Brother BC800 Service Manual Download Page 89

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Main unit

Needle-presser unit

Z zigzag cam attachment

1. Attach the rubber

to the shaft

of the base holder assembly.

2. Apply a bead of EPNOC AP (N) 0 to the Z zigzag cam shaft

of the base

holder assembly.

3. Attach the Z zigzag cam

to the shaft

*Key point

• Align the mark on the Z zigzag cam

with the mark on the Z

pulse motor

4. Attach the retaining ring (E3).
5. Apply a light covering of EPNOC AP (N) 0 to the gear of the Z zigzag cam

and the circumference of the cam.

Start movie clip (CD-ROM version only)

Apply EPNOC AP (N) 0 to the Z zigzag cam shaft of
the base holder assembly

Bead

XC8387***

Apply EPNOC AP (N) 0 to the gear of the Z zigzag cam
and the circumference of the cam.

Light covering

XC8387***

Summary of Contents for BC800

Page 1: ...sembly 3 Assembly Please click on mark to start the movie The CD ROM version of service manual contains movie SERVICE MANUALFOR COMPUTERIZED SEWING MACHINE 10 2005 8 2016 LOW END COMPUTER SERIES c 2010 Brother Industries Ltd All rights reserved CONFIDENTIAL ...

Page 2: ......

Page 3: ...LIST of UPDATE RECORD Jul 2010 Date Added Models Contents CONFIDENTIAL Aug 2015 BC800 Aug 2016 FS50 ...

Page 4: ...ssembly removal 2 9 Button removal 2 9 Front panel and LCD removal 2 9 SV keytop removal 2 10 Base plate rubber removal 2 10 Upper cover thread guide removal 2 10 Main PCB assembly removal 2 11 Main PCB ASSY disassembly 2 11 Power PCB assembly removal 2 12 Power PCB ASSY disassembly 2 12 Inlet assembly removal 2 12 FC jack removal 2 13 Main motor assembly removal 2 13 Main motor ASSY disassembly 2...

Page 5: ...rank removal 2 28 Thread take up lever link removal 2 29 Needle bar assembly removal 2 29 Needle bar ASSY disassembly 2 29 Needle holder assembly removal 2 30 Needle holder ASSY disassembly 2 31 Presser bar removal 2 32 Z zigzag lever assembly removal 2 32 Z zigzag lever disassembly 2 33 Z zigzag camp removal 2 33 Shaft bushing removal 2 33 Presser foot lifter removal 2 33 Thread release lever rem...

Page 6: ...SSY assembly 3 20 Base cover attachment 3 20 Accessory table attachment 3 21 Feed unit 3 22 Lower shaft bushing attachment 3 23 Lower shaft assembly attachment 3 23 Timing pulley D attachment 3 23 FPM holder assembly attachment 3 24 FPM assembly 3 24 Vertical lever attachment 3 25 Feed adjuster assembly attachment 3 26 Feed adjuster ASSY assembly 3 26 Feed arm A assembly attachment 3 27 Feed arm B...

Page 7: ... adjustment for needle bar unit and rotary hook unit 4 7 Needle interference left right adjustment 4 8 Needle bar rise adjustment 4 9 Needle bar height adjustment 4 10 Needle interference adjustment 4 11 Adjust the needle thread block 4 12 Presser bar height and parallel adjustment 4 13 Inner rotary hook bobbin thread tension 4 14 Feed forward reverse adjustment 4 15 Bobbin winder uneven bobbin wi...

Page 8: ...ssy Power LE 5 6 BH switch assy 5 7 LED lamp left supply assy 5 8 Needle bar unit 5 9 Upper side of shutter cover 5 10 FC jack supply assy 5 11 6 Failure Investigation for Electronic Parts 6 1 Error message list 6 2 ...

Page 9: ...vi ...

Page 10: ...1 1 1 Outline of Mechanism Main Mechanisms 1 2 Driveline 1 3 Positions of electronic components 1 4 Control system block diagram 1 5 Operation of other electronic components 1 7 ...

Page 11: ...of Mechanism Main Mechanisms Sewing Machine Upper shaft mechanism Side feed mechanism Feed Rotary hook mechanism Bobbin winder mechanism Thread guide mechanism Needle bar Presser mechanism Needle threader mechanism ...

Page 12: ...r crank rod Needle bar block Needle bar Needle bar supporter assy Needle Pulley Upper shaft Needle bar crank Needle bar crank rod Thread take up counter weight Needle bar block Feed dog Outer rotary hook Timing pulley D Timing belt Pulley Upper shaft pulley Upper shaft Vertical adjusting screw F pulse motor Feed bar Feed arm A Lower shaft Feed arm b assy Lower shaft gear Feed module Timing pulley ...

Page 13: ...ronic components Sewing Machine Power PC assy Power switch Inlet assy LED Lamp SR assy SS VR PCB assy LCD PCB assy Main PCB assy NP sensor BH change switch assy LED Lamp SL assy PFSW S assy BH switch lever F pulse motor BWSW S assy Z pulse motor ...

Page 14: ...WER SUPPLY PCB SWITCHING POWER 30V 5V CIRCUIT MAIN MOTOR DRIVE CIRCUIT POWER SWITCH INLET BHSW BWSW CPU EEPROM RESET IC ZPM DRIVER ZPM FPM LED PCB LIGHT WHITE COLOR LED LEFT LED PCB LIGHT WHITE COLOR LED RIGHT FPM DRIVER NP SENSOR 2 NP SENSOR 1 SP SENSOR FOOT CONTROLLER JACK MAIN MOTOR LCD Z KEY X2 BK SW F KEY X2 PATTERN SELECTION X4 ...

Page 15: ...0V 5V CIRCUIT MAIN MOTOR DRIVE CIRCUIT POWER SWITCH INLET BHSW BWSW CPU EEPROM BUZZER RESET IC ZPM DRIVER ZPM FPM LED PCB LIGHT WHITE COLOR LED LEFT LED PCB LIGHT WHITE COLOR LED RIGHT FPM DRIVER NP SENSOR 2 NP SENSOR 1 SP SENSOR FOOT CONTROLLER JACK MAIN MOTOR LCD Z KEY X2 F KEY X2 PATTERN SELECTION X4 SSVR PCB SS SW BK SW NP SW SPEED VR ...

Page 16: ...rear ends of the buttonhole according to the BH presser and lever BH button hole lever switch This switch detects whether the BH lever is up or down NP sensor This sensor detects the drive timing for the pulse motor for zigzagging and feed the vertical stop position for the needle It detects the upper shaft angle of rotation using a shutter attached to the upper shaft and an optical sensor Speed s...

Page 17: ...1 8 ...

Page 18: ...2 1 2 Disassembly Main parts 2 2 Feed unit 2 19 Needle presser unit 2 27 With the CD ROM version click to start the movie clip ...

Page 19: ...2 2 Main parts location diagram Main unit ...

Page 20: ...Main unit Disassembly 1 Accessory table removal 1 Remove the accessory table 1 1 2 Bottom cover removal 1 Remove the screw 1 and then remove the base cover 1 2 Remove the screw 2 and then remove base cover A 2 1 1 1 2 ...

Page 21: ...eedle plate B assembly 2 1 2 3 1 Needle plate B ASSY disassembly 1 Remove the cutter cover 2 from the needle plate B assembly 1 2 Remove the spring plate 3 from the cutter cover 2 and then remove the NT lower thread cutter 4 3 Remove the 2 slide button hooks 5 and then remove the slide button 6 2 1 5 6 5 4 3 ...

Page 22: ... removal 1 Remove the screw 1 and then remove the face plate assembly 1 1 1 4 1 Face plate A ASSY disassembly 1 Remove the screw 1 and then remove the cutter cover assembly 1 2 Remove the CS retaining ring 2 and then remove the NT lower thread cutter 3 2 3 1 1 ...

Page 23: ...ve screws 1 front 1 pc 2 rear 1 pc and 3 rear 5 pcs and then remove the front cover Key point Disconnect the SSVR PCB lead wire connector 1 and the operation PCB lead wire connector 2 from the main PCB assembly 3 located near the front cover 1 2 1 3 3 3 2 ...

Page 24: ...ch spring 2 from the thread tension holder assembly 1 2 Remove the thread dial shaft 3 Key point Turn the dial clockwise until it stops 3 Remove the thread tension dial 4 and the thread tension plate assembly 5 4 Remove the spring 6 washer 7 tension disc washer 8 thread release plate 9 washer 7 tension disc B and then tension disc A A in this order from the caulking shaft of the thread tension hol...

Page 25: ...2 from thread take up holder B 1 3 Remove the thread take up spring 3 from the thread catching spring case 2 4 Remove the thread guide wire 4 from thread take up holder B 1 1 2 1 3 2 4 1 7 LED lamp removal 1 Disconnect the LED lamp connector 2 from the operation PCB 1 2 Remove the screw 1 and then remove the LED lamp 3 1 3 1 2 ...

Page 26: ...then remove the SSVR PCB assembly 3 Key point Remove the bands 2 locations securing the cords of the operation PCB assembly 1 and the SSVR PCB assembly 3 1 2 2 1 3 1 2 9 Button removal 1 Remove the 2 selecting buttons 1 2 Remove manual button A 2 and manual button B 3 3 Remove the SS button 4 the backstitching button 5 and the NP button 6 2 3 1 6 5 4 10 Front panel and LCD removal 1 Remove the 2 s...

Page 27: ... keytop 1 Key point Press the SV keytop hooks 2 locations from the inside of the front cover to remove the SV keytop 1 12 Base plate rubber removal 1 Remove the 2 base plate rubbers 1 1 13 Upper cover thread guide removal 1 Remove the upper cover thread guide 1 1 ...

Page 28: ...Disassembly 14 Main PCB assembly removal 1 Remove the 2 screws 1 2 Remove the main PCB assembly 1 1 1 14 1 Main PCB ASSY disassembly 1 Remove the screw 1 2 Remove the main PCB plate spring 1 and then remove the main PCB 2 1 2 1 ...

Page 29: ...point Hold the hook on the inlet assembly connector 3 and pull it out 1 2 2 1 3 15 1 Power PCB ASSY disassembly 1 Disconnect the power lead wire assembly connector 1 2 Remove the screw 1 and then remove the power plate spring 2 3 Remove the screw 2 and then remove the insulator sheet 3 4 Remove the power PCB 4 1 2 1 2 3 4 16 Inlet assembly removal 1 Remove the screw 1 and then remove the inlet ass...

Page 30: ...bly 2 1 2 18 Main motor assembly removal 1 Remove the 2 screws 1 and then remove the main motor assembly 1 2 Remove the motor belt 2 from the main motor assembly 1 1 2 1 18 1 Main motor ASSY disassembly 1 Remove the motor fan 1 2 Remove the 2 screws 1 and then remove the main motor 3 from the motor holder 2 1 1 2 3 ...

Page 31: ...sembly 1 1 1 S09 S09 19 1 Tension pulley ASSY disassembly 1 Remove the screw 1 and then remove the tension pulley holder 2 from the tension pulley assembly 1 1 1 2 20 Feed unit assembly removal 1 Remove the 2 screws 1 and then remove the upper shaft bearing presser 1 2 Remove the 2 screws 2 and then remove the feed unit assembly 2 1 1 2 2 ...

Page 32: ... the needle bar crank 2 and then remove timing belt 420 5GT 6 4 and timing belt 372 2GT 6 5 2 3 4 5 1 1 2 1 22 Needle presser unit removal 1 Peel the label and then remove the screw 1 2 Remove the 2 screws 2 and then remove the needle presser unit 1 1 2 1 23 Plate spring removal 1 Remove the adjusting screw 1 2 Remove the 2 screws 1 and then remove the adjusting plate 2 and the plate spring 3 1 2 ...

Page 33: ...in thread cutter holder 2 from the bobbin base assembly 1 and then remove the NT lower thread cutter 3 1 3 2 25 Bobbin winder assembly removal 1 Remove the screw 1 and then remove the bobbin winder shaft stopper 1 and the bobbin winder spring 2 2 Remove the 2 screws 2 and then remove the bobbin winder assembly 3 3 Remove the rubber ring 4 from the bobbin winder pulley 2 1 1 2 4 3 ...

Page 34: ... spool pin spring 1 and pull out the spool pin 2 2 Peel the spool pin stand 3 2 1 3 27 Bobbin presser removal 1 Remove the screw 1 and then remove the bobbin presser 1 1 1 28 Thread guide assembly removal 1 Remove the screw 1 and then remove the thread guide assembly 1 1 1 ...

Page 35: ...2 18 Main unit Main parts 29 Base plate rubber removal 1 Remove the screw 1 and then remove the plain washer M 3 5 1 and rubber cushion A 2 2 Remove the base plate rubber 3 1 1 2 3 ...

Page 36: ...2 19 Disassembly Feed unit location diagram Main unit ...

Page 37: ... 1 Needle plate A ASSY disassembly 1 Remove the screw 1 and then remove the F gear stopper plate 1 2 Remove the screw 2 and then remove the stopper plate 2 2 1 2 1 2 Spring removal 1 Remove the spring S10 S10 3 Inner rotary hook bracket assembly removal 1 Remove the screw 1 and then remove the inner rotary hook bracket assembly 1 1 1 ...

Page 38: ...pring 2 Remove the M5 nut 1 3 Remove the vertical adjuster screw assembly 2 1 2 S04 S10 6 Outer rotary hook removal 1 Remove the screw 1 and then remove the outer rotary hook shaft 1 washer 6 2 outer rotary hook assembly 3 spacer 4 and washer 6 2 1 4 1 3 2 7 Shaft supporter removal 1 Remove the 2 screws 1 and then remove the shaft supporter 1 and the collar 2 1 1 2 1 ...

Page 39: ...lip CD ROM version only Retaining ring CS4 1 2 9 Needle plate supporter shaft B removal 1 Remove nut 1 M3 1 2 Remove needle plate supporter shaft B 2 and feed arm supporter 3 Key point Press the hook on the feed arm supporter 3 from the rear of the feed bar to remove the supporter 3 Remove the feed arm supporter 3 from the needle plate supporter shaft B 2 1 3 2 2 3 2 3 ...

Page 40: ...feed shaft 3 3 Remove the feed arm A assembly 4 and the thrust wafer 2 Start movie clip CD ROM version only 2 4 1 2 2 1 3 10 1 Feed arm B ASSY disassembly 1 emove the retaining ring CSTW 3 5 and then remove the feed arm B assembly 1 and the polyester slider 2 2 Remove the screw 1 and then remove the feed supporting plate 4 and feed supporting plate B 5 from the feed arm B 3 1 Retaining ring CSTW 3...

Page 41: ...1 Feed adjuster disassembly 1 Remove spring and then remove the F gear 2 from the feed adjuster 1 S05 1 2 S05 S05 12 Vertical lever removal 1 Remove the 4 retaining rings E3 2 Pull out the vertical feed shaft 1 and then remove the plain washer L4 2 spring vertical lever 3 and drop knob 4 Start movie clip CD ROM version only 4 2 1 3 Retaining ring E3 Retaining ring E3 Retaining ring E3 S07 S07 ...

Page 42: ... holder assembly 1 2 1 1 S08 S08 13 1 FPM disassembly 1 Remove the lead wire assembly FPM LE 1 2 Remove the 2 screws 1 and the remove the FPM 2 3 Remove the rubber 3 1 2 1 3 14 Timing pulley D removal 1 Remove the 2 screws 1 and then remove timing pulley D 1 2 Remove the retaining ring E6 and then pull out the lower shaft bushing 2 1 2 1 Retaining ring E6 ...

Page 43: ...ssembly 2 Key point Push down the lower shaft assembly 2 to remove it Check that the gear does not contact the base plate 3 Remove the 2 screws 1 and then remove the thrust wafer 1 and the set collar 3 1 2 Retaining ring E6 1 1 3 2 16 Lower shaft bushing removal 1 Remove the 3 screws 1 2 Remove bushing presser B 1 and the lower shaft bushing 2 1 2 1 ...

Page 44: ...2 27 Disassembly Needle presser unit location diagram Main unit ...

Page 45: ... assembly removal 1 Remove the screw 1 and then remove the LED lamp left assembly 1 1 1 3 BH switch assembly removal 1 Remove the screw 1 and then remove the BH switch assembly 1 1 1 4 Thread take up lever and needle bar crank removal 1 Remove the needle bar crank rod 1 2 Remove the screw 1 and then remove the needle bar crank 3 from the thread take up lever 2 1 2 1 3 ...

Page 46: ...w 1 and then pull the shaft 2 out of the base holder Start movie clip CD ROM version only 1 2 3 1 Retaining ring E5 6 Needle bar assembly removal 1 Loosen the screws 1 and 2 and then pull the needle bar 1 down and remove the needle thread block 2 and the needle bar block 3 Start movie clip CD ROM version only 1 2 3 2 1 6 1 Needle bar ASSY disassembly 1 Remove the screw 1 and then remove the needle...

Page 47: ...sembly removal 1 Remove springs and 2 Remove the screw 1 and then remove the shaft 1 needle holder block 2 and needle holder assembly 3 Key point Pull out the needle holder assembly from the top Start movie clip CD ROM version only 1 1 2 S02 S03 3 S02 S03 ...

Page 48: ...sembly 1 Remove spring 2 Remove the screw 1 and then remove the plate 1 3 Remove the screw 2 Pull out the shaft 2 and then remove needle holder shaft A 3 4 Remove the screw 3 and then remove the zigzag adjusting nut 4 Start movie clip CD ROM version only 3 4 1 2 3 1 S01 2 S01 ...

Page 49: ...resser feed holder assembly 4 2 Remove the J foot 5 from the presser feed holder assembly 4 3 Remove the screw 2 and then remove the presser feed holder assembly 4 Start movie clip CD ROM version only 1 2 1 5 4 2 3 9 Z zigzag lever assembly removal 1 Remove the retaining ring E4 and then remove the Z zigzag lever 1 2 Remove the polyester slider 2 Start movie clip CD ROM version only 1 Retaining ri...

Page 50: ...al 1 Remove the retaining ring E3 and then remove the Z zigzag cam 1 2 Remove the rubber 2 Start movie clip CD ROM version only 1 2 Retaining ring E3 11 Shaft bushing removal 1 Remove the 2 screws 1 and then remove the shaft bushing 1 1 1 12 Presser foot lifter removal 1 Remove the retaining ring E4 and then remove the presser foot lifter 1 1 Retaining ring E4 ...

Page 51: ...read release lever 1 and the spring 2 2 1 Retaining ring CS4 14 Lock nut removal 1 Remove the lock nut 1 and then remove the screw 1 1 1 15 Z pulse motor removal 1 Remove the 2 screws 1 and then remove the Z pulse motor 1 1 1 16 Presser switch assembly removal 1 Remove the screw 1 and then remove the presser switch 1 1 1 ...

Page 52: ...3 1 3 Assembly Main parts 3 2 Feed unit 3 22 Needle presser unit 3 34 With the CD ROM version click to start the movie clip ...

Page 53: ...3 2 Main parts location diagram Main unit ...

Page 54: ...arm bed cover 2 Temporarily tighten the screw 1 Key point Tighten the screw after performing 4 16 Bobbin winder uneven bobbin winding and bobbin winding amounts adjustment 1 Torque 0 88 1 18 N m 1 1 Giza Tite 4X12 Color Gold 3 Bobbin presser attachment 1 Attach the bobbin presser 1 with the screw 1 Key point Place the bobbin presser with the smaller end facing the rear Tighten the screw after perf...

Page 55: ...ol pin stand 1 so that it does not protrude from the attachment section 2 Insert the spool pin 2 into the arm bed cover Insert the pin from the grooved end 3 Attach the spool pin spring 3 to the arm bed cover Key point Check that the spool pin 2 moves lightly 1 2 3 ...

Page 56: ...in winder shaft stopper 4 4 Set the bobbin winder spring 5 and then the bobbin winder shaft stopper 4 to the stopper attachment section of the arm bed cover and secure them with the screw 2 Key point Check that the bobbin winder spindle base passes over the bobbin winder spring when the bobbin winder is switched Check that the bobbin winder spring returns to the original position when the bobbin w...

Page 57: ...hread cutters 2 and the bobbin thread cutter holder 3 to the bobbin base assembly 1 1 2 3 7 Plate spring attachment 1 Attach the adjusting plate 1 and then the plate spring 2 from the inside of the arm bed cover with the 2 screws 1 2 Tighten the adjusting screw 3 to the plate spring 2 1 Torque 0 78 1 18 N m 1 2 3 1 3 1 2 Taptite Bind B M4X10 Color Gold ...

Page 58: ...s 1 and 2 1 pc and 2 pcs respectively Key point Lift the presser foot lifter 2 and insert it into the hole on the arm bed cover 3 to set the needle presser unit 1 to the attachment position Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 2 Torque 1 18 1 57 N m 2 1 2 1 Screw Pan M3X25 Color Silver Giza Tite 5X20 Color Gold ...

Page 59: ...ing presser 7 so that the projecting part of 7 is positioned at the upper right And attach the right upper shaft bearing presser 8 so that the projecting part of 8 is positioned at the lower shaft 5 Apply 1 or 2 drops of OILER to the matching section of the upper shaft and the upper shaft bushing 6 Align the D cut face of the needle bar crank with the screw hole on the thread take up lever crank a...

Page 60: ...ower shaft 4 and the lower shaft bushing 2 Apply OILER to the matching section of the lower shaft and the lower shaft bushing 1 2 drops XZ0206 1 Torque 1 18 1 57 N m 2 Torque 1 18 1 57 N m 1 1 2 3 2 4 Giza Tite 5X16 Color Gold Giza Tite 5X16 Color Gold 11 Upper shaft and lower shat phase matching 1 Rotate the upper shaft 1 until the trench on the upper shaft pulley 2 is at the front 2 Turn the low...

Page 61: ...ulley assembly 1 and secure the tension pulley assembly with the screw 1 1 Torque 1 18 1 57 N m 1 1 2 3 Screw Pan S P washer M4X8DA Color Silver 13 Main motor assembly attachment 1 Hang the motor belt 2 over the main motor assembly 1 2 Attach the main motor assembly 1 to the arm bed cover assembly with the 2 screws 1 Key point Perform 4 4 Motor belt tension adjustment 1 Torque 0 29 0 49 N m 1 2 1 ...

Page 62: ...bed cover assembly 2 Attach the jack nut 2 from the outside of the arm bed cover assembly Key point Pass the lead wire of the FC jack assembly 1 through the rear of the main motor 2 1 15 Inlet assembly attachment 1 Attach the inlet assembly 1 with the screw 1 1 Torque 0 78 1 18 N m 1 1 Taptite Bind B M4X10 Color Gold ...

Page 63: ...nnector 4 to the power PCB 2 3 Attach the inlet assembly connector 5 to the power PCB 2 1 Torque 0 78 1 18 N m 2 Torque 1 18 1 57 N m 5 2 2 1 2 4 3 1 Taptite Bind B M4X10 Color Gold Screw Bind M4X8 Color Silver 16 1 Power PCB ASSY assembly 1 Attach the power PCB 2 and the insulator sheet 3 to the insulation cover 1 with the screw 1 2 Attach the power plate spring 1 with the screw 2 1 2 Torque 0 39...

Page 64: ...r cover 3 2 Main PCB assembly 4 with the 2 screw 1 Key point Refer to 5 1 Special Instructions of Wiring for wiring details 1 Torque 0 78 1 18 N m 1 4 1 3 2 Taptite Bind B M4X10 Color Gold 17 1 Main PCB assembly 1 Attach the main PCB plate spring 2 and the main PCB 3 to the shutter cover 1 with the screw 1 1 Torque 0 39 0 78 N m 1 3 1 2 Taptite Bind B M3X8 Color Gold 18 Upper cover thread guide at...

Page 65: ...1 1 20 SV keytop attachment 1 Attach the SV keytop 1 1 21 Front panel LCD attachment 1 Attach the LCD 1 and the front panel 2 with the 2 screws 1 Key point Insert the LCD cable 3 into the hole in the upper section of the front cover 1 Torque 0 39 0 78 N m 2 1 1 3 Taptite Bind B M3X8 Color Gold ...

Page 66: ...ttach the operation PCB assembly 1 with the 2 screws 1 2 Attach the SSVR PCB assembly 2 with the 3 screws 2 Key point Insert the speed dial of the SSVR PCB assembly 3 into the slot on the SV keytop 4 3 Connect the LCD cable 5 to the operation PCB assembly 1 Key point Bind the operation PCB cord and SSVR PCB cord and secure these with two bands Refer to 5 1 Special Instructions of Wiring for wiring...

Page 67: ...8 1 18 N m 2 2 1 1 Taptite Bind B M4X14 Color Gold 25 1 Thread tension holder ASSY assembly 1 Attach tension disc A 2 tension disc B 3 washer 4 thread release plate 5 tension disc washer 6 washer 7 and spring 8 in this order to the caulking shaft of the thread tension holder assembly 1 2 Attach the thread tension adjusting screw to the thread tension plate 9 3 Engage the ridge of the thread tensio...

Page 68: ...up holder B assembly 1 to the ridge of the thread hanging section on the thread take up spring and attach the thread take up spring to thread take up holder B assembly 1 with the screw 1 Key point Attach the thread hanging section on the thread take up spring to the section between the ribs of the thread catching spring case Insert the 2 ribs of the thread catching spring case into the slot on thr...

Page 69: ...he shutter cover 4 while preventing them from lifting or disconnecting Refer to 5 1 Special Instructions of Wiring for wiring details 2 Attach the front cover to the arm bed cover with screws 1 front 1 pc 2 rear 1 pc and 3 rear 5 pcs 1 Torque 0 88 1 18 N m 2 Torque 0 88 1 18 N m 3 Torque 1 18 1 57 N m 2 1 3 1 3 3 2 Giza Tite 4X12 Color Gold Giza Tite 4X25 Color Gold Giza Tite 5X16 Color Gold ...

Page 70: ... 1 Attach the NT lower thread cutter 2 to the cutter cover 1 and then attach the CS retaining ring 3 Key point Insert the narrow edge of the NT lower thread cutter 2 into the cutter cover 1 first Align the tab of the CS retaining ring with the groove on the shaft of the cutter cover 1 2 Attach the cutter cover assembly to face plate A 4 with the screw 1 1 Torque 0 39 0 78 N m 3 2 1 1 Taptite Bind ...

Page 71: ...edle plate B ASSY assembly 1 Attach the slide button 1 to needle plate B 2 2 Attach the NT lower thread cutter 3 and the spring plate 4 to the cutter cover 5 3 Attach the cutter cover to needle plate B 2 5 2 1 3 4 29 Base cover attachment 1 Attach the base cover 1 with the screw 1 2 Attach base cover A 2 with the screw 2 1 Torque 0 39 0 78 N m 2 1 1 2 Screw Flat B M3X8 Color Gold ...

Page 72: ...3 21 Main parts Main unit Assembly 30 Accessory table attachment 1 Attach the accessory table 1 1 ...

Page 73: ...3 22 Feed unit location diagram Main unit ...

Page 74: ...them to the lower shaft bushing 4 3 Insert the thrust washer 5 into the lower shaft assembly 2 and attach the retaining ring E6 4 Push the lower shaft assembly 2 from the retaining ring side move the set collar 1 to the lower shaft bushing 4 and then secure them with the 2 screws 1 Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 1 3 1 2 5 2 4 Retaining ring E6 Set Screw Socket CP M4X4 ...

Page 75: ...tach the screw 2 Start movie clip CD ROM version only 1 2 Torque 0 59 0 78 N m S08 2 1 1 S08 2 2 3 S08 Bolt Socket M4X25 Color Black Screw M3X8 Color Black 21 5 SPRING XC2537 4 1 FPM assembly 1 Attach the rubber 2 to the caulking shaft of the FPM holder assembly 1 2 Attach the FPM 3 with the 2 screws 1 3 Apply 1 or 2 drops of FBK OIL RO 100 to the shaft bushing of FPM 3 4 Attach the lead wire asse...

Page 76: ...ft 1 is closer to the retaining ring and hold this end and insert the shaft from the left side of the base plate assembly 2 Attach the 2 retaining rings E3 3 Place the groove on the vertical feed shaft 1 inside the base plate assembly 6 and attach the retaining ring E3 4 Move the vertical feed shaft to the left and attach the retaining ring E3 Start movie clip CD ROM version only S07 2 3 1 4 5 Ret...

Page 77: ...haft of the feed adjuster assembly 1 3 Attach the feed adjuster assembly 3 to the base plate assembly Apply OILER to the shaft of the feed adjuster assembly 1 2 drops XZ0206 S06 3 2 S06 2 1 S06 S06 SPRING XC2531 8 8 9 9 5 5 6 1 Feed adjuster ASSY assembly 1 Attach the flat side of the F gear 1 to the shaft of the feed adjuster 2 and then attach the ends of spring to the F gear 1 and the feed adjus...

Page 78: ...nt Insert the horizontal feed shaft 8 through the feed arm A assembly 1 so that the hole on the shaft faces FPM and align this hole with the hole on the base plate assembly 6 5 Attach the feed supporting plate 9 and feed supporting plate B 8 to the feed arm B assembly 3 with the screw 2 6 Insert the thrust washer 7 and the set collar 9 into the horizontal feed shaft 8 and then secure them with the...

Page 79: ...m A assembly 1 2 Apply a bead of MOLYKOTE EM 30L to the shaft of the feed arm A assembly 1 3 Attach the feed arm B assembly 3 to the shaft of the feed arm A assembly 1 and then attach the retaining ring CSTW 3 5 Apply MOLYKOTE EM 30L to the shaft of the feed arm A assembly Bead XC8385 2 1 Retaining ring CSTW 3 5 3 ...

Page 80: ...aft B attachment 1 Insert the feed arm supporter 1 into the needle plate supporter shaft B 2 and attach them to the base plate assembly 3 2 Tighten nut 1 M3 4 3 Move the feed arm supporter 1 down and fit the hook 5 to the base plate assembly 3 2 5 1 1 2 3 2 1 3 4 ...

Page 81: ...ger to prevent it from rotating when the feed adjuster assembly 4 contacts the F pulse motor gear 3 Align the feed adjuster assembly 4 with the F gear teeth 6 and engage them with the FPM gear 1 Key point Check that the mark 7 on the feed adjuster assembly 4 is aligned with the mark 8 on the FPM gear 4 Apply a bead of EPNOC AP N 0 to the circumference of the F gear 6 Start movie clip CD ROM versio...

Page 82: ...ed arm A assembly 1 4 Insert the polyester slider 2 into the left shaft of the feed arm A assembly 1 and then attach the retaining ring CS4 ApplyMOLYKOTE EM 30L to the shaft of the feed arm A assembly Bead XC8385 Retaining ring CS4 1 2 2 3 11 Shaft supporter attachment 1 Insert the collar 2 between the shaft supporter 1 and the base plate assembly and secure the shaft supporter with the 2 screws 1...

Page 83: ...the outer rotary hook assembly so that the mark is at the front Start movie clip CD ROM version only Apply EPNOC AP N 0 to the groove on the outer rotary hook shaft Light covering XC8387 1 Torque 0 78 1 18 N m 1 4 5 1 2 3 Set Screw Socket CP M4X4 Color Black 13 Vertical adjuster screw assembly attachment 1 Attach the vertical adjuster screw assembly 1 2 Attach the M5 nut 2 to the vertical adjuster...

Page 84: ...djustment 1 Torque 0 59 0 78 N m 1 1 2 Screw Pan S P washer M3X6 Color Silver 16 Spring attachment 1 Attach the spring S04 S10 S10 28 SPRING XC6364 17 Needle plate A assembly attachment 1 Attach the needle plate A assembly 1 with the 2 screws 1 1 Torque 0 78 1 18 N m 1 1 Screw M4 Color Silver 17 1 Needle plate A ASSY assembly 1 Attach the F gear stopper plate 1 with the screw 1 2 Attach the stoppe...

Page 85: ...3 34 Needle presser unit location diagram Main unit ...

Page 86: ...trench of the base holder assembly 2 1 Torque 0 78 1 18 N m 1 1 2 Screw Bind M3X6 Color Silver 2 Z pulse motor attachment 1 Attach the Z pulse motor 1 to the base holder assembly with the 2 screws 1 2 Apply 1 or 2 drops of FBK OIL RO 100 to the shaft bushing 2 of the Z pulse motor 1 Apply FBK OIL RO 100 to the shaft bushing of the Z pulse motor 1 2 drops XC8388 1 Torque 0 78 1 18 N m 1 1 2 Screw B...

Page 87: ...tachment 1 Apply a bead of EPNOC AP N 0 to the caulking shaft 2 of the base holder assembly 1 2 Attach the thread release lever 3 and the spring 4 to the caulking shaft 2 of the base holder assembly 1 and then attach the retaining ring CS4 Key point Position the tip of the spring at the top and align the spring with the hole on the thread release lever 3 Secure 0 2 mm between the thread release le...

Page 88: ...t lifter 2 Apply EPNOC AP N 0 to the presser foot lifter attachment shaft of the base holder assembly Bead XC8387 Apply EPNOC AP N 0 to the cam face of the pressure foot lifter Bead XC8387 1 2 Retaining ring E4 3 6 Shaft bushing attachment 1 Attach the shaft bushing 2 to the base holder assembly 1 with the 2 screws 1 Key point Tighten the 2 screws 1 in the following order temporarily tighten the l...

Page 89: ...y point Align the mark on the Z zigzag cam 4 with the mark on the Z pulse motor 5 4 Attach the retaining ring E3 5 Apply a light covering of EPNOC AP N 0 to the gear of the Z zigzag cam 4 and the circumference of the cam Start movie clip CD ROM version only Apply EPNOC AP N 0 to the Z zigzag cam shaft of the base holder assembly Bead XC8387 Apply EPNOC AP N 0 to the gear of the Z zigzag cam and th...

Page 90: ...aft 1 of the base holder assembly 3 Attach the Z zigzag lever assembly 3 and then attach the retaining ring E4 Key point Place the caulking shaft 4 on the left side of the Z zigzag cam 5 Start movie clip CD ROM version only Apply EPNOC AP N 0 to the Z zigzag lever shaft of the base holder assembly Bead XC8387 2 1 3 4 5 Retaining ring E4 8 1 Z zigzag lever ASSY assembly 1 Attach the Z zigzag cap 2 ...

Page 91: ...resser bar 1 presser bar clamp 5 and spring 6 in this order to the base holder 4 5 Temporarily tighten the screw 2 to the presser bar clamp 5 Key point Tighten after performing 4 13 Presser bar height and parallel adjustment Adjust the distance from the base holder bottom face to the tip of the presser bar 1 to approximately 50 mm Apply OILER to the circumference of the presser bar upper 20 mm Lig...

Page 92: ...the needle holder assembly into the small hole on the needle holder block 7 and then insert the shaft of the shaft assembly 8 into the hole on the needle holder block 7 and the hole on the base holder 3 Secure them with the screw 1 5 Attach springs and Key point Set spring with the longer hook down Start movie clip CD ROM version only Apply FBK OIL RO 100 to the circumference of needle holder shaf...

Page 93: ...lder shaft A 3 so that the narrow end of the shaft is on the left side 4 Insert the plate 6 into the groove on the shaft 5 and then attach them to the needle holder assembly 4 with the screw 2 5 Attach the screw 3 6 Attach spring to the plate 6 and the needle thread slider 7 Start movie clip CD ROM version only Apply OILER to the circumference at the top of the needle holder 1 2 drops XZ0206 1 Tor...

Page 94: ...h the screw 1 Key point The screw 1 should be on the right side when the groove on the needle bar assembly 2 faces the front 1 1 2 1 Needle Clamp Screw Color Black 12 Thread take up lever link attachment 1 Insert the shaft 1 into the base holder 2 and then align the screw 1 with the trench on the base holder 2 and tighten it temporarily 2 Attach the thread take up lever link 3 3 Apply a light cove...

Page 95: ...ttach the thread take up lever assembly 4 5 Tighten the screw 2 6 Temporarily tighten the needle bar block 7 and the needle thread block 8 with the screw 3 Apply MOLYKOTE EM 30L to the thread take up lever attachment section of the needle bar crank Light covering XC8385 Apply MOLYKOTE EM 30L to the shaft of the thread take up lever Light covering XC8385 1 Torque 1 18 1 57 N m 2 Torque 0 59 0 78 N ...

Page 96: ...ign the boss 2 on the LED lamp L assembly 1 with the hole on the base holder 3 1 Torque 1 18 1 57 N m 1 1 3 2 Screw Pan S P washer M4X8DA Color Silver 16 Threader hook attachment 1 Pull the needle thread slider 1 toward you and then align the D cut of the threader hook assembly 2 with the D cut of the needle thread shaft 3 1 3 2 ...

Page 97: ...3 46 ...

Page 98: ... 4 9 Needle bar height adjustment 4 10 Needle interference adjustment 4 11 Adjust the needle thread block 4 12 Presser bar height and parallel adjustment 4 13 Inner rotary hook bobbin thread tension 4 14 Feed forward reverse adjustment 4 15 Bobbinwinder unevenbobbinwindingandbobbinwindingamounts adjustment 4 16 BH lever switch position adjustment 4 17 Forward and back adjustment of needle and pres...

Page 99: ...perations F feed operations Operating speed 3 point needle drop Press 2 times and select pattern number Switches left base line center base line right base line with each stitch Pressing stops the base line from changing 0 mm none Any speed may be selected using the speed control key Feed adjustment Press 5 times and select pattern number 100 stitches forward on the left base line 100 stitches rev...

Page 100: ... assembly 2 With a force of 1 96 N 200 g pushing on the center of the belt adjust the tension pulley assembly position for a deflection of 4 5 mm 3 Tighten the pan S P washer M4X8 screw on the tension pulley assembly XC2277001 Push pull gauge 3 N Pan head screw S P washer M4x8 Tension pulley assembly 4 5mm 1 96N 200g ...

Page 101: ...wo in the motor holder 2 With a force of 0 98 N 100 g pushing on the center of the belt adjust the motor pulley position for a deflection of 3 4 mm 3 Tighten the giza tite 5 x 16 two in the motor holder XC2277001 Push pull gauge 3 N GIZA TITE 5x16 Motor holder 3 4mm 0 98N 100g ...

Page 102: ... plate move to the right to open the tension disc and then pass the Schappe Spun Sewing Thread 60 through the tension disc 7 Pull the thread with a tension gauge and adjust the thread tension adjusting screw depth for 0 372 0 421 N 38 43g 8 Remove the 2 screws and then remove the thread guide A assembly 9 Attach the front panel and manual buttons A B with the 2 screws 10 Attach the thread guide A ...

Page 103: ...d insert the tip of the needle into the needle hole 5 Loosen the zigzag adjusting nut screw 3X10 6 Adjust the zigzag adjusting nut so that the left base line center base line right base needle drop is uniform to the left and right of the needle plate A needle hole 7 Tighten the zigzag adjusting nut screw 3X10 Key point Refer to the next page to adjust the needle drop position when it cannot be adj...

Page 104: ... must sound four times 3 Select pattern number 02 4 Press the REV key four times to select the left base line 5 Turn the pulley manually so that the top of the needle passes through the needle hole 6 Loosen GIZA TITE 5X16 2 locations 7 Move the rotary hook unit right and left to adjust the position so that the needle top is aligned with the V groove in the needle hole 8 Tighten GIZA TITE 5X16 2 lo...

Page 105: ... hand and insert the tip of the needle into the needle hole 3 Loosen the screw 3 x 10 4 Adjust the needle holder shaft block to the left or right so that the left base line right base line needle drop is uniform forward and back with respect to the needle plate A hole 5 Tighten the screw 3X10 Screw 3x10 ...

Page 106: ...screws socket CP M5 x 5 two on lower shaft pulley D 9 Rotate the outer rotary hook manually so that the right edge of the needle is aligned with the tip of the outer rotary hook when the needle bar is raised 2 9 to 3 3 mm from the reference line of the lowest point 10 Fully tighten the set screws socket CP M5 x 5 on lower shaft pulley D 11 Attach the base cover Socket set screws CP M5x5 2 pcs Lowe...

Page 107: ...ulley by hand until the right edge of the needle and the tip of the outer rotary hook meet 8 Loosen the set screw socket CP M4 x 4 in the needle bar block 9 Adjust the height of the needle bar for 1 0 1 4 mm between the top of the needle hole and lower edge of the outer rotary hook tip NOTE Needle hole turned forward 10 Tighten the socket set screw FT M4X4 to secure the needle bar block 11 Perform...

Page 108: ...ttern number 02 5 Remove screws M4 two and remove needle plate A 1 6 Loosen screw pan M3 x 25 7 Hand turn the pulley until the right edge of the needle and the outer rotary hook tip meet 8 Adjust the gap between the needle and the outer rotary hook tip front and back to 0 1 mm or less using the tightening depth of the adjusting screw 9 Install and fully tighten screw pan M3 x 25 Pan head screw M3x...

Page 109: ...t screw FT M4X4 Key point Slant the needle thread block slightly to the left approximately 1 degree and attach it Adjust so that the upper edge of the threading hook and the upper edge of the needle hole are at the same height NOTE If the needle thread block is slanted to far to the left the hook will not operate and threading cannot be done Fig 1 If the needle thread block is slanted too far to t...

Page 110: ...e set screw CP M5 x 10 in the presser bar clamp assy 5 Adjust the height of the presser bar so that there is 6 0 6 5 mm between the top of needle plate A and the bottom of the presser foot NOTE Adjust the presser bar so that the needle plate feed dog hole and the presser are parallel to prevent slanting during serging and damage to the needle Top face of needle plate 6 0 6 5mm Socket set screw CP ...

Page 111: ...h Schappe Spun Sewing Thread 60 in the inner rotary hook and thread 2 Pull the thread with a tension gauge and adjust the tension adjusting screw so that it is 0 1 0 12 N 10 12 g XA9153001 Tension gauge 30 0 3 N 0 1 0 12mm 10 12g Schappe Spun Sewing Thread 60 Sprig adjusting screw ...

Page 112: ...rd and backward feed length 5 Remove base cover A 6 Loosen the FPM holder assy screw 3 x 8 7 Adjust the forward and reverse feed using the FPM holder assy screw 4 x 25 Key point When a material of two layers of broadcloth with paper in between is given 100 stitches forward and reverse Feed forward and reverse mode the forward side should be 0 10 mm longer than the reverse side Tightening the screw...

Page 113: ...nts adjustment 1 Move the bobbin winder tension assy up and down to adjust uneven bobbin winding 2 Turn the bobbin presser left and right and adjust the winding quantity Key point The target for the bobbin winding quantity is filling 80 90 of the diameter Bobbin presser ...

Page 114: ...H1 Key point With the presser foot lifter raised pull the BH presser foot forward as much as possible and check that BH0 comes into contact with BH2 and that BH2 has some slack With the presser foot lifter raised push the BH presser foot back as much as possible and check that BH0 comes into contact with BH1 and that BH1 has some slack Pull the PH presser all the way out and then returns it 2 pitc...

Page 115: ...lley by hand and insert the tip of the needle into the needle hole 2 Loosen the locknut 3 Adjust the needle tip to the front back center position of the needle hole using the set screw socket CP M4X12 4 Tighten the lock nut Socket set screw CP M4x12 Lock nut Needle hole Needle tip ...

Page 116: ... that on the F pulse motor gear 5 Loosen the screw bind 3 x 8 temporarily install needle plate A and adjust the forward reverse and left right positions of the feed dog Key point Adjust the gap between the forward edge of the feed dog middle tooth and feed plate A front to back to 3 2 3 8 mm Adjust the left and right gaps between the feed dog and needle plate A to be approximately the same Make su...

Page 117: ...eing careful that the vertical feed adjuster assembly does not turn 5 With the feed dog in the lowest position check that the feed dog is 0 3 mm or more below the upper surface of needle plate NOTE When the feed dog is too high problems such as abnormal noise bad feed quantities and the cloth not being fed arise When the feed dog is too low problems such as bad feed quantities and the cloth not be...

Page 118: ...he inner rotary hook in the outer rotary hook 2 Loosen screw bind 3X6 3 Adjust the inner rotary hook bracket assy attachment position so that contact between the inner rotary bracket assy and inner rotary hook is 1 6 1 8 mm and fully tighten screw bind 3X6 1 6 1 8mm GIZA TITE 5x16 ...

Page 119: ...4 22 ...

Page 120: ...2 Operation PCB supply assy and SSVR PCB supply assy 5 3 Operation PCB supply assy 5 4 Lead wire assy FPM LE 5 5 Lead wire assy Power LE 5 6 BH switch assy 5 7 LED lamp left supply assy 5 8 Needle bar unit 5 9 Upper side of shutter cover 5 10 FC jack supply assy 5 11 ...

Page 121: ...5 2 Adjustment LED lamp right supply assy Pass the lead wires between 2 bosses and then attach the thread guide assy B ...

Page 122: ...sy and SSVR PCB supply assy Lead wires should be tied near the edge of cover Lead wires should be tied just above the leftmost rib S33 and S34 models S36 and S37 models Lead wires should be tied near the edge of cover Lead wires should be tied just above the leftmost rib ...

Page 123: ...5 4 Adjustment Operation PCB supply assy S36 and S37 models S33 and S34 models ...

Page 124: ...5 5 Adjustment Special Instructions of Wiring Lead wire assy FPM LE No slack Wind the lead wires around the rib once Pass the lead wires through the ferrite core ...

Page 125: ...5 6 Adjustment Lead wire assy Power LE Lead wires should pass inside the rib ...

Page 126: ...5 7 Adjustment Special Instructions of Wiring BH switch assy ...

Page 127: ...5 8 Adjustment LED lamp left supply assy Pass a band through the hole of base holder and tie the lead wires with the band ...

Page 128: ... Instructions of Wiring Needle bar unit Tie the lead wires to depressed portion of presser switch holder with a band Cut end should face front Pass a band through the hole of base holder and tie the lead wires with the band ...

Page 129: ...5 10 Adjustment Upper side of shutter cover Lead wires should pass under the ribs There should be some slack in lead wires Lead wires should be put inside the rib ...

Page 130: ...5 11 Adjustment Special Instructions of Wiring FC jack supply assy Lead wires should pass behind the motor ...

Page 131: ...5 12 ...

Page 132: ...6 1 6Failure Investigation for Electronic Parts Perform resistance measurements after turning off the power and detaching the connectors to be measured from the PCB Error message list 6 2 ...

Page 133: ...it SW Pushing S S or NP or BK button continually F03 Key pressed continually with power ON operation system SW Pushing button continually except S S or NP or BK switch F04 FC disconnect FC disconnects F05 Dirty speed sensor No encorder signal than the rated value F06 NP sensor disconnect NP sensor disconnect F07 Speed VR disconnect Speed volume disconnect F08 Power failure DC power is not in the r...

Page 134: ...LOW END COMPUTER SERIES 22M04HF885S33 34 36 37 LOW ENDCOMPUTERSERIES ...

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Brother BC800, Service Manual

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