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Brother KE-430F Series, Service Manual

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Brother KE-430F Series Service Manual Download Page 2

KE-430F, BE-438F 

 
This service manual is intended for KE-430F and BE-438F; be sure to read the KE-430F/BE-438F 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. 
If you have any questions regarding this product, please contact a Brother dealer. 
 

Summary of Contents for KE-430F Series

Page 1: ...KE 430F BE 438F Please read this manual before making any adjustments ELECTRONIC DIRECT DRIVE LOCKSTITCH BAR TACKER ELECTRONIC DIRECT DRIVE LOCKSTITCH BUTTON SEWER SERVICE MANUAL ...

Page 2: ...ly 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 If you have any questions regarding this product please contact a Brother dealer ...

Page 3: ... which follow this term indicate situations where failure to follow the instructions could result in death or serious injury CAUTION The instructions which follow this term indicate situations where failure to follow the instructions may result in minor or moderate injury Symbols This symbol indicates something that you should be careful of The picture inside the triangle indicates the nature of t...

Page 4: ...orrect operation In the event of an electrical storm turn off the power and disconnect the power cord from the wall outlet Lightning may cause problems 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 approxim...

Page 5: ...ing 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 the oil out of the reach of children Maintenance and inspection Maintenance and inspection of the sewing machine should only be carried out by a qualifie...

Page 6: ... removing the cover 3 Safety devices Eye guard Finger guard Solenoid cover Thread take up cover Side cover Rear cover etc 6 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 7 Direction of operation 4 Be careful to avoid injury from the moving thread take up 8 Do not hold...

Page 7: ...KE 430F BE 438F v 2559B 2520B 2521B Transformer box 100V 400V system only 2522B Rear cover Solenoid cover Oil tank Finger guard Eye guard Thread take up cover Side cover ...

Page 8: ...LEL MOVEMENT OF SEWING PATTERNS 41 7 USING SD CARDS 43 7 1 Notes on handling SD cards commercially available 43 7 2 Structure of an SD card folder 43 7 3 Preparation for reading and writing data 44 7 4 Reading additional pattern data 45 7 5 Writing additional pattern data to an SD card 46 7 6 Reading memory switch data 47 7 7 Writing memory switch data to the SD card 48 7 8 Reading program data 49...

Page 9: ...hread tension 103 11 1 1 Upper and lower thread tension 104 11 1 2 Thread take up spring 105 11 1 3 Arm thread guide C 106 11 1 4 Needle bar bush thread guide D 106 11 2 Adjusting the needle bar height 106 11 3 Adjusting the needle bar lift amount and the driver needle guard 107 11 4 Adjusting the needle clearance 107 11 5 Adjusting the shuttle race thread guide 108 11 6 Rotary hook lubrication am...

Page 10: ...KE 430C SERIES IN KE 430F AND BE 438F 133 14 INSTALLING THE 2 PEDAL FOOT SWITCH OPTION 134 15 ELECTRIC MECHANISM 135 15 1 Precautions at the time of adjustment 135 15 2 Components inside and outside the control box and in the operation panel 136 15 3 Fuse explanation 137 15 4 Connectors 138 15 4 1 Connector positions 138 15 4 2 Contact failure 140 15 5 Troubleshooting 144 15 5 1 Troubleshooting fl...

Page 11: ...nsion set Standard equipment Thread wiper device Standard equipment Thread trimmer device Standard equipment Thread nipper device 03 0K 0F specifications Standard equipment 05 specifications Option Option Data storage method Flash memory Any sewing pattern can be added using SD card Data recording media SD card 2 Number of cycle programs Up to 30 can be registered up to 50 steps each 89 sewing pat...

Page 12: ...e arm by two people as shown in the illustration When holding the machine head do not hold it by the pulse motor 1 or the solenoid 2 otherwise it may damage the pulse motor 1 or the solenoid 2 Tilting back the machine head 1 Pack away any tools which are near the table 2 Secure the foot A so that the table will not move and then pull the arm with both hands to tilt back the machine head While supp...

Page 13: ...t you want to sew into that program number 2 Set the parameters such as X scale Y scale sewing speed and upper thread tension This completes the program When actually sewing select the program number and then start sewing 1 Depending on the memory switch settings the height of the work clamp button clamp can also be set by means of parameters 2 The PS300B can be used to create patterns and load th...

Page 14: ...rams can be set Patterns 1 to 89 1 to 64 for the 438F are listed in 2 2 List of Sewing Patterns KE 430F and 2 3 List of Sewing Patterns BE 438F in the CD instruction manual Pattern number 1 Program number 1 Parameter Program number 2 Pattern number 2 Parameter Program number 3 Pattern number 3 Parameter Programnumber89 Pattern number 89 Parameter Pattern numbers 200 to 999 Programnumbers200to999 P...

Page 15: ...ng program numbers pattern numbers and parameters Standard programs Additional available patterns Preset Not preset Set by user Initial value Model 430F 438F 430F 438F 430F 438F 430F 438F Sewing program No 1 89 1 64 90 199 65 199 200 999 800 programs 1 89 1 64 1 999 Pattern No Fixed at same number as sewing program Number set when program is created 512 programs from 200 to 999 X scale 20 200 100 ...

Page 16: ...on 2 Memory switch setting mode Advanced Refer to 4 3 Setting memory switches Advanced 6 Error log display function Refer to 4 6 Checking the error history 3 Input check function Refer to 4 7 Input checking method 7 Home position adjusting mode Refer to 11 18 Adjusting the home position 4 Output check function Refer to 4 8 Output checking method 8 Treadle position adjustment mode Refer to 11 22 Se...

Page 17: ... 11 19 Adjusting the main shaft motor standard position 11 Protect setting mode Refer to 4 10 Protection settings 10 Digital tension output correction mode Refer to 11 20 Correcting the digital tension output 12 Version update Refer to 7 13 Updating the control program version 2603B 2604B 2605B 2606B ...

Page 18: ...wer thread counter setting mode Refer to the CD Instruction Manual 6 Pattern data editing mode Refer to 5 3 Switching to pattern editing mode 3 Production counter setting mode Refer to the CD Instruction Manual 7 Parallel movement mode Refer to 6 X and Y parallel movement of sewing patterns 4 Program mode Refer to the CD Instruction Manual 8 SD data read write mode Refer to 7 3 Preparation for rea...

Page 19: ...hat have been changed from default settings will appear in order 3 Change the memory switch setting Press the or key to change the setting value The flashing display means that the setting has not yet been applied You can make the initial setting appear in the display by pressing the RESET key 4 Apply the changed setting Press the ENTER key The menu display will change from flashing to illuminated...

Page 20: ...p operation during pause split program ON The work clamp button clamp cannot rise automatically during a pause split program OFF The work clamp button clamp can rise automatically during a pause split program 060 0 3000 ms 0 10 Time after the work clamp button clamp drops until the upper shaft starts rotating 070 1 2 1 1 Type of foot switch used 1 Foot switch 2 2 pedal foot switch option 071 1 2 1...

Page 21: ... at the sewing start Enabled when No 100 is set to OFF 430F 200 3200 sti min 152 438F 200 2700 sti min 1 100 2nd stitch sewing speed at the sewing start Enabled when No 100 is set to OFF 430F 200 3200 sti min 153 438F 200 2700 sti min 1 100 3rd stitch sewing speed at the sewing start Enabled when No 100 is set to OFF 430F 200 3200 sti min 154 438F 200 2700 sti min 1 100 4th stitch sewing speed at ...

Page 22: ...speed will be limited by this value 164 ON OFF OFF Thread trimming operation prevention ON All thread trimming operations are disabled OFF Thread trimming is carried out in accordance with the sewing data 165 20 20 degrees 0 1 Stop position at highest needle position stop Becomes higher Becomes lower 166 10 500 ms 150 10 Delay time until reverse operation starts during highest needle position stop...

Page 23: ...hen the work clamp switch is depressed 253 1 0 2 0 1 Moving method to the sewing start point 0 Depress the foot switch to the 2nd step for a two pedal foot switch depress the start switch while the program number is flashing 1 Press the RESET key while the program number is flashing 2 Press the special external input switch option input IN3 while the program number is flashing 260 80 80 degrees 2 ...

Page 24: ...iming reference for the first three stitches at the sewing start 0 Feed start reference Makes the timing uniform at the start of feed 1 Needle up reference Changes the timing at the start of feed so that the feed moves half the feed width when the needle bar is at its highest position 2 Feed end reference Makes the timing uniform at the end of feed 270 0 2 2 2 Moving method to the sewing start poi...

Page 25: ...4 ON OFF ON Display for program numbers 1 to 89 1 to 64 for BE 438F ON Program numbers 1 to 89 1 to 64 for the BE 438F are displayed during program number selection operations OFF Program numbers 1 to 89 1 to 64 for the BE 438F are skipped during program number selection operations so that these numbers cannot be selected If no other programs have been recorded the setting will return to ON 405 ON...

Page 26: ...m are not enlarged or reduced 465 1 3 1 1 Setting parallel movement amount for sewing pattern 1 The parallel movement amount for the currently selected program can be set in parallel movement mode The movement amount is initialized when the power is turned off and when the program number pattern number X scale or Y scale is changed 2 The parallel movement amount for the currently selected program ...

Page 27: ...ram mode and sewing standby mode Item Setting range and initial value Display during program mode Display during sewing standby mode Work clamp button clamp height raised 430F 10 17mm 438F 6 13mm Setting units 1mm Initial settings are 430F 14mm 438F 10mm Work clamp button clamp height intermediate drop 430F 1 17mm 438F 1 13mm Setting units 1mm Initial setting is 1mm This is displayed when memory s...

Page 28: ...ng range and initial value Display during program mode Display during sewing standby mode X parallel movement amount 9 9 9 9mm Setting units 0 1mm Initial setting is 0 0mm direction Work clamp button clamp moves to the left Y parallel movement amount 9 9 9 9mm Setting units 0 1mm Initial setting is 0 0mm direction Work clamp button clamp moves forward 2784B 2785B 2786B 2787B Initial value Initial ...

Page 29: ...eakage sensor available by special order ON Used OFF Not used 555 1 ON OFF OFF Sewing start sensing sensitivity for thread breakage sensor available by special order ON 10 stitches at sewing start OFF 5 stitches at sewing start 430F 03 ON 430F 05 OFF 430F 0K ON 430F 0F ON 566 2 ON OFF 438F OFF Thread nipper device installation ON Installed The thread nipper device only operates when all of the fol...

Page 30: ...gnal output angle offset Error processing settings 600 699 No Setting range Initial value Setting units Setting details 650 1 2 0 2 0 1 Error release method when operation has stopped 0 Press the RESET key on the operation panel 1 Press the STOP switch available by special order 2 Press the external input switch EXIN2 651 2 ON OFF OFF Needle stop position when sewing is interrupted by the STOP swi...

Page 31: ...ed specified at the operation panel exceeds 2000 sti min thread winding will be limited to 2000 sti min OFF Upper limit is not limited to 2000 sti min Thread winding is carried out at the speed specified at the operation panel Specification and destination settings 800 899 No Setting range Initial value Setting units Setting details 430F 03 3 5 K F 3 430F 05 3 5 K F 5 430F 0K 3 5 K F K 430F 0F 3 5...

Page 32: ... switch No 071 to select the desired operation mode from the following In the following table the term work clamp refers to the work clamp button clamp Foot switch Setting value No 071 Neutral 1st step 2nd step 1 Work clamp raised Work clamp maximum drop Sewing machine start 2 Work clamp raised Work clamp intermediate drop Work clamp maximum drop sewing machine start 1st step 2nd step Neutral 4441...

Page 33: ...k clamp raised Work clamp maximum drop Work clamp raised Sewing machine start 1 2 Work clamp raised Work clamp maximum drop 1 Work clamp raised Work clamp intermediate drop Work clamp intermediate drop Work clamp maximum drop Work clamp raised Work clamp maximum drop Sewing machine start 1 3 Work clamp maximum drop 1 Work clamp raised Sewing machine start 1 4 Work clamp raised Work clamp maximum d...

Page 34: ...in in the error history and so they will not be displayed 2 Press the or key 4 to change the order of the error history number The history stores 99 entries 01 to 99 in order starting from the most recent No 01 is the most recent entry If there are no error codes E will be displayed The production counter when the error occurred will appear in the PROGRAM No display 2 and the menu display 3 in uni...

Page 35: ... check list to check the key and sensor responses 4 When returning to normal operation turn power off and then on again Input check list Item No Item name Input status Check items and checking methods 1 orX on oFF X feed motor home position sensor position Move the work clamp button clamp manually in the X direction Left ON right OFF 2 EnX 999 999 X feed motor encoder counter value Move the work c...

Page 36: ...input check The key name will be displayed while a key is pressed ON display Key name rESt RESET key tESt TEST key tHrE THREAD CLAMP key tEn TENSION key SELE SELECT key UP M key dn M key UP S SECTION key dn S SECTION key UP t TENSION key dn t TENSION key F1 Function key F1 F2 Function key F2 F3 Function key F3 F4 Function key F4 Ent ENTER key 11 FtA 0 255 Foot switch analog value Depress the foot ...

Page 37: ...ction on is displayed for the retract direction 19 Enn 999 999 Thread nipper motor encoder counter value Press the key to move the thread nipper in the home position direction Press the key to move the thread nipper in the retract direction Retract direction down home direction up When the power is turned on the position will be 0 20 in1 on oFF Option input IN1 21 in2 on oFF Option input IN2 22 in...

Page 38: ... the key is being pressed 4 For item numbers 55 onward depress the foot switch to the 2nd step For a 2 pedal foot switch depress the start switch The operation for that check item will be carried out while the foot switch is being depressed 5 When returning to normal operation turn power off and then on again Item No Item name Operation 51 PM X When the key is pressed the work clamp button clamp w...

Page 39: ... rear cover and check the operation 62 dtEn The digital tension solenoid is turned ON for the specified period 63 WiP The external wiper solenoid is turned ON for the specified period 64 oP 1 Option output 1 turns on 65 oP 2 Option output 2 turns on 66 oP 3 Option output 3 turns on 67 oP 4 Option output 4 turns on 68 oP 5 Option output 5 turns on 69 oP 6 Option output 6 turns on 70 oP 7 Option out...

Page 40: ...display 4 will change as follows each time the or key 3 is pressed PROGRAM No display 4 Software Menu display 2 example 1 Mn Main control program 1 0 00 2 Mt Motor control program 1 00 3 PL Panel control program 1 00 4 in Main IPL 1 00 5 it Motor IPL 1 00 6 iL Panel IPL 1 00 3 Press the TEST key 5 to return to the normal display The sewing machine will switch to home position detection standby 262...

Page 41: ...isallowed depending on the protection level Protected items have been preset for each level Refer to Table of protection levels and corresponding protected items on page 33 7 You can change the protection setting for each of the 21 items individually Set to ON disallowed or OFF allowed for each item All items are set to OFF at the time of shipment from the factory 3 Press the ENTER key 3 to store ...

Page 42: ... 1 and the TEST key 2 and the ENTER key 3 turn on the power switch The previous starting method A or b will be displayed in the menu display The method is set to A at the time of shipment from the factory 2 Press the or key 5 to select the next starting method Starting method Details A Protect setting mode can be started using either Method A or Method B B Protect setting mode can only be started ...

Page 43: ...m No 6 XY enlarge change during wait Possible if 100 or less 7 XY enlarge reduce change during wait 8 Sewing speed during wait 9 Slow start during wait 10 Work clamp button clamp height during wait 11 Tension during wait 12 Lower thread counter change during wait 13 Production counter clear during wait 14 Lower thread counter setting mode 15 Production counter setting mode 16 Program setting mode ...

Page 44: ... Tension Code T6 Tension Code T4 Tension Code T1 Upper thread tension 75 Upper thread tension 125 Upper thread tension 110 Upper thread tension 75 Example When sewing program No 900 into which pattern No 200 has been programmed Example Editing in pattern editing mode Pattern No 200 Needle Drop No Section No Tension Code 1st stitch 1 T1 2nd stitch to 9th stitch 2 T6 10th stitch to 27th stitch 3 T4 ...

Page 45: ...5 EDITING PATTERN DATA 35 KE 430F BE 438F 5 2 Work flowchart 2922B ...

Page 46: ... condition is referred to as pattern editing mode 5 4 Checking pattern data You can check the tension information section numbers and tension codes in pattern data 1 Carry out steps 1 to 3 in 5 3 Switching to pattern editing mode to switch to pattern editing mode When you press the or key the work clamp button clamp will move one stitch at a time The section number and tension code and the number ...

Page 47: ...rn editing mode to switch to pattern editing mode Press the F1 key and the F4 key at the same time The pattern number which is to be copied will be displayed in the PROGRAM No display Copy will be displayed in the menu display Pt will be displayed in the section No display The pattern number for the copy destination will be displayed in the tension display 2 Press the TENSION keys to select the pa...

Page 48: ...on code will flash 3 or or To add a tension code press the ENTER key A new tension code will be added and the sewing machine will return to pattern editing mode As well as this a section will be added and the numbers for subsequent sections will be incremented by 1 If you would like to return to pattern editing mode without adding a tension code press the or key If you would like to end pattern ed...

Page 49: ...like to change 2 Press the TENSION keys to select the desired tension code T1 to T9 The tension code will flash 3 or or To change the tension code press the ENTER key The tension code will be changed and the sewing machine will then return to pattern editing mode If you would like to return to pattern editing mode without changing a tension code press the or key If you would like to end pattern ed...

Page 50: ...displayed in the menu display 3 When you press the SECTION keys the delete selection display will switch between all sections and an individual section 4 or To delete the section press the ENTER key The specified tension code will be deleted and the sewing machine will return to pattern editing mode As well as this the section will also be deleted and the numbers for subsequent sections will be de...

Page 51: ...et will be displayed in the menu display in mm units The sewing machine will not switch to parallel movement mode if memory switch No 465 is set to 3 Set it to 1 or 2 3 Depress the foot switch to the 2nd step Home position detection will be carried out The pattern number will change to illuminated 4 Each time the or key is pressed the work clamp button clamp will move by 0 05 mm In X scale paralle...

Page 52: ...mount Press the ENTER key The amount of parallel movement in the vertical direction will be confirmed and the menu display will change to illuminated 9 Ending parallel movement mode TEST indicator switches off Press the TEST key The display will return to the normal display and the sewing machine will change to home position standby If you would like to return to step 4 press the SELECT key instea...

Page 53: ...ded SD cards are those sold by SanDisk and Panasonic Cards from other manufacturers may use different formatting methods and may not work correctly as a result For additional information refer to the instruction manual included with the SD cards that you have purchased This product is compatible with SD cards that have been formatted using the FAT16 32 method Cards that have been formatted using o...

Page 54: ...ress the or key to select the mode Read write mode list PROGRAM No display Menu display Setting items r 1 Ptn Reads additional pattern data from the SD card w 2 Ptn Writes additional pattern data to the SD card r 3 MEM Memory switch settings are read from the SD card w 4 MEM Memory switch settings are written to the SD card r 5 PrG Reads sewing program data and cycle program data from the SD card ...

Page 55: ...LL will be the only thing displayed 3 While reading Pattern number being read appears in the tension display Press the ENTER key The buzzer will sound and the selected pattern data will be read from the folder on SD card and copied into the sewing machine s memory If no additional pattern data exists an error buzzer will sound 4 When the display returns to the status in step 1 reading of the addit...

Page 56: ...rs displayed will only be those that are in the sewing machine memory If there is no data in the memory ALL will be the only thing displayed 3 While writing Pattern number being written appears in the tension display Press the ENTER key The buzzer will sound and the selected pattern data will be written to the SD card If no additional pattern data exists an error buzzer will sound 4 When the displ...

Page 57: ...l be read from the SD card and stored in the sewing machine memory and the memory switch settings will then be applied If no memory switch data exists an error buzzer will sound 3 When the display returns to the status in step 1 reading of the memory switch data is complete If you would like to use any other read write modes press the or key to select the mode and then run it 4 Ending read write m...

Page 58: ...on display Press the ENTER key The buzzer will sound and the memory switch data will be copied to the SD card 3 When the display returns to the status in step 1 writing of the memory switch data is complete If you would like to use any other read write modes press the or key to select the mode and then run it 4 Ending read write mode TEST indicator switches off Press the TEST key 2664B 2902B 2663B...

Page 59: ... be read from the SD card and stored in the sewing machine s memory and the sewing programs and cycle programs will then be set If no program data or cycle program data exists an error buzzer will sound 3 When the display returns to the status in step 1 reading of the program data is complete If you would like to use any other read write modes press the or key to select the mode and then run it 4 ...

Page 60: ...n display Press the ENTER key The buzzer will sound and the memory switch data will be copied to the SD card 3 When the display returns to the status in step 1 writing of the program data is complete If you would like to use any other read write modes press the or key to select the mode and then run it 4 Ending read write mode TEST indicator switches off Press the TEST key 2666B 2414B 2666B 2667B ...

Page 61: ...e ENTER key The buzzer will sound and the sewing program data cycle program data memory switch settings and additional pattern data will be read from the SD card and stored in the sewing machine s memory If no program data or cycle program data exists an error buzzer will sound 3 When the display returns to the status in step 1 reading of the sewing machine data is complete If you would like to us...

Page 62: ...ears while program data is being written Press the ENTER key The buzzer will sound and the sewing program data cycle program data memory switch settings and additional pattern data will be read from the SD card and stored in the sewing machine s memory 3 When the display returns to the status in step 1 writing of the sewing machine data is complete If you would like to use any other read write mod...

Page 63: ...while log data is being written Press the ENTER key The buzzer will sound and the error log data and memory switch log data will be copied to the SD card 3 When the display returns to the status in step 1 writing of the log data is complete If you would like to use any other read write modes press the or key to select the mode and then run it 4 Ending read write mode TEST indicator switches off Pr...

Page 64: ...il you hear a beep 4 1 Mn will appear in the PROGRAM No display and control program version stored on the SD card will appear in the menu display 5 Press the or key to select the program to be updated Control program PROGRAM No display Menu display Main 1 Mn Motor 2 Mt Panel 3 PL If there is no program to be updated which is stored on the SD card will appear in the menu display 6 WAIT will appear ...

Page 65: ...d take up mechanisms 8 2 Lower shaft and shuttle race mechanisms 2524B The mechanisms operate in the order of the numbers given in the illustrations 1 Pulley 2 Upper shaft 3 Thread take up crank 4 Needle bar crank 5 Needle bar connecting 5 Thread take up rod assembly lever assembly 6 Needle bar clamp 7 Needle bar 2523B 1 Pulley 2 Upper shaft 3 Crank rod assembly 4 Rock gear 5 Lower gear 6 Lower sh...

Page 66: ...embly 8 Work clamp arm lever plate 9 Work clamp arm lever shaft 10 Work clamp arm lever 11 Work clamp When the work clamp pulse motor is turned off the work clamp lifter plate rises and work clamps lower 7 Button clamp rod 8 Button clamp lever 9 Button clamp holder hook assembly 10 Button clamp holder shaft 11 Button clamp When the work clamp pulse motor is turned off the button clamp rod rises an...

Page 67: ... When the work clamp pulse motor is turned off the thread wiper operates in the opposite direction 1 Pulse motor T assembly 2 Gear 16 3 Cam gear 4 Cam shaft 5 Thread wiper cam 6 Thread wiper driving lever 7 Thread wiper rod assembly 8 Connecting plate 9 Thread wiper arm assembly ...

Page 68: ...t 4 Y feed rack shaft clamp 5 Feed bracket sub assembly 8 5 Feed mechanism Sewing patterns are created through combinations of X and Y movements 2528B 2529B Y direction X direction 1 Pulse motor X assembly 2 Feed gear 3 X feed gear 4 X feed lever 5 Regulator block assembly 6 Feed bracket sub assembly ...

Page 69: ...d trimmer 21 Thread trimmer collar Thread trimmer solenoid ON 18 Thread trimmer solenoid assembly 19 Thread trimmer link 20 Thread trimmer rod H assembly 21 Movable knife lever 22 Movable knife connecting plate 23 Movable knife 2530B 1 Upper shaft 2 Pulse motor T assembly 3 Gear 16 4 Cam gear 5 Cam shaft 6 Thread trimmer driving cam 7 Cam lever thread trimmer 8 Thread driving lever 9 Thread trimme...

Page 70: ...chanism KE 430F 03 0F 0K specifications only 1 Pulse motor P assembly 2 Motor lever 3 TR link 4 Thread driving lever 5 Connecting plate R 6 TN Connecting plate assembly F 7 Thread nipper D assembly 8 Thread nipper U 2531B 2532B 1 Tension solenoid 2 Bolt 3 Tension release bar 4 Tension release pin ...

Page 71: ...ling optional accessories be sure to use only genuine Brother parts Brother will not be held responsible for any accidents or problems resulting from the use of non genuine parts 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 To prevent accidents and problems do not modify the ...

Page 72: ...sh upward and remove horizontally 9 2 Work clamp arm mechanism BE 438F KE 430F 2534B 2535B 1 Set screw 2 Needle 3 Needle bar thread guide 4 Bolts 2 pcs 5 Plain washers 2 pcs 6 Work clamp arm assembly 7 Screws 2 pcs 8 Feed plate 5 Set screws 2 pcs Loosen 6 Button clamp holder shaft 7 Button clamp holder 8 Screws 2 pcs 9 Feed plate ...

Page 73: ...7B 1 Rubber cap 2 Screw 3 Needle bar Pull out 4 Needle bar clamp 5 Slide block 6 Rubber caps 3 pcs 7 Set screws 2 pcs Loosen 8 Set screws 2 pcs Loosen 9 Thread take up support 10 Set screw collar 11 Screw Loosen 12 Needle bar connecting rod assembly 13 Rubber cap 14 Set screws 3 pcs Loosen 15 Needle bar crank 16 Washer 17 Thread take up lever assembly 18 Washer 19 Bolts 2 pcs 20 Slide block guide ...

Page 74: ...9 DISASSEMBLY KE 430F BE 438F 64 9 4 Upper shaft mechanism Continued on next page 2538B 1 Screws 2 pcs 2 Grease support F 3 Bolt 4 Crank rod washer 5 Crank rod base ...

Page 75: ...rews 2 pcs Loosen 17 Set screws 2 pcs Loosen 18 Set screws 2 pcs Loosen 19 Screws 2 pcs 20 Plain washers 2 pcs 21 Bobbin winder unit 22 Set screws 2 pcs Loosen 23 Bolts 4 pcs 24 Motor assembly 25 Thread trimmer cam 26 Joint assembly 27 Upper shaft 28 Pulley gear R If the motor assembly cannot be removed insert the bolts 23 into these two tapping holes and gradually tighten them to remove the motor...

Page 76: ...r if at all possible otherwise grease will leak out 1 Bolt Loosen 2 Driver 3 Adjusting stud Pull out 4 Set screw Loosen 5 Screw 6 Oil tube support 7 Screw 8 Cord holder U3 9 Shuttle race base assembly 2540B If the adjusting stud 3 will not pull out screw a M3 or similar screw 1 into the tap hole and then pull on the M3 or similar screw 1 so that the adjusting stud 3 can be removed ...

Page 77: ...forward 20 Rock gear 21 Set screws 4 pcs Loosen 22 Lower shaft assembly 23 Rubber seal L 24 Bearing bush assembly Tap out the rubber seal L 23 and the bearing bush together toward the rear 25 Oil seal 26 Bearing bush assembly Tap out the oil seal 25 and the bearing bush together toward the front 2549B 2547B The rubber seal and the oil seal cannot be reused so have new parts ready for use ...

Page 78: ...9 DISASSEMBLY KE 430F BE 438F 68 9 6 Lubrication 2542B 1 Bolts 2 pcs 2 Bolts 2 pcs 3 Plain washers 2 pcs 4 Oil tank plate 5 Oil tank nut 6 Oil tank assembly ...

Page 79: ...et screw Loosen 7 Regulator block assembly 8 Feed bracket sub assembly 9 Bolts 4 pcs 10 Feed bracket support plate 11 Bolt sockets S P washers 3 pcs 12 Y motor setting plate Pulse motor Y assembly 13 Y feed rack shaft 14 Bolt 15 X feed gear 16 Bolt sockets S P washers 3 pcs 17 X motor setting plate Pulse motor X assembly 18 X feed lever Pull upward 2545B 2543B 2544B ...

Page 80: ... Retaining ring E 3 Screws 2 pcs 4 Plain washers 2 pcs 5 Thread wiper arm assembly 6 Retaining ring E 7 Plain washer 8 O rings 2 pcs 9 Connecting plate Pull upward 10 Set screw Loosen 11 Retaining ring E 12 Plain washer 13 Wiper shaft 14 Thread wiper rod assembly Pull forward 2546B ...

Page 81: ... 9 Retaining ring E 10 Driving thread trimmer shaft 11 Cam lever thread trimmer 12 Plain washer 13 Springs 2 pcs 14 Bolts 2 pcs 15 Spring hook 16 Set screws 2 pcs Loosen 17 Retaining ring E 18 Lever shaft 19 Drive lever w clamp lifter 20 Plain washer 21 Thread wiper driving lever 22 Plain washer 23 Set screws 2 pcs Loosen 24 Set screw collar 25 Set screws 6 pcs Loosen 26 Cam shaft 27 Cam gear 28 T...

Page 82: ...7 otherwise the work clamp lifter plate assembly may fall down KE 430F BE 438F 2550B 30 Rubber cap 31 Link shoulder screw 32 Link 33 Set screw Loosen 34 Retaining ring E 35 Lever shaft 36 Plain washer 37 Lifter lever assembly 38 Needle bar guide slide block 39 Nuts 2 pcs 40 Button clamp roller shaft 41 Plain washer 42 Roller 43 Button clamp rod Pull upward 44 Set screw Loosen 45 Button clamp lever...

Page 83: ...n release pin 4 Nut 5 Plain washer 6 Set screw Loosen 7 Tension stud assembly Pull out 8 Thread take up spring 2553B 2552B 1 Screws 2 pcs 2 Solenoid cover 3 Screws 2 pcs 4 Tension solenoid 5 Bolts 2 pcs 6 Spring washers 2 pcs 7 Plain washers 2 pcs 8 Solenoid setting plate 9 Bolt 10 Nut 11 Plain washer 12 Solenoid cushion 13 Tension release bar ...

Page 84: ... wave spring 11 Set screws 2 pcs Loosen 12 Thread nipper lever shaft 13 Retaining ring E 14 Washer 15 Thread nipper lever 16 Bolts 2 pcs 17 Washers 2 pcs 18 TN connecting plate R 19 TN connecting plate F assembly 20 Shoulder screw 21 Thread nipper D assembly 22 Collar 23 Spacer 24 Shoulder screw 6 0 9 25 Thread nipper U 26 Spring 27 Screws 2 pcs 28 Plain washers 2 pcs 29 Spring hook plate 30 Set s...

Page 85: ... 2 pcs Loosen 2 Thread trimmer cam 3 Screws 3 pcs 4 Fan 5 Set screws 2 pcs Loosen 6 Guide shaft 7 Spring 8 Nut 9 Shoulder screw B 10 Driving lever 11 Set screws 2 pcs Loosen 12 Retaining ring C 13 Collar shaft 14 Thread trimmer collar 15 Screws 2 pcs 16 Flat screws 2 pcs 17 Needle plate 2556B 2555B ...

Page 86: ...9 Bolts 3 pcs 40 Thread trimmer solenoid assembly 41 Shoulder screw 42 Connecting plate 6 1 8 43 Set screw Loosen 44 Movable knife lever shaft 45 Shoulder screw 6 35 6 46 Movable knife lever 47 Thread trimmer rod H assembly 48 Movable knife shoulder screw 49 Thrust washer 50 Movable knife collar 51 Movable knife assembly 52 Movable knife spacer 53 Screws 2 pcs 54 Spring washers 2 pcs 55 Plain wash...

Page 87: ...9 DISASSEMBLY KE 430F BE 438F 77 9 14 Shuttle hook mechanism 2558B 1 Bobbin case assembly 2 Shuttle race base setting claw Open to right and left 3 Shuttle race base 4 Shuttle hook ...

Page 88: ...idents and problems do not modify the machine yourself Brother will not be held responsible for any accidents or problems resulting from modifications made to the machine number indicates part names only The numbers do not indicate the order of assembly Apply grease to the required places when reassembling the parts and once every two years 10 1 Thread trimmer mechanism 1 Apply grease to the porti...

Page 89: ...e centers of the holes is 309 5 0 5 mm 28 Plain washer 29 Spring washer 30 Bolt 31 Thread trimmer link 32 Solenoid shaft 33 Set screws 2 pcs Tighten 34 Thread trimmer link 35 Washer wave spring 36 Link shoulder screw 37 Nut 38 Thread trimmer solenoid assembly 39 Bolts 3 pcs 40 Connecting plate 41 Shoulder screw 6 1 8 2835B Push the thread trimmer solenoid assembly 38 downward gently to install it ...

Page 90: ...11 16 Adjusting the tension release amount 1 Tension release bar 2 Tension solenoid 3 Solenoid setting plate 4 Plain washers 2 pcs 5 Spring washers 2 pcs 6 Bolts 2 pcs 7 Solenoid cushion 8 Plain washer 9 Nut 10 Bolt 11 Screws 2 pcs 12 Solenoid cover 13 Screws 2 pcs 2837B Adjust the thread take up spring height while referring to 11 1 2 Thread take up spring 1 Tension bracket 2 Thread take up sprin...

Page 91: ...iper shaft 3 Plain washer 4 Retaining ring E 5 Set screw Tighten 6 O rings 2 pcs 7 Connecting plate 8 Plain washer 9 Retaining ring E 10 Thread wiper arm assembly 11 Plain washers 2 pcs 12 Screws 2 pcs 13 Retaining ring E 14 Set screw Tighten 2838B 少量 Gently push the wiper shaft 2 while tightening the set screw 5 Adjust while referring to 11 15 Adjusting the thread wiper ...

Page 92: ...lder screw 6 0 9 9 Thread nipper spacer 10 Thread nipper collar 11 Thread nipper D assembly 12 Thread nipper shoulder screw 13 TN connecting plate F assembly 14 TN connecting plate R 15 Bolts 3 pcs 16 Motor bracket rear assembly 17 Washers 2 pcs 18 Bolts 2 pcs 19 Lever shaft 20 Washer 21 Retaining ring E 22 Thread nipper lever 23 Set screws 2 pcs Tighten 24 Washer wave spring 25 Link shoulder scre...

Page 93: ...ive lever w clamp lifter 15 Lever shaft 16 Retaining ring E 17 Set screws 2 pcs Tighten 18 Plain washer 19 Cam lever thread trimmer 20 Driving thread trimmer shaft 21 Retaining ring E 22 Set screws 2 pcs Tighten 23 Gear 16 24 Pulse motor T assembly 25 Set screws 2 pcs Tighten 26 Bolts 4 pcs 27 Motor bracket assembly 28 Bolts 3 pcs 29 Link shoulder screw 2840B Set so that the worn surface is on the...

Page 94: ... 2864B Make sure the harness connector is facing the correct way 2842B Align the positions of hole a in the cam gear 6 and hole b in the motor bracket 27 The cam gear 6 also has a slot c in it so make sure the correct hole is used Motor bracket C 2863B Set the first set screws 8 and 10 in the clockwise direction to the screw stop position A Screw stop side 2841B Set the first two set screws 25 in ...

Page 95: ...8F moves smoothly 30 Button clamp lever holder 31 Bolts 2 pcs 32 Button clamp lever 33 Plain washer 34 Button clamp lever shaft 35 Retaining ring E 36 Set screw Tighten 37 Button clamp roller shaft 38 Roller 39 Button clamp roller shaft 40 Plain washer 41 Nuts 2 pcs 42 Needle bar guide slide block 43 Lifter lever assembly 44 Plain washer 45 Lever shaft 46 Retaining ring E 47 Set screw Tighten 48 L...

Page 96: ...gear 6 so that the index marks are as close together as possible and then tighten the bolt 7 so that the gears move smoothly in the axial direction with no play Set so that the clearance between the feed gear 1 and the pulse motor X assembly 2 is 0 5 mm and then align the two set screws 3 with the screw stops as shown in the illustration and tighten them 2848B 2847B Screw stop 2846B Make sure that...

Page 97: ...he four bolts 11 Continued on next page 8 Y feed rack shaft 9 Retaining ring E 10 Feed bracket support plate 11 Bolts 4 pcs Temporarily tighten 12 Feed bracket sub assembly 13 Regulator block assembly 14 Set screw 15 Feed bracket cover 16 Screws 6 pcs 17 Y feed rack shaft cramp 18 Bolt 2851B Grease Set screw Remove the set screw and apply grease and then retighten the set screw 2852B ...

Page 98: ...rness faces correctly Harness connector For the BE 438F be particularly careful that the mechanism is in the correct position shown in the illustration 1 Provisionally tighten the three bolts with washer 22 so that the distance shown in the illustration is 95 mm with the screw stop of the pulse motor Y assembly 20 is facing the same way as the harness connector 2 Move the pulse motor Y assembly 20...

Page 99: ...e drops to the home position standard plate If the needle does not drop to point A carry out the following adjustments NOTE Be careful not to let the needle touch the home position standard plate 6 Loosen the bolt 5 and move the home position standard plate 1 to the left or right to adjust so that the needle drops to point A If play occurs in the axial direction tighten the M6 or similar bolt 7 on...

Page 100: ...e 25 Plain washers 2 pcs 26 Screws 2 pcs 1 Tighten the screw 5 of the thread take up crank 4 so that it is aligned with the hole in the upper shaft 1 2 While pressing the thread take up crank 4 so that there is no play in it tighten the two set screws 7 Apply adhesive Threebond 1401 or similar to the thread section of the screw 5 Apply adhesive Threebond 1324 or similar to the outer circumference ...

Page 101: ...tion d crank rod assembly 2 and balancer 20 1 Apply grease to the rock gear shaft assembly 2 2 Tighten the two set screws 19 so that there are gaps of 0 2 mm at both the front and rear of the crank rod assembly 2 Tighten the set screw so that the screw stop a on the motor shaft is in the same phase as the screw stop b on the upper shaft 1 Tighten the set screw so that the screw stop c on the threa...

Page 102: ...ews 2 pcs Tighten 12 Rubber caps 3 pcs 13 Rubber cap 14 Needle bar connecting rod assembly 15 Screw Tighten 16 Slide block Left hand thread 3006B Inside hole Align the set screw 9 with the screw stop Align the set screw 11 with the screw stop Screw stop Horizontal When tightening the two set screws 11 first turn the pulley approximately 10 times to the position where it turns smoothly Fit the beve...

Page 103: ...edge of the needle bar bush when the machine pulley is turned to lower the needle bar 18 to its lowest position and then set the cut section so that it is facing forward and tighten the screw 19 4647Q Needle bar bush With the needle bar 18 near its highest position apply grease inside the holes 2862B Cut section Inside hole 17 Needle bar clamp 18 Needle bar Insert from above 19 Screw 20 Rubber cap...

Page 104: ...ASE BZL 300P or GREASE BZL 302R specified by Brother to the portions indicated by the white arrows Continued on next page 1 Shuttle race base assembly 2 Oil tube support 3 Screw 4 Cord holder U3 5 Screw 6 Adjusting stud 7 Set Screw Tighten 2869B GREASE BZL 302R GREASE BZL 302R ...

Page 105: ...he grooves 8 Rock gear 9 Rock gear shaft assembly 10 Rock gear shaft R 11 Set screws 2 pcs Tighten 12 Set screws 2 pcs Tighten While pushing the rock gear shaft assembly 9 and rock gear shaft R 10 so that there is no play in the axial direction tighten the two set screws 11 Notch facing straight down GREASE BZL 300P Take up the play 2870B 2871B Take up the play ...

Page 106: ...outer circumferences of the oil seal 13 and rubber seal L 16 when inserting the oil seal 13 and rubber seal L 16 into the holes in the bed Temporarily tighten 2873B 2874B 13 Oil seal 14 Bearing bush assembly 15 Lower shaft assembly 16 Rubber seal L 17 Bearing bush assembly 18 Set screws 4 pcs Tighten 19 Driver 20 Bolt Temporarily tighten 21 Set screws 4 pcs 22 Positioning plate 23 Screws 4 pcs Ali...

Page 107: ...r cover 25 Screws 5 pcs 26 Grease support F 27 Screws 2 pcs 28 Rubber caps 2 pcs Remove the rubber cap 1 and apply grease and then reinstall the rubber cap 1 Insert as far as this 16g of grease 1 Rubber cap 1 Turn the pulley to set the needle bar to near its lowest position 2 Insert the grease nozzle 3 into the gear box as far as the lower shaft gear 2 and apply 16g of grease BZL 500 grease ...

Page 108: ... the driver needle guard and 11 4 Adjusting the needle clearance 2879B 1 Needle bar thread guide 2 Needle 3 Set screw 4 Shuttle hook 5 Shuttle race base 6 Shuttle race base setting claw Close 7 Bobbin case assembly 2878B 2880B Adjust while referring to 11 6 Rotary hook lubrication amount 1 Oil tank assembly 2 Oil tank nut 3 Oil tank plate 4 Plain washers 2 pcs 5 Bolts 2 pcs 6 Bolts 2 pcs ...

Page 109: ...ing washers 2 pcs KE 430F only 13 Screws 2 pcs KE 430F only 14 Needle plate 15 Screws 2 pcs 16 Flat screws 2 pcs 2883B 2882B 2881B 1 Apply grease to the pin 1 of the movable knife and then insert it into the hole in the movable knife connecting plate 2 and then while inserting the pin 3 of TN connecting plate assembly F into the hole in the thread nipper D assembly 4 install the needle plate 14 2 ...

Page 110: ...te 6 Support shaft 7 Needle hole 2886B 2885B a Sliding portion of the work clamp Apply small amount of grease b Sliding portion of the work clamp arm lever shaft and the work clamp arm levers R and L c Round portion of the work clamp arm lever plate d Slider of work clamp support shaft Push the work clamp arm lever plate 3 in the direction of the arrow to raise the work clamp 4 by about 5 mm set s...

Page 111: ...ng assembly 1 Feed plate 2 Screws 2 pcs 3 Button clamp holder 4 Button clamp holder shaft 5 Set screws 2 pcs 6 Nuts 2 pcs Adjusting screw Compression spring After installing check that the needle passes into the button hole without touching the button Refer to 11 13 Adjusting the position of the button clamp BE 438F 2888B 2889B ...

Page 112: ... Shuttle race cover assembly 2 Washer wave spring 2 pcs 3 Shoulder screws 8 2 2 pcs 4 Face plate assembly 5 Screws 3 pcs 6 Eye guard assembly 7 Bolts 2 pcs 8 Side cover 9 Screws 4 pcs 10 Rear cover 11 Screws 4 pcs 12 Top cover 13 Screws 4 pcs 2890B ...

Page 113: ...y cause the machine head to topple over 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 1...

Page 114: ...will be maintained When using a 2 pedal foot switch option In the sewing standby condition and during test operation standby the thread tension which has been set in the SECTION No 1 sewing start section will be output while the work clamp button clamp is lowered while the work clamp switch is being depressed regardless of the section which appears in the SECTION No display 1 on the operation pane...

Page 115: ... spring tension N 0 2 0 4 0 6 1 0 0 15 0 35 Thread take up spring height Loosen the set screw 1 and turn the tensioner body to adjust the thread take up spring height Thread take up spring tension Adjust by turning the shaft 2 with a screwdriver NOTE When the spring height stroke is great or the spring tension is insufficient it may cause the thread end length to vary after thread trimming 2320B 2...

Page 116: ... thread guide D 1 is at the middle of the needle bar 2 NOTE If needle bar bush thread guide D 1 is not in the correct position the thread may pull out or skipped stitches may occur 11 2 Adjusting the needle bar height 1 Loosen the two bolts 1 and then remove the eye guard assembly 2 2 Turn the pulley in the direction of the arrow to move the needle bar to the lowest position Then remove the rubber...

Page 117: ...en the bolt 2 3 Move the driver 3 back and forth to adjust so that it is touching the needle when the tip of the rotary hook is aligned with the center of the needle and then tighten the bolt 2 NOTE If the needle contact pressure from the driver 3 is too great skipped stitches may occur On the other hand if the driver 3 is not touching the needle the tip of the inner rotary hook will obstruct the ...

Page 118: ...tary hook lubrication amount KE 430F 05 specifications KE 430F 03 0K 0F specifications BE 438F 1 Tilt back the machine head 2 Loosen the two bolts 1 and then adjust by moving the oil tank assembly 2 up or down KE 430F 05 specifications The standard position is when the centers of the two bolts 1 are aligned with the reference line on the oil tank plate 3 KE 430F 03 0K 0F specifications BE 438F The...

Page 119: ...in this position move the thread trimmer solenoid assembly 2 back and forth 4 Set the thread trimmer collar 3 so that it is touching against the outside of the thread trimmer cam 4 and then while pushing the thread trimmer solenoid assembly 2 down tighten the three bolts 1 5 Install the top cover side cover and rear cover Set so that the clearance section A is 0 mm and then check that there is a c...

Page 120: ...s close to its lowest position 5 Loosen the bolt 6 6 Move thread trimmer rod H assembly 7 back and forth to adjust so that the ridge line on the movable knife 8 is touching the edge of the index mark 9 and then while keeping the parts in this position tighten the bolt 6 7 Turn the pulley so that the thread trimmer driving lever 4 is in the reverse position and then while pushing thread trimmer rod...

Page 121: ...ife 6 and the fixed knife 7 cut the thread cleanly 7 Apply grease to the pin 12 of the movable knife and then insert it into the hole in the movable knife connecting plate 13 and then while inserting the pin 15 of TN connecting plate assembly F into the hole in the thread nipper D assembly 14 install the needle plate 5 8 Check that the center of the needle hole and the tip of the needle are aligne...

Page 122: ...p of the work clamp arm lever plate 2 and to the sliding part of the work clamp 4 grease is already applied at the time of shipment and check that the movement becomes easier 11 11 Adjusting the button clamp lift amount BE 438F Adjust so that the actual maximum lift amount for the button clamp is 13 mm above the top of the needle plate when the maximum work clamp height has been set to 13 mm using...

Page 123: ...mp BE 438F 1 Loosen the two bolts 1 and adjust the button clamp base 2 by moving it 2 Carry out test feeding to check that the needle will go through the button hole with no contact 11 14 Adjusting the thread trimmer cam position 1 Remove the top cover 2 Loosen the two set screws 1 and then adjust the position of the thread trimmer cam 3 so that the distance between the edge of the collar shaft 2 ...

Page 124: ... the thread wiper 1 is aligned with the center of the needle at the needle bar stop position NOTE Check that the needle bar thread guide 3 and the thread wiper base shaft 4 are not touching at this time Thread wiper racking width adjustment 1 Remove the side cover 2 Loosen the set screw 1 and adjust so that the distance from the thread wiper to the center of the needle is as shown in the illustrat...

Page 125: ...sion so that distance a is 1 9 0 1 mm Figure B Select a spacer that can maintain the distance a without becoming bent when the tension solenoid 4 operates Refer to 11 1 1 Upper and lower thread tension for details on operating the thread tension 5 Loosen the bolt 9 and adjust the sideways position of the set collar 10 so that the opening amount b for the tension discs is 0 mm After adjusting retig...

Page 126: ...e front and back rock gear collars 6 slightly to adjust so that the phase of the front and back rock gear collars 6 is about the same within 10 degrees If the backlash amount play is small it will result in wear in the rock gear 7 and the lower shaft gear 8 If the backlash amount play is large it will result in wear in the rock gear 7 and the lower shaft gear 8 and also result in increased noise d...

Page 127: ...illuminates 4 Depress the foot switch to the 2nd step for a 2 pedal foot switch depress the start switch 1 Home position detection for the X feed or Y feed motor will be carried out based on the currently displayed offset value orG will illuminate in the PROGRAM No display If you press the RESET key for 2 seconds or more at this time the offset value will be reset to 0 and home position detection ...

Page 128: ...pear from the TENSION display 7 Repeat steps 5 and 6 to set the home position to the correct position 8 Press the ENTER key to confirm the offset value The offset value will illuminate in the menu display If the offset value has not been provisionally confirmed if JoG is illuminated the invalid buzzer will sound 9 End adjustment mode TEST indicator switches off Press the TEST key The display will ...

Page 129: ...ion for the work clamp lift motor will be carried out based on the currently displayed offset value orG will illuminate in the PROGRAM No display If you press the RESET key for 2 seconds or more at this time the offset value will be reset to 0 and home position detection for the work clamp lift motor will be carried out 5 1 Remove the top cover Press the key until the TR driving lever 1 is at the ...

Page 130: ...7 Repeat steps 5 and 6 to set the home position to the correct position 8 Press the ENTER key to confirm the offset value The offset value will illuminate in the menu display If the offset value has not been provisionally confirmed if JoG is illuminated the invalid buzzer will sound 9 End adjustment mode TEST indicator switches off Press the TEST key The display will return to the normal display a...

Page 131: ...the foot switch to the 2nd step Home position detection for the thread nipper motor will be carried out based on the currently displayed offset value orG will illuminate in the PROGRAM No display If you press the RESET key for 2 seconds or more at this time the offset value will be reset to 0 and home position detection for the thread nipper motor will be carried out 6 Press the or key to change t...

Page 132: ...bly 1 is not inside the hole 2 in the needle hole plate When the F3 key is pressed the thread nipper D assembly 1 will move to the thread release position F3 will illuminate in the SECTION No display 9 Depress the foot switch to the 2nd step to return the thread nipper motor to the home position The SECTION No display will stop illuminating 10 Repeat steps 6 to 9 to set the home position 11 Press ...

Page 133: ...rection of the arrow UP will flash in the SECTION No display and dn will flash in the TENSION display If nothing is displayed turn the pulley by hand until the displays appear 4 Turn the pulley in the direction of the arrow to lower the needle bar from its highest position to the height shown in the illustration at left 5 Press the ENTER key UP will illuminate in the SECTION No display and dn will...

Page 134: ... indicator switches off Press the TEST key The display will return to the normal display and the sewing machine will switch to home position detection standby 7 Turn off the power switch and install the needle the needle bar thread guide and the feed plate 2404B ...

Page 135: ...display 1 will illuminate in the SECTION No display and a value from 0 to 39 will illuminate in the menu display respectively The value in the menu display may vary for individual sewing machines No of measurement Standard tension value for digital tension gf 1st 20 2nd 80 3rd 180 The procedure for correcting the tension output from the digital tension involves carrying out the procedure of measur...

Page 136: ...easurement will illuminate in the SECTION No display and the allowable setting range will illuminate in the menu display Refer to the table below The value in the menu display may vary for individual sewing machines NOTE If you need to enter a value which is greater than the allowable setting range in the table problems may occur with the digital tension Refer to 11 16 Adjusting the tension releas...

Page 137: ...pressing the and key turn on the power switch PdL will illuminate in the PROGRAM No display and 1 Frt will illuminate will illuminate in the menu display 2 Memorizing the maximum forward position With the foot switch depressed all the way forward wait until the value in the TENSION display stabilizes and then press the ENTER key XXX indicates the treadle depression voltage 3 Memorizing the neutral...

Page 138: ...ill be displayed in the menu display NOTE If the foot switch operations are not carried out correctly END will not be displayed and the buzzer will sound After 1 Frt is displayed in the menu display repeat the operation from step 2 6 Turn off the power switch 2830B ...

Page 139: ...it It is recommended that you use commercially available NIPPON OIL CORPORATION Powernoc WB 2 grease for the work clamp 1 12 2 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 applied The sewing machine will not operate at this time eve...

Page 140: ...od of time and the sewing machine will be forcibly prevented from operating for safety reasons If this happens apply grease and carry out the reset procedure If you continue to use the sewing machine after carrying out the reset procedure but without applying grease problems with the sewing machine may result Applying grease Use Brother specified Grease unit SB1275 001 1 Removing the grease assemb...

Page 141: ...remaining inside the eccentric wheel 3 6 Insert the grease nozzle into the holes in the eccentric wheel 3 and apply the grease Insert the grease nozzle into both holes to apply the grease in order to make sure that the grease is applied evenly without missing any parts 7 Check that enough grease has been applied so that it is overflowing slightly from the edges 8 Return the grease cover 6 to its o...

Page 142: ...be attach the cap securely and store the tube in a cool dark place The grease should be used as quickly as possible When using the grease again remove any old grease from inside the nozzle first Store the tube away carefully once the tube has been opened otherwise the grease remaining inside the tube may deteriorate and this may affect its lubricating performance Resetting the grease up counter On...

Page 143: ...438C install it as follows KE 430F Install using the two screws 1 and the accessory feed plate cover 2 screw 3 and washer 4 as shown in the illustration BE 438F Install using the two screws 1 and the accessory feed plate cover 2 and screw 3 as shown in the illustration 4868Q For KE 430F For KE 430C Countersink 4869Q Do not use the screws for feed plate that is used for the KE 430C 4870Q 4871Q For ...

Page 144: ...ion will also occur 1 Insert the foot switch conversion harness 1 into connector P15 on the main PCB 2 Connect the connector 2 for the 2 pedal foot switch to the foot switch conversion harness 1 3 Temporarily remove the screw 4 from the ground terminal of the control box and then connect the two ground wires 3 in the 2 pedal foot switch harness to the ground terminal and retighten the screw to the...

Page 145: ...the power is turned off before doing the following Opening and closing the control box Replacing fuses Separating and joining connectors Measuring resistance Doing anything with a possibility of touching something inside the control box Some adjustments require measuring the voltage while the power is turned on with the control box kept open In such a case be careful not to touch any place other t...

Page 146: ...tes the voltages which are required for control operations Conversion transformer box 100V 110V 380V 400V AC specifications only Steps down the power supply voltage and generates the voltages that are required for the control box NF box For Europe Eliminates electrical noise that is transmitted along the power supply line Panel PCB Secured inside the operation panel This PCB controls indications o...

Page 147: ...he specified ones listed below If a component on a PCB is damaged the fuses may blow again soon even after they have been replaced No Part name Part code When a fuse has blown F1 F2 Fuse 15AFB glass tube fuse 15A 250V A10193 001 The power indicator is not illuminated and nothing operates Motor PCB 2930B ...

Page 148: ...ncluding 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 15 4 1 Connector positions Main PCB Motor PCB Refer to the diagram in 15 3 Fuse explanation 2931B ...

Page 149: ...15 ELECTRIC MECHANISM 139 KE 430F BE 438F Power PCB Panel PCB 2932B 2687B ...

Page 150: ...rk clamp button clamp operation in the forward back Y direction Error E210 E211 E214 E215 or E216 is displayed Problem with work clamp button clamp operation in the sideways X direction Error E200 E201 E204 E205 or E206 is displayed The feed motor does not operate for home position detection immediately after the power is turned on Error E300 is displayed Work clamp mechanism Problem Connector No ...

Page 151: ... no error display Digital tension does not operate There is no error display Error E690 is displayed Sewing operation Problem Connector No and position The power indicator is not illuminated and nothing operates Machine operation is unstable The main shaft motor does not operate correctly Error E130 is displayed 2939B 2940B 2941B 2942B 2943B ...

Page 152: ...operation panel key does not have any effect The sewing machine does not operate when the foot switch is depressed No error display Error E055 is displayed after the power is turned on Error E452 is displayed after the power is turned on The machine does not start up with the brother display appearing Continued on next page 2944B 2945B 2946B 2947B 2948B ...

Page 153: ...em Connector No and position Only the power indicator illuminates Nothing appears on the operation panel display The sewing machine does not operate when the foot switch is depressed Error E130 is displayed Error E131 is displayed 2949B 2951B 2950B ...

Page 154: ...ymbols and their meanings Switch operation Set up operation or condition Yes or no decision making process The procedure to follow continues on the next page The error status number in the first column of the table of 15 5 2 Problem solution and measures Turning off of the power switch 2707B 2952B ...

Page 155: ...15 ELECTRIC MECHANISM 145 KE 430F BE 438F 2953B ...

Page 156: ...15 ELECTRIC MECHANISM 146 KE 430F BE 438F 2954B ...

Page 157: ...15 ELECTRIC MECHANISM 147 KE 430F BE 438F 2955B ...

Page 158: ...ce Doing anything with a possibility of touching something inside the control box Injury When separating or rejoining connectors and measuring something be careful not to cut your fingers on metal parts such as heat sinks and covers 2 When replacing a fuse be sure to use a new one of the same quality and capacity as the old one Before adjustment 1 While the power is turned off check each connector...

Page 159: ...he range of the specification voltage 10 After inspecting turn off the power switch and connect the power supply connector 3 Blown fuse Remove fuses F1 and F2 from the motor PCB and check the continuity OK if there is continuity GFUSE15A 15A 250V 4 Malfunction of motor PCB 1 Remove P2 DCIN from the power PCB turn the power back on and then check LD2 red on the motor PCB OK if illuminated After che...

Page 160: ...if illuminated After checking turn off the power switch wait for one minute or more and then insert P1 into the main PCB and P1 P2 and P3 into the motor PCB Motor PCB assembly 8 Malfunction of panel PCB Disconnect connector P1 POWER2 from the main PCB and connectors P1 MT ENC and P2 MAIN from the motor PCB and then turn on the power switch and check LD2 red on the power PCB OK if illuminated After...

Page 161: ...anel PCB Operation panel assembly Panel PCB assembly Panel harness 4 If E131 is displayed there is a poor connection of the synchronizer Check that connector P11 RESOLVER and P1 MT ENC is connected to the motor PCB and that connector P6 MT ENC is connected to the main PCB 5 If E400 and E401 is displayed there is a connection fault between the main PCB motor PCB and the panel PCB a Check LD3 green ...

Page 162: ...r and measure the voltage between pins 3 4 of the cord connector No 3 No 4 OK if the voltage is approximately 2 V at neutral approximately 4 V when the foot switch is depressed as far as it will go and approximately 0 5 V when it is depressed backward Foot switch 3 Malfunction of foot switch and cord option Check that the power is turned off Disconnect the foot switch from the foot switch adapter ...

Page 163: ...s a blown fuse a Remove fuses F1 and F2 from the motor PCB and check the continuity OK if there is continuity b If fuse F1 or F2 is blown check the resistance values between each pin of the relay connector between the machine motor and the motor PCB and between each terminal of the fuses OK if ohms c If the fuses blow again after they are replaced replace the motor PCB GFUSE15A 15A 250V Motor PCB ...

Page 164: ...ty between terminals 1 and 2 3 and 4 of P21 OK if ohms c Insert P21 and P24 into the main PCB turn on the power switch and then check LD1 red on the power PCB OK if illuminated If LD1 is illuminated during the check in step 1 but it does not illuminate when P1 and P24 are connected there is a malfunction of the main PCB d Check LD1 orange on the main PCB OK if illuminated Main PCB assembly 3 If th...

Page 165: ...ty between terminals 1 and 2 3 and 4 of P22 OK if ohms c Insert P22 and P24 into the main PCB turn on the power switch and then check LD1 red on the power PCB OK if illuminated If LD1 is illuminated during the check in step 1 but it does not illuminate when P1 and P24 are connected there is a malfunction of the main PCB d Check LD1 orange on the main PCB OK if illuminated Main PCB assembly 3 If th...

Page 166: ...uity between terminals 1 and 2 3 and 4 of P23 OK if ohms c Insert P23 and P24 into the main PCB turn on the power switch and then check LD1 red on the power PCB OK if illuminated If LD1 is illuminated during the check in step 1 but it does not illuminate when P1 and P24 are connected there is a malfunction of the main PCB d Check LD1 orange on the main PCB OK if illuminated Main PCB assembly 3 If ...

Page 167: ... of the main PCB a Disconnect connector P1 POWER2 from the main PCB and check the continuity between terminals 1 and 2 of P1 OK if ohms b Disconnect connector P4 TPM from the main PCB and check the continuity between terminals 1 and 2 3 and 4 of P4 OK if ohms c Insert P1 and P4 into the main PCB turn on the power switch and then check LD1 red on the power PCB OK if illuminated If LD1 is illuminate...

Page 168: ...k clamp arm assembly Error status 12 The TEST indicator does not light when the TEST key is pressed Probable causes Check repair adjust Parts to be replaced Malfunction of panel PCB Check that connector P3 PANEL is connected to the motor PCB and that connector P1 MAIN is connected to the panel PCB Panel PCB assembly Panel harness Error status 13 The feed mechanism does not slowly move stitch by st...

Page 169: ... to any equipment that generates strong electrical interference 4 If E111 E130 E131 E132 or E133 is displayed after the sewing machine operates there is a malfunction of the motor PCB Refer to steps 1 to 4 in 5 Resolver stator assembly Motor PCB assembly 5 If E111 E130 E132 or E133 is displayed after the sewing machine operates there is a malfunction of the motor PCB or of the machine motor If an ...

Page 170: ...f sewing data that contains 15 stitches or less Resolver stator 430 assembly Motor PCB assembly Motor 430 assembly Error status 18 The machine cannot produce correct stitches Probable causes Check repair adjust Parts to be replaced 1 Malfunction of synchronizer Refer to step 1 in 17 2 If uneven seams are being sewn there is a malfunction of the pulse motor or the mechanism is incorrectly adjusted ...

Page 171: ...lenoid Disconnect main PCB connector P3 SOL2 and measure the resistance between pins 1 2 of the cord connector OK if 6 8 ohms Tension solenoid 6 Malfunction of main PCB a Turn on the power switch and check LD2 green on the main PCB OK if illuminated b Turn off the power switch and with connector P2 SOL1 disconnected from the main PCB check the continuity between terminals 3 and 6 of connector P2 o...

Page 172: ...or status 21 SD card read write mode cannot be activated Probable causes Check repair adjust Parts to be replaced 1 If E420 is displayed the SD card is incorrectly inserted a Check the direction of insertion of the SD card Insert the card so that it matches the direction of the pattern on the card cover b Check the insertion of the SD card 2 If E420 is displayed the SD card is incorrectly formatte...

Page 173: ...s turned on or there is a problem with the STOP switch connection Turn off the power and then check that connector P9 on the main PCB is properly connected E016 Problem with the STOP switch connection when the power was turned on Turn off the power and then check that connector P9 on the main PCB is properly connected E025 The foot switch was depressed to the 2nd step when the power was turned on ...

Page 174: ...nism related errors Code Cause and remedy E200 X feed motor home position cannot be detected Problem with X feed motor or poor X encoder connection Turn off the power and then check that connectors P17 and P21 on the main PCB are properly connected E201 X feed motor stopped abnormally Turn off the power and check that there is no problem with the X feed direction E204 X feed motor stopped abnormal...

Page 175: ...heck the data in the media E424 Insufficient space in media Press the RESET key 1 to clear the error Use different media E425 Error occurred while writing to media Press the RESET key 1 to clear the error Use the specified type of media Check if the media is write protected and if it has enough free space E427 A pattern registered in a cycle program has been erased Press the RESET key 1 to clear t...

Page 176: ... data for the 438F Press the RESET key 1 to clear the error Read data for the same sewing machine model E582 Memory switch version does not match Press the RESET 1 key to clear the error Read data for the same version E583 Parameter version does not match Press the RESET key 1 to clear the error Read data for the same version 1 If the main PCB version is 1 5 00 or later press the key or switch whi...

Page 177: ...ent Repeat the version update procedure E880 Version update requests cannot be received Turn off the power and then turn it back on again E881 Version updating did not complete normally Turn off the power and then repeat the version update procedure E882 Communication error between main PCB and panel PCB detected Turn off the power and then check that connector P1 on the panel PCB connector P5 on ...

Page 178: ... position of the thread wiper P 114 Work clamp lift amount is incorrect KE 430F Incorrect position of work clamp arm lever plate Adjust the work clamp lift amount P 112 Button clamp lift amount is incorrect BE 438F Incorrect position of button clamp holder hook Adjust the button clamp lift amount P 112 Adjust the height of the thread wiper P 114 The thread wiper is obstructing the needle Adjust th...

Page 179: ...bbin case are damaged File smooth or replace the affected part Clearance between needle and rotary hook tip is too great Adjust the needle clearance P 107 Incorrect needle and rotary hook timing Adjust the needle bar lift amount P 107 Driver is contacting needle more than is necessary Adjust the driver needle guard P 107 Needle is bent Replace the needle Skipped stitches occur Needle is installed ...

Page 180: ...arating the threads insufficiently Adjust the position of the shuttle race thread guide P 108 Upper thread is not properly tight Adjust the upper thread tension CD Instruction manual Uneven needle thread Adjust the sub tension CD Instruction manual Needle thread is too long Adjust the sub tension When using the thread nipper device Turn the tension nut to adjust the upper thread trailing length to...

Page 181: ...18 7 SEGMENT DISPLAY LIST 171 KE 430F BE 438F 18 7 SEGMENT DISPLAY LIST 4268M ...

Page 182: ...MEMO 172 KE 430F BE 438F ...

Page 183: ...MEMO 173 KE 430F BE 438F ...

Page 184: ...SERVICE MANUAL 2011 Brother Industries Ltd All Rights Reserved KE 430F BE 438F I0070967B 2011 04 B 2 ...

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