Brother LK3-B438E Mark II Instruction Manual Download Page 1

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LK3-B438E

INSTRUCTION MANUAL

Please read this manual before using the machine.
Please keep this manual within easy reach for quick reference.

ELECTRONIC LOCKSTITCH BUTTON SEWER

Summary of Contents for LK3-B438E Mark II

Page 1: ...LK3 B438E INSTRUCTION MANUAL Please read this manual before using the machine Please keep this manual within easy reach for quick reference ELECTRONIC LOCKSTITCH BUTTON SEWER ...

Page 2: ...re safe 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 The instructions which follow this term indicate situations where failure to follow the instruc tions could cause injury when using the machine or physical damage to equipment and sur roundings Symbols This symbol indicates some...

Page 3: ...nstallation should be carried out by two or more people Do not connect the power cord until installation is complete otherwise the machine may operate if the foot switch is pressed by mistake which could result in injury Hold the machine head with both hands when tilting it back or returning it to its original position Furthmore after tilring back the machine head do not push the face plate side o...

Page 4: ...ouch any of the moving parts or press any objects against the machine while sewing as this may result in personal injury or damage to the machine If an error occurs in machine or if abnormal noises or smells are noticed immediately turn off the power switch Then contact your nearest Brother dealer or a qualified technician If the machine develops a problem contact your nearest Brother dealer or a ...

Page 5: ...t all times when using the machine If the labels have been removed or are difficult to read please contact your nearest Brother dealer 3 Warning labels 1 Hazardous voltage will cause injury Turn off main switch and wait 5 minutes before opening this cover Un voltage non adapté provoque des blessures Eteindrel interrupteur et attendre 5 minutes avantd ouvrir le capot Hochspannung verletzungsgefahr ...

Page 6: ...n holder 25 7 9 Adjustment by the accessory spring 25 8 SEWING 26 9 MAINTENANCE AND INSPECTION 27 9 1 Cleaning the rotary hook 27 9 2 Lubrication 28 9 3 Draining the oil 29 9 4 Cleaning the control box air inlet port 29 9 5 Cleaning the eye guard 29 9 6 Checking the needle 29 10 STANDARD ADJUSTMENTS 30 10 1 Adjusting the needle bar height 30 10 2 Adjusting the needle bar lift amount 30 10 3 Adjust...

Page 7: ...5 y 1 2 o u 3 i e q w Safety devices qPower switch 0Finger guard wControl box 1Eye guard eOperation panel 2Thread take up cover rFoot switch 3Belt cover tMotor 4Motor cover yTension release lever 5Thread take up solenoid cover uPulley iSpool stand oThread take up lever ...

Page 8: ... 000 stitches which can be added Solenoid type Shuttle hook Standard equipment Standard equipment P ROM Any sewing pattern can be added using BAS PC 300 16 49 sewing patterns are set already Up to 100 patterns can be added Total number of stitches of stored data which can be added is within 10 000 Three phase 400W induction motor Machine head 47kg Operation panel 0 6kg Control box 9 19kg depending...

Page 9: ...ton holes 2 3 4 4 Sewing pattern No of threads 6 8 10 12 16 20 6 10 12 5 5 5 7 7 7 5 5 5 7 7 7 6 6 8 8 8 8 10 10 12 12 6 6 8 8 10 10 12 12 No of crossover stitches __ __ __ __ __ __ __ __ __ __ __ __ __ 1 1 3 1 1 0 0 0 0 No of stitches 13 15 17 19 23 27 13 17 19 22 28 22 28 20 24 26 28 32 26 30 34 38 Standard sewing length X 3 4mm 0mm 2 6mm 3 4mm Standard sewing width Y 0mm 3 4mm 2 4mm 3 4mm Progr...

Page 10: ...e starts or press the foot switch once more after sewing of the first side is completed 2 SPECIFICATIONS 22 2 3 35 2 3 16 17 30 18 19 31 45 20 32 33 21 34 46 47 48 49 No of button holes 4 Sewing pattern No of threads 6 5 8 7 10 9 6 6 8 8 10 10 12 12 6 6 8 8 10 10 6 6 10 10 6 6 10 10 6 6 8 8 10 10 12 12 No of crossover stitches 1 1 1 1 1 1 1 0 0 0 1 1 0 0 1 1 1 1 No of stitches 19 23 27 20 24 28 32...

Page 11: ...ton holes 4 Sewing pattern No of threads 6 6 8 8 10 10 12 12 6 6 8 8 10 10 6 6 10 10 No of crossover stitches 0 0 0 0 0 0 0 0 0 No of stitches 26 30 34 38 26 30 34 26 34 Standard sewing length X 3 4mm 2 4mm Standard sewing width Y 3 4mm 3 4mm Program No The following programs require the solenoid thread wiper OP ...

Page 12: ...e cure 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 motor CAUTION 3 INSTALLATION 3 1 Power table Use the power table which has be...

Page 13: ...ttle to the right of oval hole on motor NOTE Tighten the nuts y so that the clearance between the table and the cushion collars e is approximately 1 mm 3 3 Installing the motor pulley Place the motor pulley q onto the shaft of the motor w so that the key groove is aligned and then tighten the set screw e so that the center of the V groove in the motor pulley q is aligned as closely as possible wit...

Page 14: ...ashers i and nuts o as shown in the illustration above At this time leave a gap of approximately 3 mm between the work table and the top of the box Use two nuts o at each installation location and make sure that both nuts are tightened 3 Close the covers panel mounting assembly w and main P C board mounting plate e and tighten them with the screws q The main P C board mounting plate e will be open...

Page 15: ... into the holes for the cushions q and then secure it in place with the five nails e so that the oil pan w is not at an angle 2 While pushing the oil pan w down from above screw in the oil container r Place the two cushions q 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 nails w 3 INSTALLATION w w e q r w q q ...

Page 16: ...ll the cords t out as shown in the illustration above in order to prevent them from being clamped by the machine head 3 Install the hinge presser y with the two screws u 3 9 Installing the head rest Tap the head rest q into the table hole NOTE Tap the head rest securely into the table hole 3 10 Installing the liquid cooling tank optional 1 Remove the rubber plug and then push the liquid cooling ta...

Page 17: ...r screws r The vertical orientation of the front frame e is the same whether it is installed to the top or the bottom of the work table 3 Insert the connector cord t into the control box through the hole at the side of the box Refer to 3 13 Connecting the cords for details on connecting the cord 4 Secure the connector cord t with the staples in three places 3 12 Connecting the ground wire Connect ...

Page 18: ...he illustration 7 Loosen the screw 1 and then attach the ground cord 0 for the upper shaft motor as shown in the illustra tion 8 Securely connect connectors P1 to P8 and P11 as indicated in the table 9 Secure the cords q with the cord clamps 2 and 3 10 Close the cord presser plate y in the direction of the black arrow and secure it by tightening the screws t NOTE Check that the cords do not get pu...

Page 19: ...ley assembly to the right and left so that there is 9 10 mm of deflection in the V belt q when it is gently pushed in the middle with a force of ap proximately 10 N After adjusting tighten the bolt A to secure the left pulley assembly 5 Move the right tension pulley so that there is a gap of about 1 mm between it and the V belt q and then tighten the bolt B to secure the right pulley assembly NOTE...

Page 20: ...asher 0 and flat washer 1 as shown in Figure A If foot switch support plate B 3 is used in a back to front position it can be used as shown in Figure B 1 Remove the screw 4 and rubber plug 5 Note that the spring 6 will come out when the screw 4 is removed 2 Turn foot switch support plate B 3 back to front and then install it with the bolt 7 spring washer 8 and flat washer 9 as shown in Figure B NO...

Page 21: ... while referring to the spool stand instruction manual and then install the spool stand q at the right side of the work table 3 20 Installing the eye guard Attach all safety devices before using the sewing machine If the machine is used without these de vices attached injury may result Install the eye guard assy w to the face plate q with the two screws e 3 INSTALLATION w q e r t y u q 3 19 Instal...

Page 22: ...ow 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 Nisseki Sewing Libe 10 for the machine oil 4 1 Lubrication...

Page 23: ...rn r TEST indicator Illuminates when the TEST switch has been pressed t BOBBIN WIND switch Press this switch to wind the lower thread y 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 u to 1 illuminates and the setting for that menu item appears in the display 4 The illiminated indicator changes...

Page 24: ... the Y scale set ting 0 SPEED indicator Illuminates when the SELECT switch y is pressed to shown the speed set ting 1 COUNTER indicator Illuminates when the SELECT switch y is pressed to show the bobbin thread or production counter setting 2 DISPLAY SET switches Used to change the menu details which are displayed in the window 4 3 User program switches Used to set and select user programs 4 Displa...

Page 25: ...lash ing in the display window The setting is displayed as a per centage Depress the foot switch to the second step The display will stop flashing and illuminates steadily and the feed mechanism will move to the sewing start position 1 2 3 Press the SELECT switch y until the SPEED indicator il luminates Press the DISPLAY SET switches 2 until the de sired speed setting is flash ing in the display w...

Page 26: ...cator will switch off and the test mode will be cleared 7 Depress the foot switch The work clamp will rise and the preparation for sewing will be completed TE S T T E S T 1st step 2nd step 6 CHECKING THE SEWING PATTERN When checking by operating only the feed mechanism To ensure safety during use You can prevent accidental changes being made to programs by setting DIP switches 7 and 8 to ON When D...

Page 27: ...is depressed by mistake and serious injury could result Refer to the table at right for details on which needle and thread to select NOTE Use buttons which have a hole diameter that is greater than the value given in the table to ensure that the needle does not touch the button 7 2 Installing the needle CAUTION CAUTION Loosen the set screw q insert the needle w as far as it will go so that the gro...

Page 28: ...fore winding is com pleted depress it once more while pressing and holding the BOBBIN WIND switch w 7 Remove the bobbin hook the thread onto the knife r and then pull the bobbin in the direction of the arrow to cut the thread 6 Release the foot switch e 5 The bobbin presser q will automatically return to its original position after a set amount of thread 80 90 of the bobbin capacity has been wound...

Page 29: ...m of thread 7 6 Thread tension reference guide w e r 7 CORRECT USE Weaker Stronger Weaker Stronger w q 7 6 1 Lower thread tension Adjust the thread tension to the weakest possible ten sion by turning the thread tension nut q until the bob bin case will not drop by its own weight while the thread end coming out of the bobbin case is held 7 6 2 Upper thread tension Turn the tension nut q main tensio...

Page 30: ... mark A To adjust the position loosen the screw w and then move arm thread guide Rq When sewing thick material move arm thread guide Rq to the left The thread take up amount will be come greater When sewing thin material move arm thread guide Rq to the right The thread take up amount will become less 7 6 6 Thread take up amount Loosen the screw q and move the stopper 3 57 nut w to adjust the opera...

Page 31: ...firm that the button is securely held by the holder 2 Loosen the set screw q while the button is held by the holder Move the adjusting plate w so that the space between the adjusting plate w and screw e is approximately 0 5 1 0 mm then tighten the set screw q 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 Ins...

Page 32: ...am number will flash in the display 4 Place the material to be sewn under the button clamp and then depress the foot switch When the foot switch is pressed to the 1st step the button clamp will lower If you would like to shift the position of the material release the foot switch The button clamp will then rise again When the foot switch is pressed to the 2nd step the machine will start operating W...

Page 33: ...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 9 1 Cleaning the rotary hook 1 Pull the shuttle race cover toward you to open it and then remove the bobbin case 2 Open the setting claw q in the direction indicated by the arrow and then re...

Page 34: ...to the felt until it is slightly soaked NOTE4 Use only specified Brother oil Nisseki Sewing Libe 10 for the machine oil 1 Fill the arm side oil tank with oil When setting up the sewing machine and when it hasn t been used for an extended period of time be sure to add 2 3 drops of oil at the place indicated by the arrow 2 Fill the bed side oil tamk with oil 3 Add oil to the felt q of the shuttle ra...

Page 35: ...trol box q at least once a month If the machine is used while the air inlet port is blocked the inside of the control box will overheat When this happens the overheating error code E d0 will be displayed and you will not be able to operate the sewing machine 9 5 Cleaning the eye guard Wipe the eye guard clean with a soft cloth NOTE Do not use solvents such as kerosene or thinner to clean the eye g...

Page 36: ...itions and check that they op erate correctly before using the machine 10 STANDARD ADJUSTMENTS 10 STANDARD ADJUSTMENTS w e e CAUTION 10 1 Adjusting the needle bar height Turn the machine pulley to move the needle bar to the lowest position Then remove the rubber plug w loosen the set screw e and then move the needle bar up or down to adjust so that the highest reference line reference line A is al...

Page 37: ...he needle resulting in an excessively high amount of friction 10 4 Adjusting the needle clearance Turn the machine pulley to align the tip of the rotary hook with the needle center line Then loosen the set screw q and turn the eccentric shaft w 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 rac...

Page 38: ... take up solenoid r To reduce the thread take up amount move the stopper e upward To increase the thread take up amount move the stopper e 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 Furthermore if the sub thread tension i...

Page 39: ...rod lever pin i 4 Remove the movable knife o and replace it with a new one At this time check that the movable knife o and the fixed knife 0 cut the thread cleanly If necessary adjust by using the appropriate movable knife washer 1 supplied as accessories Apply grease to the outside of the collar 2 at this time 5 Install the fixed knife 0 at a distance of 0 5 mm from the needle hole plate 3 6 Plac...

Page 40: ...ain the cutting performance of the knife A B C D Cutting edge Movable knife Fix knife 13mm e w q 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 q loosen the screw w and adjust the button clamp holder hook e by moving it up a...

Page 41: ...t tight enough 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 q and adjust the button holder body w by moving it 2 Check that the needle will go through the button hole with no contact Refer to 6 CHECKING THE SEWING PATTERN w q ...

Page 42: ...e stop position and should not be loosened If the index mark w is not inside the mark r when the sewing machine is started error code E 50 will be displayed Turn the machine pulley to move the index mark w to the correct position and then start the sewing machine 10 12 Adjusting the thread wiper 1 Loosen the set screw w and move the wiper arm support e up or down to adjust so that the clearance be...

Page 43: ...ynchronizer 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 switches at the side of the operation panel are changed at this time the number of the DIP switch which was changed will be displaye...

Page 44: ... If the input voltage is normal the input voltage conditions will be shown in the display window t as indicated in the table above 5 Press the TEST switch e 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 instan...

Page 45: ...o 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 mecha nism will move to the left If the DISPLAY SET switch is pressed while the X SCALE indicator is illuminated the feed mecha nism will move to the right If the DISPLAY SET switch is pressed while the Y SCALE indicator is illuminated the feed mecha nism will m...

Page 46: ...ess the RE SET switch r The COUNTER indicator t and the SPEED indi cator w will illuminate and the production counter will be displayed in the display window y Press the RESET switch r to reset the produc tion counter to 0000 You can also press the DISPLAY SET switches u to set the production counter to the desired value 3 When the foot switch is depressed the sewing ma chine will start sewing 4 I...

Page 47: ...ls Two pedals Raising the presser at the sewing end Presser is raised automatically Presser is raised by pressing the pedal Presser is raised automatically then it is lowered by pressing the pedal Presser is kept lifted while the pedal is pressed DIPA 1 12 CHANGING FUNCTIONS USING THE DIP SWITCHES 12 1 Operation panel DIP switches The operation panel DIP switches q are used to change functions whi...

Page 48: ... not carried out Switch DANGER 12 3 DIP switches inside the control box Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box Touching areas where high volt ages are present can result in severe injury The DIP switches q inside the control box are used to change functions which do not often ...

Page 49: ...cator t will illuminate 4 Press the DISPLAY SET switches 0 to select the number for the program that you would like to record 3 Press the SELECT switch e The PROGRAM NO indicator r will illuminate 2 Turn on the power switch While pressing the TEST switch w press the SE LECT switch e All of the menu indicators r to i will illuminate and the mode will switch to recording mode In addition PP 1 will a...

Page 50: ...h the number selected will be cleared If you press and hold the RESET switch 2 until after the buzzer has sounded twice all user programs will be cleared NOTE If data has been recorded in user programs P1 P2 P3 and P4 and you then clear the data in user program P2 the contents of P3 will be transferred to P2 and the contents of P4 will be transferred to P3 1 Press the DISPLAY SET switches 0 to sel...

Page 51: ...e also enlarged and reduced Normally stitches with a pitch of less than 1 mm are not enlarged or reduced Test feeding will be performed at the same speed as that for actual sewing This is used for checking feeding operation After sewing is finished the work clamp automatically opens and closes once practice operation Switch SELECT PROGRAM NO RESET COUNTER X SCALE Y SCALE SPEED P TEST BOBBIN WIND P...

Page 52: ...ng start Sensitivity during sewing is three stitches memo 23 When DIP switch A 8 is simultaneously ON setting values changed using the operation panel are ignored memo 24 memo 2F memo 30 memo 31 memo 32 memo 33 memo 34 memo 35 memo 36 memo 37 memo 38 memo 39 memo 3A memo 3b memo 3c memo 3d memo 3E memo 3F memo 40 memo 4F Possible setting range 0 30 0 30 12 27 1 15 0 5 3 9 1 20 1 20 1 20 1 20 1 20 ...

Page 53: ...display window 0 to indicate that cycle sewing program No 1 is be ing recorded Programs P2 P3 and P4 switches can also be used for pro gramming 5 Press the SELECT switch e The PROGRAM No indicator r will illuminate and 1 will appear in the display window 0 6 Press the DISPLAY SET switches 1 to select the number for the user program that you would like to record 7 Press the SELECT switch e 2 will a...

Page 54: ...corded user program Using a cycle sewing 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 o if you would like to clear cycle sewing program No 1 Pc 1 will be displayed 3 Press the RESET switch 2 The...

Page 55: ...Turn off the power and check if connectors P3 is disconnected Turn off the power and then turn the machine pulley to check if the machine has locked up Check the synchronizer connection Check if connectors P11 P12 and P13 are disconnected Turn off the power and check the ground wire connection Press the RESET switch and then set the enlargement ratio again Press the RESET switch and then reset the...

Page 56: ...n DIP switch A 8 was set to ON Heat sink of control circuit board is abnormally hot Malfunction of EEPROM malfunction of main circuit board Solenoid short circuit malfunction of main circuit board or power relay is not operating malfunction of power supply circuit board Bad connection in cable between power supply circuit board and main circuit board Abnormal current detected in power supply circu...

Page 57: ... 6 4 8 4 8 4 8 1 4 8 AL S52075 001 S52071 001 BR BL S52076 001 Standard S52072 001 Standard CR CL S52077 001 S52073 001 DR DL S52078 001 S52074 001 AR 1 5 2 2 5 3 HW S40917 001 S52081 001 HT HX S40925 001 S52082 001 Standard HU S52079 001 HV S52080 001 HS 1 5 φ3 6 φ2 φ3 6 φ2 0 8 φ3 6 φ2 1 2 φ3 2 φ1 6 1 5 φ3 2 φ1 6 0 8 φ3 2 φ1 6 1 2 Button clamp spacer Needle hole plate ...

Page 58: ... Thread wiper does not operate correctly The thread wiper is obstructing the needle Clearance beween thread wiper and needle tip Adjust the height of the thread wiper 36 Thread wiper position is incorrect Thread wiper position Adjust the operating distance of the thread wiper 36 Lower thread winds to one side Bobbin winder thread tension stud height is incorrect Bobbin winder thread tension stud h...

Page 59: ...nsion is too strong Lower thread tension Adjust the lower thread tension 23 Corners of needle hole plate or bobbin care are damaged Damage File smooth or replace the affected part Clearance between needle and rotary hook tip is too great Needle clearance Adjust the needle clearance 31 Incorrect needle and rotary hook timing Needle bar lift amount Adjust the needle bar lift amount 30 Driver is cont...

Page 60: ...timing Needle bar lift amount Adjust the needle bar lift amount 30 Shuttle race thread guide is not separating the threads Shuttle race thread guide position Adjust the position of the shuttle race thread guide 31 Shuttle race thread guide is not separating the threads Shuttle race thread guide position Adjust the position of the shuttle race thread guide 31 Upper thread is not properly tight Uppe...

Page 61: ...ibility to select the best method of working Two step foot switch This is a pedal type foot switch Liquid cooling tank This helps to prevent thread breakages caused by friction when using synthetic threads Fill the tank with silicone oil 100 mm2 s Solenoid thread wiper This wipes the thread independently of the work clamp op eration 17 OPTIONAL PARTS ...

Page 62: ...INSTRUCTION MANUAL BROTHER INDUSTRIES LTD NAGOYA JAPAN Printed in Japan 118 V38 S91V38 002 2000 02 B 1 ...

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