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Brother HE-800A Service Manual

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

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Table of Contents

   Related Manuals for Brother HE-800A

   Summary of Contents for Brother HE-800A

  • Page 1 HE-800A SERVICE MANUAL Please read this manual before using the machine. Please keep this manual within easy reach for quick reference. ELECTRONIC LOCKSTITCH BUTTON HOLER...
  • Page 2: Safety Instructions

    This service manual is intended for HE-800A; be sure to read the HE-800A instruction manual before this manual. Carefully read the “SAFETY INSTRUCTIONS” below and the whole of this manual to understand this product before you start maintenance. As a result of research and improvements regarding this product, some details of this manual may not be the same as those for the product you purchased.
  • Page 3: Notes On Safety

    Furthermore, do not excessively bend the cords or secure them too firmly with staples, Contact your Brother dealer or a qualified electrician otherwise there is the danger that fire or electric for any electrical work that may need to be done.
  • Page 4: Maintenance And Inspection

    Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the Use both hands to hold the machine head when tilting electrical system.
  • Page 5: Warning Labels

    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 removed or are difficult to read, please contact your nearest Brother dealer. Safety devices Be sure to connect the ground.
  • Page 6: Table Of Contents

    4-6 . Adjusting the needle and hook timing ・・・・・・・・・・・ 83 2-21 . Feed mechanism (2) ・・・・・・・・・・・・・・・・・・・・・・・・・ 44 4-6-1 . Adjusting the clearance between 2-22 . Lower thread trimmer mechanism (1) ・・・・・・・・・ 45 needle and hook point・・・・・・・・・・・・・・・・・・・・・ 84 2-23 . Lower thread trimmer mechanism (2) ・・・・・・・・・ 46 HE-800A...
  • Page 7 4-23 . Adjusting the rotary hook lubrication ・・・・・・・・・・ 102 5-27 . Needle does not zigzag or noise occurs 4-24 . Adjusting the needle up stop position・・・・・・・・・ 103 when needle zigzags・・・・・・・・・・・・・・・・・・・・・・・・ 121 4-25 . Adjusting the V-belt tension・・・・・・・・・・・・・・・・・・ 103 5-28 . Sewing machine stops during sewing・・・・・・・・・ 121 HE-800A...
  • Page 8 6-5-2 . Circuit board DIP switches・・・・・・・・・・・・・・・・ 141 6-6 . Description of machine motor parameters ・・・・・ 143 6-7 . Input check list ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 144 6-8 . Output check list ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 147 6-9 . Error code table・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 148 6-10 . Control circuit block diagram・・・・・・・・・・・・・・・・・ 153 HE-800A...
  • Page 9: Mechanical Descriptions

    4. The needle bar (11) is secured to the needle bar clamp (7), and it moves smoothly up and down while being guided by the bushings at the top and bottom of the needle bar guide (12) and needle bar bracket (13). HE-800A...
  • Page 10: Upper Shaft, Lower Shaft And Rotary Hook Mechanisms ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2

    3. The timing pulley (5) is secured to the lower shaft (6), and it transmits the rotation to the rotary hook joint (7) that is secured to the end of the lower shaft (6). 4. The rotary hook (8) is secured to the rotary hook joint (7) and rotates fully together with the rotary hook joint (7). HE-800A...
  • Page 11: Needle Zigzag Mechanism ・・・・・・・・・・・・・・・・・・・・・・3

    (5) that is linked onto the end of the zigzag lever F assembly (4) to move in a reciprocal motion. 3. The needle bar bracket slide block (5) is linked to the groove in the needle bar bracket (6) and causes the needle bar bracket (6) to move in a reciprocal motion. HE-800A...
  • Page 12: Presser Foot Lifter Mechanism ・・・・・・・・・・・・・・・・・・・・4

    (12) that is secured to the bottom edge of the feed arm (11) up and down. 5. Feed arm support (14) that is connected to the feed arm (13) is hooked onto the presser roller bracket (12), and it moves the work clamp (15) up and down. HE-800A...
  • Page 13: Feed Mechanism ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・5

    3. The feed arm (8) is connected to the feed arm support (5), and it moves the work clamp (9) that is installed to the feed arm (8) and the length feed plate (10) that is installed to the feed arm support (5) back and forth. HE-800A...
  • Page 14: Cutter Mechanism ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・6

    3. The cutter driving kink (5) that is secured to the end of the cutter driving arm (4) is moved up and down. 4. The driving shaft holder assembly (6) is linked to the cutter driving link (5), and this causes the cutter driving shaft (7) that is connected to the driving shaft holder assembly (6) to move up and down. HE-800A...
  • Page 15: Thread Breakage Detection Mechanism ・・・・・・・・・・7

    (3). When a thread breakage occurs, the cutter bar fixed plate assembly (1) drop by its own weight and moves the thread guide (2) in the direction of the arrow. 2. When the sensor (4) detects the cutter bar fixed plate assembly (1), the sewing machine stops and the cutter is prevented from dropping. HE-800A...
  • Page 16: Lubrication Mechanism

    4. The oil which collects in the jaw of the arm, is absorbed by the felt (23) and is drawn up by the plunger pump (2) through the tube (D), and it is then returned to the oil tank (E) by the plunger pump (2). HE-800A...
  • Page 17: Lower Shaft And Rotary Hook Lubrication ・・・・・・・9

    3. The oil that is supplied to the rotary hook (7) can be adjusted by turning the screw (8) to vary the amount by which the rubber presser (9) presses down on the collar (10) that the wick passes through. HE-800A...
  • Page 18: Tension Release Mechanism

    3. The tension release link (4) that is connected to the tension release solenoid link (3) operates with the shoulder screw (5) as a pivot and presses against the tension release pin (6). 4. The tension release pin (6) presses against the tension disc presser (7) to release the tension discs. HE-800A...
  • Page 19 (12) moves in the direction of the arrow. 6. When the tension release cam (12) presses against the tension release pin (13), the tension release pin (13) presses against the tension disc presser (14) to release the tension discs. HE-800A...
  • Page 20: Upper Thread Trimmer Mechanism

    After 1.5-2.5 mm of feed, The upper thread is the upper thread scissors clamped and cut. gradually start to open. After approximately The upper thread Sewing ends. 4.6mm of feed, the upper scissors move forward. thread scissors are fully open. 4058Q HE-800A...
  • Page 21 (22) that is secured to the setting plate (21). 9. Upper thread trimmer M (23) that is installed to the upper thread trimmer assembly (22) comes into contact with the work clamp, so that upper thread trimmer M (23) closes and cuts the thread. HE-800A...
  • Page 22: Upper Thread Scissors

    (Figure B). At this time, section D of the opening cam (3) fits into the upper thread trimmer assembly (5) so that the upper thread trimmer assembly (5) cannot move in the direction of arrow C. HE-800A...
  • Page 23 (8) separates from the back stopper (10), the upper thread trimmer lever (9) is pulled in the direction of arrow E by the spring (11), and the upper thread trimmer assembly (5) changes from the condition in Figure F to the one in Figure G and the upper thread trimmer opens fully. HE-800A...
  • Page 24: Lower Thread Trimmer Mechanism

    (9), so that when the lower thread trimmer cam lever (7) operates, the lower thread trimmer cam (9) moves with it and the movement is transmitted to the lower thread trimmer cam connecting rod (10) that is connected to the lower thread trimmer cam (9). HE-800A...
  • Page 25 (22) that is secured to the fixed knife (21) moves over the cam section of the base plate (23) so that the movable knife (22) starts to close. When the lower thread retainer (17) has finished operating, the movable knife (22) meshes fully with the fixed knife (21) and cuts the lower thread. HE-800A...
  • Page 26 12.The opening plate (25) presses against the collar (24) that is installed to the lower thread clamp plate (18) and the lower thread clamp plate (18) rotates centering on the shoulder screw (30), so that the clamped lower thread is released by the lower thread presser (31) and the lower thread clamp plate (18). HE-800A...
  • Page 27: Disassembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・ ・・ ・・19

    Disassembly should only be carried out by a Use only the proper replacement parts as qualified technician. specified by Brother. Turn off the power switch before disassembly, If any safety devices have been removed, be otherwise the machine may operate if the...
  • Page 28: Rotary Hook Mechanism

    1. Remove the two screws (1), and then remove the rotary hook holder (2). 2. Loosen the two set screws (3), and then remove the rotary hook (4). 3. Loosen the two set screws (5), and then remove the rotary hook joint assembly (6) from the lower shaft. HE-800A...
  • Page 29: Lubrication Mechanism (1)

    3. Remove the two screws (7), and then remove the felt support (6) from the bed. 4. Remove the end of the felt (8) from the bush (9). 5. Remove the spring (10) and the collar (11) from the bush (9). 6. Remove the wick (5) from the collar (11). HE-800A...
  • Page 30: Plunger Pump Mechanism

    M (14). 10.Remove the oil tube (18) from the inlet hole to the right of bush M (14). 11.Remove the two screws (19), and then remove the two plungers (20) and the two compression springs (21) from bush M (14). HE-800A...
  • Page 31: Oil Terminal Mechanism

    8. Disconnect the oil tube (13) that is connected between the oil terminal and the plunger pump from the oil terminal (9). 9. Remove the oil pipe B (14), the oil cap (15), the packing (16), the collar (17) and the wick (18) from the oil terminal (9). HE-800A...
  • Page 32: Needle Zigzag Mechanism

    3. Remove the felt (6), and then remove the wick (7) from the bush F (8). 4. Remove the felt (9), and then remove the wicks (10) and (11) from the bush F (8). 5. Remove the felt (12) from the bush F (8). HE-800A...
  • Page 33: Thread Breakage Detection Mechanism

    4. Remove the two screws (8), and then remove the thread breakage sensor assembly (9). 5. Remove the thread breakage perceiving shaft (7) from the arm. 6. Remove the plain washers (10) and (11) and the screw (12), and then remove the thread guide (13) from the thread breakage perceiving shaft (7). HE-800A...
  • Page 34: Upper Thread Trimmer Mechanism

    6. Remove the nut (17) and the spring washer (18), and then remove the roller shaft (19) from the support plate (12). 7. Remove the bolt (20), and then remove the longitudinal feed arm assembly (21) from the trimmer driving lever (22). 8. Remove the two retaining rings (23), and then remove the longitudinal feed arm roller (24). HE-800A...
  • Page 35 15.Remove the screw (41), and then remove the spring hook plate (42) from the upper thread trimmer lever assembly (32). 16.Remove the rubber cap (43). 17.Loosen the two set screws (45) of the set screw collar assembly (44), and then remove the upper thread trimmer fulcrum shaft (27). HE-800A...
  • Page 36: Presser Bar Mechanism

    10.Remove the plain washer (19) and the retaining ring (20), and then remove the roller (21) from the roller shaft (18). 11.Remove the shoulder screw (22), and then remove the presser bar lifter link (23) from the presser bar guide bracket (24). HE-800A...
  • Page 37: Needle Bar And Thread Take-up Mechanism (1)

    10.Remove the slide block (19) of the needle bar bracket assembly (15) from the zigzag lever shaft (20). 11.Remove the bolt (21), and then remove the needle bar guide (22) from the needle bar bracket assembly (15). 12.Loosen the screw (23) of the needle bar clamp (16), and then remove the needle bar (9). HE-800A...
  • Page 38: Needle Bar And Thread Take-up Mechanism (2)

    4. Remove the thread take-up lever set (6) and the washer (7) from the thread take-up crank (8). 5. Remove the needle bar bracket slide block (9). 6. Remove the two bolts (10) and the screw (11), and then remove the crank rod guide (12). HE-800A...
  • Page 39: Lubrication Mechanism (2)

    5. Remove the cord holder (7), screw (8) and washer (9), and then disconnect the oil tube (10) that is connected between the oil terminal and the oil outlet. 6. Remove the screw (11), and then remove the felt holder (12). 7. Remove the oil tube assembly (13). HE-800A...
  • Page 40: Upper Shaft And Tension Pulley Mechanisms

    6. Loosen the two set screws (14), and then remove the bobbin winder pulley (15). 7. Loosen the two set screws (16), and then remove the timing pulley U assembly (17). 8. Remove the timing belt (18). 9. Remove the ball bearing (19). HE-800A...
  • Page 41: Cutter Mechanism (1)

    6. Remove the spring (12) from the cutter driving arm assembly (13) and the tension release shaft (14). 7. Remove the nut (15), and then remove the adjusting screw assembly (16) from the arm. 8. Loosen the two set screws (17), and then remove the cutter driving shaft (9). 9. Remove the oil rejector (18). HE-800A...
  • Page 42: Cutter Mechanism (2)

    10.Remove the three bolts (19), and then remove the cutter solenoid (2) from the cutter solenoid bracket (4). 11.Remove the spring washer (20) and the two nuts (21), and then remove the solenoid stopper (22) from the solenoid plunger. HE-800A...
  • Page 43: Needle Zigzag Mechanism

    4. Remove the bolt (11), and then remove the zigzag lever F assembly (12) and the thrust washer (13). 5. Loosen the set screw (14), and then remove the zigzag connecting rod shaft (15) and the zigzag lever (16). HE-800A...
  • Page 44: Presser Lifter Mechanism (1)

    8. Loosen the four set screws (18), and then remove the two guide shafts (19) and the guide bracket (17). 9. Remove the bolt (20), and then remove the bearing holder (21). 10.Remove the two linear ball bearings (22) from the guide bracket (17). HE-800A...
  • Page 45: Presser Lifter Mechanism (2)

    2. Remove the two set screws (6), and then remove the gear (7) from the pulse motor FT (for presser lifter) (3). 3. Remove the two set screws (8), and then remove the motor lever (9) from the pulse motor N assembly (for needle zigzag) (4). HE-800A...
  • Page 46: Presser Lifter Mechanism (3)

    8. Remove the two O-ring (18) and the two trimmer driving levers (19). 9. Remove the spacer (20), washer D (21) and bolt (22), and then remove the knee lifter lever (23) from the presser lifter connecting rod assembly (24). HE-800A...
  • Page 47: Tension Release Mechanism (1)

    7. Remove the plunger pin (14), and then remove the plunger (12), tension release rubber assembly (15) and the tension release solenoid link (16). 8. Remove the two screws (17), and then remove the tension release solenoid (18) from the solenoid holder (19). HE-800A...
  • Page 48: Tension Release Mechanism (2)

    10.Remove the two shoulder screws (33), and then remove the adjusting lever (32) and the tension take-up lever (34) from the lever link (35). 11. Remove the screw (36), and then remove the thread guide cover (37) and the arm thread guide L (38). HE-800A...
  • Page 49: Bobbin Presser Mechanism

    4. Remove the shoulder screw (8), and then remove the auxiliary plate (7) and the opening plate (3). 5. Loosen the set screw (9), and then remove the bobbin presser (10) from the bobbin presser bracket assembly (6). 6. Remove the screw (11) and the nut (12). 7. Remove the spring hook U (13). HE-800A...
  • Page 50: Feed Mechanism (1)

    4. Remove the screw (10), and then remove the feed home position sensor (6) from the feed sensor support plate (9). 5. Remove the two screws (11), and then remove the feed motor cover (12). 6. Remove the two screws (13), and then remove the DC fan motor 40 assembly (5) from the feed motor cover (12). HE-800A...
  • Page 51 18.Remove the two retaining rings (34), and then remove the linear bush (35) from the feed arm support (16). 19.Remove the two screws (36), and then remove the two ball bearing stoppers (37). 20.Remove the two linear bushes (38) for the feed guide shaft B (31). HE-800A...
  • Page 52: Feed Mechanism (2)

    7. Remove the two bolts (21) and spring washers (22), and then remove the length feed plate (23) from the feed arm support (10). 8. Remove the four screws (24), and then remove the two feed presser plates (25). HE-800A...
  • Page 53: Lower Thread Trimmer Mechanism (1)

    8. Remove the two screws (21), and then remove the lower thread retainer (22) from the lever assembly (23). 9. Remove the screw (24) and collar (25), and then remove the lever assembly (23) from the base plate (5). 10.Remove the screw (26). HE-800A...
  • Page 54: Lower Thread Trimmer Mechanism (2)

    (21) from the lower thread trimmer cam (22). 14.Remove the retaining ring (23), and then remove the roller (24). 15.Remove the nut (25), and then remove the roller shaft (26) from the lower thread trimmer cam lever (14). HE-800A...
  • Page 55: Lower Shaft And Idle Pulley Mechanisms

    3. Loosen the two set screws (6), and then remove the timing pulley assembly (7) from the lower shaft (5). 4. Loosen the two set screws (8), and then remove the shaft (9). 5. Remove the collar (10) and the idle pulley (11). HE-800A...
  • Page 56: Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・ ・・・・・・48

    4. Place the set screw collar assembly (8) onto the lower shaft (7), and then tighten the two set screws (9) after checking the thrust direction. * The screw flat should align with the set screw which comes first when the lower shaft is rotated in the rotation direction. 5. Install the cover (10) with the two screws (11). HE-800A...
  • Page 57: Lower Thread Trimmer Mechanism (1)

    11.Connect the lower thread trimmer link assembly (22) and the lower thread trimmer cam connecting rod (6) with the shoulder screw (24). 12.Install the opening plate assembly (25) with the shoulder screw (26). 13.Install the plate spring (27) as shown in the illustration. HE-800A...
  • Page 58: Lower Thread Trimmer Mechanism (2)

    11.While pushing the base plate (2) to the right so that the needle (25) is in the center of the needle hole (26) in the longitudinal direction, securely tighten the four screws (24). 12.Connect the lower thread trimmer link assembly (27) and the knife driving lever (8) with the shoulder screw 4.37 (28). HE-800A...
  • Page 59: Feed Mechanism (1)

    * If there is no tension gauge available, apply a force of 5 N at the middle of the timing belt (12) span and adjust so that the amount of deflection at this time is 3.5 mm. 15.Place the belt holder (25) onto the timing belt (12), and then install it to the feed arm (6) with the two bolts (26). HE-800A...
  • Page 60 20. Pass the cords for the feed pulse motor (18), DC fan motor 40 assembly (27) and feed home position sensor (31) through the four cord holders (36), and secure to the bed with the four screws (37) and the two plain washers (38). HE-800A...
  • Page 61: Feed Mechanism (2)

    10.Insert the spring (21) into the work clamp assembly (20), and then install the work clamp assembly (20) to the feed arm assembly (17) with the shoulder screw (22). 11.Install the feed arm support (23) and the opening cam assembly (24) to the feed arm assembly (17) with the to screws (25). HE-800A...
  • Page 62: Bobbin Presser Mechanism

    8. Turn on the power, and after the sewing machine returns to the home position, turn the screw (3) and the nut (4) to adjust so that the clearance between the bobbin presser (5) and the edge of the bed is approximately 12.5 HE-800A...
  • Page 63: Tension Release Mechanism (1)

    With the tension release link (12) pushed in the direction of the arrow B (Figure C), move the tension release solenoid assembly (14) so that the tension discs are open by 0.5 to 1.0 mm, and then tighten the two screws (15). HE-800A...
  • Page 64: Tension Release Mechanism (2)

    (35). (Tension stud assembly (36)) 11.Provisionally install the tension release lever bracket (37) to the tension stud assembly (36). 12.Attach the spring (38). 13.Install the tension release lever (39) with the shoulder screw (40). 14.Fully tighten the tension stud assembly (36). HE-800A...
  • Page 65: Presser Lifter Mechanism (1)

    12.Install the driving lever roller (25) and the ball bearing (26) to the trimmer driving levers (12) with the two shoulder screws (27). 13.Install the presser lifter connecting rod set (6) to the arm with the lifter shaft A (28) and the set screw (29). HE-800A...
  • Page 66: Presser Lifter Mechanism (2)

    3. Install the pulse motor N assembly (for needle zigzag) (1) and the pulse motor FT assembly (for presser lifter) (4) to the motor bracket (9) with the four bolts (7) and the three bolts (8) so that the directions of the cords are as shown in the illustration. (Motor bracket assembly (10)) HE-800A...
  • Page 67: Presser Lifter Mechanism (3)

    10.Install the clamp sensor plate (16) with the flat screw (17). 11.Install the clamp sensor (18) with the screw (19). 12.Install the clamp sensor dog (20) to the upper thread trimmer driving link (22) with the two screws (21). HE-800A...
  • Page 68: Needle Zigzag Mechanism

    (20) by tightening the set screw (19). 10.Install the zigzag sensor plate (15) to the motor bracket (22) with the two screws (21) so that each screw is in the middle of the slot. HE-800A...
  • Page 69: Cutter Mechanism (1)

    15.Install the cutter solenoid bracket (17) to the arm with the four screws (25). 16.Check that the plunger of the cutter solenoid (12) moves easily. 17.Insert the oil tube (18) and the cord of the cutter solenoid (12) in between tube support U (26) and the arm. HE-800A...
  • Page 70: Cutter Mechanism (2)

    7. Install the cutter sensor assembly (14) with the screw (16) so that the clearance between the cutter sensor assembly (14) and the solenoid stopper (15) is 4.5 mm. * At this time, be careful not to clamp the wick (17). HE-800A...
  • Page 71 If using the flat cutter (28), install with the screw (25) so that there is a clearance of 1.5 - 2.0 mm between the cutter and the top of the needle plate. HE-800A...
  • Page 72: Upper Shaft And Tension Pulley Mechanism

    12.Install the pulley assembly (21) with the two set screws (22) so that the screw flat should align with the set screw which comes first when the lower shaft is rotated in the rotation direction, and so that the clearance between it and the synchronizer assembly (19) is 0.5 mm. HE-800A...
  • Page 73: Lubrication Mechanism (1)

    6. Install the oil tube (11) that is connected to the oil terminal and the plunger pump with the tube support M (12) and the screw (13), pass it through the arm hole (14), and then secure it to the arm with the fastening band (15). * At this time, bind the oil tube carefully so as not to break it. HE-800A...
  • Page 74: Needle Bar And Thread Take-up Mechanisms (1)

    6. Secure the thread take-up crank (8) by tightening the two set screws (9). 7. Insert the support shaft (10) and secure it by tightening the set screw (11) so that the thread take-up moves smoothly with no play. HE-800A...
  • Page 75: Needle Bar And Thread Take-up Mechanisms (2)

    11.When the needle bar (2) is at its maximum zigzag position, tighten the set screws (16) and (19) against the needle bar bracket assembly (1), and then loosen them again by about 1/4 of a turn each. Then tighten the nuts (17) and (20). 12.Insert the needle bar thread guide (21) into the needle bar (2). HE-800A...
  • Page 76: Presser Bar Mechanism

    13.Remove the gauge (21) and turn off the power. 14.Insert the spring guide (23), compression spring (24) and plain washer (25), and with the presser adjusting screw (26) at a height of 30 mm, tighten the presser adjusting nut (27). HE-800A...
  • Page 77: Upper Thread Trimmer Mechanism

    11.Place the driving arm roller (28) onto the roller shaft (24), and secure it with the retaining ring (29). 12.Install the support plate (27) and the stopper (30) to the trimmer driving arm (33) with the two bolts (31) and plain washers (32). HE-800A...
  • Page 78 20.Attach the larger hooks of the two springs (45) to the pins (46) on the arm, and the smaller hooks to the upper thread trimmer lever set (34). 21.Install the upper thread trimmer assembly (47) to the upper thread trimmer lever set (34) with the screw (48), spring washer (49) and plain washer (50). HE-800A...
  • Page 79: Thread Breakage Detection Mechanism

    5. Install the lever stopper (12) at the correct angle with the screw (13). 6. Provisionally install the lever stopper (14) with the screw (15). * After installing, carry out the steps in “4-17. Adjusting the thread breakage detector”. HE-800A...
  • Page 80: Lubrication Mechanism (2)

    5. Pass the wick (11) through the tube support U (10) and push it firmly into the zigzag lever shaft lubrication hole. 6. Install the tube support U (10) with the screw (12). 7. Pass the oil tube (13) around the outside of the tube support U (10) as shown in the illustration. HE-800A...
  • Page 81: Needle Zigzag Mechanism

    3. Pass the oil tube (1) around the outside of the tube support U (2) as shown in the illustration so that it does not touch the solenoid stopper (11), and then pass it in between the cutter solenoid (12) and the arm. HE-800A...
  • Page 82: Oil Terminal Mechanism

    (11) with the fastening band (21). 10.Install the wick base support (11) with the two screws (22). 11.Insert the felt (23), and then install the cap (24) with the screw (25). HE-800A...
  • Page 83: Plunger Pump Mechanism

    9. Install the pump filter (18) to the oil filter bracket (21) with the two springs (19) and the two screws (20). 10.Insert the oil tube (7) that is connected between the plunger and the filter through the oil filter bracket (21). 11.Install the oil filter bracket (21) to the bed with the three screws (22). HE-800A...
  • Page 84: Rotary Hook Lubrication Mechanism

    * As a guide for the lubrication amount, the optimum position can be obtained if the screw (11) is tightened as much as possible and then loosened about two turns. Refer to “4-23. Adjusting the rotary hook lubrication” to check and adjust the lubrication amount. HE-800A...
  • Page 85: Rotary Hook Mechanism

    4. Install the rotary hook holder (5) with the two screws (6). 3-24. Covers 4281Q 1. Install the cover (1), the face plate (2) and the eye guard assembly (3). 2. Install the rear cover (4), the belt cover (5) and the top cover (6). HE-800A...
  • Page 86: Adjustment

    Ask your Brother dealer or a qualified Use only the proper replacement parts as electrician to carry out any maintenance and specified by Brother.
  • Page 87 * Operate the feed mechanism when the condition is as shown in figure A. * If it is pushed in the direction of arrow b at the condition shown in figure B, the condition will change to that shown in figure A. 4282Q HE-800A...
  • Page 88: Adjusting The Needle Zigzag Home Position Sensor Position

    If the needle bar is at its furthest zigzag position, place the stopper screws (4) and (5) against the needle bar bracket (3), and then turn them back about 1/4 of a turn. Then tighten the nuts (6) and (7). HE-800A...
  • Page 89: Adjusting The Feed Home Position Sensor Position

    2. If the clearance between the feed arm support (1) and the linear bushing (2) is 2 mm, the following adjustment is not necessary. If the clearance is not 2 mm, turn off the power. 3. Loosen the screw (3) and adjust the position of the feed sensor support plate (4). 4. Repeat the procedure from step 1. HE-800A...
  • Page 90: Adjusting The Work Clamp Home Position Sensor Position

    (6) of the driving lever (5), and this may cause the motor to go out of step. 5. After making this adjustment, carry out “4-18. Adjusting the thread tension at the tack tension control” and "4-14. Adjusting the upper thread trimming". HE-800A...
  • Page 91: Adjusting The Needle Bar Height

    (6) with the center of the needle when the needle bar contacts the gauge. * Different gauges are used for each of the two specifications -2 and -3, so make sure that the gauge being used matches the specifications and application for the sewing machine being adjusted. HE-800A...
  • Page 92: Needle And Hook Point

    Loosen the set screws (3) and move the rotary hook (4) forward or back until there is a clearance of 0.01 to 0.08 mm between the needle (1) and the hook point (2). * When tightening the set screws (3), tighten the one on the screw stop side first. HE-800A...
  • Page 93: Adjusting The Inner Rotary Hook And Rotary Hook Holder Overlap

    * Adjust the lift amount (including the play in the work clamp (1) and the pin (3) to 10 mm. If it is set to more than 10 mm, the work clamp will start lifting before lower thread trimming is complete, which may result in thread trimming errors. Furthermore, it may also cause the presser foot lifter pulse motor to go out of step. HE-800A...
  • Page 94: Adjusting The Work Clamp Lateral Position

    Loosen the screw (3), and then adjust the cutter sensor setting plate (4) so that there is a clearance of 4.5 ± 0.5 mm between the side of the cutter sensor (1) and the edge of the solenoid stopper (2). 4301Q HE-800A...
  • Page 95: Adjusting The Cutter Installation Position

    4. Check that the edge of the cutter holder (10) is touching the stepped section of the cutter driving shaft (11), and then tighten the bolt (9). 5. After adjusting, push the upper thread scissors (2) back to its original position (Fig. A). HE-800A...
  • Page 96: When Using The Special Needle Plate

    If using the flat cutter (2), install with the screw (1) so that there is a clearance of 1.5 - 2.0 mm between the cutter and the top of the needle plate. * After adjusting, push the upper thread scissors back to its original position (Fig. A in “4-12. Adjusting the cutter installation position”). HE-800A...
  • Page 97: Adjusting The Upper Thread Trimming

    4-14-5. Adjusting the cutting depth of the upper thread scissors 4316Q 4-14-6. Adjusting the installation height of the upper thread scissors 4317Q 4-14-7. Adjusting the upper thread scissors gradual opening timing 4318Q 4-14-8. Adjusting the upper thread scissors opening timing 4319Q HE-800A...
  • Page 98: Assembly Position

    2. Check that the overlap between the stopper (2) fixed to the trimmer driving arm assembly (1) with the bolt and the stop plate (4) of the upper thread trimmer lever set (3) is 1 mm. 3. If adjustment is necessary, loosen the bolt (5) and move the trimmer driving arm assembly (1) back and forward to adjust. HE-800A...
  • Page 99: Thread Scissors At The Sewing Start

    U (4) is aligned with the edge of the needle hole. Note: If this adjustment is not carried out, it may result in thread trimming errors or needle breakages. HE-800A...
  • Page 100: Thread Scissors

    (6) and the opening cam bracket (8) is 0 - 0.5 mm. Note: If the stopper (7) is adjusted so that it presses too firmly, it may cause the presser foot lifter pulse motor to go out of step. HE-800A...
  • Page 101: Adjusting The Installation Height Of The Upper Thread Scissors

    If the upper thread scissors (5) touch the work clamp (6), the work clamp lifter pulse motor may get out of step. * If the tilting of the work clamp (6) causes skipped stitches to occur when sewing material joints, use the accessory auxiliary sheet (7) as shown in the illustration. HE-800A...
  • Page 102: Adjusting The Upper Thread Scissors Gradual Opening Timing

    (1) and prevent the upper thread scissors (2) from opening when the work clamp is lowered. 4. Apply grease to the inclined face C of the opening cam (1). 5. Check that the upper thread scissors (2) gradually start opening after the material has been fed by 1.5 - 2.5 HE-800A...
  • Page 103: Adjusting The Upper Thread Scissors Opening Timing

    6. Turn the power back on, set the sewing machine to the home position and then press the RESET key to check the distance A. 7. Check the operation in test feed mode. * Refer to the operating procedure given in “1-10. Upper thread trimmer mechanism”. HE-800A...
  • Page 104: Adjusting The Lower Thread Trimming

    If the lower thread retaining amount is too great This can cause problems such as poor sealing at the sewing start, or wound lower thread sticking out of the rear tack. HE-800A...
  • Page 105: Adjusting The Lower Thread Clamp Opening Timing

    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 (5) and the opening plate (4). HE-800A...
  • Page 106: Adjusting The Lower Thread Clamp Opening Amount

    (2) presses the bobbin firmly before the lower thread retainer (7) starts to hold the lower thread. Note: If this timing is reversed, it will cause problems such as an excess trailing length of upper thread. HE-800A...
  • Page 107: Adjusting The Thread Breakage Detector

    7. When the thread guide (3) is moved to position B and then released, check that it moves smoothly back to position A. 8. If the thread guide (3) does not move smoothly, check that the clearance between the thread breakage detection lever (2) and the arm is 0.1 - 0.5 mm. HE-800A...
  • Page 108: Adjusting The Thread Tension At The Tack Tension Control

    2. Loosen the set screw (1), and then move the tension stud bracket assembly (2) in and out to adjust so that the tension disc opening amount is 0.5 - 1.0 mm. 3. Check that the tension discs are fully closed when the power is turned off. 4358Q HE-800A...
  • Page 109: Adjusting The Upper Thread Feeding Amount

    * If you do not have a spring gauge, adjust the tension with the bolt (1) and the nut (2) so that the amount of belt deflection is approximately 3.5 mm when a force of 5 N is applied in the middle of the belt span. Then tighten the three screws (3). HE-800A...
  • Page 110: Adjusting The Upper Shaft Timing Belt

    * Furthermore fine adjustments can then be made using the rotary hook joint screw (4). * If the lubrication amount has been reduced, run the machine for 200 - 300 sewing cycles and then check it again. Note: If lubrication stops, it will cause problems such as rotary hook seizure and thread breakages. HE-800A...
  • Page 111: Adjusting The Needle Up Stop Position

    An abnormal noise may be heard due to V-belt slipping, and e. The V-belt may become too loose and contact with the cover. If any such problems occur, adjust by following the 4367Q procedure described above. HE-800A...
  • Page 112: Troubleshooting

    5. TROUBLESHOOTING 5. TROUBLESHOOTING CAUTION Turn off the power switch and disconnect the power cord before carrying out troubleshooting, otherwise the machine may operate if the treadle is depressed by mistake, which could result in injury. 5-1. Upper thread breakage Cause Check Remedy...
  • Page 113: Skipped Stitches

    Adjust the arm thread guide position Instruction manual Bobbin case Damaged outside Polish with buff or replace the part. bobbin case and bent * Use the HE-800A bobbin case. bobbin holder spring, etc. 5-2. Skipped stitches Cause Check Remedy Page Needle...
  • Page 114: Uneven Seams

    5. TROUBLESHOOTING Cause Check Remedy Page Thread tension Zigzag thread upper Adjust the upper thread tension appropriately. Instruction thread tension manual Needle bar plate Vertical and longitudinal Reduce the needle bar play, or replace the parts. needle bar play Lower thread clamp Lower thread retainer...
  • Page 115: Lower Thread Is Lifted Up At The Sewing Start

    6 – 7 mm. Lower thread clamping ⋅ If the lower thread clamp and lower thread presser force are bent, replace them. ⋅ Check that the screws are tightened. Screw Lower thread clamp 3999Q HE-800A...
  • Page 116: Uneven Seams

    5. TROUBLESHOOTING 5-5. Uneven seams (3) ……Seam lifts up at the sewing start Seam lifts up and does not tighten at the sewing start Cause Check Remedy Page Upper thread Upper thread scissors Adjust the timing so that the upper thread scissors scissors gradual opening timing gradually start opening when the feed mechanism...
  • Page 117: Uneven Seams

    * Setting the vector shape to a rectangle can be manual effective when the width is less than the bar tack width. Needle plate Needle plate ⋅ When using knit material, replace with the –3 needle plate. ⋅ Replace with a needle plate with a smaller needle hole. HE-800A...
  • Page 118: Uneven Seams

    Adjust the lower thread tension. manual Bobbin case Damaged outside Polish with buff or replace the part. bobbin case and bent * Use the HE-800A bobbin case. bobbin holder spring, etc. Stitch patterns Purl stitch, whip stitch Set using parameter number 11. Instruction manual...
  • Page 119: Upper Thread Run Out

    ⋅ Adjust the bar tack tension discs opening amount to 0.5 - 1.0 mm by removing the top cover and moving the tension release cam. Zigzag tension Tack tension 0.5 - 1 mm 4008Q HE-800A...
  • Page 120 5. TROUBLESHOOTING Cause Check Remedy Page Upper thread feeding Thread take-up amount Loosen the screw to decrease thread take-up amount so that upper thread does not pull out of scissors assembly at the sewing start. Screw Increase Decrease 4000Q Rotary hook Needle bar height and Adjust the needle and hook timing.
  • Page 121: Unraveling Of Thread Trimmed By Upper Thread Trimmer Assembly

    0.5 - 1.0 mm by removing the top cover and tension discs) moving the tension release cam. Zigzag tension Tack tension 0.5 - 1 mm 4008Q Work clamp Work clamp lifting speed Use memory switch No. 02 to retard the work clamp Instruction manual lifting speed. HE-800A...
  • Page 122: Upper Thread Mis-trimming

    5. TROUBLESHOOTING 5-15. Upper thread mis-trimming Cause Check Remedy Page Upper thread trimmer Installation position Adjust the installation position of upper thread assembly upper thread trimmer trimmer assembly by moving the setting plate assembly assembly. ⋅ Upper thread trimmer longitudinal position adjustment ⋅...
  • Page 123: Needle Breakage

    Adjust the gap between needle and rotary hook to rotary hook 0.01 - 0.08 mm. (Adjust to as large as possible without causing skipped stitches to occur.) * Check that rotary hook point does not strike needle in zigzag motion. HE-800A...
  • Page 124: Imperfect Cutter Function (imperfect Material Cutting)

    5. TROUBLESHOOTING Cause Check Remedy Page Needle plate Needle plate position Adjust the forward/back position of the needle plate so that the needle is in the center of the needle hole. Bisect 4014Q Burr on the screw hole Polish with buff. edge (in event of uneven material feeding) Check the chamfered side...
  • Page 125: Cutter Does Not Return

    ⋅ Use parameter number 08 to set the knife X position alignment. Cutter Cutter play Adjust the cutter bar guide so that the cutter operates smoothly with no play. Cutter knife bending Use the cutter holder (option) to prevent the cutter knife from becoming bent. 4019Q HE-800A...
  • Page 126: Upper Thread Mis-winding

    5. TROUBLESHOOTING 5-22. Upper thread mis-winding Cause Check Remedy Page Upper thread Installation height Adjust the upper thread scissors installation height. scissors Upper thread scissors Adjust the timing so that the upper thread scissors gradual opening timing gradually start opening when the feed mechanism moves about 1.5 - 2.5 mm.
  • Page 127: Work Clamp Is Not Raised

    * If the lower thread tension is too strong, the motor may go out of step. Use memory switch No. 02 to reduce the work clamp lifting speed setting to make the lifting speed slower. Instruction manual Buff this section to reduce the thread retaining resistance. 4023Q HE-800A...
  • Page 128: Lower Thread Is Not Trimmed (pulls When Material Is Removed)

    5. TROUBLESHOOTING Cause Check Remedy Page Upper thread Upper thread scissors Adjust the upper thread scissors to the standard scissors operation setting. Work clamp home Work clamp home Adjust the work clamp home position sensor position sensor position sensor position position.
  • Page 129: Needle Does Not Zigzag Or Noise Occurs When Needle Zigzags

    ⋅ Push the thread driving arm in the direction of the arrow to set the thread trimming mechanism to the home position. Thread driving arm 4026Q HE-800A...
  • Page 130: Electric Components And Software

    While the power is turned on, the cooling fan of the control box operates; be careful not to get caught in it. When separating or rejoining connectors, and measuring something, be careful not to cut your fingers on metal parts such as heat sinks and covers. HE-800A...
  • Page 131: Components Inside The Control Box And The Operation Panel

    4368Q Sub circuit board (rear) Fan 1 (circulation) Fan 2 (ventilation) 2-step power supply circuit board Transformer 1-step power supply circuit board Air inlet Main circuit board Control box Panel PCB Operation panel 3584Q HE-800A...
  • Page 132: Fuse Explanation

    The feed motor and presser foot motor do 5A-250V) not operate. Fuse 6A The cutter solenoid does not operate. (glass tube fuse, 153242-000 AC200V 6A-250V) Main circuit board 1-step power supply 2-step power supply circuit board circuit board 4369Q HE-800A...
  • Page 133: Connectors

    Most of the machine trouble is due to connector problems including improper connection or sufficient contact. Therefore, be sure to check if each connector is correctly inserted and that there is no contact failure between pins and wires before starting troubleshooting procedures. 6-4-1. Connector positions Main circuit board 4370Q Sub circuit board 4371Q HE-800A...
  • Page 134 6. ELECTRIC COMPONENTS AND SOFTWARE 1-step power supply circuit board 4372Q 2-step power supply circuit board 4373Q Panel PCB 4374Q HE-800A...
  • Page 135: Signal Names For Connectors And

    • One of error E-02, E-62, E-63 and E-64 is displayed. Needle up stop position signal Needle down stop position signal P4 [PANEL] Pin no. Signal name Probable symptoms due to poor contact • The operation panel does not operate. KEY0 KEY1 KEY2 SENSOR BUZZER HE-800A...
  • Page 136 Pin no. Signal name Probable symptoms due to poor contact Stop NC signal • The stop switch is not activated. • The thread breakage detection does not operate normally. Stop NO signal +24V Thread breakage detection signal P8V (+8V) HE-800A...
  • Page 137 AC18V (N) input AC18V (A) input AC18V (A) input AC18V (B) input AC18V (B) input AC18V (C) input AC18V (C) input AC18V (D) input AC18V (D) input AC18V (E) input AC18V (E) input AC18V (F) input AC18V (F) input HE-800A...
  • Page 138 • Error E-44 is displayed. +24V • The valve does not operate. Feed PM clock Work clamp PM clock Work clamp PM direction signal Feed PM direction signal Work clamp PM current control signal Feed PM current control signal PM current OFF signal HE-800A...
  • Page 139 • Error E-08 is displayed. signal Feed PM overcurrent signal Work clamp overcurrent signal +55V relay input signal +55V voltage watch signal Cutter return signal Cutter signal Cutter signal Spare solenoid 1 Spare solenoid 2 Spare solenoid 3 HE-800A...
  • Page 140 +55V relay output signal • One of error E-06 and E-07 is displayed. • +55 V (power supply for driving the feed mechanism and +55V OFF signal work clamp PM) control is not possible. • Error E-44 is displayed. HE-800A...
  • Page 141 MP0V P7 [OPSEN2] Pin no. Signal name Probable symptoms due to poor contact +24V • Cutter does not operate. • Error E-08 is displayed. Input signal spare 4 +24V Input signal spare 5 +24V Cutter home position sensor signal HE-800A...
  • Page 142 Probable symptoms due to poor contact +55V (Special edition) +55V +55V Spare solenoid driving current 7 Spare solenoid driving current 8 Spare solenoid driving current 9 P12 [FAN2] Pin no. Signal name Probable symptoms due to poor contact +24V (Special edition) Spare input HE-800A...
  • Page 143 • Error E-08 is displayed. signal Feed PM overcurrent signal Work clamp overcurrent signal +55V relay input signal +55V voltage watch signal Cutter return signal Cutter signal Cutter signal Spare solenoid 1 Spare solenoid 2 Spare solenoid 3 HE-800A...
  • Page 144 • The zigzag home position can not be found. DC300V • The zigzag mechanism does not operate. DC0V • Error E-05 is displayed. Pin no. Signal name Probable symptoms due to poor contact • Voltage error occurs. Resistance • Error E-95 is displayed. Resistance HE-800A...
  • Page 145 • The feed home position and work clamp home position can ACIN (Power supply input) not be found. ACIN (Power supply input) • The feed mechanism and work clamp mechanism do not operate. EARTH • One of error E-06 and E-07 is displayed. HE-800A...
  • Page 146 6. ELECTRIC COMPONENTS AND SOFTWARE 5. Circuit board connectors [Panel PCB] P1 [PANEL] Pin no. Signal name Probable symptoms due to poor contact • The operation panel does not operate. KEY0 KEY1 KEY2 SENSOR BUZZER HE-800A...
  • Page 147: Description Of Dip Switches

    Display setting during automatic mode = production counter (Default: 0) 2-cycle sewing ON (All programs will be set to 2-cycle sewing regardless of the setting for parameter No. 55.) 2-cycle sewing OFF Upper thread breakage detection disabled Upper thread breakage detection enabled Programs disabled Programs enabled HE-800A...
  • Page 148 * If the programs are initialized when Nos. 3, 4 and 5 are set to OFF, OFF and ON respectively, the initial value for parameter No. 02 - Cutter size will be set to 6.0 mm. (Normal default value is 13.0 mm.) HE-800A...
  • Page 149: Circuit Board Dip Switches

    ON/OFF Setting items Default Three warning beeps Continuous warning beep Zigzag motor energization is turned off during pauses or when a thread breakage occurs Zigzag motor energization is not turned off during pauses or when a thread breakage occurs HE-800A...
  • Page 150 During standing pedal operation, the work clamp lowers only while the work clamp pedal is being depressed. During standing pedal operation, the work clamp keeps lowering when the work clamp pedal is released. 100V, 110V specifications ON/OFF 200V, 220V, 230V, 380V, 400V specifications HE-800A...
  • Page 151: Description Of Machine Motor Parameters

    5 - 70 (faster for larger values) Machine motor stopping speed 150 - 200 rpm Spare Spare Spare Spare * For 100 V and 110 V specifications, the initial value of the parameter No. 03 is set to 13. HE-800A...
  • Page 152: Input Check List

    * Turn the switch on and off to check it, and move the object by hand to check the sensor. 4. When returning to normal operation, turn power off and then on again. <Example> When checking the cloth presser switch (Segment 4-A) Check whether a response occurs here 3559Q HE-800A...
  • Page 153 Panel DIP switch A-No.2 Segment 3-B Panel DIP switch A-No.3 Segment 3-C Panel DIP switch A-No.4 Segment 3-D Panel DIP switch A-No.5 Segment 3-E Panel DIP switch A-No.6 Segment 3-F Panel DIP switch A-No.7 Segment 3-G Panel DIP switch A-No.8 Segment 3-D.P HE-800A...
  • Page 154 * When the treadle is depressed forward, the value becomes larger, and when it Pedal switch analog value is depressed backward, the value becomes smaller. * The neutral position is set to 78 ± 3 at the time of shipment from the factory. HE-800A...
  • Page 155: Output Check List

    Note: If the work clamp is not at the home position, the check code cannot be changed. * This function can be used to make fine adjustments to the position of the work clamp. (Refer to "4-14-5. Adjusting the cutting depth of the upper thread scissors".) HE-800A...
  • Page 156: Error Code Table

    Cutter home position sensor is off. 3. Check that connector P23 on the main P.C. board and connector P13 on the sub P.C. board are properly connected. 4. Check the operation of the cutter home position sensor monitor lamp. HE-800A...
  • Page 157 Use the programming device (the programming software E-53 Multi-working knife error for the electronic pattern sewer or a programmer) to delete multi-working knife operations. Overall cycle program stitch no. error E-54 Clear the cycle program to reset the error automatically. (Exceeds 3,000 stitches.) HE-800A...
  • Page 158 3. Check that connectors P3 and P6 on the main P.C. E-90 (Excessive load during sewing.) board are properly connected. 4. Check that machine motor harness connector CN7 and power supply harness connector CN8 on the 1-step power supply circuit board are properly connected. HE-800A...
  • Page 159 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 program mode. C. By initializing all programs Refer to "12-1. Initializing all programs” in the instruction manual. HE-800A...
  • Page 160 6. ELECTRIC COMPONENTS AND SOFTWARE HE-800A...
  • Page 161: Control Circuit Block Diagram

    6. ELECTRIC COMPONENTS AND SOFTWARE 6-10. Control circuit block diagram 4380Q HE-800A...
  • Page 162 SERVICE MANUAL http://www.brother.com/ Printed in Japan HE-800A I3120853F 2004.02. F (1)

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