
needle sewing is set.
This confirmation message 
appears after the machine is 
turned on and the carriage of the 
embroidery unit has moved to its 
initial position.
Memo
If you want to turn the alarm off, press  . See page 16 for more details.