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Brother LH4-B800E, Service Manual

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Brother LH4-B800E Service Manual Download Page 30

LH4-B800E

2 - 5

2. DISASSEMBLY

t

t

r

r

e

w

q

o

i

u

y

For long-hole specifications (-5)

Remove feed guide shaft B-5 (for long-hole) 

q

.

Remove feed guide shaft A-5 (for long-hole) 

w

 and feed arm support -5 (for long-hole) 

e

.

Remove the two ball bearing stoppers B (for long-hole) 

r

, and then remove the two linear bushes 

t

.

Remove the screw 

y

, and then remove the linear bush stopper plate (for long-hole) 

u

.

Remove the linear bush 9.53 (for long-hole) 

i

 from the feed arm support -5 (for long-hole) 

o

.

Summary of Contents for LH4-B800E

Page 1: ...SERVICE MANUAL ELECTRONIC LOCKSTITCH BUTTON HOLER Please read this manual before making any adjustments LH4 B800E ...

Page 2: ...take up lever and consequently there is always a danger of injury that can be caused by these parts Follow the instructions from training personnel and instructors regarding safe and correct operation before operating the machine so that you will know how to use it correctly SAFETY INSTRUCTIONS Indications DANGER The instructions which follow this term indicate situations where failure to follow t...

Page 3: ...ecure you run a high risk of receiving a serious electric shock and problems with correct operation may also occur The ambient temperature should be within the range of 5 C to 35 C during use Temperatures which are lower or higher than this may cause problems with correct operation The relative humidity should be within the range of 45 to 85 during use and no dew formation should occur in any devi...

Page 4: ...tective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin otherwise in flammation 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 children If the power switch needs to be left on when carrying out some adjustment be ...

Page 5: ...fan or press any objects against the machine as this may result in personal injury or damage to the machine The following warning labels appear on the sewing machine Please follow the instructions on the labels at all times when using the machine If the labels have been re moved or are difficult to read please contact your nearest Brother dealer 3 Warning labels q w e e r t Eyeguard Thread take up...

Page 6: ...g mechanism 2 13 2 8 Cutter mechanism 2 14 2 9 Upper shaft and tension pulley mechanism 2 16 2 10 Needle bar and thread take up mechanism 2 17 2 11 Presser bar mechanism 2 19 2 12 Upper thread trimmer mechanism 2 20 2 13 Thread breakage detection mechanism 2 22 2 14 Lubrication mechanism 2 23 2 15 Rotary hook mechanism 2 29 3 ASSEMBLY 3 1 3 1 Lower shaft and idle pulley mechanism 3 1 3 2 Lower thr...

Page 7: ...ng the needle up stop position 4 28 4 24 Adjusting the V belt tension 4 28 5 TROUBLESHOOTING GUIDE 5 1 5 1 Needle thread breakage 5 1 5 2 Skipped stitches 5 3 5 3 Uneven seams 1 Beginning of sewing 1 5 4 5 4 Uneven seams 2 Around rear tack or front tack 5 6 5 5 Uneven seams 3 Loose thread end at end backtack 1 5 6 5 6 Uneven seams 4 Sticking in needle plate 5 6 5 7 Uneven seams 5 All stitches 5 7 ...

Page 8: ...on to the needle bar clamp u via the needle bar crank rod t and needle bar bracket slide rod y At this time the needle bar crank rod t moves together with the crank rod guide o via the needle bar bracket slide rod i It moves along the slot in the needle hole of the thread take up 0 by means of the needle bar crank r 3 The needle bar 1 is secured to the needle bar clamp u and it moves smoothly up a...

Page 9: ... 2 The timing belt r is attached to timing pulley U e and it accurately transmits the rotation of the upper shaft to the timing pulley t 3 The timing pulley t is secured to the lower shaft y and it transmits the rotation to the rotary hook joint u that is secured to the end of the lower shaft y 4 The rotary hook i is secured to the rotary hook joint u and rotates fully together with the rotary hoo...

Page 10: ...ing rod w 2 The zigzag lever e is secured to the zigzag lever F assembly r and causes the needle bar bracket slide block t that is linked onto the end of the zigzag lever F assembly r to move in a reciprocal motion 3 The needle bar bracket slide block t is linked to the groove in the needle bar bracket y and causes the needle bar bracket y to move in a reciprocal motion t r e w q y ...

Page 11: ...e up and down 3 The movement of the presser foot lifter connecting rod y is transmitted via the knee lifter lever u upper thread trimmer driving link i and knee lifter lever o to move the presser bar guide bracket assembly 0 up and down 4 The feed arm 1 is secured to the presser bar guide bracket assembly 0 and it moves the presser roller bracket 2 that is secured to the bottom edge of the feed ar...

Page 12: ...pulse motor q 2 The feed arm support t is secured to the timing belt r The feed arm support t moves back and forth while being guided by feed guide shaft A y and feed guide shaft B u 3 The feed arm i is connected to the feed arm support t and it moves the work clamp o that is installed to the feed arm i and the length feed plate 0 that is installed to the feed arm support t back and forth e q 0 o ...

Page 13: ...ger and it turns the cutter driving arm r via the cutter driving link e 3 The cutter driving link t that is secured to the end of the cutter driving arm r is moved up and down 4 The driving shaft holder assembly y is linked to the cutter driving link t and this causes the cutter driving shaft u that is connected to the driving shaft holder assembly y to move up and down t r e w q u y ...

Page 14: ...are secure to the thread breakage perceiving shaft e When a thread breakage occurs the cutter bar fixed plate assembly q drop by its own weight and moves the thread guide w in the direction of the arrow 2 When the sensor r detects the cutter bar fixed plate assembly q the sewing machine stops and the cutter is prevented from dropping e w q r ...

Page 15: ...nd from there it is supplied to parts such as the needle bar clamp 3 3 Oil is supplied from the support shaft 4 to the thread take up 5 4 Oil is supplied to bush M 6 5 Oil is supplied to zigzag lever bush R 7 6 Oil is supplied to the motor lever shaft 8 and from there it is supplied to the zigzag connecting rod shaft 9 Oil which splatters inside the arm is collected by the felt 0 and is supplied t...

Page 16: ...il which is drawn up by the wick e passes through the felt r and the rotary hook joint t to the felt y where it is supplied to the rotary hook u 3 The oil that is supplied to the rotary hook u can be adjusted by turning the screw i to vary the amount by which the rubber presser o presses down on the collar 0 that the wick passes through e w q i u y More Less t r 0 o ...

Page 17: ...ow and the movement is transmitted to the tension release solenoid link e that is connected to the plunger w 3 The tension release link r that is connected to the tension release solenoid link e operates with the shoulder screw t as a pivot and presses against the tension release pin y 4 The tension release pin y presses against the tension disc presser u to release the tension discs r e w q u y t...

Page 18: ...r driving link i in the direction of the arrow 4 The needle roller 0 that is secured to the end of the tension release driving lever o is linked to the cam groove of the upper thread trimmer driving link i so that when the upper thread trimmer driving link i operates the tension release driving lever o that is secured to the tension release shaft 1 moves in the direction of the arrow 5 The tension...

Page 19: ...Upper thread trimming 1 Sewing starts machine starts 2 After 1 5 2 5 mm of feed the upper thread scissors gradually start to open 3 After approximately 4 6 mm of feed the upper thread scissors are fully pen 4 Sewing ends 6 The upper thread is clamped and cut 7 The upper thread scissors re tract and the presser foot lifts 8 The presser foot drops Presser foot drops Presser foot lifts ...

Page 20: ...ng levers o and 0 operate 5 When the trimmer driving levers o and 0 operate the longitudinal feed arm 5 and trimmer driving arm 6 that are secured to the trimmer driving levers o and 0 move in the direction of the arrow 6 When the longitudinal feed arm 5 operates the upper thread trimmer lever 8 that is attached to the longitudinal feed arm roller 7 at the end of the longitudinal feed arm 5 moves ...

Page 21: ...e direction of the arrow forward 2 When upper thread trimmer M r touches against the ridge line on the opening cam e the upper thread trimmer gradually starts to open Figure B At this time section D of the opening cam e fits into the upper thread trimmer assembly t so that the upper thread trimmer assembly t cannot move in the direction of arrow C r e w q Figure A Figure B r e r e t C D ...

Page 22: ...4 When the back plate e and the stop plate r lock together and clamp the upper thread trimmer lever t and the stop plate r separates from the back stopper y the upper thread trimmer lever t is pulled in the direction of the arrow by the spring u and the upper thread trimmer assembly i changes from the condition in Figure A to the one in Figure B and the upper thread trimmer opens fully e q u y w t...

Page 23: ... the arrow 3 The presser foot lifter connecting rod y is connected to the lower thread trimmer cam lever u so that the lower thread trimmer cam lever u moves 4 The roller i that is installed to the end of the lower thread trimmer cam lever u is linked to the cam groove in the lower thread trimmer cam o so that when the lower thread trimmer cam lever u operates the lower thread trimmer cam moves wi...

Page 24: ... to operate 8 When the lower thread retainer i operates the collar 0 that is installed to the lower thread clamp plate o moves over the ridge line of the cam of the lower thread retainer i and the lower thread retainer i starts to close and engages with the lower thread presser 1 so that the lower thread is clamped 9 The lower thread retainer i then continues operating 10 The fixed knife 2 is secu...

Page 25: ...the roller shaft e moves over feed guide shaft B q and the opening plate w rotates centering on the shoulder screw t 12 The opening plate w presses against the collar u that is installed to the lower thread clamp y and the lower thread clamp y rotates centering on the shoulder screw i so that the clamped lower thread is released by the lower thread presser o and the lower thread clamp y t r e w q ...

Page 26: ...n remove the set screw collar assembly r from the lower shaft t Loosen the set screw y and then remove the timing pulley assembly u from the lower shaft t Loosen the two set screws i and then remove the shaft o Remove the collar 0 and the idle pulley assembly 1 2 1 Lower shaft and idle pulley mechanism t r e q u y w 0 o i 1 ...

Page 27: ...lever 4 Remove the shoulder screw 5 and the screw 6 and then remove the lower thread presser 7 from the base plate o Remove the shoulder screw 8 plain washer 9 and spring washer 0 and then remove the lower thread clamp plate assembly 1 from the base plate o Remove the shoulder screw 2 collar 3 washer U 4 and washer D 5 and then remove the knife driving lever 4 from the base plate o Remove the two ...

Page 28: ...ing ring 6 Remove the lower thread trimmer cam lever 1 Loosen the two set screws 9 Remove the two lever shafts 0 Remove the lower thread trimmer cam assembly 1 from the cover 2 Remove the cover 2 Remove the driving lever roller 3 and the shoulder screw 4 and then remove the lower thread trimmer cam connect ing rod y from the lower thread trimmer cam 8 Remove the retaining ring 5 and then remove th...

Page 29: ... Loosen the bolt 9 Remove the three screws 0 and the three plain washers 1 Loosen the two set screws 2 and then remove the pulley A assembly 3 Remove the four bolts 4 and then remove the motor mounting bracket 5 from the feed pulse motor r Loosen the set screw 6 and then remove the support shaft 8 Remove the timing belt 8 and the pulley B assembly 7 Remove the two ball bearings 688ZZNR 9 Loosen th...

Page 30: ...d guide shaft A 5 for long hole w and feed arm support 5 for long hole e Remove the two ball bearing stoppers B for long hole r and then remove the two linear bushes t Remove the screw y and then remove the linear bush stopper plate for long hole u Remove the linear bush 9 53 for long hole i from the feed arm support 5 for long hole o ...

Page 31: ...then remove the feed arm assembly r and feed arm support shaft o from the feed arm support 0 Remove the two eye bolts 1 and the two plain washers 2 and then remove the support plate 3 from the feed arm 4 Remove the two eye bolts 5 and the two plain washers 2 and then remove the cam 6 from the support plate 3 Remove the eye bolt 7 and the flat washer 8 and then remove the feed cover 9 from the feed...

Page 32: ... screw t and then remove the bobbin presser bracket y and the auxiliary plate u Remove the shoulder screw i and then remove the auxiliary plate u and the opening plate e Loosen the set screw o and then remove the bobbin presser 0 from the bobbin presser bracket y Remove the screw 1 and the nut 2 Remove spring hook U 3 2 4 Bobbin presser mechanism t r e q 0 0 o i u y 3 2 1 w ...

Page 33: ...e shoulder screw i and then remove the tension release link t Remove the bolt o and then remove the plate 0 plunger 1 and spring 2 Remove the plunger pin 3 and then remove the plunger 1 and the tension release solenoid link 5 Remove the two screws 6 and then remove the tension release solenoid 7 from the solenoid holder 8 2 5 Tension release mechanism 0 1 4 2 3 0 1 4 2 3 0 1 4 2 3 0 1 4 2 3 t t r ...

Page 34: ...arm Remove the two tension discs 6 tension disc presser 7 tension disc presser 8 tension adjusting spring 9 washer 0 and tension nut 1 from the sub tension stud 2 Remove the screw 3 and the washer 4 and then remove the thread take up lever assembly 5 from the tension release shaft 6 Remove the shoulder screw 7 and then remove the washer 8 from the arm Remove the shoulder screw 9 and the washer 0 a...

Page 35: ...four screws i and the screw o Remove the two positioning pins 0 Remove the motor bracket assembly 1 from the top of the arm Loosen the set screw 2 and then remove the driving arm presser 3 and the washer 4 Remove the four bolts 6 and then remove the presser driving arm 7 from the guide bracket 8 Loosen the four set screws 9 and then remove the two guide shafts 0 and the guide bracket 8 Remove the ...

Page 36: ... the pulse motor FT assembly for presser lifter e from the motor bracket r Remove the set screw t and then remove the gear 15 75 y from the pulse motor FT assembly for presser lifter e Remove the set screw u and then remove the motor lever i from the pulse motor N assembly for needle zigzag w t r e e w q q i u y w ...

Page 37: ...Remove the retaining ring 3 and then remove the tension release shaft 4 tension release cam 5 and tension release driving lever 6 Remove the shoulder screw 0 and then remove the presser lifter connecting rod set e and the lifter shaft assembly 1 Remove the two O rings 8 and the two trimmer driving levers 9 Remove the spacer 2 plain washer D 3 and bolt 4 and then remove the knee lifter lever 5 from...

Page 38: ...u from the motor lever i Remove the screw 0 and then remove the sensor 1 from the zigzag sensor plate w Remove the bolt 2 Remove the thrust washer 3 and the zigzag lever 4 and then remove the zigzag lever F assembly 5 Loosen the set screw 2 remove the zigzag connecting rod shaft 0 and then remove the zigzag lever 4 and the zigzag connecting rod y 2 7 Needle zigzag mechanism t r e w q 0 i u y 5 4 3...

Page 39: ...older u Remove the bolt i and then remove the cutter holder u from the cutter driving shaft o Remove the screw 0 and then remove the knife sensor assembly 1 Remove the spring 2 from the cutter driving arm assembly 3 and the tension release shaft 4 Remove the nut 5 and then remove the adjusting screw assembly 6 from the arm Loosen the two set screws 7 and then remove the cutter driver shaft o Remov...

Page 40: ... Remove the four screws 3 and then remove the cutter bar guide 4 Remove the cutter driving arm assembly 2 from the arm Remove the cutter driving link 9 needle bar bracket slide block 0 and driving shaft holder assembly 1 from the cutter driving arm assembly 2 Remove the washer i and retaining ring E6 o and then remove the cutter link bracket assembly 0 from the cutter link shaft 1 Remove the three...

Page 41: ...the screw i and the set screw o and then remove the thread take up crank 0 from the upper shaft assembly 1 Loosen the two set screws 2 and then remove the set screw collar assembly 3 Loosen the two set screws 4 and then remove the bobbin winder pulley 5 Loosen the set screw 6 and then remove the timing pulley U assembly 7 Remove the timing belt 8 Remove the bearing 9 2 9 Upper shaft and tension pu...

Page 42: ...le bar thread guide o Loosen the set screw 0 and then remove the needle bar bracket support shaft 1 Remove the wick 2 Remove the needle bar bracket assembly 3 from the arm Remove the slide block 5 of the needle bar clamp 4 from the thread take up lever set 6 Remove the slide block 7 of the needle bar bracket assembly 3 from the zigzag lever shaft 8 Remove the bolt 9 and then remove the needle bar ...

Page 43: ...aft w Remove the wick e Loosen the two set screws r Remove the thread take up lever set u and the washer i from the thread take up crank o Remove the needle bar bracket slide block t Remove the two bolts 0 and the screw 1 and then remove the crank rod guide y 0 y 1 t r e q o i u y w ...

Page 44: ...set screw 2 Remove the presser bar 1 and then remove the oil rejector 3 and the presser bar guide bracket assembly u Remove the rubber cap 4 Remove the screw 5 and then remove the needle bar guide 6 Loosen the set screw 7 and then remove the roller shaft 8 from the presser roller bracket 0 Remove the plain washer 9 and the retaining ring 0 and then remove the roller 1 from the roller shaft 8 Remov...

Page 45: ...E 2 20 2 DISASSEMBLY 2 12 Upper thread trimmer mechanism Remove the screw q spring washer w and plain washer e and then remove the upper thread trimmer assembly r from the upper thread trimmer lever t t r w q e ...

Page 46: ...ove the washer 7 and the two shoulder screws 8 and then remove the upper thread trimmer lever set w from the upper thread trimmer fulcrum shaft 9 Remove the roller 5 Remove the screw 0 and the plain washer 1 and then remove the setting plate 2 from the upper thread trimmer lever assembly 3 Remove the nut 4 and the plain washer 5 and then remove the support shaft 4 from the setting plate 2 Remove t...

Page 47: ...rew i and then remove the cutter bar fixing plate u from the thread breakage perceiving shaft o Remove the two screws 0 and then remove the thread breakage sensor assembly Take the thread breakage perceiving shaft o out from the arm Remove the plain washer 2 plain washer 3 and screw 4 and then remove the thread guide 5 from the thread breakage perceiving shaft o 2 13 Thread breakage detection mech...

Page 48: ...e the screw q and then remove tube support U w Remove the wicks e and r and then disconnect the oil tube t Remove the felt y and then remove the wick u from bush F i 2 14 Lubrication mechanism Shaft bush mechanism t r r e e w q i u y w ...

Page 49: ...H4 B800E 2 24 2 DISASSEMBLY Needle zigzag mechanism Remove the screw q and then remove the felt support w from the motor bracket e Remove the screw r and then remove the tube support t t t r r e w q q w ...

Page 50: ... plunger pump Remove the screw t and then remove the tube support y Remove the cord holder i screw o and washer 0 and then disconnect the oil tubes 1 and u that are connected between the oil terminal and the oil outlet Remove the screw 2 and then remove the felt holder 3 Remove the felt 4 and then disconnect the oil tube u t r r e q q u y 1 w 0 0 o o i i u u 1 1 u 4 3 2 t 0 o i u y 4 3 2 1 ...

Page 51: ...utlet from the tube support 7 Remove the screw 8 and then remove the tube support 7 from the wick base support i Remove the oil tube 6 that is connected between the oil terminal and the oil outlet from the wick base support i Disconnect the oil tube 9 that is connected between the oil terminal and the oil outlet from the oil terminal 5 Disconnect oil pipe B 0 from the oil terminal 5 Remove the oil...

Page 52: ...et and from the bed Remove the oil tube 3 that is connected between the oil teminal and the plunger pump from the lubricating holeto the left of bush M 4 Remove the screw 5 and then remove the tube support 6 from the oil tube 7 and from the bed Remove the outlet oil tube 7 from the lubricating hole to the right of bush M 4 Remove the oil tube e that is connected between the plunger and the filter ...

Page 53: ...lt support t Remove the wick y from the felt support t Remove the two screws u and then remove the felt support t from the bed Remove the end of the felt i from the bush o Remove the spring 0 from the bush o Remove the collar 1 from the bush o Remove the wick y from the collar 1 Rotary hook lubricating mechanism t r e q u u y w 0 0 o o i y y 1 ...

Page 54: ...move the two screws q and then remove the rotary hook holder w Loosen the set screw e and then remove the rotary hook r Loosen the set screw t and then remove the rotary hook joint assembly y 2 15 Rotary hook mechanism t r e q y w e ...

Page 55: ...LH4 B800E 2 30 2 DISASSEMBLY ...

Page 56: ...the lower shaft y with the set screw u and then place the set screw collar assembly i onto the lower shaft y and then install the lower shaft y to the bed After checking the thrust direction securely tighten the set screw o The screw stop position is the start of the rotation direction Install the cover 0 with the two screws 1 3 1 Lower shaft and idle pulley mechanism r e q w Insert e t Align edge...

Page 57: ... play Insert the roller r into the lower thread trimmer cam o and then install it to the bed with the lower thread trimming cam shaft 4 washer 5 and retaining ring 6 Secure by tightening the set screw 7 Connect the presser lifter connecting rod set 8 and the lower thread trimmer cam lever w using plain washer D 0 and the bolt 1 Install the lower thread trimmer link assembly 2 with the shoulder scr...

Page 58: ...Install the fixed knife set 0 to the knife driving lever i with the two screws 1 Install the needle plate 2 with the pan screw 3 so that it is parallel to the base plate w Provisionally install the base plate w to the top of the bed with the four screws 4 While pushing the base plate w to the right so that the needle 5 is in the center of the needle hole 6 in the longitu dinal direction securely t...

Page 59: ...provisionally tighten it with the three screws 2 and the three washers 3 Push the motor mounting bracket 7 in the direction of the arrow with a force of 100 N and then securely tighten the screws 2 Gently tighten the eye bolt 4 If there is no tension gauge available apply a force of 5 N at the middle of the timing belt 3 span and adjust so that the amount of deflection at this time is 3 5 mm Place...

Page 60: ...linear bushes u to the positions for long hole specifications With feed guide shaft A 5 for long hole i inserted into the feed arm support 5 for long hole o insert into the bed Insert feed guide shaft B 5 for long hole 0 into the feed arm support 5 for long hole o Install so that the reference line on feed guide shaft B 5 for long hole 0 is aligned with the edge of the feed arm support 5 for long ...

Page 61: ... u to the feed arm support r with the eye bolt i and the plain washer o Install the cam 0 to the support plate 3 with the two eye bolts 4 37x5 1 and the two plain washers 2 Install the support plate 3 to the feed arm 5 with the two eye bolts 4 and the two plain washers 2 Feed arm assembly 6 Install the feed arm assembly 6 to the feed arm support r with the feed arm support shaft 7 Secure the feed ...

Page 62: ...e bobbin case u Install the auxiliary plate i and the opening plate o with the shoulder screw 0 Install the bobbin presser bracket w and the auxiliary plate i to the bed with the shoulder screw 1 Install the opening plate o to the rotary hook cover 3 with the shoulder screw 2 Attach the two extension springs 4 Turn on the power After the mechanism moves to the home position turn the screw e and th...

Page 63: ... 3 so that the tension release link 1 protrudes from the edge of the tension stud bracket assembly 6 on the arm by 19 2 0 2 mm Then securely tighten the screw 4 Insert the tension release pin 7 into the tension stud bracket assembly 6 and then insert it into the arm Tighten the screw 8 so that the tension discs are open by 0 5 to 1 mm when the tension release link 1 is pushed in the direction of t...

Page 64: ...er foot Loosen the screw 3 and then adjust the thread tension by adjusting the clearances between the tension release cam 4 and the tension release pin 2 as shown in the illustration Press the RESET key to raise the presser foot and then check that the opening clearance between the tension discs is 0 5 to 1 mm Then press the RESET key again to lower the presser foot and check that the tension disc...

Page 65: ...the O ring 3 to the tension release shaft 2 and then insert into the arm At this time insert the tension release cam 4 pass the tension release driving lever 1 through the tension release cam 4 and then install the retaining ring 5 While pushing the tension release shaft 2 in the direction of the arrow A push the tension release driving lever 1 in the direction of the arrow B to align it with the ...

Page 66: ... the pulse motor FT assembly for presser lifter r with the set screw y so that the dimensions are as shown in the illustration Install the pulse motor N assembly for needle zigzag q and the pulse motor FT assembly for presser lifter r to the motor bracket u with the bolts i so that the directions of the cords are as shown in the illustration Motor bracket assembly o t r r e w q q o i i u y 1 0 3 1...

Page 67: ...e presser driving arm 6 and insert into the motor bracket assembly o Provisionally tighten the set screw 0 Then tighten the bolt 7 and the set screw 0 so that the presser driving arm 6 moves up and down easily and so that there is no play in the gear Insert the motor bracket assembly o into the arm from the top Position it using the two positioning pins 1 and then install it by tightening the four...

Page 68: ... position it in the thrust direction using the thrust washer 1 and the zigzag lever w Then secure zigzag lever assembly F 0 by tightening the bolt 2 Install the sensor 3 to the zigzag sensor plate 5 with the screw 4 Insert the wick 6 into the motor lever shaft 7 Place the washers 8 onto the motor lever shaft 7 Pass the motor lever shaft 7 through the zigzag connecting rod e and the washers 8 so th...

Page 69: ...as shown in the illustration Install the cutter solenoid 1 to the cutter solenoid bracket 3 with the three bolts 2 At this time install so that the oil tube 7 passes underneath the cutter solenoid bracket 3 Connect the cutter driving link 8 and the cutter link bracket 9 with the shoulder screw 0 Provisionally install the bolt 1 Cutter link bracket assembly 2 Install the cutter link bracket assembl...

Page 70: ...m from the processed surface of the arm jaw Attach the spring 1 to the cutter driving arm assembly 2 and the tension release shaft 3 Install the knife sensor assembly 4 with the screw 6 so that the clearance between the knife sensor assembly 4 and the solenoid stopper 5 is 4 5 mm At this time be careful not to clamp the wick 9 Install the cutter holder 7 to the cutter driving shaft q with the bolt...

Page 71: ...o that the top of the cutter blade and the top of the needle plate are aligned when the cutter 3 is pushed down manually to its lowest position For a flat cutter 8 tighten the screw 4 so that it is 1 5 to 2 mm from the top of the needle plate 2 3 6 0 3 mm 4 7 8 Lowest position Lowest position Top of needle plate 1 5 2 mm Top of needle plate ...

Page 72: ...y r using the thread take up crank 1 and the two set screws 4 so that there is no play Provisionally install the tension pulley assembly 5 with the two bolts 6 and the two plain washers 7 Set the phase between the upper shaft and the lower shaft so that the mating mark A on the lower shaft timing pulley 8 is facing straight down when the upper shaft assembly r is at the needle up stop position Whi...

Page 73: ...nto the thread take up lever set t and then install it to the thread take up crank u Insert the needle bar bracket slide block r into the groove in the crank rod guide q Secure the thread take up lever set t by tightening the two set screws i Insert the support shaft 0 and secure it by tightening the set screw 1 so that the thread take up moves smoothly with no play 3 10 Needle bar and thread take...

Page 74: ...e needle bar bracket support shaft 0 through the arm Insert the needle bar bracket support shaft 0 and then secure it by tightening the set screw 1 so that there is no play in the needle bar bracket assembly q Insert the needle bar bracket guide 2 into the arm and then secure it by tightening the set screw 3 so that there is no play in the needle bar bracket assembly q Install the set screw 5 and ...

Page 75: ...d then secure it by tightening the screw 7 Tap in the rubber cap 0 Install the presser roller bracket 4 to the presser bar 8 with the screw 1 Connect the presser bar guide bracket assembly t and the knee lifter lever u with the shoulder screw 2 Place a 10 mm gauge 4 underneath the work clamp 3 Turn on the power After the mechanism moves to the home position check that the setting for memory switch...

Page 76: ... 1 Install the support plate 9 and the stopper 2 to the trimmer driving arm 5 with the eye bolts 3 and the plain washers 4 Trimmer driving arm assembly Install the upper thread trimmer lever set 5 to the upper thread trimmer fulcrum shaft q with the two washers 6 and shoulder screws 7 Place the roller 8 onto the support stud 2 of the upper thread trimmer lever set 5 and then place it into the groo...

Page 77: ...LH4 B800E 3 22 3 ASSEMBLY Install the upper thread trimmer assembly q to the upper thread trimmer lever w with the screw r spring washer t and plain washer y t r w q y ...

Page 78: ...tall the thread breakage sensor assembly y with the two screws u Secure the cutter bar fixing plate i to the thread breakage perceiving shaft q with the set screw o Install the balancer 0 to the cutter bar fixing plate i with the screw 1 Install the lever stopper 2 at the correct angle with the screw 3 Provisionally install the lever stopper 4 with the screw 5 3 13 Thread breakage detection mechan...

Page 79: ...rmly so that the wick r inside bush F w is touching the wick q and is also touching the upper shaft t If the wick is not pushed in firmly enough seizure of the upper shaft may occur 3 14 Lubrication mechanism Shaft bush mechanism Push so wick touches t r e w q Wick should not pro trude from here Push so they touch the upper shaft Push ...

Page 80: ... push it firmly into the upper shaft lubrication hole Pass the wick e through tube support U w and push it firmly into the zigzag lever shaft lubrication hole Install tube support U w with the screw r Pass the oil tube t around the outside of tube support U w as shown in the illustration ...

Page 81: ...he motor bracket 0 with the screw o so that the felt y of the felt support t is gently touching the felt i of the zigzag connecting rod u Pass the oil tube q around the outside of tube support U w as shown in the illustration so that it does not touch the solenoid stopper 1 and then pass it in between the cutter solenoid 2 and the arm t i u y t r e q 0 o 2 w t r e w q o i u y 2 1 ...

Page 82: ...r the cord holder u Install the tube support 0 with the screw 1 and then secure the oil tube t and the oil tube y that is connected between the oil terminal and the oil outlet so that they do not touch the pulse motor for presser lifter Install the oil tube 2 that is connected to the oil terminal and the plunger pump with tube support M 3 and the screw 4 pass it through the arm hole 5 and then sec...

Page 83: ...support 0 with the screw o Attach the oil tube 1 to the tube support i and then install the oil terminal w to the wick base support 0 with the two screws 5 Pass the wick 6 from the needle bar bracket the wick 7 from the bush and the wick 8 from the support shaft through the oil tube 5 and then install felt base A 9 to the wick base support 0 with the screw 0 Install the oil tube 1 for lubricating ...

Page 84: ...il tube 4 that is connected between the oil terminal and the plunger pump through the lubricating hole to the left of the bush r Pass the oil tube 6 that is connected between the oil terminal and the oil outlet through tube support D 5 Secure tube support D 5 to the bed with the screw 7 Secure the four tubes that are coming out from the bush r to the bed in two places as shown in the illustration ...

Page 85: ...port y to the bed with the two screws u Pass the wick q through the felt support y and tie a knot in it Pass the wick i through the felt support y and then tie a knot in it Insert the rubber presser o into the bed and then secure it with the spring 0 and the screw 1 As a guide to the rotary hook lubrication amount fully tighten the screw 1 and then loosen it by about two turns To check and adjust ...

Page 86: ... the set screw w Tighten the set screw r so that the lubrication port A of the hook e and the lubrication port B of the rotary hook joint assembly q are aligned Then adjust the needle clearance and timing Install the rotary hook holder t with the two screws y 3 15 Rotary hook mechanism t r e q y w A B r Screw stop side ...

Page 87: ...LH4 B800E 3 32 3 ASSEMBLY ...

Page 88: ...hanism do it at a position where the thread trimmer mechanism will not operate the position where the presser foot pulse motor is at the home position If this is not done the lower thread retainer and the feed guide shaft may alternately push against the lower thread clamp and the opening plate and damage may result 4 When pushing the knife down by hand be careful not to let it touch the upper thr...

Page 89: ...er of the needle plate hole turn off the power 3 Loosen the screw q and then adjust the vertical position of the needle zigzag sensor assembly w The adjustment required is only slight so move the needle zigzag sensor assembly w a little bit at a time 4 Repeat the procedure from step 1 After adjusting check that the needle bar bracket e and the stopper screws r and t are not touching when in test f...

Page 90: ...e home position Then press the RESET key to lower the presser foot 2 If the clearance between the feed arm support q and the linear bushing w is 2 mm the following adjustment is not necessary If the clearance is not 2 mm turn off the power 3 Loosen the screw e and adjust the position of the feed sensor support plate r 4 Repeat the procedure from step 1 ...

Page 91: ...on Then press the RESET key to lower the presser foot 2 If the clearance between the feed arm support q and the bed processed surface w is 2 mm the following adjustment is not necessary If the clearance is not 2 mm turn off the power 3 Loosen the screw e and adjust the position of the feed sensor support plate r 4 Repeat the procedure from step 1 ...

Page 92: ...sensor The final position is determined when making the adjustment in 4 13 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 presser foot is lowered If the adjustment is not correct the presser foot may touch the upper thread trimmer ...

Page 93: ... sewing machine being adjusted 4 Tighten the set screw e 5 Install the rubber cap w Check that the knife flank of the needle bar is at a right angle to the knife If the installation positions are not correct the needle bar and knife may touch when the needle zigzags which may result in noise or cause the needle to break Lowest position Turn on the power and set the sewing machine to the home posit...

Page 94: ...etween needle and hook point Loosen the screws e and move the rotary hook r forward or back until there is a clearance of 0 01 to 0 08 mm between the needle q and the hook point w Needle plate thickness Application Gauge Clothing 2 Knitted wear Knitted wear 3 Long hole specifica tions 5 Thin knitted wear S13595 001 Gauge 815 2 S13596 001 Gauge 815 3 S13597 001 Gauge 805 2 ...

Page 95: ...esser foot pressure will be about 70 N 4 8 Adjusting the work clamp lift amount Turn on the power and set the sewing machine to the home position before making this adjustment 1 Check that memory switch No 05 presser foot height at neutral position is set to 10 mm If it is not set to 10 mm set it to 10 mm 2 Place a 10 mm gauge under the work clamp q and then loosen the screw w to make the adjustme...

Page 96: ...k clamp window After adjusting operate the presser foot lifter pedal and check that the work clamp moves up and own smoothly After adjusting check the upper thread trimmer mechanism and adjust if necessary 4 10 Adjusting the knife home position sensor position 1 Loosen the screw q and then adjust the knife sensor assembly r so that there is a clearance of 4 5 0 5 mm between the side of the sensor ...

Page 97: ...er DL r so that the clearance between the needle bar and the cutter is 0 3 mm 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 In addition loosen the screw t and adjust the cutter X direction using cutter holder M y so that the cutter goes into the center of the cutter groove Loosen the screw u and move the...

Page 98: ...tter installation height Lowest position Lowest position Top of needle plate Top of needle plate Adjust so that the upper thread trimmer knife and the cutter do not touch when the cutter is pushed down by hand If the upper thread trimmer knife extends below the cutter pull the stop plate q forward and move the upper thread trimmer assembly w to the left Fig A Fig B 1 Install the cutter with the sc...

Page 99: ...d scissors gradual opening timing 4 13 7 8 4 3 2 2 1 Adjusting the upper thread scissors opening timing 4 13 8 9 5 4 3 1 When adjusting for the first time 4 13 Adjusting the upper thread trimming When the home position sensor position has been changed When the longitudinal feed arm position has been changed When the trimmer driving arm position has been changed When the lateral position of the upp...

Page 100: ...ed with the edge of the washer w If they are not aligned loosen the bolt e and move the longitudinal feed arm assembly r back and forth to adjust Check the presser foot home position sensor position Refer to 4 3 Adjusting the presser foot home position sensor position 1 Turn on the power and set the sewing machine to the home position Then press the RESET key to lower the presser foot 2 Check that...

Page 101: ...the needle when they open When this adjustment is carried out also carry out the checks and adjustments in 4 13 8 Adjusting the upper thread scissors opening timing 4 13 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 q forward until the upper thread trimmer assembly w ...

Page 102: ...ving arm q forward until the driving arm roller e is at its highest position on the cam of the upper thread trimmer lever w 2 Loosen the screw r and then adjust the driving arm roller e so that the clearance between the stopper y of the upper thread trimmer assembly t and the opening cam bracket u is 0 0 5 mm If the stopper y is adjusted so that it presses too firmly it may cause the presser foot ...

Page 103: ... then move the upper thread scissors t up or down to adjust so hat the clearance between the upper thread scissors t and the work clamp y is approximately 1 mm NOTE The work clamp y will tilt when sewing material joints so adjust so that the upper thread scissors t do not touch the work clamp y If the upper thread scissors t are touching the work clamp y it may cause the presser foot lifter pulse ...

Page 104: ... is parallel to the feed direction 2 Loosen the screw r and then adjust so that the distance b between the rising section B of the upper thread scissors e and the tip of the opening cam w is approximately 0 5 mm when the upper thread scissors e are closed If you would like the scissors to start opening earlier make the distance smaller However if the distance is too small check that the work clamp...

Page 105: ... to adjust so that the clearance between the back plate w and the cam e is approximately 2 mm Reduce this clearance if you would like the upper thread scissors to open more quickly 3 Check that the distance A between the upper thread scissors y and the center of the needle u is 5 5 6 mm If the distance A is less than about 4 5 mm the upper thread scissors y may touch the needle when they open whic...

Page 106: ...ller Larger 1 Turn on the power and set the sewing machine to the home position 2 Loosen the screw q and then adjust the lower thread retainer w 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 e is sitting securely on top of the lower thread retainer cam A If the lower thread is pulli...

Page 107: ...guide shaft B e with the edge of the feed arm support q When the feed mechanism moves by 6 7 mm the opening plate r moves and the lower thread lamp t opens To change the opening timing loosen the set screw w and move feed guide shaft B e to the left or right The end of the thread which is being held by the lower thread clamp t is wound around inside the seam If the opening timing is too early it c...

Page 108: ...m lever y back in the direction of the arrow move the feed mechanism If the feed mechanism is moved when the lower thread trimming has been carried out the mechanisms will press against each other which may result in damage to the lower thread clamp t and the opening plate r ...

Page 109: ...ning amount 1 Loosen the screws q and then adjust so that the distance between the lower thread clamp t and the lower thread presser y is approximately 5 mm when the feed guide shaft w is projecting out at the front and is firmly touching the roller r of opening plate B e Approx 5 mm ...

Page 110: ... turn the screw t to adjust so that the clearance A between the bobbin presser w and the edge of the bed is approximately 12 5 mm Turn off the power move the lower thread trimmer cam lever y by hand in the direction of the arrow so that the bobbin presser w is firmly pressing the bobbin and then check that the lower thread retainer u is starting to hold the lower thread If this timing is reversed ...

Page 111: ...ction lever e against the stopper t 3 Loosen the screw u and then change the position of the balancer i to adjust the balance between the thread breakage detection lever e and the thread guide r 4 Turn on the power and set the sewing machine to the home position Then press the RESET key to lower the presser foot 5 Loosen the screw o and then adjust so that the thread breakage detector sensor 0 tur...

Page 112: ... the presser foot is raised In addition press the RESET key once more and check that the tension discs are fully closed when the presser foot is lowered 4 18 Adjusting the thread tension at the zigzag tension control Position the tension release solenoid as described in 3 5 Tension release mechanism before carrying out this adjustment Turn on the power and set the sewing machine to the home positi...

Page 113: ...in upper thread clamping errors 4 20 Adjusting the feed timing belt 1 Remove the adjustment bolt q 2 Loosen the three screws w so that the feed pulse motor e moves easily 3 While using a spring gauge to push the notch in the motor mounting bracket r with a force of 98 N tighten the screws w 4 Check that the timing belt t moves smoothly 5 Gently tighten the adjustment bolt q If you do not have a sp...

Page 114: ...djusting the rotary hook lubrication To oil tank More Less More Less 1 Remove the rubber stopper q 2 Turn the adjusting screw w 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 4000 rpm for three cycles to sew about 114 stitches Use Kraft paper e or similar to catch the oil drops As a guide the optimum position ...

Page 115: ... started error code E 02 will be displayed Turn the machine pulley q to move the index mark w to the correct position and then start the sewing machine 4 24 Adjusting the V belt tension 1 Remove the screw and then remove the belt cover 2 Turn the two nuts w to adjust so that there is 10 14 mm of deflection in the V belt q when it is pressed at the midway point with a force of 5 N NOTE If the V bel...

Page 116: ...read properly Instruction Thread path Flaw or abrasion on the thread path Polish with buff Replace the part Especially pay attention to finishing around needle plate hole Rotary hook point Rotary hook edge Polish with buff Replace the part Flaw on the rotary hook holder Polish with buff Replace the part 4 8 Thread tension Sub thread tension Zigzag chain stitch Adjust the needle thread tension 1 2 ...

Page 117: ...the gap Widen the gap 0 01 0 08 mm to such a degree that rotary hook point does not strike needle in zigzag motion 4 6 Rotary hook lubrication Adjust the quantity of lubrication oil Too small quantity of lubrication oil will cause thread breakage Check the quantity of lubrication as follows When the number of stitches is about 114 sew 20 stitches and using craft paper check that the number of spla...

Page 118: ...dle center Needle bar height and needle bar rise Refer to 5 1 Needle thread breakage Gap between needle and rotary hook Tension Strength of sub thread tension zigzag portion Adjust the upper thread tension to the appropriate tension Instruction Needle bar play Vertical and longitudinal needle bar play Reduce the needle bar play or replace the parts Lower thread clamp Lower thread retainer cam shou...

Page 119: ...in thread tension Whip stitch 0 15 0 25N Purl stitch 0 05 0 15N Holding the thread steady the bobbin case should gently descend under the force if its own weight Instruction Spring Apply spring Lower thread retainer position Adjust lower thread retainer position Adjust lower thread retainer so that a 35 40 mm thread leader is left after trimming 4 19 Bobbin presser position Adjust the bobbin press...

Page 120: ...fts up and does not tighten at the sewing start Beginning of sewing 4 Uneven sewing pitch Bird s nests form at the sewing start and after 5 6 mm the sewing pitch suddenly increases 1 2 mm Cause Check Solution page Upper thread scissors Upper thread scissors gradual opening timing Adjust the gradual opening timing of the upper thread scissors Upper thread scissors gradually start opening when the f...

Page 121: ...s 3 Loose thread end at end backtack 1 Uneven material feeding Presser foot pressure Increase presser foot pressure 4 8 Upper clamping foot When using knit material replace with the 3 thread clamp and needle plate Using the thin 5 needle plate and flat work clamp can be effective Upper thread scissors opening timing Adjust to an appropriate opening timing 4 17 4 18 Lower thread clamp opening timin...

Page 122: ... rotary hook overlap amount Adjust the rotary hook stopper and inner rotary hook overlap amount 4 8 Rotary hook Lubrication Decrease the quantity of lubrication oil Adjust it with oil adjusting shaft Check the quantity of lubrication as follows When the number of stitches is about 114 sew 20 30 stitches and using the craft paper check that the number of splashed oil spots is about 10 Too small qua...

Page 123: ...ssembly Upper thread trimmer driving spring Change if transformed Tension release timing End of tension release at the beginning of sewing Retard the tension release timing Change using parameter No 63 Instruction Opening amount of zigzag tension discs and bar tack tension discs Adjust the release dimension Adjust the zigzag tension discs by moving the tension stud bracket in and out Adjust the ba...

Page 124: ...ewing 2 Lower thread lifted up Lower thread snapping Reduce the lower thread retaining speed presser foot rise speed Change using the memory switch Instruction Lower thread snapping Lower thread retainer lower thread clamp and lower thread presser plate finish Finish so that lower thread does not snap Lower thread clamp timing Refer to 5 3 Uneven seams 1 Beginning of sewing 2 Lower thread lifted u...

Page 125: ...on discs and bar tack tension discs particularly zigzag tension discs Refer to 5 8 Needle thread runout Upper clamping foot Presser foot rise speed Reduce the presser foot rise speed Change using memory switch No 02 Instruction Cause Check Solution page Upper thread trimmer assembly Upper thread trimmer assembly position Refer to 5 8 Needle thread runout Operating pressure of upper thread trimmer ...

Page 126: ...er to 5 8 Needle thread runout Machine stopping position Cam Upper thread scissors opening timing adjustment The cam should open the stop plate properly Refer to 4 13 8 Adjusting the upper thread scissors opening timing Opening cam Upper thread scissors gradual opening timing Refer to 4 13 7 Adjusting the upper thread scissors gradual opening timing Presser foot home position sensor Presser foot h...

Page 127: ... 5 1 Needle thread breakage Gap between needle and rotary hook Needle plate Needle plate position Adjust needle plate front and rear position Locate the needle at the center of needle hole Burr on the screw hole edge in event of uneven material feeding Polish with buff Upper thread trimmer assembly Needle strikes upper thread trimmer Adjust so that the scissors do not touch the needle Refer to 5 1...

Page 128: ...e Increase the setting value for materials that are heavy or difficult to cut Instruction Solenoid stopper Nut Check for a loose nut Tighten securely Cutter sensor position Adjust the cutter sensor position Check for a loose mounting screw 4 9 Cause Check Solution page Cutter Cutter blade If the blade is worn or chipped sharpen it or replace it Instruction Sticks in material Needle plate Replace w...

Page 129: ...y Refer to 5 11 Needle strikes upper thread trimmer Lateral position of upper thread scissors Adjust the lateral position of the upper thread scissors 4 14 Stitch quality Needle thread tension Decrease tension to such a degree that it does not influence stitch quality Instruction Zigzag width in the zigzag stitch portion Widen zigzag width to such a degree that it does not influence stitch quality...

Page 130: ...eard Cause Check Solution page Presser foot height setting Check the presser foot height setting Change the settings of memory switch Nos 04 05 and 06 Instruction Presser foot lifter pulse motor Cord connection Check the cord connections and contacts Presser lifter pulse motor gear Check for loose gear set screw ...

Page 131: ...rimmer and presser lifter mechanisms Securely tighten all screws Presser foot lifter height Memory switch Nos 04 05 and 06 Adjust so that the memory switch setting value matches the presser foot rise height If the presser foot rise height is too high the lower thread trimming and presser foot rising will become harder and the pulse motor may go out of step Instruction threading Bobbin thread threa...

Page 132: ...scissors Adjust the cam position 4 17 4 18 Feed home position sensor Feed home position sensor position Adjust the feed home position sensor position 4 3 Feed timming belt Feed timing belt tension Adjust the feed timing belt 4 26 5 16 Lower thread is not trimmed pulls when material is removed 5 17 Feed mechanism does not operate or motor is out of step O K NG Cause Check Solution page Machine stop...

Page 133: ... the stopper position 4 2 Cause Check Solution page Thread breakage detector Thread breakage detector position Adjust the thread breakage detector If the detector is not adjusted sewing may stop even when the thread is not broken 4 24 Emergency stop Panel DIP switch A 3 When panel DIP switch A 3 is set to ON an emergency stop occurs when the treadle is depressed If the treadle is pressed firmly an...

Page 134: ...nd 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 touch any place other than that for the measurement In addition always keep in mind that a high voltage remains for 5 minutes after the po...

Page 135: ... 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 the control b...

Page 136: ...cuit board 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 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 operate The panel does not operate DC300V 2 step p...

Page 137: ...d that there is no contact failure between pins and wires before starting troubleshooting procedures Connector positions Main circuit board Sub circuit board P1 FAN2 P4 PANEL P3 SYNC P7 PEDAL P6 POWER P13 FAN12 P10 HEAD P9 HPEDAL P11 ORG P19 OPSOL P15 DC300V P14 AC18V P16 NPM P23 EXPAND2 P20 AC17 AC30V P22 EXPAND1 P1 EXP1 P2 FDPM P3 PER P4 VALV P5 FTPM P6 POWER P7 OPSEN2 P8 CUTTER P9 OPSEN1 P10 FA...

Page 138: ...LH4 B800E 6 5 6 ELECTRIC MECHANISM 1 step power supply circuit board Panel PCB 2 step power supply circuit board CN1 CN2 CN3 CN4 CN5 CN6 P1 POWER P3 PER P4 ACIN P1 PANEL ...

Page 139: ...me Symptoms resulting mainly from poor contact 1 5V The panel does not operate 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 P3 SYNC Pin No Signal name Symptoms resulting mainly from poor contact 1 5V 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 2 Encoder signal...

Page 140: ... from poor contact 1 P8V 8V The home position can not be found The presser foot does not operate The machine does not operate One of error E 30 E 31 and E 32 is displayed 2 PEDAL signal 3 0V 4 N8V 8V P9 HPEDAL Standing operation pedal option Pin No Signal name Symptoms resulting mainly from poor contact 1 P8V 8V The home position can not be found The presser foot does not operate The machine does ...

Page 141: ...breakage detection signal 9 10 P8V 8V 11 0V P11 ORG Pin No Signal name Symptoms resulting mainly from poor contact 1 24V The home position can not be found One of error E 05 E 06 and E 07 is displayed 2 Zigzag home position signal 3 0V 4 5V 5 24V 6 Feed home position signal 7 0V 8 5V 9 24V 10 Presser foot home position signal 11 0V 12 5V P13 FAN12 Pin No Signal name Symptoms resulting mainly from ...

Page 142: ...05 is displayed 2 AC18V D10V 3 4 5 AC18V N 6 AC18V N 7 8 9 AC18V A 10 AC18V A 11 12 13 AC18V B 14 AC18V B 15 16 17 AC18V C 18 AC18V C 19 20 21 AC18V D 22 AC18V D 23 24 25 AC18V E 26 AC18V E 27 28 29 AC18V F 30 AC18V F P15 DC300V Pin No Signal name Symptoms resulting mainly from poor contact 1 DC300V The zigzag home position can not be found The zigzag mechanism does not operate Error E 05 is displ...

Page 143: ...ing current C 4 Zigzag PM driving current D 5 Zigzag PM driving current F 6 P19 OPSOL Pin No Signal name Symptoms resulting mainly from poor contact 1 Spare solenoid The tension release solenoid does not operate 2 3 Tension release solenoid 4 5 40V 6 40V P20 AC17 AC30V Pin No Signal name Symptoms resulting mainly from poor contact 1 AC30V The tension release solenoid does not operate The control b...

Page 144: ...yed 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 2 5V 3 5V 4 5V 5 24V 6 24V 7 24V 8 24V 9 Feed PM clock 10 Presser foot PM clock 11 12 13 Presser foot PM direction signal 14 Feed PM direction signal 15 Presser foot PM current control signal 16 Feed PM current control signal 17 PM current OFF signal 18 ...

Page 145: ... One of error E 05 E 06 and E 07 is displayed The cutter does not operate Error E 08 is displayed 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 Presser foot 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 re...

Page 146: ... 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 2 5V 3 5V 4 5V 5 24V 6 24V 7 24V 8 24V 9 Feed PM clock 10 Presser foot PM clock 11 12 13 Presser foot PM direction signal 14 Feed PM direction signal 15 Presser foot PM current control signal 16 Feed PM current control signal 17 PM current OFF sig...

Page 147: ...inly from poor contact 1 Presser foot PM driving current A The presser foot home position can not be found The presser foot mechanism does not operate Error E 07 is displayed 2 Presser foot PM driving current B 3 Presser foot PM driving current C 4 Presser foot PM driving current D 5 Presser foot PM driving current F P3 PER Pin No Signal name Symptoms resulting mainly from poor contact 1 Relay inp...

Page 148: ...P0V 5 24V 6 0V 7 M55V Cutter 8 M55V Cutter 9 MP0V 10 MP0V P7 OPSEN2 Pin No Signal name Symptoms resulting mainly from poor contact 1 24V The cutter does not operate Error E 08 is displayed 2 5V 3 Input signal spare 4 4 0V 5 24V 6 5V 7 Input signal spare 5 8 0V 9 24V 10 5V 11 Cutter home position sensor signal 12 0V P8 CUTTER Pin No Signal name Symptoms resulting mainly from poor contact 1 Cutter d...

Page 149: ...AN1 Pin No Signal name Symptoms resulting mainly from poor contact 1 24V The feed pulse motor cooling fan does not spin 2 FAN1 signal 3 0V P11 OPSEN1 Pin No Signal name Symptoms resulting mainly from poor contact 1 55V Special edition 2 55V 3 55V 4 Spare solenoid driving current 7 5 Spare solenoid driving current 8 6 Spare solenoid driving current 9 P12 FAN2 Pin No Signal name Symptoms resulting m...

Page 150: ... One of error E 05 E 06 and E 07 is displayed The cutter does not operate Error E 08 is displayed 2 nput signal spare 2 3 nput signal spare 3 4 nput signal spare 4 5 nput signal spare 5 6 Cutter home position sensor signal 7 Feed PM overcurrent signal 8 Presser foot 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...

Page 151: ... R 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 2 AC200 T 3 4 CN3 Pin No Signal name Symptoms resulting mainly from poor contact 1 AC220 R 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 2 3 AC...

Page 152: ...ainly from poor contact 1 DC300V The zigzag home position can not be found The zigzag mechanism does not operate Error E 05 is displayed 2 DC0V CN6 Pin No Signal name Symptoms resulting mainly from poor contact 1 Resistance Voltage error occurs Error E 95 is displayed 2 Resistance ...

Page 153: ...g mainly from poor contact 1 ACIN The feed home position and presser foot home position can not be found The feed mechanism and presser foot mechanism do not operate One of error E 06 and E 07 is displayed 2 ACIN 3 4 EARTH P3 PER Pin No Signal name Symptoms resulting mainly from poor contact 1 Relay input signal The zigzag home position feed home position and presser foot home position can not be ...

Page 154: ...NISM Panel PCB P1 PANEL Pin No Signal name Symptoms resulting mainly from poor contact 1 5V The panel does not operate 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 ...

Page 155: ...ifts when pedal is depressed Presser foot lifts after sewing is complete Emergency stop using presser foot lifter switch enabled during automatic sewing Emergency stop using presser foot lifter switch disabled during automatic sewing Display setting during automatic mode lower thread counter Default 100 Display setting during automatic mode production counter Default 0 2 cycle sewing ON All progra...

Page 156: ...4 0 mm Needle plate size 7 3 mm Max needle zigzag feed width 6 0 mm Work clamp size 7 3 47 mm 6 0 40 mm Work clamp size 6 8 47 mm 5 4 40 mm Work clamp size 5 4 24 5 mm 4 0 20 mm Work clamp size 5 4 36 mm 4 0 32 mm DIPSWB 1 2 3 4 5 6 7 8 ON OFF ON OFF ON ON ON ON ON OFF ON OFF ON ON OFF OFF OFF ON ON OFF ON OFF OFF OFF ON OFF OFF OFF ON OFF ON ON ON OFF OFF ON OFF OFF Default OFF OFF OFF OFF OFF OF...

Page 157: ...x screws q and then open the operator s side cover w of the control box NOTE When opening the cover w hold it securely so that it does not fall down 2 Change the setting of the DIP switch e Refer to the DIP switch table for an explana tion of the functions of each DIP switch 3 Close the cover w of the control box and tighten the six screws q DIPSW1 1 2 3 4 5 6 7 8 ON OFF ON OFF ON OFF ON OFF ON OF...

Page 158: ... 8 ON OFF ON OFF ON OFF ON ON ON OFF OFF ON OFF OFF ON OFF ON OFF ON OFF Setting item Pedal for standing operation Pedal for seated operation Starting possible only when presser foot is lowered Starting possible regardless of presser foot position 100V 110V specifications 200V 400V specifications No ...

Page 159: ...hown in the parameter display LED can be changed by pressing the parameter keys The display flashes while it is being changed When the ENTER key is pressed the value appearing in the parameter display LED is accepted the display stops flashing When the motor select key is pressed machine motor parameter setting mode will then end and the sewing machine will start up normally No Setting items Setti...

Page 160: ...ine pully by hand to raise the needle Turn off the power Turn off the power Turn off the power Turn off the power Turn off the power Turn off the power Return the treadle to the neutral position Return the treadle to the neutral position Return the treadle to the neutral position Turn off the power Turn off the power Turn off the power Turn off the power Turn off the power Turn off the power Excee...

Page 161: ...e to keep the program which exceeds the area Press the SELECT key Select a different program number Press the ENTER key If the data for the selected program number does not exceed the sewing area the error will be cleared B By initializing the program While pressing the ENTER key press the RESET key All parameters 00 to 69 for the program will then be initialized and the machine will switch to pro...

Page 162: ...re is still an error even after replacing the thread breakage detection sensor replace the main circuit board E 02 1 Turn the pulley manually to set the needle to its highest position 2 Check if connector P3 on the main circuit board is securely inserted and if any harness is broken or short circuited 3 Replace the synchronizer 4 If there is still an error even after replacing the synchronizer rep...

Page 163: ...sition sensor replace the sub circuit board 5 If there is still an error even after replacing the sub circuit board replace the main circuit board E 20 1 With the power turned off check for problems with feeding and check that the presser foot moves smoothly 2 Check if connectors P2 feed and P5 presser foot on the sub circuit board are securely inserted and if any harness is broken or short circui...

Page 164: ... or short circuited 3 Check if connectors P10 and P13 on the sub circuit board are securely inserted and if any harness is broken or short circuited 4 Check if connectors P22 and P23 on the main circuit board are securely inserted and if any harness is broken or short circuited 5 Replace the 2 step power supply circuit board 6 Replace the sub circuit board 7 Replace the main circuit board E 51 E 5...

Page 165: ... the upper shaft locks or not 2 Check if connector P3 on the main circuit board is securely inserted and if any harness is broken or short circuited 3 Replace the synchronizer 4 If there is still an error even after replacing the synchronizer replace the main circuit board E 74 1 Replace the main circuit board E 75 1 Replace the main circuit board E 80 E 81 1 Make sure that ROM chips of the main c...

Page 166: ...the timing belt is attached 2 Turn the machine pulley by hand and check that the upper shaft does not lock and the pulley is not loose 3 Check if connectors P3 and P6 on the main circuit board are securely inserted and if any harness is broken or short circuited 4 Check if machine motor harness connector CN7 and power supply harness connector CN8 on the 1 step power supply circuit board are secure...

Page 167: ...TOUT3 TOUT2 24V 24V 24V 5V 5V 5V B8B XHA S0V 32 S0V 30 15 EXP2 P13 S0V 14 15 16 17 4 3 2 S0V 1 28 EXP1 P1 S0V PE7 PF7 PF4 17 18 19 20 21 22 23 24 25 26 27 31 16 12 11 TOUT4 10 TOUT1 9 8 7 6 24V 5 4 3 2 5V 1 S0V 29 13 14 PF3 PF0 PHDR 32VS 28 AC18V P14 AC18F AC18E AC18E AC18D AC18D AC18C AC18C 16 17 18 19 20 21 22 23 24 25 26 27 30 15 12 11 AC18A 10 AC18A 9 8 7 AC18N 6 AC18N 5 4 3 AC18D10 2 AC18D10 ...

Page 168: ...SERVICE MANUAL Printed in Japan 118 H80 I1050811H 2001 07 H 1 BROTHER INDUSTRIES LTD 15 1 Naeshiro cho Mizuho ku Nagoya 467 8561 Japan Phone 81 52 824 2177 ...

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