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Brother BC800 Service Manual

For computerized sewing machine; low-end computer series.
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SERVICE MANUAL FOR
COMPUTERIZED SEWING MACHINE
LOW-END COMPUTER SERIES
The CD-ROM version of service manual contains movie!
CD-ROM version of service manual contains movies "2. Disassembly"
"3. Assembly".Please click on
mark to start the movie.
10.2005.
2010 Brother Industries, Ltd.
c
CONFIDENTIAL
8.2016.
All rights reserved.

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Table of Contents

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   Summary of Contents for Brother BC800

  • Page 1 COMPUTERIZED SEWING MACHINE LOW-END COMPUTER SERIES The CD-ROM version of service manual contains movie! CD-ROM version of service manual contains movies "2. Disassembly" "3. Assembly".Please click on mark to start the movie. 10.2005. 2010 Brother Industries, Ltd. CONFIDENTIAL 8.2016. All rights reserved.
  • Page 3 LIST of UPDATE RECORD Date Added Models Contents Jul.2010 CONFIDENTIAL Aug.,2015 BC800 Aug.,2016 FS50...
  • Page 4: Table Of Contents

    1. Outline of Mechanism ................1 - 1 Main Mechanisms ................1 - 2 Driveline ..................1 - 3 Positions of electronic components ..............1 - 4 Control system block diagram ................1 - 5 Control system block diagram ................1 - 6 Operation of other electronic components ............1 - 7 2.
  • Page 5 Needle plate A ASSY disassembly ...................2 - 20 Spring removal ..........................2 - 20 Inner rotary hook bracket assembly removal ...................2 - 20 Feed dog removal ..........................2 - 21 Vertical adjuster screw assembly removal ..................2 - 21 Outer rotary hook removal .......................2 - 21 Shaft supporter removal ........................2 - 21 Feed bar removal ..........................2 - 22 Needle plate supporter shaft B removal ...................2 - 22...
  • Page 6 Tension pulley ASSY assembly ....................3 - 10 Main motor assembly attachment ....................3 - 10 Main motor assembly .........................3 - 10 FC jack attachment ..........................3 - 11 Inlet assembly attachment ........................3 - 11 Power PCB assembly attachment ....................3 - 12 Power PCB ASSY assembly .....................3 - 12 Main PCB assembly attachment ......................3 - 13 Main PCB assembly ........................3 - 13 Upper cover thread guide attachment ....................3 - 13...
  • Page 7 Z zigzag cam attachment .........................3 - 38 Z zigzag lever assembly attachment ....................3 - 39 Z zigzag lever ASSY assembly ....................3 - 39 Presser bar attachment ........................3 - 40 Needle holder assembly attachment ....................3 - 41 Needle holder ASSY assembly ....................3 - 42 Needle bar assembly attachment ......................3 - 43 Needle bar ASSY assembly .......................3 - 43 Thread take-up lever link attachment ....................3 - 43...
  • Page 8 Lead wire assy, Power-LE .................5 - 6 BH switch assy ....................5 - 7 LED lamp left supply assy .................5 - 8 Needle bar unit ....................5 - 9 Upper side of shutter cover ................5 - 10 FC jack supply assy ..................5 - 11 6.
  • Page 10: Outline Of Mechanism

    Outline of Mechanism Main Mechanisms ............ 1 - 2 Driveline ..............1 - 3 Positions of electronic components ......1 - 4 Control system block diagram ........1 - 5 Operation of other electronic components ....1 - 7 1 - 1...
  • Page 11: Main Mechanisms

    Outline of Mechanism Main Mechanisms Sewing Machine Bobbin winder mechanism Thread guide mechanism Needle bar / Presser mechanism Upper shaft mechanism Needle threader mechanism Side feed mechanism Feed / Rotary hook mechanism 1 - 2...
  • Page 12: Driveline

    Outline of Mechanism Driveline A) Up and down movement of needle bar, movement of thread take-up lever and zigzag mechanism Thread take-up Upper shaft Pulley counter weight Needle bar crank Thread take-up lever Needle bar crank rod Needle bar block Needle bar supporter Z zigzag lever Z zigzag cam...
  • Page 13: Positions Of Electronic Components

    Outline of Mechanism Positions of electronic components Sewing Machine LCD PCB assy SS-VR PCB assy LED Lamp SR assy Power PC assy Power switch/Inlet assy BWSW-S assy PFSW-S assy Z pulse motor BH change switch assy NP sensor BH switch lever Main PCB assy LED Lamp SL assy F pulse motor...
  • Page 14: Control System Block Diagram

    Outline of Mechanism Control system block diagram CPS33 S34 PFSW BHSW MAIN PCB BWSW SENSOR 2 SENSOR 1 SENSOR FOOT CONTROLLER JACK DRIVER EEPROM DRIVER RESET IC LED PCB LIGHT WHITE COLOR MAIN MOTOR LED (LEFT) FRONT POWER SUPPLY PCB COVER SWITCHING POWER OPERATION PCB...
  • Page 15: Control System Block Diagram

    Outline of Mechanism Control system block diagram CPS36 S37 PFSW BHSW MAIN PCB BWSW SENSOR 2 SENSOR 1 SENSOR FOOT CONTROLLER JACK BUZZER DRIVER EEPROM DRIVER RESET IC LED PCB LIGHT WHITE COLOR MAIN MOTOR LED (LEFT) FRONT POWER SUPPLY PCB COVER SWITCHING POWER OPERATION PCB...
  • Page 16: Operation Of Other Electronic Components

    Outline of Mechanism Operation of other electronic components Start/Stop (SS) Switch ..... . Switch for starting and stopping the sewing machine. The machine operates at a slow speed while the switch is being held down.
  • Page 17 1 - 8...
  • Page 18: Disassembly

    Disassembly Main parts........2 - 2 Feed unit........2 - 19 Needle-presser unit ....... 2 - 27 With the CD-ROM version, click to start the movie clip. 2 - 1...
  • Page 19 Main unit Main parts location diagram 2 - 2...
  • Page 20: Accessory Table Removal

    Main unit Main parts Accessory table removal 1. Remove the accessory table 1. Bottom cover removal 1. Remove the screw 1, and then remove the base cover 1. 2. Remove the screw 2, and then remove base cover A 2. 2 - 3...
  • Page 21: Needle Plate B Assembly Removal

    Main unit Main parts Needle plate B assembly removal 1. Remove the needle plate cover 1. 2. Remove the needle plate B assembly 2. Needle plate B ASSY disassembly 1. Remove the cutter cover 2 from the needle plate B assembly 1. 2.
  • Page 22: Face Plate Assembly Removal

    Main unit Main parts Face plate assembly removal 1. Remove the screw 1, and then remove the face plate assembly 1. Face plate A ASSY disassembly 1. Remove the screw 1, and then remove the cutter cover assembly 1. 2. Remove the CS retaining ring 2, and then remove the NT lower thread cutter 3.
  • Page 23: Front Cover Removal

    Main unit Main parts Front cover removal 1. Remove screws 1 (front, 1 pc.), 2 (rear, 1 pc.), and 3 (rear, 5 pcs.), and then remove the front cover. *Key point • Disconnect the SSVR PCB lead wire connector 1 and the operation PCB lead wire connector 2 from the main PCB assembly 3 located near the front cover.
  • Page 24: Thread Tension Holder Assembly And Thread Take-up Holder B Removal

    Main unit Main parts Thread tension holder assembly and thread take-up holder B removal 1. Remove the two screws 1. 2. Remove the thread guide A assembly 1. 3. Remove the screw 2. 4. Remove the thread guide B assembly 2. Thread tension holder ASSY disassembly 1.
  • Page 25: Thread Take-up Holder B Disassembly

    Main unit Main parts Thread take-up holder B disassembly 1. Remove the screw 1. 2. Remove the thread catching spring case 2 from thread take-up holder B 3. Remove the thread take-up spring 3 from the thread catching spring case 4.
  • Page 26: Operation Pcb Assembly And Ssvr Pcb Assembly Removal

    Main unit Main parts Operation PCB assembly and SSVR PCB assembly removal 1. Remove the 2 screws 1, and then remove the operation PCB assembly 1. 2. Disconnect the LCD cable 2 from the operation PCB assembly 1. 3. Remove the 3 screws 2, and then remove the SSVR PCB assembly 3. *Key point •...
  • Page 27: Sv Keytop Removal

    Main unit Main parts SV keytop removal 1. Remove the SV keytop 1. *Key point • Press the SV keytop hooks (2 locations) from the inside of the front cover to remove the SV keytop. Base plate rubber removal 1. Remove the 2 base plate rubbers 1. Upper cover thread guide removal 1.
  • Page 28: Main Pcb Assembly Removal

    Main unit Main parts Main PCB assembly removal 1. Remove the 2 screws 1. 2. Remove the main PCB assembly 1. 14-1 Main PCB ASSY disassembly 1. Remove the screw 1. 2. Remove the main PCB plate spring 1, and then remove the main PCB 2. 2 - 11...
  • Page 29: Power Pcb Assembly Removal

    Main unit Main parts Power PCB assembly removal 1. Remove screws 1 and 2 (2 pcs. /1pc.), and then remove the power PCB assembly 1. 2. Disconnect the main motor lead wire 2 and the inlet assembly connector *Key point •...
  • Page 30: Fc Jack Removal

    Main unit Main parts FC jack removal 1. Remove the jack nut 1, and then remove the FC jack assembly 2. Main motor assembly removal 1. Remove the 2 screws 1, and then remove the main motor assembly 1. 2. Remove the motor belt 2 from the main motor assembly 1. 18-1 Main motor ASSY disassembly 1.
  • Page 31: Tension Pulley Assembly Removal

    Main unit Main parts Tension pulley assembly removal 1. Remove spring 2. Remove the 2 screws 1, and then remove the tension pulley assembly 1. 19-1 Tension pulley ASSY disassembly 1. Remove the screw 1, and then remove the tension pulley holder 2 from the tension pulley assembly 1.
  • Page 32: Upper Shaft Assembly Removal

    Main unit Main parts Upper shaft assembly removal 1. Remove the screw 1. 2. Remove the 4 screws 2, and then remove the 2 upper shaft bearing pressers 1. 3. Remove the upper shaft assembly 3 from the needle bar crank 2, and then remove timing belt 420-5GT-6 4 and timing belt 372-2GT-6 5.
  • Page 33: Bobbin Base Assembly Removal

    Main unit Main parts Bobbin base assembly removal 1. Remove the bobbin base assembly 2 from the bobbin winder shaft 1. 24-1 Bobbin base ASSY disassembly 1. Remove the bobbin thread cutter holder 2 from the bobbin base assembly 1, and then remove the NT lower thread cutter 3. Bobbin winder assembly removal 1.
  • Page 34: Spool Pin Removal

    Main unit Main parts Spool pin removal 1. Remove the spool pin spring 1 and pull out the spool pin 2. 2. Peel the spool pin stand 3. Bobbin presser removal 1. Remove the screw 1, and then remove the bobbin presser 1. Thread guide assembly removal 1.
  • Page 35: Base Plate Rubber Removal

    Main unit Main parts Base plate rubber removal 1. Remove the screw 1, and then remove the plain washer (M 3.5) 1 and rubber cushion A 2. 2. Remove the base plate rubber 3. 2 - 18...
  • Page 36 Main unit Feed unit location diagram 2 - 19...
  • Page 37: Feed Unit

    Main unit Feed unit Needle plate A assembly removal 1. Remove the 2 screws 1, and then remove the needle plate A assembly 1. Needle plate A ASSY disassembly 1. Remove the screw 1, and then remove the F gear stopper plate 1. 2.
  • Page 38: Outer Rotary Hook Removal

    Main unit Feed unit Feed dog removal 1. Remove the 2 screws 1, and then remove the feed dog 1. Vertical adjuster screw assembly removal 1. Remove spring 2. Remove the M5 nut 1 3. Remove the vertical adjuster screw assembly 2. Outer rotary hook removal 1.
  • Page 39: Feed Bar Removal

    Main unit Feed unit Feed bar removal 1. Remove the retaining ring (CS4). 2. Remove the polyester slider 1, feed bar 2, and polyester slider 1 in this order. Start movie clip (CD-ROM version only) Retaining ring CS4 Needle plate supporter shaft B removal 1.
  • Page 40: Feed Arm A Assembly Removal

    Main unit Feed unit Feed arm A assembly removal 1. Remove the screw 1, and then remove the set collar 1 and the thrust wafer 2 in this order. 2. Remove the screw 2, and then remove the horizontal feed shaft 3. 3.
  • Page 41: Feed Adjuster Assembly Removal

    Main unit Feed unit Feed adjuster assembly removal 1. Remove the feed adjuster assembly 1, polyester slider 2, and spring in this order. Start movie clip (CD-ROM version only) 11-1 Feed adjuster disassembly 1. Remove spring , and then remove the F gear 2 from the feed adjuster Vertical lever removal 1.
  • Page 42: Fpm Holder Assembly Removal

    Main unit Feed unit FPM holder assembly removal 1. Remove the screw 1, and then remove spring 2. Remove the screw 2, and then remove the FPM holder assembly 1. 13-1 FPM disassembly 1. Remove the lead wire assembly (FPM-LE) 1. 2.
  • Page 43: Lower Shaft Assembly Removal

    Main unit Feed unit Lower shaft assembly removal 1. Remove the retaining ring (E6), and then remove the thrust washer 1. 2. Remove the lower shaft assembly 2. *Key point • Push down the lower shaft assembly 2 to remove it. •...
  • Page 44 Main unit Needle-presser unit location diagram 2 - 27...
  • Page 45: Needle-presser Unit

    Main unit Needle-presser unit Threader hook assembly 1. Pull the needle thread slider 1 toward you, and then remove the threader hook assembly 2. LED lamp left assembly removal 1. Remove the screw 1, and then remove the LED lamp left assembly 1. BH switch assembly removal 1.
  • Page 46: Thread Take-up Lever Link Removal

    Main unit Needle-presser unit Thread take-up lever link removal Retaining ring E5 1. Remove the retaining ring (E5) and spring washer 1, and then remove the thread take-up lever link 3 from the shaft 2. 2. Remove the screw 1, and then pull the shaft 2 out of the base holder. Start movie clip (CD-ROM version only) Needle bar assembly removal 1.
  • Page 47: Needle Holder Assembly Removal

    Main unit Needle-presser unit Needle holder assembly removal 1. Remove springs 2. Remove the screw 1, and then remove the shaft 1, needle holder block 2, and needle holder assembly 3. *Key point • Pull out the needle holder assembly from the top. Start movie clip (CD-ROM version only) 2 - 30...
  • Page 48: Needle Holder Assy Disassembly

    Main unit Needle-presser unit Needle holder ASSY disassembly 1. Remove spring 2. Remove the screw 1, and then remove the plate 1. 3. Remove the screw 2. Pull out the shaft 2, and then remove needle holder shaft A 3. 4.
  • Page 49: Presser Bar Removal

    Main unit Needle-presser unit Presser bar removal 1. Remove the screw 1. Pull out the presser bar 1, and then remove the spring 2 and the presser bar clamp 3. *Key point • Remove the presser bar 1 and the presser feed holder assembly 4.
  • Page 50: Z Zigzag Lever Disassembly

    Main unit Needle-presser unit Z zigzag lever disassembly 1. Pull out the Z zigzag cap 2 from the Z zigzag lever 1. Z zigzag camp removal Retaining ring E3 1. Remove the retaining ring (E3), and then remove the Z zigzag cam 1. 2.
  • Page 51: Thread Release Lever Removal

    Main unit Needle-presser unit Thread release lever removal 1. Remove the retaining ring (CS4), and then remove the thread release lever 1 and the spring 2. Retaining ring CS4 Lock nut removal 1. Remove the lock nut 1, and then remove the screw 1. Z pulse motor removal 1.
  • Page 52: Assembly

    Assembly Main parts........3 - 2 Feed unit........3 - 22 Needle-presser unit ....... 3 - 34 With the CD-ROM version, click to start the movie clip. 3 - 1...
  • Page 53 Main unit Main parts location diagram 3 - 2...
  • Page 54: Base Plate Rubber Attachment

    Main unit Main parts Base plate rubber attachment 1. Attach the base plate rubber 1 to the arm bed cover. • Attach rubber cushion A 2 and the plain washer (M3.5) 3 to the arm bed cover with the screw 1. Torque Taptite, Pan B ·...
  • Page 55: Spool Pin Attachment

    Main unit Main parts Spool pin attachment 1. Attach the spool pin stand 1 so that it does not protrude from the attachment section. 2. Insert the spool pin 2 into the arm bed cover. Insert the pin from the grooved end.
  • Page 56: Bobbin Winder Assembly Attachment

    Main unit Main parts Bobbin winder assembly attachment 1. Attach the rubber ring 1 to the bobbin winder pulley. 2. Insert the bobbin winder shaft 2 into the groove on the arm bed cover, and secure the shaft with the 2 screws 1. 3.
  • Page 57: Bobbin Base Assembly Attachment

    Main unit Main parts Bobbin base assembly attachment 1. Attach the bobbin base assembly 1. Bobbin base ASSY assembly 1. Attach the 2 NT lower thread cutters 2 and the bobbin thread cutter holder 3 to the bobbin base assembly 1. Plate spring attachment 1.
  • Page 58: Needle-presser Unit Attachment

    Main unit Main parts Needle-presser unit attachment 1. Attach the needle-presser unit 1 to the arm bed cover with screws 1 and 2 (1 pc. and 2 pcs. respectively). *Key point • Lift the presser foot lifter 2 and insert it into the hole on the arm bed cover 3 to set the needle-presser unit 1 to the attachment position.
  • Page 59: Upper Shaft Assembly Attachment

    Main unit Main parts Upper shaft assembly attachment 1. Pass timing belt 420-5GT-6 (timing belt) 2 and timing belt 372-2GT-6 (motor belt) 3 to the upper shaft assembly 1. 2. Attach the needle bar crank 5 to the thread take-up lever crank 4. 3.
  • Page 60: Feed Unit Assembly Attachment

    Main unit Main parts Feed unit assembly attachment 1. Fit the feed unit 1 to the arm bed cover attachment position, and secure them with the 2 screws 1. 2. Fit the lower shaft bushing 2 to the arm bed cover attachment position, set the lower shaft bearing presser 3, and secure them with the 2 screws 2.
  • Page 61: Tension Pulley Assembly Attachment

    Main unit Main parts Tension pulley assembly attachment 1. Attach the tension pulley assembly 1 to the arm bed cover with the 2 screws 1. 2. Attach spring *Key point • Perform "4 - 3 Timing belt tension adjustment. Torque Giza Tite ·...
  • Page 62: Fc Jack Attachment

    Main unit Main parts FC jack attachment 1. Insert the FC jack assembly 1 from the inside of the arm bed cover assembly. 2. Attach the jack nut 2 from the outside of the arm bed cover assembly. *Key point •...
  • Page 63: Power Pcb Assembly Attachment

    Main unit Main parts Power PCB assembly attachment 1. Attach the power unit assembly 1 with screws 1 and 2 (1 pc. and 2 pcs. respectively). *Key point • Attach the power plate spring 3 to the upper screw 2. 2.
  • Page 64: Main Pcb Assembly Attachment

    Main unit Main parts Main PCB assembly attachment 1. Insert the bobbin winder switch of the main PCB 2 into the slot on the bobbin winder stopper plate 1, and then insert the boss on the arm bed cover into the screw hole on the shutter cover 3. 2.
  • Page 65: Base Plate Rubber Attachment

    Main unit Main parts Base plate rubber attachment 1. Attach the 2 base rubber plates 1. SV keytop attachment 1. Attach the SV keytop 1. Front panel LCD attachment 1. Attach the LCD 1 and the front panel 2 with the 2 screws 1. *Key point •...
  • Page 66: Button Attachment

    Main unit Main parts Button attachment 1. Attach the SS button 1, the backstitching button 2, and the NP button 3. 2. Attach manual button A 4, manual button B 5, and 2 selecting buttons Operation PCB assembly and SSVR PCB assembly attachment 1.
  • Page 67: Led Lamp Attachment

    Main unit Main parts LED lamp attachment 1. Attach the LED lamp 1 with the screw 1. 2. Attach the LED lamp connector 2 to the operation PCB 3. *Key point • Secure the LED lamp lead wire 1 to the rib on the front cover. •...
  • Page 68: Thread Take-up Holder B Assembly

    Main unit Main parts 25-2 Thread take-up holder B assembly 1. Attach the wire 2 to thread take-up holder B assembly 1. 2. Insert the tip of the thread take-up spring 3 into the second hole from the bottom on the thread catching spring case 4, secure 9.7 to 10.7 mm from the top of the groove on thread take-up holder B assembly 1 to the ridge of the thread hanging section on the thread take-up spring, and attach the thread take-up spring to thread take-up holder B assembly 1 with the...
  • Page 69: Front Cover Attachment

    Main unit Main parts Front cover attachment 1. Connect the SSVR PCB connector 1 and the operation PCB connector 2 to the main PCB 3. *Key point • Pass the lead wires to the hook section of the shutter cover 4 while preventing them from lifting or disconnecting.
  • Page 70: Face Plate A Assembly Attachment

    Main unit Main parts Face plate A assembly attachment 1. Attach the face plate A assembly 1 with the screw 1. Torque Taptite, Cup P · M4X20 0.78 – 1.18 N Color; Silver 27-1 Face plate A ASSY assembly 1. Attach the NT lower thread cutter 2 to the cutter cover 1, and then attach the CS retaining ring 3.
  • Page 71: Needle Plate B Assembly Attachment

    Main unit Main parts Needle plate B assembly attachment 1. Attach the needle plate B assembly 1. 2. Attach the needle plate cover 2 to the needle plate B assembly 1. 28-1 Needle plate B ASSY assembly 1. Attach the slide button 1 to needle plate B 2. 2.
  • Page 72: Accessory Table Attachment

    Main unit Main parts Accessory table attachment 1. Attach the accessory table 1. 3 - 21...
  • Page 73 Main unit Feed unit location diagram 3 - 22...
  • Page 74: Feed Unit

    Main unit Feed unit Lower shaft bushing attachment 1. Attach the lower shaft bushing 2 and bushing presser B 3 to the base plate assembly 1 with the 3 screws 1. Taptite, Bind B Torque M3X6 · 0.39 – 0.78 N Color;...
  • Page 75: Fpm Holder Assembly Attachment

    Main unit Feed unit FPM holder assembly attachment 1. Insert the FPM holder assembly 1 into the feed adjuster shaft 3 of the base plate assembly 2. 2. Insert spring between the base plate assembly 2 and the FPM holder assembly 1, and secure them with the screw 1.
  • Page 76: Vertical Lever Attachment

    Main unit Feed unit Vertical lever attachment 1. Insert the vertical feed shaft 1 into the inside of the drop knob 2, and Retaining ring E3 then insert the plain washer (L4) 3, spring , vertical lever 4, and drop knob 5 in this order. Retaining ring E3 *Key point •...
  • Page 77: Feed Adjuster Assembly Attachment

    Main unit Feed unit Feed adjuster assembly attachment 1. Insert the polyester slider 2 into the shaft of the feed adjuster assembly 1, and then attach spring *Key point • Insert the spring from the smaller end. 2. Apply 1 or 2 drops of OILER to the shaft of the feed adjuster assembly 1. 3.
  • Page 78: Feed Arm A Assembly Attachment

    Main unit Feed unit Feed arm A assembly attachment 1. Insert the feed arm A assembly 1 from the rear of the base plate assembly 2, and then insert the square shaft 4 of the feed arm B assembly 3 into the feed adjuster 5.
  • Page 79: Feed Arm B Assy Assembly

    Main unit Feed unit Feed arm B ASSY assembly 1. Insert the polyester slider2 into the shaft of the feed arm A assembly 1. 2. Apply a bead of MOLYKOTE EM-30L to the shaft of the feed arm A assembly 1. 3.
  • Page 80: Needle Plate Supporter Shaft B Attachment

    Main unit Feed unit Needle plate supporter shaft B attachment 1. Insert the feed arm supporter 1 into the needle plate supporter shaft B 2, and attach them to the base plate assembly 3. 2. Tighten nut 1 (M3) 4. 3.
  • Page 81: Fpm Gear Engagement

    Main unit Feed unit FPM gear engagement 1. Rotate the FPM gear 1 clockwise until the stopper 2 of the FPM gear 1 contacts the shaft 3 of the bushing B assembly . 2. Rotate the feed adjuster assembly 4 to the point 5 it contacts the FPM gear 1.
  • Page 82: Feed Bar Attachment

    Main unit Feed unit Feed bar attachment 1. Insert the polyester slider 2 to the left shaft of the feed arm A assembly 2. Apply a bead of MOLYKOTE EM-30L to the shaft of the feed arm A assembly 1. 3.
  • Page 83: Outer Rotary Hook Attachment

    Main unit Feed unit Outer rotary hook attachment 1. Apply a light covering of EPNOC AP (N) 0 to the groove on the outer rotary hook shaft 1. 2. Insert the outer rotary hook shaft 1 into the the spacer 4 and outer rotary hook assembly 2 .
  • Page 84: Inner Rotary Hook Bracket Assembly Attachment

    Main unit Feed unit Inner rotary hook bracket assembly attachment 1. Align the inner rotary hook bracket 1 with the boss on the base plate assembly 2, and temporarily tighten the screw 1. *Key point • Tighten the screw after performing "4 - 21 Inner rotary hook bracket position adjustment."...
  • Page 85 Main unit Needle-presser unit location diagram 3 - 34...
  • Page 86: Needle-presser Unit

    Main unit Needle-presser unit Presser switch assembly attachment 1. Attach the presser switch assembly 1 to the base holder assembly with the screw 1. NOTE • Engage the ridge of the presser switch 1 with the trench of the base holder assembly 2. Screw, Bind Torque M3X6...
  • Page 87: Lock Nut Attachment

    Main unit Needle-presser unit Lock nut attachment 1. Attach the screw 1 to the lock nut 1. *Key point • Screw 1 the screw in half way. 2. Attach the screw 1 to the base holder assembly. *Key point • Tighten the screw until the lock nut 1 contacts the base holder assembly.
  • Page 88: Presser Foot Lifter Attachment

    Main unit Needle-presser unit Presser foot lifter attachment 1. Apply a bead of EPNOC AP (N) 0 to the presser foot lifter shaft 1 of the base holder assembly. 2. Attach the presser foot lifter 2 to the shaft 1. 3.
  • Page 89: Z Zigzag Cam Attachment

    Main unit Needle-presser unit Z zigzag cam attachment 1. Attach the rubber 2 to the shaft 1 of the base holder assembly. 2. Apply a bead of EPNOC AP (N) 0 to the Z zigzag cam shaft 3 of the base holder assembly.
  • Page 90: Z Zigzag Lever Assembly Attachment

    Main unit Needle-presser unit Z zigzag lever assembly attachment 1. Attach the polyester slider 2 to the Z zigzag lever shaft 1 of the base holder assembly. 2. Apply a bead of EPNOC AP (N) 0 to the Z zigzag lever shaft 1 of the base holder assembly.
  • Page 91: Presser Bar Attachment

    Main unit Needle-presser unit Presser bar attachment 1. Attach the presser feed holder assembly 2 to the presser bar 1 with the screw 1. 2. Attach the J foot 3. 3. Apply a light covering of OILER to the circumference of the presser bar 1 (upper 20 mm).
  • Page 92: Needle Holder Assembly Attachment

    Main unit Needle-presser unit Needle holder assembly attachment 1. Apply 1 or 2 drops of FBK OIL RO 100 to the circumference of needle holder shaft A 1 of the needle holder assembly. 2. Apply 1 or 2 drops of MOLYKOTE M DISPERSIOIN to the circumference of the needle holder assembly 2.
  • Page 93: Needle Holder Assy Assembly

    Main unit Needle-presser unit 10-1 Needle holder ASSY assembly 1. Attach the zigzag adjusting nut 1 with the screw 1. 2. Apply OILER to the circumference at the top of the needle holder 2. 3. Pass the needle holder shaft A 3 from the end with the hole through the rear of the needle holder assembly 4, and then pass the shaft 5 through the hole on the needle holder assembly 4 and the hole on needle holder shaft A 3 so that the narrow end of the shaft is on the left side.
  • Page 94: Needle Bar Assembly Attachment

    Main unit Needle-presser unit Needle bar assembly attachment 1. Insert the needle bar assembly 1 from the bottom of the needle holder assembly, and then insert the needle bar block 2 and the needle thread block 3 through the needle bar assembly and then through to the upper hole.
  • Page 95: Thread Take-up Lever And Needle Bar Crank Attachment

    Main unit Needle-presser unit Thread take-up lever and needle bar crank attachment 1. Apply a light covering of MOLYKOTE EM-30L to the thread take-up lever attachment section of the needle bar crank 1. 2. Attach the thread take-up lever 2 to the needle bar crank 1 with the screw 1.
  • Page 96: Led Lamp Left Assembly

    Main unit Needle-presser unit LED lamp left assembly 1. Attach the LED lamp L assembly 1 with the screw 1. NOTE • Align the boss 2 on the LED lamp L assembly 1 with the hole on the base holder 3. Torque Screw, Pan (S/P washer) ·...
  • Page 97 3 - 46...
  • Page 98: Adjustment

    Adjustment Test Mode Test mode ..........4 - 2 Adjustment Timing belt tension adjustment ....4 - 3 Motor belt tension adjustment....4 - 4 Upper thread tension adjustment.... 4 - 5 Three point needle drop adjustment ..4 - 6 Needle drop position adjustment for needle bar unit and rotary hook unit 4 - 7 Needle interference left/right adjustment 4 - 8 Needle bar rise adjustment .....
  • Page 99: Test Mode

    Adjustment Test mode 1. Starting in test mode • With the front cover in place press while turning the power on; the buzzer will sound four times, and test mode will start. 2. Mode selection • Press and select pattern number (mode). 3.
  • Page 100: Timing Belt Tension Adjustment

    Adjustment Timing belt tension adjustment 1. Loosen the pan (S/P washer) M4X8 screw on the tension pulley assembly. 2. With a force of 1.96 N (200 g) pushing on the center of the belt, adjust the tension pulley assembly position for a deflection of 4 - 5 mm.
  • Page 101: Motor Belt Tension Adjustment

    Adjustment Motor belt tension adjustment 1. Loosen the giza tite 5 x 16 (two) in the motor holder. 2. With a force of 0.98 N (100 g) pushing on the center of the belt, adjust the motor pulley position for a deflection of 3 - 4 mm.
  • Page 102: Upper Thread Tension Adjustment

    Adjustment Upper thread tension adjustment 1. Remove the front cover. 2. Remove the 2 screws, and then remove the thread guide A assembly. 3. Remove the 2 screws, and then remove the front panel and manual buttons A/B. 4. Attach the thread guide A assembly with the 2 screws. 5.
  • Page 103: Three Point Needle Drop Adjustment

    Adjustment Three point needle drop adjustment 1. Attach the front cover. 2. Turn the power on while holding down the backstitching button and the selecting button (right). (The buzzer must sound four times.) 3. Select pattern number [02]. 4. Turn the pulley by hand, and insert the tip of the needle into the needle hole. 5.
  • Page 104: Needle Drop Position Adjustment For Needle Bar Unit And Rotary Hook Unit

    Adjustment Needle drop position adjustment for needle bar unit and rotary hook unit 1. Attach the front cover temporarily. 2. Hold down the backstitching button and the selecting button (right), and turn the power on (the buzzer must sound four times). 3.
  • Page 105: Needle Interference Left/right Adjustment

    Adjustment Needle interference left/right adjustment 1. Attach the front cover. 2. Turn the pulley by hand, and insert the tip of the needle into the needle hole. 3. Loosen the screw (3 x 10). 4. Adjust the needle holder shaft block to the left or right so that the left base line / right base line needle drop is uniform forward and back with respect to the needle plate A hole.
  • Page 106: Needle Bar Rise Adjustment

    Adjustment Needle bar rise adjustment 1. Attach the front cover. 2. Hold down the backstitching button and the selecting button (right), and turn the power on (the buzzer must sound four times). 3. Select pattern number [02]. 4. Press the [REV] key four times to select the left base line. 5.
  • Page 107: Needle Bar Height Adjustment

    Adjustment Needle bar height adjustment 1. Attach the front cover. 2. Remove needle plate B. 3. Hold down the backstitching button and the selecting button (right), and turn the power on (the buzzer must sound four times). 4. Select pattern number [02]. 5.
  • Page 108: Needle Interference Adjustment

    Adjustment Needle interference adjustment 1. Attach the front cover. 2. Remove the label. 3. Hold down the backstitching button and the selecting button (right), and turn the power on (the buzzer must sound four times). 4. Select pattern number [02]. 5.
  • Page 109: Adjust The Needle Thread Block

    Adjustment Adjust the needle thread block 1. Attach a needle. 2. Turn the pulley by hand, and set the needle bar at the highest point. 3. Loosen the set screw (socket FT 4 x 4). 4. Adjust the height of the needle thread block so that the threading hook passes through the needle hole, and secure the needle thread block with the socket set screw (FT, M4X4).
  • Page 110: Presser Bar Height And Parallel Adjustment

    Adjustment Presser bar height and parallel adjustment 1. Attach the J foot. 2. Raise the presser foot lifter. 3. Turn the pulley by hand, and lower the feed dog below needle plate A. 4. Loosen the set screw (CP) M5 x 10 in the presser bar clamp assy. 5.
  • Page 111: Inner Rotary Hook (bobbin Thread) Tension

    Adjustment Inner rotary hook (bobbin thread) tension 1. Set a bobbin (wound with Schappe Spun Sewing Thread #60) in the inner rotary hook and thread. 2. Pull the thread with a tension gauge, and adjust the tension adjusting screw so that it is 0.1 - 0.12 N (10 - 12 g). XA9153001 Tension gauge 30 (0.3 N) 0.1-0.12mm...
  • Page 112: Feed Forward/reverse Adjustment

    Adjustment Feed forward/reverse adjustment 1. Attach the front cover. 2. Hold down the backstitching button and the selecting button (right), and turn the power on (the buzzer must sound four times). 3. Select pattern number [05] to enter "Feed forward and backward mode." 4.
  • Page 113: Bobbin Winder (uneven Bobbin Winding And Bobbin Winding Amounts) Adjustment

    Adjustment Bobbin winder (uneven bobbin winding and bobbin winding amounts) adjustment 1. Move the bobbin winder tension assy. up and down to adjust uneven bobbin winding. 2. Turn the bobbin presser left and right, and adjust the winding quantity *Key point •...
  • Page 114: Bh Lever Switch Position Adjustment

    Adjustment BH lever switch position adjustment 1. Raise the presser foot lifter. 2. Set the BH presser two marks smaller than the maximum length. 3. Attach the BH presser foot. 4. Lower the presser foot lifter. 5. Lower the BH lever, and set to BH presser foot. 6.
  • Page 115: Forward And Back Adjustment Of Needle And Presser

    Adjustment Forward and back adjustment of needle and presser. 1. Turn the pulley by hand, and insert the tip of the needle into the needle hole. 2. Loosen the locknut. 3. Adjust the needle tip to the front/back center position of the needle hole using the set screw (socket (CP) M4X12). 4.
  • Page 116: Feed Dog Forward/reverse And Left/right Adjustment

    Adjustment Feed dog forward/reverse and left/right adjustment 1. Hold down the backstitching button and the selecting button (right), and turn the power on (the buzzer must sound four times). 2. Select pattern number [07]. 3. Remove needle plate A. 4. Press the [REV] key twice to set the feed length to 0 mm. (Check that the mark on the feed adjusting gear is aligned with that on the F pulse motor gear.) 5.
  • Page 117: Feed Dog Height Adjustment

    Adjustment Feed dog height adjustment 1. Turn lower the pulley, and bring the feed dog to its highest position. 2. Loosen the M5 nut. 3. Adjust the feed dog height so that it is 0.9 - 1.1 mm from the upper surface of needle plate A by the amount the vertical feed adjuster assembly is screwed in.
  • Page 118: Inner Rotary Hook Bracket Position Adjustment

    Adjustment Inner rotary hook bracket position adjustment 1. Set the inner rotary hook in the outer rotary hook. 2. Loosen screw (bind 3X6). 3. Adjust the inner rotary hook bracket assy. attachment position so that contact between the inner rotary bracket assy.
  • Page 119 4 - 22...
  • Page 120: Special Instructions Of Wiring

    Special Instructions of Wiring LED lamp right supply assy ....5 - 2 Operation PCB supply assy and SSVR PCB supply assy . 5 - 3 Operation PCB supply assy ....5 - 4 Lead wire assy, FPM-LE......5 - 5 Lead wire assy, Power-LE ......
  • Page 121: Led Lamp Right Supply Assy

    Adjustment LED lamp right supply assy Pass the lead wires between 2 bosses and then attach the thread guide assy B. 5 - 2...
  • Page 122: Operation Pcb Supply Assy And Ssvr Pcb Supply Assy

    Adjustment Operation PCB supply assy and SSVR PCB supply assy Lead wires should be tied near the edge of cover. Lead wires should be tied just above the leftmost rib. S33 and S34 models Lead wires should be tied near the edge of cover. Lead wires should be tied just above the leftmost rib.
  • Page 123: Operation Pcb Supply Assy

    Adjustment Operation PCB supply assy S33 and S34 models S36 and S37 models 5 - 4...
  • Page 124: Lead Wire Assy, Fpm-le

    Adjustment Lead wire assy, FPM-LE Wind the lead wires around the rib once. Pass the lead wires through the ferrite core. No slack 5 - 5...
  • Page 125: Lead Wire Assy, Power-le

    Adjustment Lead wire assy, Power-LE Lead wires should pass inside the rib. 5 - 6...
  • Page 126: Bh Switch Assy

    Adjustment BH switch assy 5 - 7...
  • Page 127: Led Lamp Left Supply Assy

    Adjustment LED lamp left supply assy Pass a band through the hole of base holder and tie the lead wires with the band. 5 - 8...
  • Page 128: Needle Bar Unit

    Adjustment Needle bar unit Pass a band through the hole of base holder and tie the lead wires with the band. Tie the lead wires to depressed portion of presser switch holder with a band. Cut end should face front. 5 - 9...
  • Page 129: Upper Side Of Shutter Cover

    Adjustment Upper side of shutter cover Lead wires should pass under the ribs. There should be some slack in lead wires. Lead wires should be put inside the rib. 5 - 10...
  • Page 130: Fc Jack Supply Assy

    Adjustment FC jack supply assy Lead wires should pass behind the motor. 5 - 11...
  • Page 131 5 - 12...
  • Page 132: Failure Investigation For Electronic Parts

    Failure Investigation for Electronic Parts * Perform resistance measurements after turning off the power, and detaching the connectors to be measured from the PCB. Error message list ............6 - 2 6 - 1...
  • Page 133 Failure Investigation for Electronic Parts Error message list Error display Cause Explain Abnormal rotation in main motor Motor runs at more than maximum speed Key pressed continually with power ON (motor unit SW) Pushing S/S or NP or BK button continually Key pressed continually with power ON Pushing button continually except S/S or NP or (operation system SW)
  • Page 134 LOW-END COMPUTER SERIES LOW-END COMPUTER SERIES 22M04HF885S33/34/36/37...

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Fs50

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