Brother BE-438C Instruction Manual Download Page 67

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INSTRUCTION MANUAL

15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177

Printed in Japan

118-V38

S91V38-202

2002.10.B(1)

Summary of Contents for BE-438C

Page 1: ...BE 438C Please read this manual before using the machine Please keep this manual within easy reach for quick reference ELECTRONIC LOCKSTITCH BUTTON SEWER INSTRUCTION MANUAL ...

Page 2: ...afe operation of this machine and to prevent accidents and injury to yourself or other people The meanings of these indications and symbols are given below Indications DANGER The instructions which follow this term indicate situations where failure to follow the instructions will almost certainly result in death or severe injury CAUTION The instructions which follow this term indicate situations w...

Page 3: ...roblems with correct operation Installation Machine installation should only be carried out by a qualified technician Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done The sewing machine weighs more than 52 kg The installation should be carried out by two or more people Do not connect the power cord until installation is complete otherwise the ...

Page 4: ...e the machine may operate if the foot switch is depressed by mistake which could result in injury Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin otherwise inflammation can result Furthermore do not drink the oil or eat the grease under any circumstances as they can cause vomiting and diarrhoea Keep...

Page 5: ...afety devices Eye guard Finger guard Thread take up cover Thread take up solenoid cover Belt cover Frame side cover etc 3 High temperature warning display 4 Be sure to connect the ground If the ground connection is not secure you run a high risk of receiving a serious electric shock and problems with correct operation may also occur 5 Direction of operation 2648Q 2750Q Eye guard Thread take up cov...

Page 6: ...E AND INSPECTION 30 9 1 Checking the needle 30 9 2 Cleaning the rotary hook 30 9 3 Lubrication 31 9 4 Draining the oil 32 9 5 Cleaning the control box air inlet port 32 9 6 Cleaning the air holes of belt cover and frame side cover 32 9 7 Cleaning the eye guard 32 10 STANDARD ADJUSTMENTS 33 10 1 Adjusting the needle bar height 33 10 2 Adjusting the needle bar lift amount 33 10 3 Adjusting the drive...

Page 7: ...Power switch 10 Finger guard 2 Control box 11 Eye guard 3 Operation panel 12 Thread take up cover 4 Foot switch 13 Belt cover 5 Motor 14 Frame side cover 6 Tension release lever 15 Thread take up solenoid cover 7 Pulley 8 Spool stand 9 Thread take up lever 2650Q 2651Q ...

Page 8: ...4 38 stitches pre set Maximum stitch number 20 000 stitches including 10 000 stitches which can be added Work clamp lifter Solenoid type Rotary hook Shuttle hook Wiper device Standard equipment Thread trimmer device Standard equipment Thread take up device Standard equipment Data storage method P ROM Any sewing pattern can be added using PS 3000 Number of user programs 16 Number of cycle programs ...

Page 9: ... pattern No of threads No of crossover stitches No of stitches Standard sewing length X Standard sewing width Y 1 6 13 2 8 15 3 10 17 4 12 19 1 5 16 23 1 6 20 27 3 4mm 0mm 2 7 6 13 2 23 10 17 2 8 2 12 19 0mm 3 4mm 2 9 5 5 5 22 2 24 7 7 7 28 2 25 5 5 5 22 2 26 3 7 7 7 28 2 6mm 2 4mm 10 6 6 1 20 11 8 8 1 24 12 8 8 3 26 13 10 10 1 28 27 4 12 12 1 32 3 14 6 6 0 26 3 28 8 8 0 30 3 15 10 10 0 34 3 29 4 ...

Page 10: ...0 2 34 10 10 1 28 2 3 22 6 6 0 26 2 3 35 10 10 0 34 2 4mm 3 4mm 46 6 6 1 20 47 8 8 1 24 48 10 10 1 28 49 4 12 12 1 32 3 4mm 3 4mm 1 Check that the button hole diameter is 2 mm or greater before using the programs 2 Do not use the button lifter spring 3 Thread is trimmed after sewing of one side is completed because there is no crossover thread to be sewn To continue sewing to the end keep the foot...

Page 11: ...ard sewing width Y 36 6 6 0 26 37 8 8 0 30 38 10 10 0 34 39 12 12 0 38 40 6 6 0 26 41 8 8 0 30 42 10 10 0 34 3 4mm 3 4mm 43 6 6 0 26 44 4 10 10 0 34 2 4mm 3 4mm Do not use the button lifter spring Note when creating additional data When sewing data with a small number of stitches 15 stitches or less is sewn repeatedly short cycle operation the upper shaft motor may overheat and the E 20 error code...

Page 12: ...ay from any moving parts Furthermore do not excessively bend the cable or secure it too firmly staples otherwise there is the danger that fire or electric shocks could occur Be sure to connect the ground If the ground connection is not secure you run the risk of receiving a serious electric shock and problems with correct operation may also occur Install the belt covers to the machine head and mot...

Page 13: ...t does not fall down 2 Install the control box with the four accessory bolts 4 spacers 5 flat washers 6 and nuts 7 as shown in the illustration above Use two nuts 7 at each installation location and make sure that both nuts are tightened 3 Close the covers panel mounting assembly 2 and main P C board mounting plate 3 and tighten them with the screws 1 The main P C board mounting plate 3 will be op...

Page 14: ...s of the oil pan 2 into the holes for the cushions 1 and then secure it in place with the five nails 3 so that the oil pan 2 is not at an angle 2 While pushing the oil pan 2 down from above screw in the oil container 4 3 5 Installing the cushions Place the two cushions 1 into the holes in the work table so that the notches are aligned with the tabs in the oil pan and secure them in place with the ...

Page 15: ...plate is not installed 3 7 Installing the machine head 1 Insert the head hinges 1 into the machine head so that they are parallel and then secure them with the two set screws 2 2 Place the machine head gently on top of the rubber cushions 3 and cushions 4 Note Pull the cords 5 out as shown in the illustration above in order to prevent them from being clamped by the machine head 3 Install the hinge...

Page 16: ...st Tap the head rest 1 into the table hole Note Tap the head rest securely into the table hole 3 9 Installing the liquid cooling tank optional 1 Remove the rubber plug and then push the liquid cooling tank 1 2 Tighten it with the set screw 2 2497Q 2498Q ...

Page 17: ... or the bottom of the work table 3 Insert the connector cord 5 into the control box through the hole at the side of the box Refer to 3 12 Connecting the cords for details on connecting the cord 4 Secure the connector cord 5 with the staples in three places 3 11 Connecting the ground wire CAUTION Be sure to connect the ground If the ground connection is not secure you run the risk of receiving a se...

Page 18: ...3 INSTALLATION 12 BE 438C 3 12 Connecting the cords 2504Q 2742Q 2502Q 2503Q ...

Page 19: ...e in order to ensure safety 8 Securely connect connectors P1 to P8 and P11 as indicated in the table below Note Check that the connector is facing the correct way and then insert it firmly until it locks into place Furthermore lock the cord clamp at the top Machine head connectors Connection location No of pins Cord mark Connection location on circuit board Cord clamps used Head position switch 9 ...

Page 20: ... Figure A If foot switch support plate B 13 is used in a back to front position it can be used as shown in Figure B 1 Remove the screw 14 and rubber plug 15 Note that the spring 16 will come out when the screw 14 is removed 2 Turn foot switch support plate B 13 back to front and then install it with the bolt 17 spring washer 18 and flat washer 19 as shown in Figure B Note If using the foot switch ...

Page 21: ...nstall the button tray holder 1 with the two flat wood screws 2 at a place convenient for operation 2 Insert the button tray 3 into the button tray holder 1 and secure them with the screw 4 CAUTION Attach all safety devices before using the sewing machine If the machine is used without these devices attached injury may result 3 17 Installing the eye guard Install the eye guard assy 2 to the face p...

Page 22: ... oil sight glass If oil is not added and the oil drops below this level there is the danger that the machine may seize during operation Note 2 Be sure to let the machine operate for a while after adding the oil Note 3 If there is no more oil on the felt of the shuttle race base problems with sewing may result so add oil to the felt until it is slightly soaked Note 4 Use only specified Brother oil ...

Page 23: ...pressed 5 BOBBIN WIND switch Press this switch to wind the lower thread 6 SELECT switch Use this switch to select a menu program number X and Y feed speed and counter Each time the switch is pressed one of the menu indicators 7 to 11 illuminates and the setting for that menu item appears in the display 14 The illuminated indicator changes as follows each time the switch is pressed PROGRAM NO indic...

Page 24: ...e SELECT switch 6 is pressed to shown the speed setting 11 COUNTER indicator Illuminates when the SELECT switch 6 is pressed to show the bobbin thread or production counter setting 12 DISPLAY SET switches Used to change the menu details which are displayed in the window 14 13 User program switches Used to set and select user programs 14 Display window This display window will indicate the current ...

Page 25: ...e display will stop flashing and illuminates steadily and the feed mechanism will move to the sewing start position This completes the setting of the program number 5 2 2 Setting the X scale and Y scale 1 Press the SELECT switch 6 until the X scale or Y scale indicator illuminates 2 Press the DISPLAY SET switches 12 until the desired scale setting is flashing in the display window The setting is d...

Page 26: ...D indicator il luminates 2 Press the DISPLAY SET switches 12 until the desired speed setting is flashing in the display window Note Be sure to check the sewing pattern refer to page 21 after setting has been completed to make sure that the needle drops down into the hole of the botton 2520Q 2603Q ...

Page 27: ...edle goes into the holes in the button without touching the button Do this for each hole position Note After checking is complete depress the foot switch to move the feed mechanism to the end position If you depress the foot switch again and keep it depresses after the feed mechanism has started to move the feeding speed will increase If you would like to stop the feed while it is moving press the...

Page 28: ...insert the needle 2 as far as it will go so that the groove is facing toward you and then tighten the set screw 1 7 3 Threading the upper thread CAUTION Turn off the power switch before threading the thread otherwise the machine may operate if the foot switch is depressed by mistake which could result in injury Thread the upper thread correctly as shown in the illustration below If the tension rel...

Page 29: ...er thread stops being wound onto the bobbin Release the BOBBIN WIND switch 3 after the machine starts operating If you release the foot switch before winding is completed depress it once more while pressing and holding the BOBBIN WIND switch 3 6 The bobbin presser 1 will automatically return to its original position after a set amount of thread 80 90 of the bobbin capacity has been wound on 7 Rele...

Page 30: ...se and then pass the thread through the slot 2 and pull it out from the thread hole 3 Check that the bobbin turns in the direction of the arrow when the thread is pulled at this time 3 Pass the thread through the lever thread hole 4 and then pull out approximately 30 mm of thread 7 6 Thread tension 7 6 1 Thread tension reference guide Thread 60 or equivalent Thread take up spring tension mm 0 4 0 ...

Page 31: ... thread tension Turn the tension nut 1 main tension to adjust the tension as appropriate for the material being sewn Furthermore turn the thread nut 2 sub tension to adjust the remaining length of upper thread to 35 40 mm when the thread take up lever is not used 7 6 4 Thread take up spring height Loosen the set screw 1 and turn the tensioner body to adjust the thread take up spring height 2536Q W...

Page 32: ...thread guide R 1 to the left The thread take up amount will become greater When sewing thin material move arm thread guide R 1 to the right The thread take up amount will become less 7 6 7 Thread take up amount Loosen the screw 1 and move the stopper 3 57 nut 2 to adjust the operating angle of the thread take up solenoid 3 To reduce the thread take up amount move the stopper 2 upward To increase t...

Page 33: ...the button is securely held by the holder 2 Loosen the set screw 1 while the button is held by the holder Move the adjusting plate 2 so that the space between the adjusting plate 2 and screw 3 is approximately 0 5 1 0 mm then tighten the set screw 1 7 9 Adjustment by the accessory spring If you would like the button to be raised up more after it is sewn install the accessory spring 1 Install the s...

Page 34: ...remove the PROM control assembly 3 from the PROM socket 4 Store the removed PROM control assembly in the special case provided 4 Bend the pins of the PROM control assembly which is to be installed 5 so that they are at an angle of approximately 90 5 Make the directions of the PROM control assembly 5 and the PROM socket 4 same so that the portions a come on the same side and press the PROM gently i...

Page 35: ...will illuminate and the program number will flash in the display 2 Depress the foot switch to the 2nd step The feed mechanism will move to the starting position and the button clamp will rise Note that if the foot switch is pressed to the 2nd step while the program number is illuminated the machine will start operating 3 Insert the button to the button holder Refer to 7 7 Inserting the button 4 Pl...

Page 36: ...arrhoea Keep the oil out of the reach of children Wait until the motor has cooled down before cleaning the air holes The motor may be hot immediately after it has been used and it may cause burns if touched 9 1 Checking the needle Always check that the tip of the needle is not broken and also the needle is not bent before starting sewing 9 2 Cleaning the rotary hook 1 Pull the shuttle race cover t...

Page 37: ...ore oil on the felt of the shuttle race base problems with sewing may result so add oil to the felt until it is slightly soaked Note 4 Use only specified Brother oil Nisseki Mitsubishi Sewing Lube 10N VG10 for the machine oil 1 Fill the arm side oil tank with oil 2 Fill the bed side oil tank with oil 3 Add oil to the felt 1 of the shuttle race base When setting up the sewing machine and when it ha...

Page 38: ... the overheating error code E d0 will be displayed and you will not be able to operate the sewing machine 9 6 Cleaning the air holes of belt cover and frame side cover Remove the belt cover 1 and the frame side cover 2 and then clean the air holes 3 After cleaning install the belt cover 1 and the frame side cover 2 If dust collects in the air holes it may cause the motor to overheat The air holes ...

Page 39: ... which may result in personal injury or damage to the machine If the power switch needs to be left on when carrying out some adjustment be extremely careful to observe all safety precautions If any safety devices have been removed be absolutely sure to re install them to their original positions and check that they operate correctly before using the machine 10 1 Adjusting the needle bar height Tur...

Page 40: ...n the machine 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 mm 10 5 Adjusting the shuttle race thread guide Install the shuttle race thread guide 1 by pushing it in the direction of the arrow so that the needle groove is aligned wit...

Page 41: ...djust the operating angle of the thread take up solenoid 4 To reduce the thread take up amount move the stopper 3 upward To increase the thread take up amount move the stopper 3 downward Note Do not increase the stroke of the thread take up lever any more than is necessary If the sub thread tension is too high the needle thread length may become too short and the thread may come out of the needle ...

Page 42: ...hread trimmer cam 4 3 In this condition turn the machine pulley to align the position of the roller 3 with the mark on the thread trimmer cam 4 4 Loosen the nut 6 and move the connecting rod lever 7 to the left or right to adjust so that the V section A is aligned with the index mark B on the needle plate when in this condition the procedure 3 and the movable knife 5 is pushed to the machine pulle...

Page 43: ...ver pin 8 4 Remove the movable knife 9 and replace it with a new one At this time check that the movable knife 9 and the fixed knife 10 cut the thread cleanly If necessary adjust by using the appropriate movable knife washer 11 supplied as accessories Apply grease to the outside of the collar 12 at this time 5 Install the fixed knife 10 at a distance of 0 5 mm from the needle hole plate 13 6 Place...

Page 44: ... times to maintain the cutting performance of the knife 10 8 Adjusting the button clamp lift amount The maximum button clamp lift amount is 13 mm from the top of the needle plate The lift amount is adjusted 10 11 mm at the time of shipment Remove the button clamp presser spring 1 loosen the screw 2 and adjust the button clamp holder hook 3 by moving it up and down If the button clamp lift amount i...

Page 45: ...ugh that the material will not slip out of place when it is slightly pulled keep pressure as slight as possible 10 10 Adjusting the position of the button holder 1 Loosen the two hexagonal bolts 1 and adjust the button holder body 2 by moving it 2 Check that the needle will go through the button hole with no contact Refer to 6 CHECKING THE SEWING PATTERN 2667Q 2668Q ...

Page 46: ...should not be loosened If the index mark 2 is not inside the mark 4 when the sewing machine is started error code E 50 will be displayed Turn the machine pulley to move the index mark 2 to the correct position and then start the sewing machine 10 12 Adjusting the thread wiper 1 Loosen the set screw 2 and move the wiper arm support 3 up or down to adjust so that the clearance between the top of the...

Page 47: ...ndicator is illuminated Synchronizer 1 When COUNTER indicator is illuminated Presser sensor ON when presser is lowered 1 The synchronizer display simultaneously displays the needle up signal 3rd digit the 24 section signal 2nd digit and the needle down signal 1st digit H L L H when the sensor is on and L when the sensor is off Needle down signal 24 section signal Needle up signal If the DIP switch...

Page 48: ... shown in the display window 5 as indicated in the table above 5 Press the TEST switch 3 again to return the display to the normal condition 10 15 Clearing all memory settings If the sewing machine stops operating normally the cause may be that an incorrect memory setting may have been made by means of the memory switch for instance In such cases carry out the following procedure to clear the memo...

Page 49: ...CALE indicator 7 or Y SCALE indicator 8 illuminates 5 Press the DISPLAY SET switches 9 to move the feed mechanism one pulse at a time If the DISPLAY SET switch is pressed while the X SCALE indicator is illuminated the feed mechanism will move to the left If the DISPLAY SET switch is pressed while the X SCALE indicator is illuminated the feed mechanism will move to the right If the DISPLAY SET swit...

Page 50: ...e is completed the number being displayed in the display window 6 will become smaller When the number of articles set by the bobbin thread counter have all been sewn 0000 will be displayed in the display window 6 and an alarm will start sounding continuously The sewing machine will not operate during this time even if the foot switch is depressed 6 Replace the bobbin and then press the RESET switc...

Page 51: ...omatically when a split is found DIPA 6 Displays the enlargement reduction ratio in millimeter units instead of as a percentage After changing this setting be sure to carry out the auto clear operation by referring to page 42 DIPA 7 Enlargement of pattern size is not available DIPA 8 Program number is fixed 12 2 Setting the presser mode Through the combination of DIP switches A 1 and A 2 on the op...

Page 52: ...t to ON DIPB 1 First two stitches are sewn at a low speed of 260 rpm DIPB 2 Last two stitches are sewn at a low speed of 260 rpm DIPB 3 DIPB 4 Last two stitches are sewn at a low speed of 700 rpm DIPB 5 First two stitches are sewn at a low speed of 400 rpm DIPB 6 Low speed sewing is not performed at the start of sewing DIPB 7 The motor operates in reverse when the upper shaft stops to return the n...

Page 53: ...s 10 to select the X scale setting that you would like to record 7 Press the SELECT switch 3 The Y SCALE indicator 6 will illuminate 8 Press the DISPLAY SET switches 10 to select the Y scale setting that you would like to record 9 Press the SELECT switch 3 The SPEED indicator 7 will illuminate 10 Press the DISPLAY SET switches 10 to select the speed setting that you would like to record 11 Press t...

Page 54: ...hes for selection Clearing the user programs 1 Switch the machine to recording mode by the procedure in steps 2 of recording a user program 2 Use the DISPLAY SET switches 10 to specify the user program number which is to be cleared of data 3 Press the RESET switch 12 The buzzer will sound and the user program with the number selected will be cleared If you press and hold the RESET switch 12 until ...

Page 55: ...itch to enable the quick taking out of the workpieces memo 02 Feed will move automatically to the next starting point at the same time as a user program is switched Normally it moves to the starting point after sewing starts memo 03 When sewing using programs the programs which have been set will be sewn in numerical order Cycle sewing mode is set memo 04 The sewing speed will be fixed at the mini...

Page 56: ... Presser can be moved up and down before the home position is detected Normally the presser cannot be moved up and down until after the home position has been detected memo 1c memo 1d memo 1E Errors can be reset using the EMERGENCY STOP switch EMERGENCY STOP switch is available as an option memo 1F Thread is not trimmed when an emergency stop occurs during sewing EMERGENCY STOP switch is available...

Page 57: ...sewing if set to 0 memo 35 3 9 100rpm 4 Changes the sewing start speed for the number of stitches specified by memo 34 memo 36 memo 37 1 20 7 5 10 Changes the feed timing one stitch be fore the sewing end 1 Fast 10 Standard 20 Slow memo 38 1 20 7 5 10 Changes the feed timing two stitches before the sewing end memo 39 1 20 7 5 1 Changes the feed timing for the third stitch at the sewing start 1 Fas...

Page 58: ...ograms P2 P3 and P4 switches can also be used for programming 5 Press the SELECT switch 3 The PROGRAM No indicator 4 will illuminate and 1 will appear in the display window 10 6 Press the DISPLAY SET switches 11 to select the number for the user program that you would like to record 7 Press the SELECT switch 3 2 will appear in the display window 10 8 Press the DISPLAY SET switches 11 to select the...

Page 59: ...k the contents of the recorded user program Clearing a cycle sewing program 1 Switch the machine to recording mode by the procedure in step 3 of recording a user program 2 Use one of the P switches user program switches to specify which cycle sewing program to clear Press the P1 switch 9 if you would like to clear cycle sewing program No 1 Pc 1 will be displayed 3 Press the RESET switch 12 The rec...

Page 60: ...ET switch and then reset the memory switches 30 and 31 or enlargement ratio E 32 The data format of the user program or mm does not match the setting of DIP switch A 6 After changing the setting of DIP switch A 6 clear all memory settings Refer to 10 16 Clearing all memory settings E 40 Length of a stitch exceeds 10 mm Press the RESET switch and then set the enlargement ratio again E 41 Abnormalit...

Page 61: ...eed motor short circuit malfunction of main circuit board or power relay is not operating malfunction of power supply circuit board Turn off the power and contact a qualified service technician E F1 Bad connection in cable between power supply circuit board and main circuit board Turn off the power and check if connectors P16 is disconnected E F2 Abnormal current detected in power supply circuit b...

Page 62: ...S49950 001 S49951 001 S49952 001 S49953 001 S49954 001 S49955 001 1 Button clamp spacer AR S52075 001 BR S52076 001 Standard CR S52077 001 DR S52078 001 AL S52071 001 BL S52072 001 Standard CL S52073 001 DL S52074 001 Needle hole plate HS S40917 001 HT S40925 001 HU S52079 001 HV S52080 001 HW S52081 001 HX S52082 001 Standard ...

Page 63: ...ition is incorrect Thread wiper position Adjust the operating dis tance of the thread wiper 40 Lower thread winds to one side Bobbin winder thread tension stud height is incorrect Bobbin winder thread tension stud height Adjust the height of the thread tension stud 23 Lower thread winding amount is incorrect Bobbin presser position is incorrect Thread winding amount Adjust the position of the bobb...

Page 64: ...ING THE SEWING PATTERN 21 Needle clearance Adjust the needle clear ance 34 Needle is touching the rotary hook Needle bar lift amount Adjust the needle bar lift amount 33 Needle is bent Bent needle Replace the needle Needle breaks Needle is too thin Needle and thread Use the correct needle for the material Movable knife is blunt Movable knife blade Replace the movable knife 37 Fixed knife is blunt ...

Page 65: ...ad is too long Thread take up lever stroke Adjust the thread take up lever stroke 35 Poor seam finish on reverse side of material Needle is striking the button Needle down setting Refer to 6 CHECKING THE SEWING PATTERN 21 Upper thread tension is too weak Upper thread tension Adjust the upper thread tension 25 Lower thread tension is too weak Lower thread tension Adjust the lower thread tension 25 ...

Page 66: ... cooling tank Solenoid thread wiper This helps to prevent thread breakage caused by friction when using synthetic threads Fill the tank with silicone oil 100mm2 s This wipes the thread independently of the work clamp operation Emergency stop switch If the emergency stop switch has been pressed during sewing the machine can be stop And you can move the feed mechanism back in steps to the desired po...

Page 67: ...INSTRUCTION MANUAL 15 1 Naeshiro cho Mizuho ku Nagoya 467 8561 Japan Phone 81 52 824 2177 Printed in Japan 118 V38 S91V38 202 2002 10 B 1 ...

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