Brother HE-800A Service Manual Download Page 146

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6. ELECTRIC COMPONENTS AND SOFTWARE

HE-800A

138

5. Circuit board connectors [Panel PCB]

P1 [PANEL]

Pin no.

Signal name

Probable symptoms due to poor contact

+5V

KEY0

KEY1

KEY2

STB

P8V

SENSOR

BUZZER

• The operation panel does not operate.

Summary of Contents for HE-800A

Page 1: ...HE 800A Please read this manual before using the machine Please keep this manual within easy reach for quick reference ELECTRONIC LOCKSTITCH BUTTON HOLER SERVICE MANUAL ...

Page 2: ...o 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 usi...

Page 3: ... power cord from the wall outlet Lightning may cause problems with correct operation Installation Machine installation should only be carried out by a qualified technician Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done The sewing machine weighs approximately 56 kg The installation should be carried out by two or more people Do not connect th...

Page 4: ... if the treadle is depressed by mistake which could result in injury Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin otherwise inflammation can result Furthermore do not drink the oil or eat the grease un der any circumstances as they can cause vomiting and diarrhoea Keep the oil out of the reach of...

Page 5: ...ous electric shock and problems with correct operation may also occur Safety devices Eye guard Finger guard Thread take up cover Belt cover Belt cover plate etc 4 Do not touch any of the cutter or press any objects against the machine while sewing as this may result in personal injury or damage to the machine 6 High temperature warning display 5 Do not touch any of the fan or press any objects aga...

Page 6: ...mechanism 1 42 2 21 Feed mechanism 2 44 2 22 Lower thread trimmer mechanism 1 45 2 23 Lower thread trimmer mechanism 2 46 2 24 Lower shaft and idle pulley mechanisms 47 3 ASSEMBLY 48 3 1 Lower shaft and idle pulley mechanisms 48 3 2 Lower thread trimmer mechanism 1 49 3 3 Lower thread trimmer mechanism 2 50 3 4 Feed mechanism 1 51 3 5 Feed mechanism 2 53 3 6 Bobbin presser mechanism 54 3 7 Tension...

Page 7: ... the zigzag tension control 100 4 20 Adjusting the upper thread feeding amount 101 4 21 Adjusting the feed timing belt 101 4 22 Adjusting the upper shaft timing belt 102 4 23 Adjusting the rotary hook lubrication 102 4 24 Adjusting the needle up stop position 103 4 25 Adjusting the V belt tension 103 5 TROUBLESHOOTING 104 5 1 Upper thread breakage 104 5 2 Skipped stitches 105 5 3 Uneven seams 1 At...

Page 8: ...anel 123 6 3 Fuse explanation 124 6 4 Connectors 125 6 4 1 Connector positions 125 6 4 2 Signal names for connectors and probable symptoms due to poor contact 127 6 5 Description of DIP switches 139 6 5 1 Panel DIP switches 139 6 5 2 Circuit board DIP switches 141 6 6 Description of machine motor parameters 143 6 7 Input check list 144 6 8 Output check list 147 6 9 Error code table 148 6 10 Contro...

Page 9: ...ts vertical motion to the needle bar clamp 7 via the needle bar crank rod 5 and needle bar bracket slide rod 6 At this time the needle bar crank rod 5 moves together with the crank rod guide 9 via the needle bar bracket slide rod 8 3 Elliptical motion is transferred to the thread hole of the thread take up 10 via the needle bar crank 4 4 The needle bar 11 is secured to the needle bar clamp 7 and i...

Page 10: ...haft 2 2 The timing belt 4 is attached to timing pulley U 3 and it accurately transmits the rotation of the upper shaft to the timing pulley 5 3 The timing pulley 5 is secured to the lower shaft 6 and it transmits the rotation to the rotary hook joint 7 that is secured to the end of the lower shaft 6 4 The rotary hook 8 is secured to the rotary hook joint 7 and rotates fully together with the rota...

Page 11: ...ction rod 2 2 The zigzag lever 3 is secured to the zigzag lever F assembly 4 and causes the needle bar bracket slide block 5 that is linked onto the end of the zigzag lever F assembly 4 to move in a reciprocal motion 3 The needle bar bracket slide block 5 is linked to the groove in the needle bar bracket 6 and causes the needle bar bracket 6 to move in a reciprocal motion 4049Q ...

Page 12: ... to move up and down 3 The movement of the presser foot lifter connecting rod 6 is transmitted via the knee lifter lever 7 upper thread trimmer driving link 8 and knee lifter lever 9 to move the presser bar guide bracket assembly 10 up and down 4 The feed arm 11 is secured to the presser bar guide bracket assembly 10 and it moves the presser roller bracket 12 that is secured to the bottom edge of ...

Page 13: ... the pulse motor 1 2 The feed arm support 5 is secured to the timing belt 4 The feed arm support 5 moves back and forth while being guided by feed guide shaft A 6 and feed guide shaft B 7 3 The feed arm 8 is connected to the feed arm support 5 and it moves the work clamp 9 that is installed to the feed arm 8 and the length feed plate 10 that is installed to the feed arm support 5 back and forth 40...

Page 14: ...lunger and it turns the cutter driving arm 4 via the cutter driving link 3 3 The cutter driving kink 5 that is secured to the end of the cutter driving arm 4 is moved up and down 4 The driving shaft holder assembly 6 is linked to the cutter driving link 5 and this causes the cutter driving shaft 7 that is connected to the driving shaft holder assembly 6 to move up and down 4052Q ...

Page 15: ...are secure to the thread breakage perceiving shaft 3 When a thread breakage occurs the cutter bar fixed plate assembly 1 drop by its own weight and moves the thread guide 2 in the direction of the arrow 2 When the sensor 4 detects the cutter bar fixed plate assembly 1 the sewing machine stops and the cutter is prevented from dropping 4053Q ...

Page 16: ... to the needle bar 12 and from there it is supplied to parts such as the needle bar clamp 13 3 Oil is supplied from the support shaft 14 to the thread take up 15 4 Oil is supplied to bush M 16 5 Oil is supplied to zigzag lever bush R 17 6 Oil is supplied to the motor lever shaft 18 and from there it is supplied to the zigzag connecting rod shaft 19 Oil which splatters inside the arm is collected b...

Page 17: ...il which is drawn up by the wick 3 passes through the felt 4 and the rotary hook joint 5 to the felt 6 where it is supplied to the rotary hook 7 3 The oil that is supplied to the rotary hook 7 can be adjusted by turning the screw 8 to vary the amount by which the rubber presser 9 presses down on the collar 10 that the wick passes through More Less More Less 4055Q ...

Page 18: ...ction of the arrow and the movement is transmitted to the tension release solenoid link 3 that is connected to the plunger 2 3 The tension release link 4 that is connected to the tension release solenoid link 3 operates with the shoulder screw 5 as a pivot and presses against the tension release pin 6 4 The tension release pin 6 presses against the tension disc presser 7 to release the tension dis...

Page 19: ...per thread trimmer driving link 8 in the direction of the arrow 4 The needle roller 10 that is secured to the end of the tension release driving lever 9 is linked to the cam groove of the upper thread trimmer driving link 8 so that when the upper thread trimmer driving link 8 operates the tension release driving lever 9 that is secured to the tension release shaft 11 moves in the direction of the ...

Page 20: ... the presser foot lifts The upper thread is clamped and cut After 1 5 2 5 mm of feed the upper thread scissors gradually start to open The upper thread scissors move forward Sewing ends After approximately 4 6mm of feed the upper thread scissors are fully open Upper thread trimming Upper thread trimmer mechanism operating sequence Presser foot drops Presser foot lifts ...

Page 21: ...mmer driving levers 9 and 10 operate 5 When the trimmer driving levers 9 and 10 operate the longitudinal feed arm 15 and trimmer driving arm 16 that are secured to the trimmer driving levers 9 and 10 move in the direction of the arrow 6 When the longitudinal feed arm 15 operates the upper thread trimmer lever 18 that is attached to the longitudinal feed arm roller 17 at the end of the longitudinal...

Page 22: ...d arm 1 moves in the direction of the arrow forward 2 When upper thread trimmer M 4 touches against the ridge line on the opening cam 3 the upper thread trimmer gradually starts to open Figure B At this time section D of the opening cam 3 fits into the upper thread trimmer assembly 5 so that the upper thread trimmer assembly 5 cannot move in the direction of arrow C Figure A Figure B 4061Q 4060Q ...

Page 23: ...rward 4 When the back plate 7 and the stop plate 8 lock together and clamp the upper thread trimmer lever 9 and the stop plate 8 separates from the back stopper 10 the upper thread trimmer lever 9 is pulled in the direction of arrow E by the spring 11 and the upper thread trimmer assembly 5 changes from the condition in Figure F to the one in Figure G and the upper thread trimmer opens fully Figur...

Page 24: ...necting rod 6 to move in the direction of the arrow 3 The presser foot lifter connecting rod 6 is connected to the lower thread trimmer cam lever 7 so that the lower thread trimmer cam lever 7 moves 4 The roller 8 that is installed to the end of the lower thread trimmer cam lever 7 is linked to the cam groove in the lower thread trimmer cam 9 so that when the lower thread trimmer cam lever 7 opera...

Page 25: ...7 starts to operate 8 When the lower thread retainer 17 operates the collar 19 that is installed to the lower thread clamp plate 18 moves over the ridge line of the cam of the lower thread retainer 17 and the lower thread clamp plate 18 starts to close and engages with the lower thread presser 20 so that the lower thread is clamped 9 The lower thread retainer 17 then continues operating 10 The fix...

Page 26: ...shaft 26 moves over feed guide shaft B 24 and the opening plate 25 rotates centering on the shoulder screw 28 12 The opening plate 25 presses against the collar 24 that is installed to the lower thread clamp plate 18 and the lower thread clamp plate 18 rotates centering on the shoulder screw 30 so that the clamped lower thread is released by the lower thread presser 31 and the lower thread clamp p...

Page 27: ... do not drink the oil or eat the grease under any circumstances as they can cause vomiting and diarrhea Keep the oil out of the reach of children Use only the proper replacement parts as specified by Brother 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...

Page 28: ...chanism 1 Remove the two screws 1 and then remove the rotary hook holder 2 2 Loosen the two set screws 3 and then remove the rotary hook 4 3 Loosen the two set screws 5 and then remove the rotary hook joint assembly 6 from the lower shaft 4071Q ...

Page 29: ...then remove the rubber presser 3 from the bed 2 Remove the wicks 4 and 5 from the felt support 6 3 Remove the two screws 7 and then remove the felt support 6 from the bed 4 Remove the end of the felt 8 from the bush 9 5 Remove the spring 10 and the collar 11 from the bush 9 6 Remove the wick 5 from the collar 11 4073Q 4075Q 4072Q 4074Q ...

Page 30: ...nnected between the oil terminal and the oil outlet and from the bed 6 Remove the oil tube 13 that is connected between the oil terminal and the plunger pump from the lubricating hole to the left of bush M 14 7 Remove the screw 15 and then remove the tube support 16 from the oil tube 17 and from the bed 8 Remove the outlet oil tube 17 from the lubricating hole to the right of bush M 14 9 Remove th...

Page 31: ...move the oil tube 10 that is connected between the oil terminal and the oil outlet from the tube support 11 6 Remove the screw 12 and then remove the tube support 11 from the wick base support 6 7 Disconnect the oil tube 10 that is connected between the oil terminal and the oil outlet from the oil terminal 9 8 Disconnect the oil tube 13 that is connected between the oil terminal and the plunger pu...

Page 32: ...move the tube support 5 2 3 5 Shaft bush mechanism 1 Remove the screw 1 and then remove the tube support U 2 2 Remove the wicks 3 and 4 and then disconnect the oil tube 5 3 Remove the felt 6 and then remove the wick 7 from the bush F 8 4 Remove the felt 9 and then remove the wicks 10 and 11 from the bush F 8 5 Remove the felt 12 from the bush F 8 4082Q 4083Q 4084Q 4086Q 4085Q ...

Page 33: ...late 5 3 Loosen the set screw 6 and then remove the cutter bar fixing plate 5 from the thread breakage perceiving shaft 7 4 Remove the two screws 8 and then remove the thread breakage sensor assembly 9 5 Remove the thread breakage perceiving shaft 7 from the arm 6 Remove the plain washers 10 and 11 and the screw 12 and then remove the thread guide 13 from the thread breakage perceiving shaft 7 408...

Page 34: ...immer driving lever 9 4 Remove the two bolts 10 and plain washers 11 and then remove the support plate 12 and the stopper 13 from the trimmer driving arm 14 5 Remove the retaining ring 15 and then remove the driving arm roller 16 6 Remove the nut 17 and the spring washer 18 and then remove the roller shaft 19 from the support plate 12 7 Remove the bolt 20 and then remove the longitudinal feed arm ...

Page 35: ... 33 and the plain washer 34 and then remove the support shaft 35 from the setting plate 31 13 Remove the two collars 36 and the screws 37 and then remove the back plate 38 and the stop plate 39 from the upper thread trimmer lever assembly 32 14 Remove the spring 40 15 Remove the screw 41 and then remove the spring hook plate 42 from the upper thread trimmer lever assembly 32 16 Remove the rubber c...

Page 36: ... bar 11 5 Loosen the set screw 12 6 Remove the presser bar 11 and then remove the oil rejector 13 and the presser bar guide bracket assembly 7 7 Remove the two rubber caps 14 8 Remove the two screws 15 and then remove the needle bar guide 16 9 Loosen the set screw 17 and then remove the roller shaft 18 from the presser roller bracket 10 10 Remove the plain washer 19 and the retaining ring 20 and t...

Page 37: ...e the needle bar thread guide 11 6 Loosen the set screw 12 and then remove the needle bar bracket support shaft 13 7 Remove the wick 14 8 Remove the needle bar bracket assembly 15 from the arm 9 Remove the slide block 17 of the needle bar clamp 16 from the thread take up lever set 18 10 Remove the slide block 19 of the needle bar bracket assembly 15 from the zigzag lever shaft 20 11 Remove the bol...

Page 38: ...the support shaft 2 2 Remove the wick 3 and the felt 4 3 Loosen the two set screws 5 4 Remove the thread take up lever set 6 and the washer 7 from the thread take up crank 8 5 Remove the needle bar bracket slide block 9 6 Remove the two bolts 10 and the screw 11 and then remove the crank rod guide 12 4104Q 4105Q ...

Page 39: ... tube 4 that is connected to the oil terminal and the plunger pump 4 Remove the screw 5 and then remove the tube support R 6 5 Remove the cord holder 7 screw 8 and washer 9 and then disconnect the oil tube 10 that is connected between the oil terminal and the oil outlet 6 Remove the screw 11 and then remove the felt holder 12 7 Remove the oil tube assembly 13 4106Q 4107Q 4108Q ...

Page 40: ...rs 6 and then remove the tension pulley assembly 7 4 Remove the screw 8 and set screw 9 and then remove the thread take up crank 10 from the upper shaft assembly 11 5 Loosen the two set screws 12 and then remove the set screw collar 13 6 Loosen the two set screws 14 and then remove the bobbin winder pulley 15 7 Loosen the two set screws 16 and then remove the timing pulley U assembly 17 8 Remove t...

Page 41: ...m the cutter holder 7 4 Remove the bolt 8 and then remove the cutter holder 7 from the cutter driving shaft 9 5 Remove the screw 10 and then remove the cutter sensor setting plate 11 6 Remove the spring 12 from the cutter driving arm assembly 13 and the tension release shaft 14 7 Remove the nut 15 and then remove the adjusting screw assembly 16 from the arm 8 Loosen the two set screws 17 and then ...

Page 42: ...n remove the cutter bar guide 11 7 Remove the cutter driving arm assembly 9 from the arm 8 Remove the cutter driving link 12 the needle bar bracket slide block 13 and the driving shaft holder assembly 14 from the cutter driving arm assembly 9 9 Remove the washer 15 and retaining ring 16 and then remove the cutter link bracket assembly 17 from the cutter link shaft 18 10 Remove the three bolts 19 a...

Page 43: ...motor lever shaft 5 the zigzag connecting rod 6 and the two washers 7 from the motor lever 8 3 Remove the screw 9 and then remover the sensor 10 from the zigzag sensor plate 2 4 Remove the bolt 11 and then remove the zigzag lever F assembly 12 and the thrust washer 13 5 Loosen the set screw 14 and then remove the zigzag connecting rod shaft 15 and the zigzag lever 16 4119Q 4120Q 4121Q 4122Q ...

Page 44: ... the four screws 9 and the screw 10 and then remove the motor bracket assembly 11 from the top of the arm 6 Loosen the set screw 12 and then remove the driving arm presser 13 and the washer 14 7 Remove the four bolts 15 and then remove the presser driving arm 16 from the guide bracket 17 8 Loosen the four set screws 18 and then remove the two guide shafts 19 and the guide bracket 17 9 Remove the b...

Page 45: ...otor FT for presser lifter 3 and the pulse motor N assembly for needle zigzag 4 from the motor bracket 5 2 Remove the two set screws 6 and then remove the gear 7 from the pulse motor FT for presser lifter 3 3 Remove the two set screws 8 and then remove the motor lever 9 from the pulse motor N assembly for needle zigzag 4 4129Q 4130Q ...

Page 46: ...sen the two set screws 10 6 Remove the retaining ring 11 and then remove the tension release shaft 12 tension release cam 13 and tension release driving lever 14 7 Remove the shoulder screw 15 and then remove the presser lifter connecting rod set 16 and the lifter lever assembly 17 8 Remove the two O ring 18 and the two trimmer driving levers 19 9 Remove the spacer 20 washer D 21 and bolt 22 and t...

Page 47: ...e solenoid assembly 6 5 Remove the shoulder screw 7 and then remove the tension release link 8 6 Remove the bolt 9 and plain washer 10 and then remove the plate 11 plunger 12 and spring 13 7 Remove the plunger pin 14 and then remove the plunger 12 tension release rubber assembly 15 and the tension release solenoid link 16 8 Remove the two screws 17 and then remove the tension release solenoid 18 f...

Page 48: ...rom the arm 6 Remove the two tension discs 16 tension disc pressers 17 and 18 tension adjusting spring 19 washer 20 and tension nut 21 from the sub tension stud 22 7 Remove the screw 23 and the washer 24 and then remove the thread take up lever assembly 25 from the tension release shaft 26 8 Remove the shoulder screw 27 and then remove the washer 28 from the arm 9 Remove the screw 29 and the washe...

Page 49: ...Remove the shoulder screw 5 and then remove the bobbin presser bracket assembly 6 and the auxiliary plate 7 4 Remove the shoulder screw 8 and then remove the auxiliary plate 7 and the opening plate 3 5 Loosen the set screw 9 and then remove the bobbin presser 10 from the bobbin presser bracket assembly 6 6 Remove the screw 11 and the nut 12 7 Remove the spring hook U 13 4147Q 4146Q 4145Q ...

Page 50: ...d home position sensor 6 3 Remove the two screws 7 and plain washers 8 and then remove the feed sensor support plate 9 4 Remove the screw 10 and then remove the feed home position sensor 6 from the feed sensor support plate 9 5 Remove the two screws 11 and then remove the feed motor cover 12 6 Remove the two screws 13 and then remove the DC fan motor 40 assembly 5 from the feed motor cover 12 4150...

Page 51: ...t screws 25 and then remove the support shaft 26 13 Remove the timing belt 27 and the pulley B assembly 28 14 Remove the two ball bearings 29 15 Loosen the set screw 30 and then remove the feed guide shaft B 31 from the feed arm support 16 16 Remove the two bolts 32 17 Remove the feed arm support 16 and the feed guide shaft A 33 18 Remove the two retaining rings 34 and then remove the linear bush ...

Page 52: ...e feed arm support shaft 9 from the feed arm support 10 4 Remove the two bolts 11 and washers 12 and then remove the support plate 13 from the feed arm 14 5 Remove the two bolts 15 and washers 16 and then remove the cam 17 from the support plate 13 6 Remove the bolt 18 and plain washer 19 and then remove the feed cover 20 from the feed arm support 10 7 Remove the two bolts 21 and spring washers 22...

Page 53: ...e the shoulder screw 10 and the screw 11 and then remove the lower thread presser 12 from the base plate 5 6 Remove the shoulder screw 13 plain washer 14 washer 15 and then remove lower thread clamp plate assembly 16 from the base plate 5 7 Remove the shoulder screw 17 collar 18 washer U 19 and washer D 20 and then remove the knife driving lever 2 from the base plate 5 8 Remove the two screws 21 a...

Page 54: ...aft 11 washer 12 and retaining ring 13 8 Remove the lower thread trimmer cam lever 14 9 Loosen the two set screws 15 10 Remove the two lever shafts 16 11 Remove the lower thread trimmer cam assembly 17 from the cover 18 12 Remove the cover 18 13 Remove the driving lever roller 19 and shoulder screw 20 and then remove the lower thread trimmer cam connecting rod 21 from the lower thread trimmer cam ...

Page 55: ...2 2 Loosen the two set screws 3 and then remove the set screw collar assembly 4 from the lower shaft 5 3 Loosen the two set screws 6 and then remove the timing pulley assembly 7 from the lower shaft 5 4 Loosen the two set screws 8 and then remove the shaft 9 5 Remove the collar 10 and the idle pulley 11 4169Q 4170Q 4171Q ...

Page 56: ...timing pulley assembly 5 to the lower shaft 7 with the two set screws 6 4 Place the set screw collar assembly 8 onto the lower shaft 7 and then tighten the two set screws 9 after checking the thrust direction The screw flat should align with the set screw which comes first when the lower shaft is rotated in the rotation direction 5 Install the cover 10 with the two screws 11 4173Q 4174Q 4172Q Alig...

Page 57: ...mbly 10 moves smoothly without any play 7 Insert the roller 4 into the lower thread trimmer cam 9 and then install it to the bed with the lower thread trimming cam shaft 14 washer 15 and retaining ring 16 8 Tighten the set screw 17 9 Connect the presser lifter connecting rod set 18 and the lower thread trimmer cam lever 2 with the spacer 19 the plain washer D 20 and the bolt 21 10 Install the lowe...

Page 58: ...the shoulder screw 14 the plain washer 15 and the washer 16 7 Install the lower thread presser 17 to the base plate 2 with the shoulder 18 and the screw 19 8 Install the fixed knife set 20 to the knife driving lever 8 with the two screws 21 9 Install the needle plate 22 with the two flat screws 23 so that it is parallel to the base plate 2 10 Provisionally install the base plate 2 to the top of th...

Page 59: ...ey B assembly 13 to the support shaft 14 with the two set screws 15 10 Install the motor mounting bracket 16 to the feed pulse motor 18 with the four bolts 17 11 Install the pulley A assembly 19 so that there is a gap of 0 5 mm between it and the motor with the two set screws 20 12 Place the timing belt 12 onto the feed pulse motor 18 and then provisionally tighten it with the three screws 21 and ...

Page 60: ...me position sensor 31 to the feed sensor support plate 33 with the screw 32 19 Install the feed sensor support plate 33 to the bed with the two screws 34 and plain washers 35 20 Pass the cords for the feed pulse motor 18 DC fan motor 40 assembly 27 and feed home position sensor 31 through the four cord holders 36 and secure to the bed with the four screws 37 and the two plain washers 38 4192Q 4191...

Page 61: ... 8 to the feed arm support 4 with the bolt 9 and the plain washer 10 6 Install the cam 11 to the support plate 14 with the two bolts 4 37 X 5 12 and plain washers 13 7 Install the support plate 14 to the feed arm 7 with the two bolts 15 and plain washers 16 Feed arm assembly 17 8 Install the feed arm assembly 17 to the feed arm support 4 with the feed arm support shaft 18 9 Tighten the set screw 1...

Page 62: ...er 5 is at the center of the bobbin case 7 4 Install the auxiliary plate 8 and the opening plate 9 with the shoulder screw 10 5 Install the bobbin presser bracket 2 and the auxiliary plate 8 to the bed with the shoulder screw 11 6 Install the opening plate 9 to the rotary hook cover 13 with the shoulder screw 12 7 Attach the two extension springs 14 8 Turn on the power and after the sewing machine...

Page 63: ...ulder screw 16 8 Adjust the position of the tension release solenoid assembly 14 using a gauge so that the tension release link 12 protrudes from the edge of the tension stud bracket assembly 17 on the arm by 19 2 0 2 mm and then tighten the two screws 15 9 Insert the tension release pin 18 into the tension stud bracket assembly 17 and then insert it into the arm 10 Tension the set screw 19 so tha...

Page 64: ...p lever assembly 13 to the tension release shaft 18 with the screw 16 and the washer 17 7 Place the two tension discs 19 tension disc pressers 20 and 21 tension adjusting spring 22 washer 23 and tension nut 24 onto the sub tension stud 25 Sub thread tension assembly 26 8 Insert the tension release pin 27 into the sub thread tension assembly 26 and then install it to the arm Adjust the thread tensi...

Page 65: ...ion release shaft 15 and then insert into the arm 8 Insert the tension release cam 17 into the tension release shaft 15 Pass the tension release shaft 15 through the tension release driving lever 14 and install the retaining ring 18 9 While pushing the tension release shaft 15 in the direction of the arrow A and also pushing the tension release driving lever 14 in the direction of the arrow B tigh...

Page 66: ...he gear 5 to the pulse motor FT assembly for presser lifter 4 with the two set screws 6 so that the dimensions are as shown in the illustration 3 Install the pulse motor N assembly for needle zigzag 1 and the pulse motor FT assembly for presser lifter 4 to the motor bracket 9 with the four bolts 7 and the three bolts 8 so that the directions of the cords are as shown in the illustration Motor brac...

Page 67: ...ser driving arm 8 and insert into the motor bracket assembly 6 Provisionally tighten the set screw 12 7 Tighten the four bolts 9 and the set screw 12 so that the presser driving arm 8 moves up and down easily and so that there is no play in the gear 8 Insert the motor bracket assembly 6 into the arm from the top 9 Position the motor bracket assembly 6 using the two positioning pins 13 and then ins...

Page 68: ...Pass the zigzag lever assembly F 10 through the arm and position it in the thrust direction using the thrust washer 11 and the zigzag lever 2 6 Secure the zigzag lever assembly F 10 by tightening the bolt 12 7 Install the sensor 13 to the zigzag sensor plate 15 with the screw 14 8 Insert the wick 16 into the motor lever shaft 17 9 Pass the motor lever shaft 17 through the zigzag connecting rod 3 a...

Page 69: ...from the factory 9 Install the solenoid stopper 13 to the solenoid plunger with the spring washer 14 and the two nuts 15 as shown in the illustration 10 Install the cutter solenoid 12 to the cutter solenoid bracket 17 with the three bolts 16 At this time install so that the oil tube 18 passes underneath the cutter solenoid bracket 17 11 Provisionally tighten the bolt 20 to the cutter link bracket ...

Page 70: ...learance between the edges of the cutter link bracket assembly 6 and the cutter solenoid 7 is 1 5 mm or when dimension A is 15 5 mm 5 Install the adjusting screw assembly 9 to the arm and secure it with the nut 10 so that the stepped section of the cutter driving shaft 1 protrudes by 5 mm from the processed surface of the arm jaw 6 Attach the spring 11 to the cutter driving arm assembly 12 and the...

Page 71: ...is in the center of the cutter groove in the needle plate 26 when the cutter is lowered 13 Tighten the two screws 23 so that the distance between the needle bar 27 and the cutter 24 is 0 3 mm 14 Install the cutter 24 with the screw 25 so that the tip A of the cutter blade is aligned with the top of the needle plate when the cutter is pressed down by hand to its lowest position If using the flat cu...

Page 72: ...read take up crank 11 and the two set screws 14 so that there is no play 8 Provisionally install the tension pulley assembly 15 with the two bolts 15 and plain washers 17 9 After installing the needle bar in 3 18 Needle bar and thread take up mechanism 2 set the phase between the upper shaft and the lower shaft so that the mating mark A on the lower shaft timing pulley 18 is facing straight down w...

Page 73: ...asher 8 4 Clamp the oil tube assembly 1 under the cord holder 6 5 Install the tube support 9 with the screw 10 and then secure the oil assembly 1 and the oil tube 5 that is connected between the oil terminal and the oil outlet so that they do not touch the pulse motor for presser lifter 6 Install the oil tube 11 that is connected to the oil terminal and the plunger pump with the tube support M 12 ...

Page 74: ... the thread take up support hole as shown in the illustration 4 Insert the washer 7 into the thread take up lever set 5 and then install it to the thread take up crank 8 5 Insert the needle bar bracket slide block 4 into the groove in the crank rod guide 1 6 Secure the thread take up crank 8 by tightening the two set screws 9 7 Insert the support shaft 10 and secure it by tightening the set screw ...

Page 75: ...nd 8 and then install it 6 Pass the wick 11 of the needle bar bracket support shaft 10 through the arm 7 Insert the needle bar bracket support shaft 10 and then secure it by tightening the set screw 12 so that there is no play in the needle bar bracket assembly 1 8 Insert the needle bar bracket guide 13 into the arm and then secure it by tightening the set screw 14 so that there is no play in the ...

Page 76: ... the two screws 13 7 Tap in the rubber cap 16 8 Install the presser roller bracket 10 to the presser bar 14 with the screw 17 9 Connect the presser bar guide bracket assembly 5 and the knee lifter lever 18 with the shoulder screw 19 10 Place a 10 mm gauge 21 underneath the work clamp 20 11 Turn on the power and after the mechanism moves to the home position check that the setting for memory switch...

Page 77: ...tall the support stud 13 to the setting plate 16 with the nut 14 and the plain washer 15 7 Install the setting plate 16 to the upper thread trimmer lever assembly 7 with the two screws 17 and plain washers 18 8 Press fit the longitudinal feed arm pin 19 onto the longitudinal feed arm 20 and then secure it by tightening the set screw 21 9 Place the longitudinal feed arm roller 22 onto the longitudi...

Page 78: ...e trimmer driving lever 44 with the bolt 43 17 Turn on the power and after the mechanism moves to the home position press the RESET key to lower the work clamp 18 Tighten the bolt 40 so that the slot of the upper thread trimmer lever set 34 and the edge of the washer 35 are aligned 19 Tighten the bolt 43 so that the stop plate 9 and the stopper 30 are in the positions shown in the illustration 20 ...

Page 79: ...nstall the thread breakage sensor assembly 6 with the two screws 7 3 Install the cutter bar fixing plate 8 to the thread breakage perceiving shaft 1 with the set screw 9 4 Install the balancer 10 to the cutter bar fixing plate 8 with the screw 11 5 Install the lever stopper 12 at the correct angle with the screw 13 6 Provisionally install the lever stopper 14 with the screw 15 After installing car...

Page 80: ...upper shaft may occur 3 Insert the wick 7 into the bush F 2 and insert the felt 8 to stop them from coming out 4 Pass the wick 9 through the tube support U 10 and push it firmly into the upper shaft lubrication hole 5 Pass the wick 11 through the tube support U 10 and push it firmly into the zigzag lever shaft lubrication hole 6 Install the tube support U 10 with the screw 12 7 Pass the oil tube 1...

Page 81: ...felt support assembly 5 to the motor bracket 10 with the screw 9 so that the felt 6 of the felt support assembly 5 is gently touching the felt 8 of the zigzag connecting rod 7 3 Pass the oil tube 1 around the outside of the tube support U 2 as shown in the illustration so that it does not touch the solenoid stopper 11 and then pass it in between the cutter solenoid 12 and the arm 4266Q 4267Q ...

Page 82: ... Install the tube support 9 to the wick base support 11 with the screw 10 7 Attach the oil tube 8 to the tube support 9 and then install the oil terminal 3 to the wick base support 11 with the two screws 12 8 Pass the wick 13 from the needle bar bracket the two wicks 14 from the bush and the wick 15 from the support shaft through the oil tube 16 and then install the felt base A 17 to the wick base...

Page 83: ...ort 9 to the bed with the screw 10 6 Insert the oil tube 11 that is connected between the oil terminal and the plunger pump through the lubricating hole to the left of the bush M 4 7 Pass the oil tube 13 that is connected between the oil terminal and the oil outlet through the tube support D 12 and then install the tube support D 12 to the bed with the screw 14 8 Secure the four tubes that are com...

Page 84: ... 5 into the hole in the bush 3 and stop it from turning 5 Install the felt support 6 to the bed with the two screws 7 6 Pass the wick 1 through the felt support 6 and then tie a knot in it 7 Pass the wick 8 through the felt support 6 and then tie a knot in it 8 Insert the rubber presser 9 into the bed and then secure it with the spring 10 and the screw 11 As a guide for the lubrication amount the ...

Page 85: ...the rotary hook 3 and the rotary hook joint assembly 1 are aligned 3 Adjust the needle clearance and timing Refer to 4 6 Adjusting the needle and rotary hook timing 4 Install the rotary hook holder 5 with the two screws 6 3 24 Covers 1 Install the cover 1 the face plate 2 and the eye guard assembly 3 2 Install the rear cover 4 the belt cover 5 and the top cover 6 4278Q 4279Q Screw stop side 4280Q ...

Page 86: ...urning off the power to make adjustments Do not force any of the parts to move as doing so may result in damage to the parts Be sure to turn the machine pulley to raise the needle bar to its highest position before making adjustments If this is not done the pulley position the direction of rotation of the rotary hook may cause the lower thread trimmer mechanism to touch the rotary hook when the lo...

Page 87: ...eed mechanism is operated arrow c the upper thread trimmer assembly 3 is forced to go behind the opening cam 4 Depending on the case the rising section 6 of scissors M 5 goes into the hollow shown in the figure and the feed mechanism cannot then operate At this time when feed mechanism home positioning is carried out the feed pulse motor goes out of step Operate the feed mechanism when the conditi...

Page 88: ... of the zigzag sensor plate 2 The adjustment required is only slight so move the zigzag sensor plate 2 a little bit at a time 4 Repeat the procedure from step 1 5 After adjusting check that the needle bar bracket 3 and the stopper screws 4 and 5 are not touching when in test feed mode If they are touching adjust the stopper screws 4 and 5 If the needle bar is at its furthest zigzag position place ...

Page 89: ... key to lower the work clamp 2 If the clearance between the feed arm support 1 and the linear bushing 2 is 2 mm the following adjustment is not necessary If the clearance is not 2 mm turn off the power 3 Loosen the screw 3 and adjust the position of the feed sensor support plate 4 4 Repeat the procedure from step 1 4287Q Feed sensor Check that they are not touching ...

Page 90: ...p sensor LED lights This is the provisional position for the work clamp home position sensor The final position is determined when making the adjustment in 4 14 8 Adjusting the upper thread scissors opening timing 4 Set the sewing machine to the home position and then press the RESET key Check that there is no impact noise and that the motor does not go out of step when the work clamp is lowered a...

Page 91: ... rubber cap 2 7 Check that the cutter flank of the needle bar 1 is at a right angle to the cutter Note If the installation positions are not correct the needle bar 1 and the cutter may touch when the needle zigzags which may result in noise or cause the needle to break 4 6 Adjusting the needle and hook timing 1 Turn on the power and set the sewing machine to the home position Then press the RESET ...

Page 92: ...01 Gauge 805 2 4 6 1 Adjusting the clearance between needle and hook point Loosen the set screws 3 and move the rotary hook 4 forward or back until there is a clearance of 0 01 to 0 08 mm between the needle 1 and the hook point 2 When tightening the set screws 3 tighten the one on the screw stop side first 4293Q 4292Q 4296Q 4295Q 4294Q 2840Q Screw stop side 2839Q 0 01 0 08 mm ...

Page 93: ...be about 70 N 4 9 Adjusting the work clamp lift amount 1 Turn on the power and set the sewing machine to the home position 2 Check that memory switch No 05 work clamp height at neutral position is set to 10 mm If it is not set to 10 mm set it to 10 mm 3 Place a 10 mm gauge under the work clamp 1 and then loosen the set screw 2 to make the adjustment Adjust the lift amount including the play in the...

Page 94: ...2 Operate the treadle and check that the work clamp moves up and down smoothly After adjusting check the upper thread trimmer mechanism and adjust if necessary 4 11 Adjusting the cutter home position sensor position Loosen the screw 3 and then adjust the cutter sensor setting plate 4 so that there is a clearance of 4 5 0 5 mm between the side of the cutter sensor 1 and the edge of the solenoid sto...

Page 95: ...m Note When replacing the cutter be careful not to allow the cutter to touch the needle bar because of any play in the cutter installation position 2 Loosen the two bolts 7 and adjust the cutter X direction using cutter holder M 8 so that the cutter 1 goes into the center of the cutter groove 3 Loosen the bolt 9 and move the cutter holder 10 to adjust the direction of rotation 4 Check that the edg...

Page 96: ...cutter installation height Adjust so that the upper thread scissors and the cutter do not touch when the cutter is pushed down by hand Fig A Fig B in 4 12 Adjusting the cutter installation position Install the cutter with the screw 1 so that the tip A of the cutter blade is aligned with the top of the needle plate when the cutter is pressed down by hand to its lowest position If using the flat cut...

Page 97: ... timing of the upper thread scissors has been changed When the opening timing of the upper thread scissors has been changed 4 4 Adjusting the work clamp home position sensor position 1 1 4 14 1 Adjusting the longitudinal feed arm assembly position 2 2 1 4 14 2 Adjusting the trimmer driving arm assembly position 3 3 2 1 4 14 3 Adjusting the lateral position of the upper thread scissors at the sewin...

Page 98: ...s aligned with the edge of the washer 2 3 If they are not aligned loosen the bolt 3 and move the longitudinal feed arm assembly 4 back and forth to adjust 4 14 2 Adjusting the trimmer driving arm assembly position 1 Turn on the power and set the sewing machine to the home position Then press the RESET key to lower the work clamp 2 Check that the overlap between the stopper 2 fixed to the trimmer d...

Page 99: ... when they open 3 After adjusting carry out 4 14 8 Adjusting the upper thread scissors opening timing 4 14 4 Adjusting the longitudinal position of the upper thread scissors 1 Turn off the power with the feed mechanism at the home position and then slowly move the trimmer driving arm 1 forward until the upper thread scissors assembly 2 is at the position shown in the illustration 2 Loosen the two ...

Page 100: ...heck code function can help with making this adjustment If you press parameter keys 4 and 5 while operating at check code 08 the presser lifter pulse motor will operate one step at a time Refer to 6 8 Output check list 2 Loosen the bolt 9 and then adjust the driving arm roller 3 so that the clearance between the stopper 7 of the upper thread scissors assembly 6 and the opening cam bracket 8 is 0 0...

Page 101: ... move the upper thread scissors 5 up or down to adjust the clearance between the upper thread scissors 5 and the work clamp 6 to approximately 1 mm Note The work clamp 6 will tilt when sewing joints so adjust so that the upper thread scissors 5 do not touch it If the upper thread scissors 5 touch the work clamp 6 the work clamp lifter pulse motor may get out of step If the tilting of the work clam...

Page 102: ...ween the rising section B of the upper thread scissors 2 and the tip of the opening cam 1 is approximately 0 5 mm when the upper thread scissors 2 are closed If you would like the scissors to start opening earlier make the distance smaller However if you make the distance smaller check that the rising section B of the upper thread scissors 2 does not touch the opening cam 1 and prevent the upper t...

Page 103: ...ck plate 1 and the cam 2 to approximately 2 mm If you would like the scissors to start opening earlier make this clearance smaller 4 Check that the distance A between the upper thread scissors 6 and the center of the needle is 5 5 6 mm 5 If the distance A is outside the range of 5 5 6 0 mm loosen the two screws 7 and move the dog 8 in the direction of the arrow slightly and then tighten the screws...

Page 104: ... two screws 1 and then adjust the lower thread retainer 2 to a distance of 1 2 mm as shown in the illustration If the lower thread retaining amount has been reduced check that the roller B of the lower thread clamp plate 3 is sitting securely on top of the lower thread retainer cam A If the lower thread is pulling up at the first stitch at the sewing start check if the lower thread is not being pu...

Page 105: ... inside the seam If the opening timing is too early it can cause problems such as poor winding or pulling up of the lower thread If the opening timing is too late it can cause problems such as stretching uneven seams or bird s nests at the sewing start depending on the type of material Note After moving the lower thread trimmer cam lever 6 back in the direction of the arrow move the feed mechanism...

Page 106: ...clamp 2 Loosen the set screw 1 and then adjust so that the bobbin presser 2 goes into the hole in the bobbin case 3 3 Check that the work clamp is at the home position and then loosen the nut 4 and turn the screw 5 to adjust the clearance A between the bobbin presser 2 and the edge of the bed to approximately 12 5 mm 4 Turn off the power move the lower thread trimmer cam lever 6 by hand in the dir...

Page 107: ...t so that the distance C at the balancer 8 is 4 mm 5 Turn on the power and set the sewing machine to the home position Then press the RESET key to lower the work clamp 6 Loosen the two screws 10 and then adjust so that the thread breakage detector sensor 9 turns on LED illuminates when the distance between the thread breakage detection lever 2 and the lever stopper 1 is 1 mm 7 When the thread guid...

Page 108: ...raised 4 Press the RESET key once more and check that the tension discs are fully closed when the work clamp is lowered 4 19 Adjusting the thread tension at the zigzag tension control Position the tension release solenoid as described in 3 7 Tension release mechanism 1 before carrying out this adjustment 1 Turn on the power and set the sewing machine to the home position Then press the RESET key t...

Page 109: ...ors 4 21 Adjusting the feed timing belt 1 Remove the bolt 1 and the nut 2 2 Loosen the three screws 3 so that the feed pulse motor 4 moves easily 3 While using a spring gauge to push the notch in the motor mounting bracket 5 with a force of 98 N tighten the screws 3 4 Check that the timing belt 6 moves smoothly 5 Gently tighten the bolt 1 and the nut 2 If you do not have a spring gauge adjust the ...

Page 110: ...the adjusting screw 2 to adjust the lubrication amount Adjust so that approximately 10 drops of oil are released when the sewing machine is run at a speed of 4 000 rpm for three cycles to sew about 114 stitches Use Kraft paper 3 or similar to catch the oil drops As a guide the optimum position can be obtained if the adjusting screw 2 is tightened as much as possible and then loosened about two tur...

Page 111: ...4 when the sewing machine is started and error code E 02 will be displayed Turn the machine pulley to move the index mark 2 to the correct position and then start the sewing machine 4 25 Adjusting the V belt tension 1 Remove the three screws and then remove the belt cover 2 Turn the two nuts 2 to adjust so that there is 10 14 mm of deflection in the V belt 1 when it is pressed at the midway point ...

Page 112: ... Thread the lower thread correctly Instruction manual Flaw or abrasion on the thread path Polish with buff or replace the part Especially pay attention to finishing around needle plate hole Flaw on the rotary hook point and rotary hook edge Polish with buff or replace the part Thread path Flaw on the rotary hook holder Polish with buff or replace the part 85 Zigzag thread upper thread tension Adju...

Page 113: ...t Insert the end of the needle shank so that it touches the top edge of the needle hole of the needle bar Bent needle Replace needle Blunt needle tip or burr Replace needle Needle Thin needle Use a needle with a count that matches the thread and material Thread take up spring Thread take up spring tension and stroke Loosen the thread take up spring tension or shorten the stroke to such a degree th...

Page 114: ...material replace with the 3 needle plate Replace with a needle plate with a smaller needle hole Joint sewing Angle of work clamp means that material is not being clamped Replace with short work clamp that matches the sewing length Use the accessory auxiliary sheet Process the work clamp assembly to match the joint section Attach or remove rubber 93 5 3 Uneven seams 1 At the sewing start Cause Chec...

Page 115: ...uce the setting for memory switch No 02 Instruction manual 5 4 Uneven seams 2 Lower thread is lifted up at the sewing start The end of the lower thread protrudes above the seam at the sewing start Cause Check Remedy Page Lower thread retainer Lower thread retaining amount Adjust the lower thread retaining amount 96 Lower thread clamp opening timing Adjust so that the lower thread clamp plate opens...

Page 116: ...ension disc opening Check the opening of the zigzag tension discs Replace the tension release solenoid 100 Thread tension Lower thread tension Adjust the lower thread tension appropriately Instruction manual Upper thread threading Thread the upper thread correctly Instruction manual Threading Lower thread threading Thread the lower thread correctly Instruction manual Stitch patterns Purl stitch wh...

Page 117: ...g timing 94 95 Upper thread scissors operation Apply grease to the inclined face of the opening cam 94 Uneven material feeding Lower thread clamp opening timing Adjust so that the lower thread clamp plate opens when the feed mechanism moves 6 7 mm 97 5 11 Uneven seams 9 Sticking in needle plate Front and rear tack sections of material gets stuck in needle hole Cause Check Remedy Page Start backtac...

Page 118: ...its for the thread Flaw on the rotary hook holder Polish with buff or replace the part 85 Rotary hook holder Rotary hook holder and inner rotary hook overlap amount Adjust the rotary hook holder and inner rotary hook overlap amount 85 Rotary hook Rotary hook lubrication Decrease the quantity of lubrication oil Note that if you reduce the amount of oil too much thread breakages may occur 102 Bobbin...

Page 119: ...ce them so that the correct force is applied Repair any damage from striking the needle Upper thread trimmer assembly Opening cam position Adjust the position so that the scissors do not touch the opening cam when the work clamp is lowered 94 End of tension release at the beginning of sewing Use parameter number 63 to retard the tension release timing Instruction manual Tension release timing Open...

Page 120: ...ead retaining amount 96 Lower thread snapping Use memory switch No 02 to retard the work clamp lifting speed Process the lower thread retainer lower thread clamp and lower thread presser plate so that they do not snap the lower thread Instruction manual Lower thread Lower thread clamp opening timing Adjust so that the lower thread clamp plate opens when the feed mechanism moves 6 7 mm 97 Slow spee...

Page 121: ...upper thread trimmer M and upper thread trimmer U Polish with buff or replace the part Tension release timing Opening amount of zigzag tension discs and bar tack tension discs particularly zigzag tension discs Adjust the zigzag tension discs by moving the tension stud bracket in and out Adjust the bar tack tension discs opening amount to 0 5 1 0 mm by removing the top cover and moving the tension ...

Page 122: ...eplace them so that the correct force is applied Repair any damage from striking the needle Trimmer driving arm Upper thread trimmer cutting depth Adjust the position of the trimmer driving arm roller 92 5 16 Needle strikes upper thread trimmer Cause Check Remedy Page Installation position of upper thread trimmer assembly Adjust the installation position of upper thread trimmer assembly by moving ...

Page 123: ...ng the sewing machine to the home position press the RESET key and then adjust the distance between the upper thread trimmer and the center of the needle when the work clamp is lowered to 5 5 6 0 mm 82 95 Upper thread trimmer lever Upper thread trimmer lever operating force Adjust so that the upper thread trimmer lever opens gently when the stop plate is separated from the stopper 5 17 Needle brea...

Page 124: ... right angle to the cutter 83 5 18 Imperfect cutter function imperfect material cutting Cause Check Remedy Page Installation position of cutter Install the cutter so that its edge is aligned with the top of the needle plate 88 Cutter blade If blade is worn or chipped sharpen it or replace it Replace with the special needle plate optional Instruction manual Cutter Damage to cutter mechanism parts L...

Page 125: ...s smoothly with no play 61 5 20 Cutter and upper thread scissors touch Cause Check Remedy Page Upper thread scissors Check if the cam opens the stop plate Adjust the cam position If the feed mechanism operates when the cam has not opened the stop plate the cutter will bump against the upper thread scissors 95 5 21 Seam is cut Cause Check Remedy Page Length of knife setting Length of knife Set para...

Page 126: ...terial is properly stretched When using knits or woven materials replace the parts with the 3 specification parts Length feed plate for specification 3 work clamp assembly for knits needle plate 1 2 for specification 3 85 Underlay Underlay is being sewn Use parameter number 52 to reduce the underlay sewing start pitch to about 0 5 Use parameter number 48 to reduce the underlay sewing speed If sewi...

Page 127: ... Check for loose screws in the upper thread trimmer lower thread trimmer and work clamp lifter mechanisms Securely tighten all screws Work clamp lifting height setting Check the work clamp lifting height setting Change the settings of memory switch Nos 04 05 06 If the work clamp lifting height is too high the lower thread trimming operation will not be timed together with the work clamp rising and...

Page 128: ...e set installation position 96 Fixed knife set Knife tip is bent or chipped Repair or replace the knife 5 26 Feed mechanism does not operate or motor is out of step Cause Check Remedy Page Feed pulse motor Cord connection Check the cord connections and contacts Upper thread scissors position Remove and re install the upper thread scissors 91 Upper thread scissors Check if the cam opens the stop pl...

Page 129: ... stop even when the thread is not broken 99 Pauses Panel DIP switch A No 3 When panel DIP switch A No 3 is set to ON sewing will pause when the treadle is depressed backward If the treadle is depressed very firmly and then released the pedal may depress backward and cause sewing to be paused Instruction manual Threading Upper thread threading Pass the thread correctly through the thread guide Inst...

Page 130: ...st 5 minutes after the power is turned off before doing the following Opening and closing the control box Replacing fuses Separating and joining connectors Measuring resistance Doing anything with a possibility of touching something inside the control box Some adjustments require measuring the voltage while the power is turned on with the control box kept open In such a case be careful not to touc...

Page 131: ...ircuit board These are secured to the bases of the first and second levels of the control box and they generate the voltages which are necessary for the various control operations Panel PCB The panel PCB is fixed to the front panel of the operation panel This PCB controls indications of the machine status and the input operation DC fan motor The DC fan motor serves as a fan to cool the inside of t...

Page 132: ...rt name Part code When a fuse has blown Voltage F1 F2 Fuse 15A 2 glass tube fuse 15A 250V 218469 001 The zigzag motor does not operate The tension release solenoid does not operate The operation panel does not operate The control box fan does not operate AC200V F3 F4 Fuse 2A250V glass tube fuse 2A 250V J02727 001 The feed motor and presser foot motor do not operate The cutter solenoid does not ope...

Page 133: ...or problems including improper connection or sufficient 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 6 4 1 Connector positions Main circuit board Sub circuit board 4370Q 4371Q ...

Page 134: ...6 ELECTRIC COMPONENTS AND SOFTWARE HE 800A 126 1 step power supply circuit board 2 step power supply circuit board Panel PCB 4372Q 4373Q 4374Q ...

Page 135: ...E 41 is displayed P3 SYNC Pin no Signal name Probable symptoms due to poor contact 1 5V 2 Encoder signal 3 Needle up stop position signal 4 Needle down stop position signal 5 0V The machine motor does not turn A machine stopping error occurs One of error E 02 E 62 E 63 and E 64 is displayed P4 PANEL Pin no Signal name Probable symptoms due to poor contact 1 5V 2 0V 3 KEY0 4 KEY1 5 KEY2 6 OC 7 A 8 ...

Page 136: ... does not operate One of error E 30 E 31 and E 32 is displayed P9 HPEDAL Standing operation pedal option Pin no Signal name Probable symptoms due to poor contact 1 P8V 8V 2 Work clamp FORSW signal 3 Backward BAKSW signal 4 0V 5 Spare INCHSW signal 6 Start PRSW signal 7 Spare HPEDAL signal The home position can not be found Work clamp does not operate The machine does not operate One of error E 30 ...

Page 137: ...due to poor contact 1 24V 2 FAN1 signal 3 0V The exhaust fan does not operate Error E 42 is displayed P14 AC18V Pin no Signal name Probable symptoms due to poor contact 1 AC18V D10V input 2 AC18V D10V input 3 4 5 AC18V N input 6 AC18V N input 7 8 9 AC18V A input 10 AC18V A input 11 12 13 AC18V B input 14 AC18V B input 15 16 17 AC18V C input 18 AC18V C input 19 20 21 AC18V D input 22 AC18V D input ...

Page 138: ...olenoid does not operate P20 AC17 AC30V Pin no Signal name Probable symptoms due to poor contact 1 AC30V input 2 AC30V input 3 4 AC17V input 5 AC17V input The tension release solenoid does not operate The control box fan does not operate One of error E 41 and E 42 is displayed P22 EXPAND1 Pin no Signal name Probable symptoms due to poor contact 1 5V 2 5V 3 5V 4 5V 5 24V 6 24V 7 24V 8 24V 9 Feed PM...

Page 139: ...does not operate P23 EXPAND2 Pin no Signal name Probable symptoms due to poor contact 1 Input signal spare 1 2 Input signal spare 2 3 Input signal spare 3 4 Input signal spare 4 5 Input signal spare 5 6 Cutter home position sensor signal 7 Feed PM overcurrent signal 8 Work clamp PM overcurrent signal 9 55V relay input signal 10 55V voltage watch signal 11 12 13 0V 14 0V 15 0V 16 0V 17 18 19 20 21 ...

Page 140: ...nd E 07 is displayed 55 V power supply for driving the feed mechanism and work clamp PM control is not possible Error E 44 is displayed The valve does not operate P2 FDPM Pin no Signal name Probable symptoms due to poor contact 1 Feed PM driving current A 2 Feed PM driving current B 3 Feed PM driving current C 4 Feed PM driving current D 5 Feed PM driving current F The feed home position can not b...

Page 141: ...E 07 is displayed P6 POWER Pin no Signal name Probable symptoms due to poor contact 1 55V for PM power supply DC55V 2 55V for PM power supply DC55V 3 P0V 4 P0V 5 24V 6 0V 7 M55V for cutter power supply DC55V 8 M55V for cutter power supply DC55V 9 MP0V 10 MP0V The work clamp home position and feed home position can not be found The work clamp mechanism and feed mechanism do not operate One of error...

Page 142: ... spare 1 4 0V 5 24V 6 5V 7 Input signal spare 2 8 0V 9 24V 10 5V 11 Input signal spare 3 12 0V 13 0V 14 0V Special edition P10 FAN1 Pin no Signal name Probable symptoms due to poor contact 1 24V 2 FAN1 signal 3 0V The feed pulse motor cooling fan does not spin P11 OPSOL Pin no Signal name Probable symptoms due to poor contact 1 55V 2 55V 3 55V 4 Spare solenoid driving current 7 5 Spare solenoid dr...

Page 143: ...rcurrent signal 8 Work clamp PM overcurrent signal 9 55V relay input signal 10 55V voltage watch signal 11 12 13 0V 14 0V 15 0V 16 0V 17 18 19 20 21 Cutter return signal 22 Cutter signal 23 Cutter signal 24 Spare solenoid 1 25 Spare solenoid 2 26 Spare solenoid 3 The feed home position and work clamp home position can not be found The feed mechanism and work clamp mechanism do not operate One of e...

Page 144: ... no Signal name Probable symptoms due to poor contact 1 AC220 R 100 110 220 380 400V specifications 2 3 AC220 T 100 110 220 380 400V specifications 4 The zigzag home position can not be found The zigzag mechanism does not operate Error E 05 is displayed The tension release solenoid does not operate CN4 Pin no Signal name Probable symptoms due to poor contact 1 AC230 240 R 230V specifications 2 3 4...

Page 145: ...e Error E 08 is displayed P3 PER Pin no Signal name Probable symptoms due to poor contact 1 Relay input signal 2 0V 3 55V relay output signal 4 55V OFF signal 5 0V The feed home position and work clamp home position can not be found The feed mechanism and work clamp mechanism do not operate One of error E 06 and E 07 is displayed 55 V power supply for driving the feed mechanism and work clamp PM c...

Page 146: ...cuit board connectors Panel PCB P1 PANEL Pin no Signal name Probable symptoms due to poor contact 1 5V 2 0V 3 KEY0 4 KEY1 5 KEY2 6 OC 7 A 8 B 9 C 10 D 11 E 12 F 13 G 14 STB 15 P8V 16 SENSOR 17 BUZZER 18 0V 19 0V 20 0V The operation panel does not operate ...

Page 147: ...mplete OFF ON 2 OFF OFF ON Pausing enabled during automatic sewing when the treadle is depressed backward 3 OFF Pausing disabled during automatic sewing when the treadle is depressed backward OFF ON Display setting during automatic mode bobbin thread counter Default 100 4 OFF Display setting during automatic mode production counter Default 0 OFF ON 2 cycle sewing ON All programs will be set to 2 c...

Page 148: ...lamp size 5 4 19 0 mm Sewing area 4 0 15 0 mm 3 4 5 OFF OFF OFF Panel DIP switches B No 7 and No 8 are enabled OFF OFF OFF ON Needle plate size 5 4 mm Max needle zigzag feed width 4 0 mm 6 OFF Needle plate size 7 3 mm Max needle zigzag feed width 6 0 mm OFF ON ON Work clamp size 7 3 47 0 mm Sewing area 6 0 40 0 mm ON OFF Work clamp size 6 8 47 0 mm Sewing area 5 4 40 0 mm OFF ON Work clamp size 5 ...

Page 149: ...ging any of the DIP switch settings 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 1 No ON OFF Setting items Default ON 1 OFF OFF ON 2 OFF OFF ON 3 OFF OFF ON 4 OFF OFF ON 5 OFF OFF ON 6 OFF OFF ON Three warning beeps 7 OFF Continuous warning beep OFF ON Zigzag motor energization is turned off during pauses o...

Page 150: ...ting possible regardless of work clamp position OFF ON During standing pedal operation the work clamp lowers only while the work clamp pedal is being depressed 3 OFF During standing pedal operation the work clamp keeps lowering when the work clamp pedal is released OFF ON 4 OFF OFF ON 5 OFF OFF ON 100V 110V specifications 6 OFF 200V 220V 230V 380V 400V specifications ON OFF ON 7 OFF OFF ON 8 OFF O...

Page 151: ...isplay LED 5 4 Press the parameter keys 6 and 7 to change the parameter setting and then press the ENTER key 1 The parameter setting will be changed and the parameter display LED 5 will stop flashing and illuminate steadily 5 Press the SELECT key 8 to change the mode to automatic mode No Setting items Setting range Unit Default 00 Machine motor stopping position 5 70 forward for larger values 1 47...

Page 152: ...nd the check mode value will be displayed in the program No LED 2 2 Press the program No keys 3 and 4 to select a desired check mode F1 F3 3 When the switch or sensor is turned on the corresponding segment on the parameter display LED 5 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 4 When returning to normal o...

Page 153: ...ion sensor Segment 3 C 16 Cutter home position sensor Segment 3 D 17 Upper thread breakage detection sensor Segment 3 F 18 Stop switch Segment 2 A 19 F1 Pause connection signal Segment 2 B 20 Panel DIP switch B No 1 Segment 4 A 21 Panel DIP switch B No 2 Segment 4 B 22 Panel DIP switch B No 3 Segment 4 C 23 Panel DIP switch B No 4 Segment 4 D 24 Panel DIP switch B No 5 Segment 4 E 25 Panel DIP swi...

Page 154: ... P 44 Circuit board DIP switch 1 No 1 Segment 1 A 45 Circuit board DIP switch 1 No 2 Segment 1 B 46 Circuit board DIP switch 1 No 3 Segment 1 C 47 Circuit board DIP switch 1 No 4 Segment 1 D 48 Circuit board DIP switch 1 No 5 Segment 1 E 49 Circuit board DIP switch 1 No 6 Segment 1 F 50 Circuit board DIP switch 1 No 7 Segment 1 G 51 F2 Circuit board DIP switch 1 No 8 Segment 1 D P 52 F3 Pedal swit...

Page 155: ...ome position 13 mm At this time the upper thread trimmer and lower thread trimmer operate together with the work clamp C 04 The buzzer sounds for one second and then the needle zigzag motor starts operating 3 mm 3 mm C 05 The buzzer sounds for one second and then the feed motor starts operating 1 mm 40 mm C 06 The buzzer sounds for one second and then the feed mechanism operates for 15 mm then mov...

Page 156: ...rd is properly connected E 02 Needle up sensor is OFF 1 Turn the pulley by hand to set the needle to its highest position 2 Check if the sewing machine operation is sluggish because of a reason such as thread tangled around the rotary hook 3 If an error still occurs after 1 and 2 are carried out check that connector P3 on the main P C board is properly connected E 05 Zigzag positioning is not carr...

Page 157: ...ntrol box is being properly ventilated 2 Clean the filter of the air intake and the cooling fan Remove dust E 41 Inside air circulation fan problem 1 Turn off the power and clean the inside air circulation cooling fan Remove dust 2 Check that connectors P13 and P20 on the main P C board are properly connected 3 Check that connectors CN2 CN3 and CN4 on the 1 step power supply circuit board are prop...

Page 158: ...e main P C board is properly connected E 64 Timing signal error during operation 1 Turn off the power 2 Turn the pulley by hand and check if the upper shaft locks or not 3 If an error still occurs after 1 is carried out check that connector P3 on the main P C board is properly connected E 70 Machine motor running error 1 Turn off the power 2 Check that machine motor harness connector CN7 on the 1 ...

Page 159: ... Turn off the power 2 Check the power supply voltage in the workplace and the power supply voltage specifications for the control box 3 Check the connection positions of connectors CN2 CN3 and CN4 on the 1 step power supply circuit board 200V specification CN2 100V 110V 220V 380V 400V specifications CN3 230V specification CN4 E 97 Machine motor locked Excessive load during sewing Motor temperature...

Page 160: ...6 ELECTRIC COMPONENTS AND SOFTWARE HE 800A 152 ...

Page 161: ...6 ELECTRIC COMPONENTS AND SOFTWARE HE 800A 153 6 10 Control circuit block diagram 4380Q ...

Page 162: ...SERVICE MANUAL HE 800A I3120853F 2004 02 F 1 http www brother com Printed in Japan ...

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