Brother BE-438D- User Manual

Page 2 - SAFETY INSTRUCTIONS; Safety indications and their meanings; Indications; DANGER; Symbols

KE-430D, BE-438D i This service manual is intended for KE-430D, BE-438D; be sure to read the KE-430D, BE-438D 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 res...

Page 3 - ii; Environmental requirements; Installation

KE-430D, BE-438D ii 2. Notes on safety DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Environ...

Page 4 - iii; CAUTION; Sewing; Cleaning

KE-430D, BE-438D iii CAUTION Sewing This sewing machine should only be used by operators who have received the necessary training in safe use beforehand. The sewing machine should not be used for any applications other than sewing. Be sure to wear protective goggles when using the machine. If goggle...

Page 5 - iv

KE-430D, BE-438D iv 3. 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. 1 2 3 Be sure to co...

Page 6 - CONTENTS

KE-430D, BE-438D CONTENTS 1. SPECIFICATIONS.................................... 1 2. FUNCTION SETTINGS ............................ 2 2-1. List of special functions when power is turned on ..... 2 2-2. List of advanced functions................................... 3 2-3. Setting memory switches (Adva...

Page 9 - FUNCTION SETTINGS; -1. List of special functions when power is turned on

2. FUNCTION SETTINGS 2 KE-430D, BE-438D 2. FUNCTION SETTINGS 2-1. List of special functions when power is turned on 1 Memory switch setting mode (Standard) Refer to the Instruction Manual. 6 Output check function Refer to “2-10. Output checking method”. 2 Memory switch setting mode (Advanced) Refer ...

Page 26 - -3. Preparation for reading and writing data; Switching to CF data read/write mode

3. USING CF CARDS 19 KE-430D, BE-438D 3-3. Preparation for reading and writing data 1 With the power turned off, insert the CF card into the CF slot. Note: • Make sure the CF card is facing the correct way. • The cover should be closed at all times except when the CF card is inserted and removed, ot...

Page 27 - -5. Writing additional sewing data to the CF card; Ending read/write mode

3. USING CF CARDS 20 KE-430D, BE-438D 3-4. Reading additional sewing data 1 Selecting the "r 1" CF data read/write mode Press the R/W key. • "-SEd" will change to " ALL". 2 Press the or key to select the program numbers (ALL, 200 - 999) that you would like to read. • If "...

Page 28 - -7. Writing memory switch data to the CF card

3. USING CF CARDS 21 KE-430D, BE-438D 3-6. Reading memory switch data 1 Selecting the "r 3" CF data read/write mode 2 While reading Press the R/W key. • The buzzer will sound and the selected memory switch data will be loaded from the CF card and copied into the sewing machine's internal mem...

Page 29 - -9. Writing user program data to the CF card

3. USING CF CARDS 22 KE-430D, BE-438D 3-8. Reading user program data 1 Selecting the "r 5" CF data read/write mode 2 While reading Press the R/W key. • The buzzer will sound and the selected user program data will be loaded from the CF card and copied into the sewing machine's internal memor...

Page 30 -

3. USING CF CARDS 23 KE-430D, BE-438D 3-10. Updating the control programs 1 Selecting the "r 7" CF data read/write mode Press the R/W key. • After a set period of time, "-SyS" will change to " vEr", and then the version number of the control program that is stored on the CF c...

Page 31 - -11. Writing error log data to the CF card

3. USING CF CARDS 24 KE-430D, BE-438D 3-11. Writing error log data to the CF card 1 Selecting the "w 8" CF data read/write mode 2 While writing Press the R/W key. • The buzzer will sound and the error log data will be copied from the internal memory onto the CF card. 3 Ending read/write mode...

Page 32 - MECHANICAL DESCRIPTIONS; -2. Lower shaft and shuttle race mechanisms

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 25 4. MECHANICAL DESCRIPTIONS 4-1. Needle bar and thread take-up mechanisms 4-2. Lower shaft and shuttle race mechanisms 1. Pulley 2. Upper shaft 3. Crank rod assy4. Rock gear 5. Lower gear 6. Lower shaft 7. Driver 8. Shuttle hook 1. Pulley 2. Upper shaft ...

Page 35 - Y direction

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 28 4-5. Feed mechanism Sewing patterns are created through combinations of X and Y movements. Y direction X direction 1. Pulse motor X assy2. Feed gear 3. X-feed gear 4. X-feed lever 5. Regulator block assy 6. Feed bracket sub assy 1. Pulse motor Y assy2. ...

Page 60 -

6. ASSEMBLY KE-430D, BE-438D 53 <Feed mechanism home position adjustment> 1. Install the home position standard plate (1) to the feed bracket sub assembly (2) with the two screws (3). 2. Gently tilt back the machine head. 3. Switch the sewing machine to home position adjustment mode. (See "...

Page 68 - Apply grease to all sliding parts during assembly.

6. ASSEMBLY KE-430D, BE-438D 61 6-12. Work clamp arm mechanism (KE-430D) Apply grease to all sliding parts during assembly. 1) Sliding portion of the work clamp (1) (Apply small amount of grease.) 2) Sliding portion of the work clamp arm lever shaft (2) and the work clamp arm levers R and L (3) 3) R...

Page 73 - -3. Adjusting the needle bar lift amount

7. ADJUSTMENT 66 KE-430D, BE-438D 7-2. Adjusting the needle bar height Turn the pulley to move the needle bar to the lowest position. Then remove the rubber cap (2), loosen the screw (3) and then move the needle bar up or down to adjust so that the second reference line from the bottom of the needle...

Page 74 - -6. Adjusting the shuttle race thread guide

7. ADJUSTMENT 67 KE-430D, BE-438D 7-5. Adjusting the needle clearance Turn the pulley to align the tip of the rotary hook with the needle center line. Then loosen the set screw (1) and turn the eccentric shaft (2) to adjust so that the clearance between the needle and the rotary hook is 0.01 - 0.08 ...

Page 75 - -8. Adjusting the position of the movable knife

7. ADJUSTMENT 68 KE-430D, BE-438D 7-8. Adjusting the position of the movable knife 1. Remove the top cover and tilt back the machine head. 2. Turn the machine pulley by hand so that the index mark (1) is near facing straight upward. 3. Loosen the bolt (2). 4. Hold the nut (3) with the spanner (10), ...

Page 76 - -9. Replacing the movable knife and fixed knife

7. ADJUSTMENT 69 KE-430D, BE-438D 7-9. Replacing the movable knife and fixed knife 1. Open the shuttle race cover, remove the two screws (1), and then remove the feed plate (2). 2. Remove the two screws (3) and the two flat screws (4), and then remove the needle plate (5). 3. Remove the movable knif...

Page 78 - -14. Adjusting the thread trimmer cam position

7. ADJUSTMENT 71 KE-430D, BE-438D 7-12. Adjusting the holding pressure (BE-438D) Loosen the nut (1) and turn the nut (2) to the point where it is just tight enough that the material will not slip out of place when it is slightly pulled (keep pressure as slight as possible). 7-13. Adjusting the posit...

Page 80 - -16. Adjusting the tension release amount; -17. Adjusting the backlash of the lower shaft gear

7. ADJUSTMENT 73 KE-430D, BE-438D 7-16. Adjusting the tension release amount 1. Loosen the nut (4) and turn the bolt (2) to adjust so that the distance between the tip of the bolt (2) and the solenoid setting plate (3) is 11.5 mm when the plunger of the tension release solenoid (1) is pushed in as f...

Page 83 - -19. Adjusting the position of the thread nipper

7. ADJUSTMENT 76 KE-430D, BE-438D 7-19. Adjusting the position of the thread nipper 1. Turn the pulley to set the needle to the needle up stop position. 2. While pressing the keys (1) simultaneously, turn on the power switch. * Keep pressing the keys (1) until the model name is displayed and the buz...

Page 85 - -20. Adjusting the needle up stop home position

7. ADJUSTMENT 78 KE-430D, BE-438D 7-20. Adjusting the needle up stop home position 1. Remove the needle, the needle bar thread guide and the feed plate. 2. Turn the pulley to move the needle bar (1) to the lowest position. 3. Remove the rubber cap (2) from the face plate, and then loosen the screw (...

Page 86 - -21. Adjusting the needle up stop position

7. ADJUSTMENT 79 KE-430D, BE-438D 7-21. Adjusting the needle up stop position The needle up stop position is adjusted using the operation panel so that the index mark (1) on the machine pulley is within the range of the marks (2) on the back cover. The standard needle up stop positions are as follow...

Page 88 - ; problems with the sewing machine may result.

8. Applying grease (When “GREASEUP” appears) 81 KE-430D, BE-438D 8. Applying grease (When “GREASEUP” appears) If “GrE” and “AS.UP" flash on the PROGRAM No. display (1) and the menu display (2) respectively, and a buzzer sounds when the power switch is turned on, it means that grease needs to be ...

Page 91 - How to install the feed plate for KE-430C series in

9. How to install the feed plate for KE-430C series in KE-430D and BE-438D 84 KE-430D, BE-438D 9. How to install the feed plate for KE-430C series in KE-430D and BE-438D If using the feed plate for the KE-430C and BE-438C, install it as follows. <KE-430D> Install using the two screws (1) and t...

Page 92 - ELECTRIC MECHANISM; 0-1. Precautions at the time of adjustment; Electric shock

10. ELECTRIC MECHANISM 85 KE-430D, BE-438D 10. ELECTRIC MECHANISM DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in sev...

Page 93 - 0-2. Components inside the control box and the operation panel; Control box

10. ELECTRIC MECHANISM 86 KE-430D, BE-438D 10-2. Components inside the control box and the operation panel Main P. C. board Secured to the side. This PCB serves to control machine operation. PMD P. C. board Secured to the bottom. This PCB drives the pulse motor and solenoids . Power supply motor P. ...

Page 96 - Panel PCB

10. ELECTRIC MECHANISM 89 KE-430D, BE-438D Power supply motor P. C. board Panel PCB 4593Q 4594Q

Page 97 - Feed mechanism

10. ELECTRIC MECHANISM 90 KE-430D, BE-438D 10-4-2. Contact failure The connectors functions are divided into five categories. Some connectors may belong to more than one group. Be sure to investigate another category if a problem is not found in one category. Feed mechanism Problem Connector No. and...

Page 98 - Thread trimmer mechanism

10. ELECTRIC MECHANISM 91 KE-430D, BE-438D Thread trimmer mechanism Problem Connector No. and position • Thread trimming is not performed. (There is no error display.) • Tension release does not operate. (There is no error display.) • Error E690 is displayed. Sewing operation Problem Connector No. a...

Page 99 - Others

10. ELECTRIC MECHANISM 92 KE-430D, BE-438D Others Problem Connector No. and position • The DC fan motor does not run. • Error E740 is displayed. • Indication is strange. • The power indicator is not illuminated. • Any operation panel key does not have any effect. • The sewing machine does not operat...

Page 104 - Electrical shock

10. ELECTRIC MECHANISM 97 KE-430D, BE-438D 10-5-2. Problem solution and measures DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present ca...

Page 106 - Malfunction of power cord

10. ELECTRIC MECHANISM 99 KE-430D, BE-438D Error status #1 The power indicator does not light when the power is turned on. Probable causes Check/ repair/ adjust Parts to be replaced 3. Malfunction of power cord Disconnect power supply motor P.C. board connector P9 (ACIN) from the P.C. board, turn on...

Page 116 - TABLE OF ERROR CODES; Switch-related errors

11. TABLE OF ERROR CODES 109 KE-430D, BE-438D 11. TABLE OF ERROR CODES DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result i...

Page 122 - SEGMENT DISPLAY LIST; A B C D E F G H I J; K L M N O P Q R S T

13. SEGMENT DISPLAY LIST 115 KE-430D, BE-438D 13. SEGMENT DISPLAY LIST 0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Page 123 - SERVICE MANUAL

SERVICE MANUAL 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177 Printed in Japan KE-430D, BE-438D I4050864H 2004.11. H (2) http://www.brother.com/

Brother BE-438D- User Manual

Table of Contents:

Summary

Other Brother Models