JUKI LK-1900A, Engineer'S Manual

Page 1: ...40014262 No E357 00 ENGINEER S MANUAL Computer controlled High Speed Bar Tacking Industrial Sewing Machine LK 1900A Series ...

Page 2: ...edures Results of Improper Adjustment and other important information which are not covered in the Instruction Manual It is advisable to use the relevant Instruction Manual and Parts List together with this Engineer s Manual when carrying out the maintenance of these machines This manual gives the Standard Adjustment on the former page under which the most basic adjustment value is described and o...

Page 3: ...er knife 22 17 Inclination of the blade point of the counter knife 24 18 Floating amount of the thread tension disk 24 19 Second thread tension connection disconnection 26 20 AT unit connection disconnection 28 21 Position of the mechanical origin 30 22 Adjusting the Y origin sensor 30 23 Adjusting the X origin sensor 32 24 Adjusting the wiper position 32 25 Adjusting the wiper spring LK 1903A onl...

Page 4: ...placing the fuse 80 2 100V 200V voltage specification changeover 80 3 Greasing parts 81 4 Parts to which grease is applied 82 5 Grease up procedures for the specified position 89 10 Table of errors 90 11 Troubles and corrective measures 93 1 Mechanical parts 93 2 Sewing conditions 95 3 Electrical components 103 12 Circuit diagrams 111 1 Block diagram A 111 2 Power supply circuit diagram A 112 3 Po...

Page 5: ... oil JUKI NEW Defrix oil equivalent to ISO VG32 Lubrication system 18 Grease 1 Penetration No 2 lithium grease 2 Templex N2 3 Juki Grease A 4 Juki Grease B Caution 2 19 Memory medium EEP ROM 128Kbyte EP ROM 32Kbyte 20 Number of stitches that Max 20 000 stitches can be stored in memory 21 Enlarging Reducing X Direction Y Direction 20 200 each 1 step facility 22 Enlarging Reducing method Pattern enl...

Page 6: ... 2 2 Configuration 1 Names of main unit Sewing machine head Work clamp foot Thread stand Operation panel Power switch Control box Pedal switch ...

Page 7: ... changes over the setting state from the panel to the sewing state where the sewing machine actu ally operates Sewing LED This LED goes off at the time of setting state and lights up at the time of sewing state Changeover can be performed with Ready key Reset key This key is used for canceling error or returning the set value to the initial value Mode key This key makes the setting mode of the mem...

Page 8: ...n shaft 3 Remove the main shaft motor Refer to 2 Removal of the main shaft motor and coupling 4 Loosen the two set screws Pay attention to possible injury at that time because the balancer begins to turn when the set screw is loosened 5 Loosen the two set screws At that time the first set screw of the set screw should be removed completely from the flat part of the main shaft 6 Loosen the two set ...

Page 9: ...ne Same procedures followed hereafter 4 Tighten the two each set screws and respectively Make sure that the first screw touches flatly on the main shaft 5 Push the hand pulley in the direction of the arrow F so that the hand pulley gear A is meshed with that the hand pulley gear B In this state fix the pulley with the two set screws 6 Mount the main shaft motor and the coupling Refer to 2 Removal ...

Page 10: ...e four motor set screws 2 To remove the coupling from the main shaft motor loosen the two set screws on the main shaft side Caution Turn the main shaft in the direction of forward rotation A A A A A The screw hole that can be seen first is the No 1 screw Loosen the screws starting with the No 2 screw Tightening should be done starting with the No 1 screw Code No 2 screw No 1 screw No 1 screw Flat ...

Page 11: ...ewise direction 2 Incorporation of the coupling in the main shaft motor 1 Provide a clearance of 0 5mm between the coupling and the main shaft motor 2 Apply the No 1 screw of the coupling to the shaft flat section of the main shaft motor and fix it 3 Meshing of the coupling 1 Apply the set screw No 1 screw of the main shaft motor side to the section between the two set screws of the main shaft and...

Page 12: ... time the second screws should be loosened first for the set screws and The first screws of the set screws and should be arranged so that they can come completely off the flat section of the oscillator shaft 3 Pull out the oscillator shaft in the direction of the arrow A 4 Remove the main shaft according to 1 Main shaft connection disconnection Then take out the crank rod unit 34 1 34 6mm Face B N...

Page 13: ...re that the first screw touches flatly on the oscillator shaft 5 Fix the large pendulum according to 6 Oscillator gear positioning 6 Mount the lengthwise feed motor and the crosswise feed motor mounting plate using the two set screws and four set screws Refer to 26 Adjusting the position of the X feed motor and the Y feed motor Adjusting the backlash of the driving gear Cautions 1 Try to turn the ...

Page 14: ...dition Axial direction Keep the close contact with the main shaft eccentric cam and the crank balancer A B 4 6mm 5 Lower shaft backlash adjustment and connection disconnection Standard Adjustment 1 Size of lower shaft backlash is 0 1mm at the tip of the driver The shaft is required to rotate smoothly 2 Define the stop position of the lower shaft so that the set screw settles almost in the center o...

Page 15: ...wo set screws 2 Turn the lower shaft rear metal in the direction of the arrow and adjust the backlash keeping the metal to contact closely with Face A Size of backlash is 0 1mm at the tip of the driver The shaft is required to rotate smoothly 3 Tighten the two set screws Caution When eliminate the backlash the direction of rotation should always be kept in the direction of the arrow 2 Lower shaft ...

Page 16: ...ndard Adjustment 6 Oscillator gear positioning Standard Adjustment 1 When the oscillator is lightly swung by a finger in the direction of the arrow the oscillator is fixed in the center position of swinging No 1 screw No 2 screw No 1 screw A ...

Page 17: ...acklash 2 The three set screws should have been loosened in advance In this case the second screw of the set screws should be loosened first Then the first one can be loosened 3 Lightly swing the whole body of the oscillator with a finger in the direction of the arrow Decide the positioning of the oscillator so that it stays in the center of swinging 4 Loosen the three set screws and then fix them...

Page 18: ...s Take them out of the oil tank 5 Release the cord clamp from the rear side of the bed of the oil drain pipe 6 Loosen the set screw and take out the driver 7 Loosen the set screw 8 Remove the set screw and pull out the shuttle race adjust shaft 9 Pull the shuttle in the direction of the arrow C and take it out 9 Adjusting the height of the needle bar Standard Adjustment C A B Upper engraved line A...

Page 19: ... needle thread clamp connector link 5 Bundle the needle thread clamp sensor cord the lubrication pipe and the oil drain pipe with the harness band 6 Pass the two oil drain pipes through the cord clamp and fix them with the set screw 7 Insert the two oil drain pipes part B in the oil tank Fix the oil tank to the frame with the set screw 8 Fix the oil drain pipe to the rear side by means of the cord...

Page 20: ... 16 10 Hook adjustment Standard Adjustment 0mm 0mm 7 5mm 0 05 0 1mm For DPX5 For DPX17 ...

Page 21: ...he needle to prevent the needle from being bent Then tighten setscrew of the driver 4 Loosen setscrew of the shuttle and adjust the longitudinal posi tion of the shuttle To do this adjustment turn shuttle race adjusting shaft clockwise or counterclockwise to provide a 0 05 to 0 1 mm clearance between needle and the blade point of inner hook 5 After adjusting the longitudinal position of the shuttl...

Page 22: ... and the motor shaft seem to be tightly coupled Pull out the motor shaft in the direction of the arrow straightforward in order not to hurt the bearing At that time the cam may come down Handle it with care not to damage it 12 Thread trimmer and presser foot origin sensor adjustment Standard Adjustment In the state of origin retrieval Start Switch ON in the test mode CP 6 the standard holes A and ...

Page 23: ...nt and make sensor adjustments Procedures of assembling 1 Start the test mode CP 6 2 Tread on the pedal for the retrieval of the thread trimmer and presser bar lifter cam origin 3 Using a bar or the like confirm that the standard holes A and B of the sewing machine frame coincide with the standard hole C of the thread trimmer and presser bar lifter cam 4 If the standard hole C of the thread trimme...

Page 24: ...sting the thread trimmer sensor Standard Adjustment Max 17mm After the completion of origin retrieval in the test mode CP 6 Start Switch ON try to press the key 6 to 8 times At that time the thread trimmer sensor is turned ON The digit display at the operation panel 10 00 B A C ...

Page 25: ...sensor adjustment 3 Press the key Confirm that the display of the operation panel is changed over from 10 00 when the key is pressed within the range of 6 to 8 times 4 If the display changeover occurs deviating from the range of 6 times to 8 times or if the display changeover does not occur at all loosen the set screw and make fine adjustments of the sensor slit in the directions of the arrow 5 Af...

Page 26: ... state the distance from the throat plate front end to the tip of the thread cutter lever small is 18 5mm 16 Adjusting the height of the moving knife and counter knife Standard Adjustment Moving knife The amount of mesh of the needle hole guide with the moving knife is 0 15mm Counter knife The height between the needle hole guide and the blade of the counter knife is 0 1 0 15mm A 18 5mm 0 5mm Movi...

Page 27: ...ght of the moving knife Adjustments should be based on the plate thickness of the washer in the above illustration If the height seems to be inadequate select and use the parts as specified below 2 Adjusting the height of the counter knife Adjust the height by prying Part A with a screwdriver or the like Adjustment Procedures Results of Improper Adjustment o If the step is too small 0 25 0 3mm bet...

Page 28: ...bbin thread uniformly the blade face of the counter knife is made to have an inclination of 0 2mm 18 Floating amount of the thread tension disk Standard Adjustment When the sewing machine power supply is turned off AT solenoid is OFF the gap between AT thread tension discs is 0 6 1mm C B 0 5mm 0 2mm 0 6 1mm Close contact 0 ...

Page 29: ... rotate and loosen the nut 4 Turn the tension releasing pin adjust collar and adjust the gap between the thread tension discs Adjustment of thread tension disc floating 5 Hold the tension releasing pin adjust collar and tighten the nut Mount the thread tension cap by means of the set screw 6 Turn on the power supply and set up the thread tension Confirm that the thread tension discs are closed Adj...

Page 30: ...2 Remove the two set screw 3 Move the AT link unit front downwards in the direction of the Arrow A and pull out the pin block from the hole of the thread tension releasing pin of the second thread tension 4 Pull out the second thread tension to remove it Arrow B 5 For reassembly follow the steps of 4 to 1 above C A B ...

Page 31: ...sion 2 When tightening the set screw this fixing action should be taken after the AT link unit front has been moved to the left side in the direction of the arrow C If it is not moved to the left side in the direction of the arrow C the amount of tension disc floating may fail to be adjusted normally 3 After reassembly follow the steps for the adjustment of thread tension disc floating and thread ...

Page 32: ... of the AT link unit rear Be careful not to drop the washer at that time Work becomes easier if the main shaft motor is removed 3 Lift the joint block of the AT unit upwards and take it off the pin block of the AT link unit rear 4 Draw out the AT link unit front from the plane side in the direction of the arrow E and remove it 5 Remove the two set screws and take out the AT solenoid unit 6 For rea...

Page 33: ...rear joints must also be secured without fail If the correct distance and parallelism are lost this can be a cause of AT malfunction and normal sewing tension cannot be obtained 3 Upon the completion of all reassembly work confirm that there is a close contact between the thrust collar and the AT solenoid unit If any clearance is perceived loosen the two set screws and assemble the AT solenoid uni...

Page 34: ...al origin Standard Adjustment 22 Adjusting the Y origin sensor Standard Adjustment A 147mm LK 1900A 1902A 146mm LK 1901A 1903A B 61mm LK 1900A 1902A 62mm LK 1901A 1903A C 74mm LK 1900A 1902A 73mm LK 1901A 1903A Work feed plate C A B ...

Page 35: ...sting the X origin sensor Adjustment Procedures Results of Improper Adjustment o The maximum area cannot be secured 1 Select the test mode No 2 CP 2 origin retrieval 2 Origin retrieval is conducted each time the pedal is trodden on Loosen the sensor slit set screw and shift the position of the sen sor slit plate Apply the work feed plate to the origin position Refer to 21 Position of the mechanica...

Page 36: ... 32 23 Adjusting the X origin sensor Standard Adjustment 24 Adjusting the wiper position Standard Adjustment Amm Above 1 5mm ...

Page 37: ...e attains 1 5mm or more Loosen 2 Loosen the screw to adjust Distance A between the wiper end plane and the needle center until this distance attains the values speci fied below After adjustments tighten the screw firmly Distance A between the needle center and the wiper end plane Amm Other thanLK 1903A 23mm to 25mm LK 1903A only 15mm to 17mm The needle stays in the position of the end of sewing an...

Page 38: ...t 26 Adjusting the position of the X feed motor and the Y feed motor Adjusting the back lash of the driving gear Standard Adjustment 1 Fix the Y feed motor by pressing it in the direction of the arrow C 2 Fix the X feed motor by pressing it in the direction of the arrow B ...

Page 39: ... position is inadequate the needle thread cannot be held correctly and this can be a cause of needle breakage Adjustment Procedures Results of Improper Adjustment 1 Loosen the two set screws and four set screws of the Y feed motor and the two set screws of the X feed motor mounting plate 2 Pressing it in the direction of the arrow C tighten the two upper set screws in the first place Then tighten ...

Page 40: ...ear cover Standard Adjustment The clearance between the feeder bar rear cover and the upper surface of the work feed presser bar is about 1mm When the feeder bar is moved in the direction of the arrow A there must be a clearance at the notch part of the sewing machine frame A 1mm Clearance Machine bed A ...

Page 41: ... feeder bar in the direction of the arrow A and confirm that there is a clearance at the notch part of the sewing machine frame If there is no clearance and there is interference with the sewing machine frame the steps of 1 2 above should be re peated again Caution 1 When tightening the set screws the feeder bar rear cover may be moved vertically Hold the feeder bar rear cover firmly while the set...

Page 42: ...ewing machine frame B A 10mm 30 Adjusting the bobbin winder amount Standard Adjustment The position of the bobbin winder lever is based on the standard that it is 14mm apart from the bobbin winder shaft Try to perform bobbin winding actually and make fine adjustments in the directions of the arrows A and B so that the amount of thread winding becomes adequate recommended value 80 90 of the bobbin ...

Page 43: ...e thread at the bobbin winder Confirm the amount of winding 1 If the amount of winding seems to be too much adjust the bobbin winder lever in the direction of the arrow A 2 If the amount of winding seems to be too less adjust the bobbin winder lever in the direction of the arrow B 3 If the winding state of the thread around the bobbin winder seems to be uneven loosen the nut and adjust the height ...

Page 44: ...n If Part B B B B B is damaged this is the cause of thread breakage hangnail of thread stain on thread etc Therefore this part should be polished by the use of a buff or the like In particu lar the rear side should be handled with care A B C B1815210000 32 Shuttle felt Standard Adjustment Two pieces of the shuttle felt are inserted in the holes of the shuttle race Confirm that the shuttle felts ar...

Page 45: ...ail to hook the needle thread o Too much motion to the rear side will cause the moving knife to fail to hook the needle thread o Too much motion to the left side will cause the moving knife to fail to hook the bobbin thread 1 If the shuttle felt seems to be protruded or it has been replaced with a new one push it in by means of tweezers or the like Caution Do not push it in excessively Align the h...

Page 46: ...ar seems to be too much around the pointed tip of the inner hook release the shuttle race ring and confirm that the dimensions of the hatched area on the rear side are 0 3 x 8mm 8m m Dimension A 0 3m m 34 Adjustment of the thread take up spring Standard Adjustment ...

Page 47: ...ead drawing amount will increase 2 Adjusting the pressure To change the pressure of the thread take up spring insert a thin screwdriver into the slot of thread tension post while screw is tightened and turn it Turning it clockwise will increase the pressure of the thread take up spring Turning it counterclockwise will de crease the pressure Adjustment Procedures Results of Improper Adjustment Thre...

Page 48: ...inge screw If the hinge screw cannot be seen from the open part of the needle thread clamp device try to move the needle thread clamp connector link by hand in the direction of A or B 2 Remove the four set screws of the needle thread clamp base and take out the needle thread clamp device Open part B A ...

Page 49: ...lete and the needle is 3 3 3 7mm and 1 7 2 3mm respectively 3 If the distance seems to be inadequate loosen the four set screws and move the needle thread clamp device for adjustment Caution For the prevention of injury the distance should be checked only if the sewing LED is unlit Press the key twice after the power supply has been turned on 4 After the completion of the above mentioned reassembl...

Page 50: ...hdrawn by 3 to 4 pulses from the needle thread clamp position Caution 1 the clearance A toward the needle thread clamp device becomes 0 Caution 1 The needle thread clamp position is known to be the one that is one step returned from the most advanced position when the key is pressed in the test mode CP 7 3 4mm 1 7 2 3mm C B A ...

Page 51: ...pulses repeat the steps 2 to 6 above until the clear ance A becomes 0 9 Tread on the pedal for needle thread clamp device origin retrieval and define the most advanced position by pressing the key once 10 Confirm that the distances between the needle thread clamp sup port plate complete and the needle are kept at 3 4mm and 1 7 2 3mm respectively 11 If the distance is found to be inadequate adjust ...

Page 52: ...ce begins to open the distance between the needle thread clamp device and the needle thread clamp base becomes 21mm 2 Needle thread clamp notch F position 1 When the needle thread clamp link complete is pushed in Direction C and Part B of the needle thread calmp support plate complete and the needle thread clamp device begins to open the distance between the needle thread clamp device and the need...

Page 53: ... the two set screws Adjustment Procedures Results of Improper Adjustment o If the distance between the needle thread clamp device and needle thread clamp base comes to leager than 21mm release timing turns so early that unthreading at the beginning of sewing is caused o If the distance between the needle thread clamp device and needle thread base comes to smaller than 21mm release tim ing turns so...

Page 54: ... 1 6 1 6 1 6 1 4 A 1 8 1 8 1 1 B ø2 8 ø3 5 ø3 5 ø3 5 C ø1 6 ø1 6 ø2 0 ø2 0 MAZ15801000 MAZ15501000 Part No 14149900 14149603 MAZ15601000 MAZ15701000 D2426284Y00 Feed plate MAZ15502000 8 5 MAZ15602000 10 MAZ15702000 12 5 Engraving Model name Option LK 1903A 305 Button type For shank buttons Max Sewing speed 1 500rpm ø8 ø20 ø1 5 or more Button configuration Configuration of shank Sewing pattern numb...

Page 55: ... Sape pcs X mm Y mm 1 34 6 6 18 44 6 2 35 8 8 19 45 8 3 10 10 20 10 3 4 0 4 12 12 21 12 5 36 6 6 22 16 6 37 8 8 23 46 6 7 10 10 24 10 0 3 4 8 12 12 25 12 9 38 6 6 26 47 6 6 10 39 8 8 3 4 3 4 27 10 10 3 4 3 4 11 10 10 28 48 6 6 12 40 6 6 29 10 10 13 41 8 8 30 49 5 5 5 14 10 10 31 8 8 8 3 0 2 5 15 42 6 6 32 50 5 5 5 16 43 8 8 33 8 8 8 17 10 10 Standard sewing lenghts X and Y given above are given as...

Page 56: ...that the test mode has become effective 2 The memory switch number can be modified with the and keys 3 Select a required number of memory switch by pressing the key then fix the number by pressing key to turn on the LED 4 Change the contents of the memory switch with the and keys 5 The factory shipment values can be recovered with the key 6 The contents of modification can be registered by pressin...

Page 57: ...it of 4 U Sewing speed for the first stitch 400 1500rpm 400 with needle thread clamp Setting possible in the unit of 100rpm U Sewing speed for the second stitch 400 3000rpm 900 with needle thread clamp Setting possible in the unit of 100rpm U Sewing speed for the third stitch 400 3000rpm 3000 with needle thread clamp Setting possible in the unit of 100rpm U Sewing speed for the 4th stitch 400 3000...

Page 58: ...o stop sewing machine 0 Disabled 0 operation with panel s reset key 1 Panel s reset key 2 External switch U Buzzer sound can be prohibited 0 No buzzer sound 2 1 Panel s operation sound 2 Panel s operation sound Error sound U No of stitches for needle thread 1 7 stitches 2 clamp release U Clamping timing of needle 10 0 0 Delayed in negative direction thread clamp 1 84 0 80 in the unit of 4 U Needle...

Page 59: ...n when work clamp foot LK 1901A this function is not LK1901A only comes down indicated 2 Operation at the time of start U Wiper operation method can be 0 Without wiper at the time of selected thread trimming on the way 1 With wiper at the time of 1 1Without return of the last wiper thread trimming on the way 2With return of the last wiper 1 When the setting No 37 1 of the 2 With wiper at the time ...

Page 60: ...abled 1 Head falling detector switch disabled U This function sets whether or not 0 Calling inoperative Setting dep Standard pattern Nos 1 to 64 the calling of the pattern data is 1 Calling operative ends on the can be individually set operative model used Standard operation panel S Initialization of model s specifications 0 LK1900ASS Setting Contents of the memory switches is executed 1 LK1900AHS...

Page 61: ...d operation moves to the selection of another test feature 5 Select the test program No by the use of the keys Test program No Test program Descriptions Input signal check The conditions of switches and sensor inputs are displayed at the LED XY motor origin sensor check Inching operation of the X Y motor operation of origin retrieval and the status of X Y origin sensors are displayed Continuous op...

Page 62: ... 58 2 Display output test After moving to the test mode the display output test is started At the intervals of one second the LEDs shown below are turn on ...

Page 63: ...eding dead point dead point position position 45 times standard 5 30 185 215 80 123 40 62 revolution 125 155 7 Main motor Phase Z 0 180 8 Temporary stop Head fall SW Thermal sensor Turn on DIPSW2 denotes a dipswitch on the MAIN board Pedal SW 1 8are lit up in the direction of 1to 8according to the amount of treading on Pedal position 128 x 8 64 x 7 32 x 6 16 x 5 8 x 4 4 x 3 2 x 2 1 x 1 3 Method of...

Page 64: ...uous operation After the completion of setting set up the pattern numbers etc in the same manner as that for ordinary operation After the completion of sewing origin retrieval of the X Y work clamp foot thread trimmer needle thread clamp motors is conducted if origin retrieval enabled has been set as per 2 above In this case automatic sewing operation is restarted after the lapse of the rest time ...

Page 65: ...hange the rpm number within the range of 400 3000rpm This setting is pos sible even when the machine is presently driven Using the key the rpm display can be changed over be tween preset rpm and actual rpm 5 CP 5 Output check Output check is carried out for the material drawing magnet of the LK1901A 1 Operation While the key is pressed the material drawing magnet ON output is generated When the ke...

Page 66: ...ng position 2 Work clamp foot lowering position lowering position during pedal operation 3 Thread trimmer position 4 Work clamp foot lowering position lowering position after thread trimming 5 Wipe out position Driving in reverse rotation is conducted when the key is pressed with the key kept pressed Caution This feature is available after the completion of ori gin retrieval of the work clamp foot...

Page 67: ...f the MAIN and SDC boards are displayed Each version comes in the type description of RR VV LL xx xx is used for the specifications of special order ing It is not displayed usually Example 01 01 01 01 01 02 01 02 01 1 Operation Display changeover is possible with the key in the order of RR VV LL xx for the MAIN board and RR VV LL xx for the SDC board According to the item selection LED RR VV LL xx...

Page 68: ...40V In the signal phase mode the power supply is connected to Pins 4 5 In the 3 phase mode the power supply is connected to Pins 4 5 6 7 Miscellaneous 1 Various printed wiring boards 1 FLT T board Single phase 100V 120V 3 phase 200V 240V Single phase 200V 240V Pulse generation is carried out for the purposes of power supply rectification noise reduction and the detection of a momentary interruptio...

Page 69: ...wer supply rectification noise reduction and the detection of a momentary interruption C 10 C 9 4 CN1 Power input Power switch CN3 Momentary interruption detection signal MAIN board CN2 Power output Main board Since single phase specifications are adopted the power supply is connected to Pins 4 5 ...

Page 70: ... the board For 85V source primary F5 4A Fuse fixed to the board For 33V source primary CN11 Power connector MAIN board 5V 12V 24V 33V 85V DIPSW 2 1 For writing off 2 2 For mode setting off 2 3 For mode setting off 2 4 For mode setting off DIPSW 1 1 For testing off 1 2 For testing off 1 3 For testing off 1 4 Penetration force off CN17 For power supply FLT board CN16 For Main shaft motor power Main ...

Page 71: ...al error in U V W 5 IPM error E901 Error output generation from IPM 6 Undervoltage E813 Source voltage 20 or more 7 Motor reverse rotation E733 Irregular motor revolutions 8 Overvoltage E811 Source voltage 20 or more 9 Power interruption Display disabled Power interruption of 40ms or more 10 Not used 11 85V power system error E903 SDC board fuse F1 blow off 12 33V power system error E904 SDC board...

Page 72: ...board CN34 For the panel CN38 For the INT board head U11 LK 1900 PROM 27C256 CN49 Temporary stop for OP CN45 Needle thread clamp PM yellow CN47 Material drawing MG LK 1901A CN46 For air for OP CN36 For BR35 CN31 Power SDC board 5V 12V 24V 33V 85V CN42 X feed PM white CN43 Y feed PM blue CN41 Foot pedal for OP CN44 Clamp PM red CN39 Active tension CN40 Pedal sensor ...

Page 73: ... switch No 241 corrected value of the active tension the number of stitches for grease up Memory switch No 245 etc are stored CN64 Presser bar lifter origin black CN65 Needle thread clamp origin Needle thread clamp operation yellow CN66 Thread trimmer operation red CN67 Fall switch red CN63 Y feed origin yellow CN62 X feed origin red Face F ...

Page 74: ... 70 7 PANEL board The PANEL board accommodates the display LEDs switches buzzer etc together with the control CPU Buzzer CPU IC socket mounted Switch 7 segment LED Face F Face R ...

Page 75: ...M is in higher pref erence Available ROM 27C256 EPROM JUKI part No HL008423000 3 Dipswitch setting 1 The penetration force is increased when 4 of Dipswitch SW1 is turned ON on the SDC board 2 If the penetration force is insufficient for thick materi als this switch should be turned ON 3 All other dipswitches should be turned OFF Caution Dipswitch changeover should be done af ter the power supply h...

Page 76: ...7 0 10 21 Straight line bartacking 18 0 10 28 Straight line bartacking 19 0 25 28 Straight line bartacking 20 0 25 36 Straight line bartacking 21 0 25 41 Straight line bartacking 22 0 35 44 Straight line bartacking 23 20 4 0 28 Lengthwise bartacking 24 20 4 0 36 Lengthwise bartacking 25 20 4 0 42 Lengthwise bartacking 26 20 4 0 56 Lengthwise bartacking 27 20 0 18 Lengthwise straight line bartackin...

Page 77: ...artacking Lengthwise bartacking Lengthwise linear bartacking Note 1 Sewing size shows the dimensions when the scale rate is 100 2 Refer to the work clamp type table indicated in the figure 8 3 in the separate sheet hereto 3 For No 22 process the work clamp foot blank for use 4 Use the patterns with marks for sewing denim 5 No 51 is for the machine used without thread clamp device other side This s...

Page 78: ...it goods bartacking Round bartacking No 41 42 43 44 45 46 47 48 49 50 Sewing size mm Length Cross wise wise 20 2 5 25 2 5 25 2 5 30 2 5 30 2 5 30 2 5 ø8 Stitch diagram Number of stitches 29 39 45 58 75 42 91 99 148 164 Lengthwise bartacking Radial bartacking Note 1 Patterns Nos 41 to 46 are arranged for the optional presser bar No 12 2 The origin is different by 5mm from that of the lengthwise bar...

Page 79: ...able at the rear face of the control box Then clamp two places with adhesive clamp In addition tighten with a screw the PK 57 ground cable as illustrated in the figure PK 57 change cable Part No M90135900A0 PK 57 Part No GPK570010B0 Adhesive clamp Part No E9607603000 3 Set the memory switches as follows Memory Switch No Set value 19 2 20 1 24 1 Ground cable ...

Page 80: ... presser blank Presser blank With knurl processed 14121701 For the stitich size right 30 x 20 With knurl processed 14121800 For the stitich size left 30 x 20 Needle hole guide A 1 6 B 2 6 With relief slit B2426280000 Standard type A 1 6 B 2 0 Without relief slit D2426282C00 F and M types A 2 3 B 4 0 Without relief slit 14109607 For heavy weight material A 2 7 B 3 7 Without relief slit D2426MMCK00 ...

Page 81: ... 77 A B SM8040302TP Name of parts Type Part No Remarks Finger guard 2 A 66 5 B 43 14135305 For lengthwise bartacking Finger guard 3 A 21 5 B 35 5 14120000 For specially ordered work clamp A B ...

Page 82: ... F H M Finger guard 13533104 Remarks Standard accessory Optional Optional Standard accessory for S standard for M knit goods type machine type machine head head 3 Table of the work clamp foot Install a finger guard suitable for each work clamp foot when replacing the work clamp foot No of the work clamp foot Spplied with F foun dation type machine head Dependsonthedes tination ...

Page 83: ...3561360 asm Work clamp foot 13548003 13554803 14116602 14116503 14116909 14116701 14137707 Without knurl Without knurl Without knurl Without knurl Feed plate Sewing specification S H S F F F F Finger guard 13548300 13533104 14135305 Remarks Optional Optional Optional Optional Optional 14137509 Right 14137608 Left Standard acces sory for H heavy weight material type machine head Standard acces sory...

Page 84: ...10 120V type can be changed over by changing the power source cable and changing over of the jumper Change over the jumper in accordance with the voltage used For the change of the connection of power source cable refer to the item Instruction manual 2 of Connecting the power source cord Caution When a wrong connection such as putting 200V type voltage at the time of setting 100V type or the like ...

Page 85: ...hium grease This type of grease is used in general sliding parts Maker name Brand name Esso Listan 2 Beacon 2 Shell Albania Nippon Oil Co Ltd Multinok 2 Epinok 2 Kyodo Oil Co Ltd Lisonix 2 Idemitsu Petrochemical Co Ltd Coronex 2 2Templex N2 Used for the feeding gear block 10g tube JUKI Part No 13525506 3Juki Grease A Used for high speed sliding parts and their peripheral parts 10g tube JUKI Part N...

Page 86: ... 82 Grease Grease Grease 4 Parts to which grease is applied 1 Presser bar lifter area 2 Wiper area Grease Grease Grease Grease Grease Grease Juki Grease A ...

Page 87: ... 83 Grease Grease 3 Thread tension area 4 Thread trimmer area Grease Juki Grease A Grease Grease Juki Grease A ...

Page 88: ... 84 Grease Grease Grease Templex N2 Grease Templex N2 Grease Grease Grease Grease Grease 5 Feed area ...

Page 89: ... 85 6 Needle bar and main shaft area 7 Lower shaft area Grease Juki Grease A Grease Juki Grease A Grease Juki Grease B Grease Juki Grease A Grease Juki Grease B Grease Juki Grease A ...

Page 90: ... 86 Grease Grease Grease Grease Grease 8 Needle thread clamp mechanism area ...

Page 91: ... 87 Grease Grease A Grease Grease Grease Grease 9 LK 1901A relations ...

Page 92: ... 88 10 LK 1903A relations Grease Grease ...

Page 93: ...specified below without fail After greas ing call the memory switch No 245 and set up 0 with the reset key Even after the display of Error Code No E220 this error code can be canceled by pressing the reset key and the machine can be used continuously Since then however this Error Code No E220 is displayed each time the power supply is turned on When the sewing machine is used further for the speci...

Page 94: ... reset switch Re start or return to origin after thread while the sewing machnine is running trimming by means of the reset switch For Refer to memory switch No 31 the details refer to the item Using the temporary stop function P 29 Notice for the grease Indicates that it is the time to replenish Replenish the grease to the specified part 9 Refer to Maintenance replacement time grease to the speci...

Page 95: ...e error Power source voltage is beyond the Check the power source voltage specified value Low voltage error Power source voltage is short Check the power source voltage Motor driver trouble Error from the motor driver is detected Turn OFF the power switch and turn ON the power switch again after some time Stepping motor power Power source of the stepping motor is not Turn OFF the power switch and ...

Page 96: ...wer switch and check whether panel and MAIN MAIN cannot be performed CN34 of MAIN circuit board is loose Communication error between Comminication between MAIN and SDC Turn OFF the power switch and check whether panel and SDC cannot be performed CN32 of MAIN circuit board or CN15 of SDC circuit board is disconnected or loose MAIN memory write in Memory write in of MAIN circuit board Turn OFF the p...

Page 97: ...arm and the motor base 1 B Backlash is too much in the Y feed Adjust backlash of Y feed pulse motor pulse motor and the motor base 3 2 Too much backlash in the Adjust backlash of the X feed gear X feed gear 3 3 Travelling torque in X direction 3 A The motor is pressed against Adjust backlash of the motor is excessive the X feed arm too strongly 3 B The feed plate or the work Tighten the set screw ...

Page 98: ...osition positioning 6 Malfunction of vertical movement 6 1 Looseness of thread trimmer Define the thread trimmer cam position and fix the cam of work clamp foot cam screw 6 2 Presser pulse motor malfun 2 A Defective the presser pulse Replace the presser pulse motor ction motor 2 B The presser pulse motor is Check the connector connections wrongly connected 6 3 Defective circuit board 3 A Circuit b...

Page 99: ...on is high Adjust the needle thread tension and the thread is excessively stretched 2 G Thread spreading section of Polish the thread spreading section of the moving the moving knife has scratches knife with buff or replace the knife 1 3 Length of bobbin thread re 3 A Level difference between the Adjust the height of the counter knife maining is not sufficient needle hole guide and the Otherwise w...

Page 100: ...ce between Adjust the clearance between needle and shuttle driver the shuttle driver and the needle 2 2 Inadequate clearance between Adjust the clearance between the needle and the the needle and the inner hook inner hook 2 3 Feed timing is defective 3 A Feed timing is slow in regard Change the feed timing by the use of the memory switch to the work pressure 2 4 Needle coming in contact Adjust the...

Page 101: ...polishing the blade point of the inner hook with Contact of the inner hook with oilstone polish it with polishing powder Properly adjust the needle the clearance between the needle and the inner hook 1 B Scratches on section B After polishing the blade point of the inner hook polish it Scratches occur when the with polishing powder needle is bent or broken 1 C Scratches on section C After polishin...

Page 102: ...buff or replace guide the needle hole guide 4 6 Finish of the needle hole is rough Replace the needle 4 7 Thread take up spring is 7 A Stroke of the thread take up Properly adjust the thread take up spring maladjusted spring is too large 7 B Thread take up spring tension Properly adjust the thread take up spring is too high 4 8 Rotation of the inner hook is 8 A Race face of the shuttle is Remove t...

Page 103: ...sitions of the presser origin sensor the moving knife is defective thread trimmer and the moving knife 5 8 Thread take up spring tension Adjust the thread take up spring is too low 6 Defective thread trimming 6 1 Sharpness of the knife is 1 A Worn out of the moving and Replace the moving and counter knives difective counter knives 1 B Engagement of the moving Properly adjust the heigh and position...

Page 104: ... the needle hole guide with a new one having hole guide is large a smaller hole diameter 7 Poorly tense stitches 7 1 Tension controller No 2 is 1 A Tension of the tension controller Properly adjust the tension of tension controller No 2 maladjusted No 2 is low 7 2 Tension controller No 2 is Adjust the thread tension releasing mechanism floating 7 3 Thread take up spring is Adjust thread take up sp...

Page 105: ... the thread path of each component with polishing powder 2 B Finish of the needle hole is defective Replace the needle 2 C Loop of the needle thread falls down Move the thread guide A to the left 8 3 Thread floating occurs at the 3 A Penetration registance of the Use a thinner needle Lower the number of needle to be used sewing start thread against the cloth is too small Needle thread clamp device...

Page 106: ...rease the sewing length to more than 10mm 10 Roll in malfunction of remaining 10 1 Protrusion of needle thread 1 A Material does not keep close Change the feed plate thread at underside material contact with the throat plate 1 B Stitch size is short Increase the sewing size to more than 10mm 1 C The needle thread is long Adjust the needle thread length to 32 36mm Trouble Cause 1 Cause 2 Check and ...

Page 107: ...tion between Check the connection between CN3 of the FLT interruption in the SDC board CN3 of the FLT board and board and CN13 of the SDC board Led 3 on SDC board CN13 of the SDC board Flashing 9 times 2 B No AC voltage is available When a sewing machine for 3 phase specifications is between Pins 4 5 of CN1 in used in a 1 phase system connect the power supply the FLT board to red and white of the ...

Page 108: ...e Servo Motor Circuit Diagram 1 B The detector circuit is out of order Replace the SDC board 7 Error E305 7 1 Irregular motor revolutions 1 A There are irregularities in the Check the presser bar and thread trimmer mechanisms Thread trimmer sensor error mechanism such as over and look for the section that is particularly overloaded loading etc or whether screws are loose 1 B Motor leads are broken...

Page 109: ... do not enter or out of order the SDC board In the case of encoder error LED3 on SDC board Flashing 3 times replace the motor as a whole See the Servo Motor Circuit Diagram 1 C There is internal disconnection Replace the SDC board in the SDC board 10 Error E731 10 1 Position signals U V W 1 A The encoder cord is broken Confirm whether each signal is delivered to CN14 Main shaft motor encoder error...

Page 110: ...put fan etc 5 times 1 B The main shaft motor is out Disconnect CN16 of the SDC board and check the of order resistance among pins See the Servo Motor Circuit Diagram 1 C The driver circuit is out of order Replace the SDC board 15 Error E903 15 1 No 85V power output of 1 A Fuse F1 of the SDC board is Check for the presence of short circuiting in the 85V Pulse motor source error the SDC board availa...

Page 111: ... sensor is broken or the connector block is disconnected 2 B The INT board connector is Check the connection of CN62 red of the INT board disconnected 2 C Sensor mounting position is Check and correct the sensor mounting position inadequate 19 Error E908 19 1 Irregular motor rotations 1 A There are irregularities in the Check the mechanism and look for the section that Y origin retrieval error mec...

Page 112: ...ng position inadequate 21 Error E913 21 1 Irregular motor rotations 1 A There are irregularities in Check the mechanism and look for the section that Needle thread clamp origin retrieval the mechanism such as is particularly overloaded or whether screws are error overloading etc loose 1 B Motor leads are broken Disconnect CN45 yellow of the MAIN board and The motor is out of order check the motor ...

Page 113: ...een 1 A The SDC MAIN cord con Check the connections in the SDC MAIN cord set MAIN SDC communication the MAIN and SDC boards nector is disconnected and check if any disconnection is present error CN15 of the SDC board and CN32 of the MAIN board LED3 on SDC board Flashing 15 times 1 B MAIN and SDC board setting All the dipswitches on the MAIN and SDC boards must is inadequate be OFF 1 C The MAIN or ...

Page 114: ... 111 12 Circuit diagrams 1 Block diagram A ...

Page 115: ... 112 2 Power supply circuit diagram A ...

Page 116: ... 113 3 Power supply circuit diagram B ...

Page 117: ... 114 4 Power supply circuit diagram C ...

Page 118: ... 115 5 Servo motor circuit diagram ...

Page 119: ... 116 6 Sensor pedal VR circuit diagram ...

Page 120: ... 117 7 MAIN PANEL board circuit diagram ...

Page 121: ... 118 8 Motor solenoid circuit diagram Thread trimmer Lifting the work clamp foot motor ...

Page 122: ...e Table stand mounting holes 8 drill Drawer stopper mounting position 1 position on rear side 9 drill x20 depth Counterbore depth 17 JUKI logotype 2x2 drill depth 10 rear side Power switch mounting holes 4x8 drill 17 drill 30 drill 51 depth Counterbore depth 16 28 drill Oil drain funnel mounting hole R2 all periphery 3x7 drill depth 6 Top of a table ...

Page 123: ...wer stopper mounting position 1 position on rear side 3x7 drill depth 6 JUKI logotype 17 drill 8 drill 28 drill 9 drill x20 depth Counterbore depth 17 2x2 drill depth 10 rear side Power switch mounting holes 4x8 drill R2 all periphery 30 drill 51 depth Counterbore depth 16 Top of a table 2 Table type for lateral Installation ...

Page 124: ...X J22967 Copyright 2003 JUKI CORPORATION All rights reserved throughout the world Please do not hesitate to contact our distributors or agents in your area for further information when necessary The description covered in this engineer s manual is subject to change for improvement of the commodity without notice 03 07 Printed in Japan E ...