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Brother BE-438D Service Manual

Brother BE-438D
107 pages
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KE-4300
BE-4380
SERVICE MANUAL
Please read this manual before using the machine.
Please keep this manual within easy reach for quick reference.
ELECTRONIC
DIRECT
DRIVE
LOCKSTITCH
BAR
TACKER
ELECTRONIC
DIRECT
DRIVE
LOCKSTITCH
BUTTON
SEWER
From the library of: Superior Sewing Machine & Supply LLC

Table of Contents

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Brother BE-438D Specifications

General IconGeneral
ModelBE-438D
Stitch Length5mm
Maximum Stitch Width7mm
Maximum Stitch Length5mm
LCD DisplayYes
Needle ThreaderAutomatic
Needle PositionYes

Summary

Service Manual

Model Identification

Identifies the KE-4300 and BE-4380 sewing machine models.

Safety Instructions and Warnings

Safety Indications and Meanings

Explains the meaning of safety symbols and indications used in the manual and on the machine.

General Safety Notes and Precautions

Details critical safety information, including electrical hazards and general handling precautions.

Environmental and Installation Requirements

Specifies environmental conditions and installation procedures for safe operation.

Sewing, Cleaning, and Maintenance Safety

Provides safety guidelines for operating, cleaning, and performing maintenance on the machine.

Machine Warning Labels

Understanding Warning Labels

Details the warning labels present on the sewing machine and their meanings.

Machine Specifications

Technical Specifications Overview

Lists the technical details and capabilities of the KE-4300 and BE-4380 models.

Function Settings and Operation

Special Functions on Power On

Details special functions accessible when the sewing machine is initially powered on.

Advanced Function Settings

Provides a list of advanced functions accessible via specific key combinations.

Memory Switch Settings (Advanced)

Guides on how to set and modify memory switches in advanced mode.

Memory Switch Configuration Details

Lists all available memory switches, their settings, and default values.

Work Clamp Mode Settings

Details how to set the operating mode for the work clamp or button clamp.

X-Y Parallel Movement for Patterns

Explains how to move sewing patterns using parallel X-Y feed mechanism adjustments.

Data Initialization and Clearing

Procedure for initializing memory switches and other saved data to restore defaults.

Error History and Diagnostics

How to access and interpret the sewing machine's error history log.

Input Device Checking

Method to check for malfunctions in operation panel keys, PCBs, and sensors.

Output Signal Verification

Procedure to check for PCB failures, mechanism breakdown, or cord breakage.

Software Version Confirmation

How to display and verify the current software version of the sewing machine.

CF Card Usage and Data Management

CF Card Handling Precautions

Guidelines for proper handling, storage, and usage of CF cards with the machine.

Reading and Writing Sewing Data

Instructions for reading additional sewing data from and writing it to the CF card.

Managing Memory Switch Data via CF Card

Procedures for reading and writing memory switch data to and from the CF card.

Transferring User Programs with CF Card

Instructions for reading user programs from and writing them to the CF card.

Updating Machine Control Programs via CF Card

Steps for updating the machine's control programs using a CF card.

Saving Error Logs to CF Card

Procedure for writing the machine's error log data to the CF card.

Mechanical System Descriptions

Needle Bar and Thread Take-up Mechanisms

Detailed description of the needle bar and thread take-up operating mechanisms.

Work Clamp Lifter and Thread Wiper Mechanisms

Explains the operation and components of the work clamp lifter and thread wiper.

Feed Mechanism Details

Description of the feed mechanism responsible for X and Y movements.

Thread Handling Mechanisms

Details the components and operation of thread trimming, tension release, and nipper systems.

Disassembly Procedures

General Disassembly Precautions

Important safety precautions and guidelines before disassembling the sewing machine.

Disassembling the Work Clamp Arm Mechanism

Step-by-step instructions for disassembling the work clamp arm assembly.

Disassembling the Needle Bar Mechanism

Detailed steps for disassembling the needle bar and related components.

Disassembling the Upper Shaft Assembly

Instructions for taking apart the upper shaft mechanism and its components.

Disassembling the Lower Shaft Assembly

Step-by-step guide to disassembling the lower shaft mechanism.

Disassembling the Feed Mechanism

Instructions for disassembling the X and Y feed mechanisms.

Disassembling the Work Clamp Lifter

Detailed procedure for disassembling the work clamp lifter components.

Disassembling the Thread Wiper Mechanism

Steps for taking apart the thread wiper mechanism.

Disassembling the Tension Release Mechanism

Instructions for disassembling the tension release solenoid and related parts.

Disassembling the Thread Nipper Mechanism

Detailed procedure for disassembling the thread nipper assembly.

Disassembling the Thread Trimmer Mechanism

Step-by-step guide to disassembling the thread trimmer components.

Disassembling the Shuttle Hook Assembly

Instructions for disassembling the shuttle hook, bobbin case, and shuttle race.

Assembly Procedures

General Assembly Guidelines

General instructions for reassembling parts, including lubrication points.

Assembling Tension Release and Thread Wiper

Details on assembling the tension release solenoid and thread wiper mechanisms.

Assembling the Thread Nipper Mechanism

Step-by-step instructions for assembling the thread nipper.

Assembling the Work Clamp Lifter Mechanism

Instructions for assembling the work clamp lifter and related parts.

Assembling the X and Y Feed Mechanisms

Detailed steps for assembling the X and Y feed mechanisms.

Assembling the Upper Shaft Mechanism

Instructions for reassembling the upper shaft and associated components.

Assembling the Needle Bar Mechanism

Detailed steps for assembling the needle bar and related parts.

Assembling the Lower Shaft Mechanism

Instructions for reassembling the lower shaft assembly.

Assembling the Shuttle Hook Mechanism

Steps for assembling the shuttle hook, bobbin case, and shuttle race.

Completing Thread Trimmer Assembly

Final steps for assembling the thread trimmer mechanism.

Assembling KE-4300 Work Clamp Arm

Instructions for assembling the work clamp arm for the KE-4300 model.

Assembling BE-4380 Work Clamp Arm

Instructions for assembling the work clamp arm for the BE-4380 model.

Installing the Machine Covers

Steps for attaching the various covers to the sewing machine.

Adjustment Procedures

Standard Thread Tension Adjustment

Guidelines for setting standard thread tension for different materials and threads.

Adjusting Upper/Lower Thread Tension and Take-up Spring

How to adjust upper/lower thread tension and thread take-up spring height/tension.

Needle Bar Height, Lift, and Driver Guard Adjustment

Procedures for adjusting needle bar height, lift amount, and driver needle guard.

Adjusting Needle Clearance and Shuttle Race Guide

How to adjust needle clearance and the shuttle race thread guide.

Setting Movable Knife Position Correctly

Detailed steps to adjust the position of the movable knife for proper cutting.

Replacing Movable and Fixed Knives

Instructions for replacing the movable and fixed thread cutting knives.

Adjusting Clamp Lift Amounts for KE-4300/BE-4380

How to adjust the lift amount for work clamps and button clamps.

Adjusting Button Clamp Pressure and Position

Procedure to adjust holding pressure and position for the button clamp.

Setting the Thread Trimmer Cam Position

Instructions for adjusting the thread trimmer cam for optimal timing.

Adjusting Thread Wiper Height, Width, and Timing

Guides on adjusting thread wiper height, racking width, and timing.

Adjusting Tension Release Amount and Lower Shaft Gear Backlash

How to adjust the tension release amount and lower shaft gear backlash.

Setting the X-Y Feed Home Position

Procedure to set the home position for the X-Y feed mechanism.

Adjusting the Work Clamp Lift Home Position

How to set the home position for the work clamp lift mechanism.

Setting the Thread Nipper Position Correctly

Instructions for adjusting the thread nipper's home position sensor and alignment.

Setting the Needle Up Stop Home Position

Procedure to adjust the needle bar to its correct up stop home position.

Calibrating the Needle Up Stop Position

How to calibrate the needle up stop position using the operation panel.

Verifying the Machine Head Switch Status

Ensuring the machine head switch is properly turned on for correct operation.

Grease Application and Reset

Responding to Grease Application Notification

Procedure for applying grease when the 'GREASEUP' notification appears.

Detailed Grease Application Steps

Step-by-step guide for applying the specified grease to machine parts.

Electric Mechanism and Components

Precautions for Electrical Adjustments

Safety precautions to take when working with the control box and electrical system.

Identifying Control Box and Panel Components

Diagram and description of the main PCBs and components within the control box.

Fuse Identification and Function

Lists fuses, their part codes, and the symptoms when a fuse blows.

Main PC Board Connector Layout

Diagram showing connector positions on the main PC board for troubleshooting.

PMD PC Board and Panel PCB Connector Details

Diagrams of connectors on PMD PC board and Panel PCB.

Connector Contact Failure Troubleshooting

Troubleshooting contact failures in feed and work clamp mechanisms.

Wiring Troubleshooting by Mechanism

Diagnosing contact failures related to thread trimmer and sewing operation.

Electrical System Troubleshooting

Diagnosing problems with the DC fan, operation panel, and foot switch.

Motor and Sensor Troubleshooting

Diagnosing errors related to motors and the machine head switch.

Error Code Reference

Switch-Related and Motor Error Codes

Lists and explains error codes related to switches and upper shaft motors.

Feed Mechanism and Work Clamp Error Codes

Lists and explains error codes for feed mechanism and work clamp issues.

Data Editing, Device, and PC Board Error Codes

Explains error codes for data editing, device errors, and PC board malfunctions.

Data Editing, Device, and PC Board Errors (Cont.)

Continues error code explanations for data editing, device, and PC board issues.

Data Editing, Device, and PC Board Errors (Final)

Final section of error codes for data editing, device, and PC board issues.

Segment Display Character Reference

List of Displayable Characters

Reference guide for characters displayed on the machine's segment display.

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