Brother LK3-B438E MKII Instruction Manual
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Brother LK3-B438E MKII Instruction Manual

Brother LK3-B438E MKII Instruction Manual

E series electronic lockstitch button sewer
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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

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Summary of Contents for Brother LK3-B438E MKII

  • 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: Safety Instructions

    Thank you very much for buying a BROTHER sewing machine. Before using your new machine, please read the safety instruc- tions below and the explanations given in the instruction manual. With industrial sewing machines, it is normal to carry out work while positioned directly in front of moving parts such as the needle and thread take-up lever, and consequently there is always a danger of injury that can be caused by these parts.
  • Page 3 2. Notes on safety DANGER 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 voltages are present can result in severe injury. CAUTION Environmental requirements The ambient temperature should be within the range...
  • Page 4 CAUTION Sewing This sewing machine should only be used by opera- If using a work table which has casters, the casters tors who have received the necessary training in safe should be secured in such a way so that they cannot use beforehand.

  • Page 5: Warning Labels

    3. Warning labels The following warning labels appear on the sewing machine. Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are difficult to read, please contact your nearest Brother dealer. Hazardous voltage Hochspannung Un voltage non adapté...

  • Page 6: Table Of Contents

    CONTENTS 9-2. Lubrication ..........28 1. NAME OF EACH PART ....... 01 9-3. Draining the oil ........29 2. SPECIFICATIONS 9-4. Cleaning the control box air inlet ......... 02 port ............29 2-1. Specifications ........2 9-5. Cleaning the eye guard ....... 29 2-2.

  • Page 7: Name Of Each Part

    1 . NAME OF EACH PART 1. NAME OF EACH PART Safety devices; qPower switch !0 F inger guard wControl box !1 E ye guard eOperation panel !2 T hread take-up cover rFoot switch !3 B elt cover t Motor !4 M otor cover yTension release lever !5 T hread take-up solenoid cover...

  • Page 8: Specifications

    2 . SPECIFICATIONS 2 . SPECIFICATIONS 2-1 . Specifications Stitch formation Single needle lock stitch Maximum sewing 2,500rpm speed Maximum pattern 0 - 6.4 0 - 6.4 mm size Needle 1#12 Dimensions of Outer diameter of button 8 - 30 mm buttons that can be (Use the optional button clamp B for diameters of 20 mm or greater.) sewn...

  • Page 9: Program List

    2 . SPECIFICATIONS 2-2 . Program list Sewing patterns are limited as shown in the table below. (Any program is available as long as the needle drops down in the hole of the button.) No. of No. of Sewing No. of No.
  • Page 10 2 . SPECIFICATIONS No. of No. of Sewing No. of No. of Standard Standard Program No. crossover button holes pattern threads stitches sewing length X sewing width Y stitches 10-9 3.4mm 3.4mm 10-10 12-12 10-10 10-10 2.4mm 3.4mm *2*3 *2*3 10-10 3.4mm 3.4mm...
  • Page 11 2 . SPECIFICATIONS The following programs require the solenoid thread wiper (OP). No. of No. of Sewing No. of No. of Standard Standard crossover Program No. button holes pattern threads stitches sewing length X sewing width Y stitches 10-10 12-12 3.4mm 3.4mm 10-10...

  • Page 12: Installation

    3. INSTALLATION 3. INSTALLATION CAUTION Machine installation should only be carried All cords should be secured at least 25 mm out by a qualified technician. away from any moving parts. Furthermore, do not excessively bend the cable or se- Contact your Brother dealer or a qualified cure it too firmly staples, otherwise there is electrician for any electrical work that may the danger that fire or electric shocks could...

  • Page 13: Installing The Motor

    3. INSTALLATION 3-2 . Installing the motor Install the motor u to the work table with the four ac- cessory bolts q, cushions w, cushion collars e, flat washers r, spring washers t and nuts y. At that time, fix by setting bolts q a little to the right of oval hole on motor.

  • Page 14: Installing The Control Box

    3. INSTALLATION 3-4 . Installing the control box Table Cushions Cushion collars 3 m m Rubber collers Flat washers Nuts 1. Remove the 12 screws q, and then open the covers (panel mounting assembly w and main P.C. board mounting plate e). NOTE: When opening the cover, hold it securely so that it does not fall down.

  • Page 15: Installing The Rubber Cushions

    3. INSTALLATION 3-5. Installing the rubber cushions Install the rubber cushions q with the nails w. 3-6 . Installing the oil pan 1. Insert the tabs of the oil pan w 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.

  • Page 16: Installing The Machine Head

    3. INSTALLATION 3-8 . Installing the machine head 1. Insert the head hinges q into the machine head so that they are parallel, and then secure them with the two set screws w. 2. Place the machine head gently on top of the rubber cushions e and cushions r. NOTE: Pull the cords t out as shown in the illustration above in order to prevent them from being clamped by the machine head.

  • Page 17: Installing The Operation Panel

    3. INSTALLATION 3-11 . Installing the operation panel The operation panel can be installed to either the top or bottom of the work table. Top of work table Bottom of work table Table Table 1. Install the rear frame q to the work table (top or bottom) with the four wood screws w. 2.

  • Page 18: Connecting The Cords

    3. INSTALLATION 3-13 . Connecting the cords Machine head connectors Connection location on circuit board Connection location No. of pins Cord mark X, Y, Sewing sensor 12-pin P1 (ORG2) Synchronizer 5-pin P2 (SYNCHRO) Machine specification 8-pin P3 (SELECT) select connector Thread take-up solenoid 5-pin P4 (SOL2)

  • Page 19: Installing The V-Belt

    3. INSTALLATION 3-14 . Installing the V-belt 1. Gently tilt back the machine head, and then place the V-belt q into the V grooves on the machine head pulley w and the motor pulley e. NOTE: After tilting back the machine head, do not push the face plate side or the pulley side from above.

  • Page 20: Installing The Belt Cover

    3. INSTALLATION 3-15 . Installing the belt cover 1. Loosen the two screws w of the upper cover q and the two screws r of bed cover Le. 2. Insert the belt cover t in the direction of the arrow, and then secure it with the two screws w, the two screws r and the screw y.

  • Page 21: Installing The Motor Cover

    3. INSTALLATION 3-17 . Installing the motor cover 1. Install the motor cover q to the motor back cover w with the screws e and the flat washers r. 2. Pass the motor shaft through the notch in the mo- tor back cover w, and then tighten the screws y and the washers u so that the clearance between the motor pulley t and the motor cover q is...

  • Page 22: Lubrication

    4 . LUBRICATION 4. LUBRICATION CAUTION Turn off the power switch before starting lubricating, otherwise the machine may operate if the foot switch is depressed by mistake, which could result in injury. Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result.

  • Page 23: Operation

    5 . OPERATION 5 . OPERATION 5-1 . Name and function of each operation panel item B430E Series PROGRAM NO. POWER X - SCALE R E S E T Y - SCALE SPEED T E S T COUNTER S E L E C T BOBBIN.WIND q POWER indicator ....
  • Page 24 5 . OPERATION B430E Series PROGRAM NO. POWER X - SCALE R E S E T Y - SCALE SPEED T E S T COUNTER S E L E C T BOBBIN.WIND i X-SCALE indicator ....Illuminates when the SELECT switch y is pressed to shown the X-scale set- ting.

  • Page 25: Operating Procedure

    5 . OPERATION 5-2 . Operating procedure Preparation Factory default Variable range Turn on the power switch. Program No. 00 * 01 - 49 (The POWER indicator q will illuminate and the pro gram number will flash in the display window !4 . ) X-scale (%) 20 - 200 Y-scale (%)

  • Page 26: Checking The Sewing Pattern

    6. CHECKING THE SEWING PATTERN 6. CHECKING THE SEWING PATTERN When checking by operating only the feed mechanism 1. Turn on the power switch. (The POWER indicator will illuminate and the program number will flash in the display window.) 2. Set the X-scale and Y-scale in accordance with the hole pitch of the buttons being used. (Refer to “5-2-2.

  • Page 27: Correct Use

    7. CORRECT USE 7. CORRECT USE 7-1 . Selecting the needle and thread Needle Thread Button hole diameter Refer to the table at right for details on which needle 1 #11 1.5mm or greater and thread to select. 1 #12 1.6mm or greater NOTE: Use buttons which have a hole diameter that is greater than the value given in the table, to ensure...

  • Page 28: Winding The Lower Thread

    7. CORRECT USE 7-4 . Winding the lower thread CAUTION Do not touch or place anything against any of the moving parts while winding the lower thread, otherwise personal injury or damage to the machine may result. 1. Place the bobbin all the way onto the shaft. 2.

  • Page 29: Replacing The Bobbin Case And Threading The Thread

    7. CORRECT USE 7-5. Replacing the bobbin case and threading the thread CAUTION Turn off the power switch before removing and replacing the bobbin case, otherwise the machine may operate if the foot switch is depressed by mistake and serious injury could result. 30mm Pull the shuttle race cover q toward Insert a new bobbin into the bobbin...
  • Page 30 7. CORRECT USE 7-6-3 . Thread take-up spring height 7-6-4. Thread take-up spring tension Lower Higher Stronger Weaker Loosen the set screw q and turn the tensioner body Turn the tension stud q with a screwdriver. to adjust the thread take-up spring height. 7-6-5.

  • Page 31: Inserting The Button

    7. CORRECT USE 7-7. Inserting the button 1. Press the cam plate q to open the button holder 2. Insert the button, making sure that the button is facing the directing shown in the illustration, then release the cam plate q. 7-8.

  • Page 32: Sewing

    8. SEWING 8. SEWING CAUTION Turn off the power switch at the following times, otherwise the machine may operate if the foot switch is depressed by mistake, which could result in injury. • Threading • When replacing the needle • When not using the machine and when leaving the machine unattended. Do not touch 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.

  • Page 33: Maintenance And Inspection

    9 . MAINTENANCE AND INSPECTION 9 . MAINTENANCE AND INSPECTION CAUTION Turn off the power switch before carrying out cleaning, otherwise the machine may operate if the foot switch is pressed by mistake, which could result in injury. Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result.

  • Page 34: Lubrication

    9 . MAINTENANCE AND INSPECTION 9-2. Lubrication NOTE1: Fill the machine with oil when the oil level is down to about one-third full in the oil sight glass. If oil is not added and the oil drops below this level, there is the danger that the machine may seize during operation.

  • Page 35: Draining The Oil

    9 . MAINTENANCE AND INSPECTION 9-3 . Draining the oil 1. Remove and empty the waste oil container q whenever it is full. 2. After emptying the waste oil container q, screw it back into its original position. 9-4 . Cleaning the control box air inlet port Use a vacuum cleaner to clean the filter in the air inlet port w of the control box q at least once a month.

  • Page 36: Standard Adjustments

    10 . STANDARD ADJUSTMENTS 10 . STANDARD ADJUSTMENTS CAUTION Maintenance and inspection of the sewing Hold the machine head with both hands machine should only be carried out by a quali- when tilting it back or returning it to its origi- fied technician.

  • Page 37: Adjusting The Driver Needle Guard

    10 . STANDARD ADJUSTMENTS 10-3 . Adjusting the driver needle guard Needle center line Turn the machine pulley to align the tip of the rotary hook with the needle center line. Then loosen the set screw w and turn the eccentric shaft e to adjust so that the driver needle guard q contacts the needle. If the needle contact pressure is too great, skipped stitches may occur.

  • Page 38: Adjusting The Thread Take-Up Amount

    10 . STANDARD ADJUSTMENTS 10-6.Adjusting the thread take-up amount Thread take-up amount (stroke) Become less Become greater At the time of shipment from the factory, the thread take-up amount (stroke) of the thread take-up lever q is set to the standard setting of 5 mm. You may need to adjust this setting depending on the sewing conditions to prevent the thread from pulling out at the sewing start.
  • Page 39 10 . STANDARD ADJUSTMENTS 10-7-1 . Replacing the movable knife and fixed knife 1. Open the large shuttle hook cover, remove the screws q and w, and then remove the feed plate e. 2. Remove the two screws r and the two screws t, and then remove the needle plate y. 3.

  • Page 40: Adjusting The Button Clamp Lift Amount

    10 . STANDARD ADJUSTMENTS 10-7-2. Adjusting the engagement of the movable knife and fixed knife Fig. 1 Movable knife Cutting Fix knife edge Cutting edge Cutting edge Cutting edge A. After the movable knife and fixed knife are properly engaged, tighten the screw as shown in Fig.1. B.

  • Page 41: Adjusting The Holding Pressure

    10 . STANDARD ADJUSTMENTS 10-9. Adjusting the holding pressure Loosen the adjusting nut q and turn the adjusting nut w to the point where it is just tight enough that the material will not slip out of place when it is slightly pulled (keep pressure as slight as possible).

  • Page 42: 10-11.Adjusting The Needle Up Stop Position

    10 . STANDARD ADJUSTMENTS 10-11. Adjusting the needle up stop position The needle up stop position is adjusted so that the index mark w on the machine pulley q is inside the mark r on the belt cover e. If adjustment is necessary, loosen the screw t at the “U”...

  • Page 43: 10-13.Checking The Input Sensor And Dip Switch Input

    10 . STANDARD ADJUSTMENTS 10-13. Checking the input sensor and DIP switch input B430E Series PROGRAM NO. POWER X - SCALE R E S E T Y - SCALE SPEED T E S T COUNTER BOBBIN.WIND S E L E C T 1.

  • Page 44: 10-14.Checking The Input Voltage

    10 . STANDARD ADJUSTMENTS 10-14. Checking the input voltage B430E Series PROGRAM NO. POWER X - SCALE R E S E T Y - SCALE SPEED T E S T COUNTER BOBBIN.WIND S E L E C T Specifications Display Notes 200V [090 - 110]...

  • Page 45: 10-16.Moving Stitch Patterns

    10 . STANDARD ADJUSTMENTS 10-16 . Moving stitch patterns · Programs which have already been programmed can be moved up, down and to the left and right. (How- ever, such patterns will be reset if the power supply is turned off or the program number is changed.) ·...

  • Page 46: Using The Counters

    11 . USING THE COUNTERS 11. USING THE COUNTERS 11-1 . Using the bobbin thread counter If you use the bobbin thread counter to set the number of articles which can be sewn with the amount of bobbin thread available, you can stop the bobbin thread running out in the middle of sewing a pattern. 1.

  • Page 47: Changing Functions Using The Dip Switches

    12 . CHANGING FUNCTIONS USING THE DIP SWITCHES 12. CHANGING FUNCTIONS USING THE DIP SWITCHES 12-1. Operation panel DIP switches The operation panel DIP switches q are used to change functions which might need to be changed depending on the sewing conditions. NOTE: Always turn off the power before setting the DIP switches.

  • Page 48: Dip Switches Inside The Control Box

    12 . CHANGING FUNCTIONS USING THE DIP SWITCHES 12-3 . DIP switches inside the control box DANGER 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.

  • Page 49: Using User Programs

    12 . CHANGING FUNCTIONS USING THE DIP SWITCHES 12-4. Using user programs User program ... It can store sixteen different programs which can include details such as the program number, X scale, Y scale and sewing speed. If you are sewing certain patterns over and aver again, it is useful to record the settings for these patterns into a user program.
  • Page 50 12 . CHANGING FUNCTIONS USING THE DIP SWITCHES Using a user program 1. Press the DISPLAY SET switches !0 to select the speed program number for the user program that you would like to use. *The user program numbers P1 to P4 can also be selected using the user program switches !1 . 2.

  • Page 51: Changing Special Functions Using The Memory Switches

    13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES 13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES The functions of the switches on the operation panel q can be changed to carry out special functions. NOTE: After changing the memory switch settings, press the power switch to turn the power off and then back on again. The memory switches “00 - 2F”...
  • Page 52 13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES Memory switches 10 - 1F Switch Motion when set to ON memo-10 The optional emergency stop switch can be used. memo-11 - memo-13 — memo-14 Solenoid wiper can be used (available as an option). memo-15 —...

  • Page 53: Using The Cycle Sewing Function

    13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES 13-1. Using the cycle sewing function What is the cycle sewing function? The cycle sewing function lets you program up to four patterns for cycle sewing of patterns in a predeter mined order. Recording a cycle sewing program 1.
  • Page 54 13. CHANGING SPECIAL FUNCTIONS USING THE MEMORY SWITCHES Using a cycle sewing program 1. When “c1-1” is flashing in the display window !0 , press the foot switch to the second step. 2. Start sewing. 3. “c1-1”, “c1-2”, “c1-3” are sewn in order for each article, and when the last-recorded pattern has been sewn, the display returns to “c1-1”.

  • Page 55: Table Of Error Codes

    14. TABLE OF ERROR CODES 14. TABLE OF ERROR CODES DANGER 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.
  • Page 56 14. TABLE OF ERROR CODES Code Cause Remedy Home position cannot be detected Turn off the power and check the connection of E-A0 (malfunction of home position sensor), or home position sensor connector P1. malfunction of power supply circuit board. Press the RESET switch.

  • Page 57: Gauge Parts List

    15. GAUGE PARTS LIST 15. GAUGE PARTS LIST • Feed plate S49950-001(Standard) S49951-001 S49952-001 S49953-001 S49954-001 12.5 • Button clamp spacer S52075-001 S52076-001(Standard) S52077-001 S52078-001 S52071-001 S52072-001(Standard) S52073-001 S52074-001 • Needle hole plate S40917-001 S40925-001 S52079-001 S52080-001 S52081-001 S52082-001(Standard) LK3-B438E Mark II...

  • Page 58: Troubleshooting

    16. TROUBLESHOOTING 16. TROUBLESHOOTING Problem Cause Check Remedy Page Distance between Adjust the height of Button clamp lifter button clamp and top the button clamp to amount is too great. of needle plate within 17 mm. Button clamp does not rise. Presser is contacting Thread wiper standby Adjust the position of...
  • Page 59 16. TROUBLESHOOTING Problem Cause Check Remedy Page Upper thread tension Adjust the upper Upper thread tension is too strong. thread tension. Install the needle so Needle is installed Needle direction that the groove is incorrectly. facing forward. Thread is too thick for Use the correct Thread and needle the needle.
  • Page 60 16. TROUBLESHOOTING Problem Cause Check Remedy Page Sharpen or replace Fixed knife is blunt. Fixed knife blade the fixed knife. Adjust the position of Shuttle race thread the shuttle race guide position Movable knife does thread guide. not pick up the thread.

  • Page 61: Optional Parts

    17. OPTIONAL PARTS 17. OPTIONAL PARTS Two-pedal foot switch ........The presser switch and the start switch have been separated, giving the operator more flexibility to select the best method of working. Two-step foot switch ......... This is a pedal-type foot switch. Liquid cooling tank .
  • Page 62 INSTRUCTION MANUAL BROTHER INDUSTRIES,LTD. NAGOYA,JAPAN Printed in Japan 118-V38 S91V38-002 2000.02. B (1)

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