Brother BE-438D Service Manual

KE-430D BE-438D Please read this manual before making any adjustments. ELECTRONIC DIRECT DRIVE LOCKSTITCH BAR TACKER ELECTRONIC DIRECT DRIVE LOCK

2. FUNCTION SETTINGS 3KE-430D, BE-438D 2-2. List of advanced functions While holding down the TEST key, press the corresponding combination key.

10. ELECTRIC MECHANISM 93KE-430D, BE-438D 10-5. Troubleshooting 10-5-1. Troubleshooting flowchart Symbols and their meanings Manual operation

10. ELECTRIC MECHANISM 94 KE-430D, BE-438D 4894Q

10. ELECTRIC MECHANISM 95KE-430D, BE-438D 4895Q

10. ELECTRIC MECHANISM 96 KE-430D, BE-438D 4896Q

10. ELECTRIC MECHANISM 97KE-430D, BE-438D 10-5-2. Problem solution and measures DANGER Wait at least 5 minutes after turning off the power switc

10. ELECTRIC MECHANISM 98 KE-430D, BE-438D Error status #1 The power indicator does not light when the power is turned on. Probable causes

10. ELECTRIC MECHANISM 99KE-430D, BE-438D Error status #1 The power indicator does not light when the power is turned on. Probable causes

10. ELECTRIC MECHANISM 100 KE-430D, BE-438D Error status #2 Error code appears on the display when the power is turned on. Probable causes Ch

10. ELECTRIC MECHANISM 101KE-430D, BE-438D Error status #4 Work clamp does not return to the home position even after the foot switch is de

10. ELECTRIC MECHANISM 102 KE-430D, BE-438D Error status #6 Error code appears on the display when the foot switch is depressed. Probable

2. FUNCTION SETTINGS 4 KE-430D, BE-438D 2-3. Setting memory switches (Advanced) 1 Menu indicators switch offTEST indicator light

10. ELECTRIC MECHANISM 103KE-430D, BE-438D Error status #7 Error code appears on the display when the foot switch is depressed. Probable ca

10. ELECTRIC MECHANISM 104 KE-430D, BE-438D Error status #8 Error code appears on the display when the foot switch is depressed. Probable

10. ELECTRIC MECHANISM 105KE-430D, BE-438D Error status #11 Work clamp does not lower. Probable causes Check/ repair/ adjust Parts to be

10. ELECTRIC MECHANISM 106 KE-430D, BE-438D Error status #17 Error code appears on the display after the machine operates. Probable causes

10. ELECTRIC MECHANISM 107KE-430D, BE-438D Error status #19 The thread trimmer does not operate. Probable causes Check/ repair/ adjust Parts

10. ELECTRIC MECHANISM 108 KE-430D, BE-438D Error status #20 The machine does not stop at the needle up stop position. (“E110” appears.) P

11. TABLE OF ERROR CODES 109KE-430D, BE-438D 11. TABLE OF ERROR CODES DANGER Wait at least 5 minutes after turning off the power switch and dis

11. TABLE OF ERROR CODES 110 KE-430D, BE-438D Work clamp-related errors Code Cause and remedy E300 Work clamp home position cannot be detected.

11. TABLE OF ERROR CODES 111KE-430D, BE-438D Data editing-related errors Code Cause and remedy E500 The enlargement ratio setting caused the sewi

12. TROUBLESHOOTING 112 KE-430D, BE-438D 12. TROUBLESHOOTING • Please check the following points before calling for repairs or service. • If the

2. FUNCTION SETTINGS 5KE-430D, BE-438D 2-4. List of memory switches No. Setting range Setting items Default Work clamp/button clamp lift timing whe

12. TROUBLESHOOTING 113KE-430D, BE-438D Problem Cause Remedy Ref. Upper thread tension is too strong. Adjust the upper thread tension. Instru

12. TROUBLESHOOTING 114 KE-430D, BE-438D Problem Cause Remedy Ref. Movable knife is blunt. Replace the movable knife. P. 69 Fixed knife is b

13. SEGMENT DISPLAY LIST 115KE-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

SERVICE MANUAL 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177 Printed in Japan KE-43

2. FUNCTION SETTINGS 6 KE-430D, BE-438D Work clamp settings No. Setting range Setting items Default Work clamp motions 1 Work clamp is raised aut

2. FUNCTION SETTINGS 7KE-430D, BE-438D No. Setting range Setting items Default Needle penetration force increase OFF Disable 161 ON Needle penetr

2. FUNCTION SETTINGS 8 KE-430D, BE-438D Operation panel settings No. Setting range Setting items Default Operation panel changing limitations 0 N

2. FUNCTION SETTINGS 9KE-430D, BE-438D Device settings No. Setting range Setting items Default Needle cooler OFF Disable 550 ON Needle cooler can

2. FUNCTION SETTINGS 10 KE-430D, BE-438D 2-5. Setting the work clamp mode The work clamp/button clamp operating mode can be

2. FUNCTION SETTINGS 11KE-430D, BE-438D 2-6. X-Y parallel movement for sewing patterns The feed mechanism can be moved to the desired position and s

2. FUNCTION SETTINGS 12 KE-430D, BE-438D 2-7. Clearing saved data (Initialization) Incorrect setting of data from sources such as memory switches c

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. C

2. FUNCTION SETTINGS 13KE-430D, BE-438D 2-8. Checking the error history The past error history can be checked by the following procedure.

2. FUNCTION SETTINGS 14 KE-430D, BE-438D 2-9. Input checking method Use this method to check for any malfunctions of the input keys at the operatio

2. FUNCTION SETTINGS 15KE-430D, BE-438D PROGRAM No. display Menu display Check code Abbreviation Input status Check items and checking methods [

2. FUNCTION SETTINGS 16 KE-430D, BE-438D 2-10. Output checking method Use the following procedure when checking for PCB-related failures, mechanism

2. FUNCTION SETTINGS 17KE-430D, BE-438D 2-11. Confirming software version TEST indicator lights Menu indicators switch

3. USING CF CARDS 18 KE-430D, BE-438D 3. USING CF CARDS 3-1. Notes on handling CF cards (purchase at local retailers) • Use only 32MB, 64MB, 128M

3. USING CF CARDS 19KE-430D, BE-438D 3-3. Preparation for reading and writing data 1 With the power turned off, insert the CF card i

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

3. USING CF CARDS 21KE-430D, BE-438D 3-6. Reading memory switch data 1 Selecting the "r 3" CF data read/write mode 2

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

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 w

3. USING CF CARDS 23KE-430D, BE-438D 3-10. Updating the control programs 1 Selecting the "r 7" CF data read/write mode Press the

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

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 254. MECHANICAL DESCRIPTIONS 4-1. Needle bar and thread take-up mechanisms

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 26 4-3. Work clamp lifter mechanism *

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 274-4. Thread wiper mechanism 1. Work clamp pulse motor2.

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 28 4-5. Feed mechanism Sewing patterns are created through combinations of X and Y movements.

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 294-6. Thread trimmer mechanism 1. Thread

4. MECHANICAL DESCRIPTIONS KE-430D, BE-438D 30 4-7. Tension release mechanism 4-8. Thread nipper mechanism

5. DISASSEMBLY KE-430D, BE-438D 315. DISASSEMBLY CAUTION Disassembly should only be carried out by a qualified technician. Turn off the power

5. DISASSEMBLY KE-430D, BE-438D 32 1. Set screw 2. Needle 3. Needle bar thread guide 4. Nuts [2 pcs] Adjusting screw Compression spring [Push upward

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 befo

5. DISASSEMBLY KE-430D, BE-438D 335-3. Needle bar mechanism 1. Rubber cap 2. Scre

5. DISASSEMBLY KE-430D, BE-438D 34 5-4. Upper shaft mechanism 1. Screw [Loosen] 2. Set

5. DISASSEMBLY KE-430D, BE-438D 355-5. Lower shaft mechanism 1. Bolt [Loosen] 2.

5. DISASSEMBLY KE-430D, BE-438D 36 5-6. Feed mechanism 1. Set screws [2 pcs: Loo

5. DISASSEMBLY KE-430D, BE-438D 375-7. Work clamp lifter mechanism 1. Spring 2. Set sc

5. DISASSEMBLY KE-430D, BE-438D 38 23. Set screw [Loosen] 24. Retaining ring,

5. DISASSEMBLY KE-430D, BE-438D 395-8. Thread wiper mechanism 5-9. Tension release mechanism

5. DISASSEMBLY KE-430D, BE-438D 40 5-10. Thread nipper mechanism 1. Shoulder screw

5. DISASSEMBLY KE-430D, BE-438D 415-11. Thread trimmer mechanism 1. Set screws [

5. DISASSEMBLY KE-430D, BE-438D 42 5-12. Shuttle hook mechanism 36. Movable knife

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

6. ASSEMBLY KE-430D, BE-438D 436. ASSEMBLY Apply grease to the required places when reassembling the parts and once every two years. 6-1. Thread

6. ASSEMBLY KE-430D, BE-438D 44 16. Driving lever 17. Thread trimmer collar 1

6. ASSEMBLY KE-430D, BE-438D 456-2. Tension release mechanism 6-3. Thread wiper mechanism Apply grease to the portions

6. ASSEMBLY KE-430D, BE-438D 46 6-4. Thread nipper mechanism Apply grease to the portions indicated by the white arrows.

6. ASSEMBLY KE-430D, BE-438D 476-5. Work clamp lifter mechanism Apply grease to the portions indicated by the white arrows.

6. ASSEMBLY KE-430D, BE-438D 48 <16> Button clamp lever <17> But

6. ASSEMBLY KE-430D, BE-438D 49 1) Face the screw stop of the pulse motor P assembly in thesame direction as the connector. 2) Turn

6. ASSEMBLY KE-430D, BE-438D 50 Engage the feed gear and the X-feed gear so that theindex marks are as close together as possible, andthe

6. ASSEMBLY KE-430D, BE-438D 51 12. Eccentric shaft 13. Ball bearing 14. Retai

6. ASSEMBLY KE-430D, BE-438D 52 30. Feed gear 31. Set screws [2 pcs] 32. Puls

KE-430D, BE-438D CONTENTS 1. SPECIFICATIONS... 1 2. FUNCTION SETTINGS... 2 2-1. List of sp

6. ASSEMBLY KE-430D, BE-438D 53<Feed mechanism home position adjustment> 1. Install the home position standard plate (1)

6. ASSEMBLY KE-430D, BE-438D 54 6-7. Upper shaft mechanism 1. Upper shaft 2. Bo

6. ASSEMBLY KE-430D, BE-438D 556-8. Needle bar mechanism Apply grease <GREASE BZL-301> specified by Brother to the portions indicated by the wh

6. ASSEMBLY KE-430D, BE-438D 56 18. Needle bar clamp 19. Needle bar [Insert from above]20. Screw 21. Ru

6. ASSEMBLY KE-430D, BE-438D 576-9. Lower shaft mechanism Apply grease <GREASE BZL-301> or <GREASE BZL-302> specified by Brother to the p

6. ASSEMBLY KE-430D, BE-438D 58 14. Lower shaft assy [Insert from the rear of

6. ASSEMBLY KE-430D, BE-438D 596-10. Shuttle hook mechanism After installing the shuttle hook, carry out the

6. ASSEMBLY KE-430D, BE-438D 60 1) Insert the pin of the movable knife assembly into thehole in the movable knife connecting plate, insert thepin of

6. ASSEMBLY KE-430D, BE-438D 616-12. Work clamp arm mechanism (KE-430D) Apply grease to all sliding parts

6. ASSEMBLY KE-430D, BE-438D 62 6-13. Work clamp arm mechanism (BE-438D) Apply grease to the portions indicated b

KE-430D, BE-438D 7-6. Adjusting the shuttle race thread guide...67 7-7. Rotary hook lubrication amount...67 7-8.

6. ASSEMBLY KE-430D, BE-438D 636-14. Covers 1. Shuttle race cover assy2. Spring washers

7. ADJUSTMENT 64 KE-430D, BE-438D 7. ADJUSTMENT CAUTION Maintenance and inspection of the sewing machine should only be carried out by a qualif

7. ADJUSTMENT 65KE-430D, BE-438D 7-1-2. Thread take-up spring < Thread take-up spring height > Loosen the set screw (1) and turn the tension

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 positi

7. ADJUSTMENT 67KE-430D, BE-438D 7-5. Adjusting the needle clearance Turn the pulley to align the tip of the rotary hook with the

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. Tu

7. ADJUSTMENT 69KE-430D, BE-438D 7-9. Replacing the movable knife and fixed knife 1. Open the shuttle race cover, remove the

7. ADJUSTMENT 70 KE-430D, BE-438D 7-10. Adjusting the work clamp lift amount (KE-430D) Adjust so that the actual maximum lift amount for the work

7. ADJUSTMENT 71KE-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 j

7. ADJUSTMENT 72 KE-430D, BE-438D 7-15. Adjusting the thread wiper <Thread wiper height adjustment> Loosen the two screws (2) and adjust the

1. SPECIFICATIONS 1KE-430D, BE-438D 1. SPECIFICATIONS 1 Ordinary materials 2 Denim 7 Foundation garments KE-430D Electronic direct drive lo

7. ADJUSTMENT 73KE-430D, BE-438D 7-16. Adjusting the tension release amount 1. Loosen the nut (4) and turn the bolt (2) to a

7. ADJUSTMENT 74 KE-430D, BE-438D 7-18. Adjusting the home position 7-18-1. X-Y feed home position 1 Turn the pulley to set the needle to the need

7. ADJUSTMENT 75KE-430D, BE-438D 7-18-2. Work clamp lift home position 1 Turn the pulley to set the needle to the needle up stop position. 2

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 po

7. ADJUSTMENT 77KE-430D, BE-438D 9. Press the key so that "P 03" is displayed in the menu display. 10. Loosen t

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

7. ADJUSTMENT 79KE-430D, BE-438D 7-21. Adjusting the needle up stop position The needle up stop position is adjusted usi

7. ADJUSTMENT 80 KE-430D, BE-438D 3 Press the or key to set the offset value (-9 - 10). • When you press the key, the needle bar wi

8. Applying grease (When “GREASEUP” appears) 81KE-430D, BE-438D 8. Applying grease (When “GREASEUP” appears) If “GrE” and “AS.UP" flash on th

8. Applying grease (When “GREASEUP” appears) 82 KE-430D, BE-438D <Applying grease> Note: • Use only the grease <BZL-301 (SA2694-001) in t

2. FUNCTION SETTINGS 2 KE-430D, BE-438D 2. FUNCTION SETTINGS 2-1. List of special functions when power is turned on 1

8. Applying grease (When “GREASEUP” appears) 83KE-430D, BE-438D <Grease application locations> <Resetti

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

10. ELECTRIC MECHANISM 85KE-430D, BE-438D 10. ELECTRIC MECHANISM DANGER Wait at least 5 minutes after turning off the power switch and disconnec

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.

10. ELECTRIC MECHANISM 87KE-430D, BE-438D 10-3. Fuse explanation When replacing a fuse, be sure to use the specified ones listed below. If a compo

10. ELECTRIC MECHANISM 88 KE-430D, BE-438D 10-4. Connectors Most of the machine trouble is due to connector problems including improper connectio

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

10. ELECTRIC MECHANISM 90 KE-430D, BE-438D 10-4-2. Contact failure The connectors functions are divided into five categories. Some connectors may

10. ELECTRIC MECHANISM 91KE-430D, BE-438D Thread trimmer mechanism Problem Connector No. and position • Thread trimming is not performed. (There i

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.