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• Page 1
  ® Computer-controlled High Speed Bar Tacking Industrial Sewing Machine LK-1900A Series ENGINEER’S MANUAL 40014262 No.E357-00…
• Page 2
  PREFACE This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance of the machine. The Instruction Manual for these machines intended for the maintenance personnel and operators at an apparel factory contains operating instructions in detail. And this manual describes “Standard Adjustment”, Adjustment Pro- cedures”, “Results of Improper Adjustment”, and other important information which are not covered in the Instruction Manual.

• Page 3: Table Of Contents

  CONTENTS 1. Specifications ………………….1 2. Configuration ………………….2 (1) Names of main unit ……………………2 (2) Names and explanation of switches on the operation panel ……….3 3. Standard adjustment ………………..(1) Main shaft connection/disconnection ………………4 (2) Removal of the main shaft motor and coupling …………..6 (3) Crank connecting rod connection / disconnection ……………

• Page 4
  5. Memory switches ………………..52 (1) Memory switch start and change ………………52 (2) Table of memory switch functions ………………53 6. Test mode ………………….57 (1) Test mode start……………………57 (2) Display output test ……………………58 (3) Method of confirmation according to each test program No……….59 7.

• Page 5: Specifications

  17 Lubricating 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.

• Page 6: Configuration

  2. Configuration (1) Names of main unit Sewing machine head Work clamp foot Thread stand Operation panel Power switch Control box Pedal switch – 2 –…

• Page 7: Names And Explanation Of Switches On The Operation Panel

  (2) Names and explanation of switches on the operation panel “Ready” key Item selection LED This key changes over the setting state from the panel LEDs of the selected items light up. to the sewing state where the sewing machine actu- ally operates.

• Page 8: Standard Adjustment

  3. Standard adjustment (1) Main shaft connection/disconnection Procedures of disassembling Loosen the set screw of the main shaft counterbalance through the screwdriver hole A, then remove the taper screw Loosen the two set screws (through the screwdriver hole B), and also the two each of At that time, loosen the second set screw first.

• Page 9
  Procedures of assembling Insert the crank rod , balancer , hand pulley gear A , bobbin winder driver wheel , and the main shaft counterbalance in the main shaft in this order, and mount the assembly on the frame. Insert the taper screw in the taper hole of the main shaft, and tighten it.

• Page 10: Removal Of The Main Shaft Motor And Coupling

  (2) Removal of the main shaft motor and coupling Procedures of disassembling 1. Removal of the main shaft motor together with coupling Loosen the two set screws on the main shaft side of the coupling . Then, remove the four motor set screws 2.

• Page 11
  Procedures of assembling 1. Mounting of the main shaft motor together with the coupling 1) Tighten the four motor set screws . Then, tighten the two set screws on the main shaft side of the coupling 2) The cords of the main shaft motor should be positioned in the sidewise direction.

• Page 12: Crank Connecting Rod Connection / Disconnection

  (3) Crank connecting rod connection / disconnection Procedures of disassembling 1. Remove the two set screws and four set screws . Then take out the lengthwise feed motor and the crosswise feed motor mounting plate 2. Loosen the three set screws and the two set screws .

• Page 13
  Procedures of assembling Mount the main shaft according to [(1) Main shaft connection/ disconnection]. Assemble the crank rod unit Adjust the clearance to 34.1 ~ 34.6mm between the under-cam of the crank rod unit and Plane B (middle metal bearing mounting plane) of the frame. Fix the cam with the set screw (Tighten the first screw so that it touches flatly on the main shaft .

• Page 14: Crank Balancer Positioning

  (4) Crank balancer positioning Standard Adjustment [Rotating direction] When the needle bar lowers and the clearance between the needle bar connecting and the needle bar bushing, lower is 4.6mm, the two set screws of the crank balancer assume the horizontal condition. [Axial direction] Keep the close contact with the main shaft eccentric cam and the crank balancer…

• Page 15
  Adjustment Procedures Results of Improper Adjustment If the main shaft eccentric cam is not fixed, this adjustment should be o If the angle for fixing the crank carried out after defining its position and fixing it. balancer is inadequate, vibration of sewing machine 1.

• Page 16: Oscillator Gear Positioning

  (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. 2 screw No. 1 screw No. 1 screw (7) Adjustment of hook oil amount Standard Adjustment –…

• Page 17
  Results of Improper Adjustment Adjustment Procedures 1. Loosen the two set screws and increase the backlash of the lower o If the position for fixing the shaft gear oscillator is inadequate, this (Caution) 1. If the lower shaft gear has insufficient backlash, can also be a cause of the the oscillator does not swing correctly.

• Page 18: Large Hook Connection / Disconnection And Oil Wick Piping

  (8) Large hook connection / disconnection and oil wick piping Procedures of disassembling 1. Loosen the four set screws 2. Cut the harness bands 3. Remove the set screw and pull the oil tank in the direction of the arrow A. 4.

• Page 19
  Procedures of assembling 1. Pass the two lubrication pipes and the oil drain pipe through the frame, and mount the shuttle 2. Hold the lubrication pipe with the lubrication pipe holder plate and fix it with the set screw At that time, make sure not to let the lubrication pipe come in contact with the thread cutter connector rod.

• Page 20: Hook Adjustment

  (10) Hook adjustment Standard Adjustment For DPX17 For DPX5 0.05~0.1mm 7.5mm – 16 –…

• Page 21
  Adjustment Procedures Results of Improper Adjustment 1. Turn the handwheel by hand. When needle bar has gone up, adjust so that lower marker line engraved on the needle bar aligns with the bottom end of the needle bar bushing , lower. 2.

• Page 22: Thread Trimmer Cam Position Adjustment And Connection / Disconnection

  (11) Thread trimmer cam position adjustment and connection / disconnection Procedures of disassembling 1. Loosen the two set screws of the thread trimmer cam (cam hereafter) 2. Loosen the two set screws and remove the sensor slit 3. Remove the four set screws and take out the presser lifting motor in the direction of the arrow.

• Page 23
  Procedures of assembling 1. Apply a proper amount of grease (Juki Grease A) to the grooved cam block of the cam , the peripheral cam block, and the rollers of the presser bar lifter link and the thread trimmer link .

• Page 24: Adjusting The Lift Of The Work Clamp Foot

  (13) Adjusting the lift of the work clamp foot Standard Adjustment Max. 17mm (14) Adjusting the thread trimmer sensor Standard Adjustment After the completion of origin retrieval in the test mode CP-6 (Start Switch ON), try to press the + key 6 to 8 at the operation panel: [10] →…

• Page 25
  Results of Improper Adjustment Adjustment Procedures 1. With the machine in stop mode, remove six setscrews of the top cover, and take off top cover 2. Apply L-shaped wrench to socket bolt of clamp , and loosen the socket bolt. 3.

• Page 26: Adjustment Of The Moving Knife And Counter Knife Position

  (15) Adjustment of the moving knife and counter knife position Standard Adjustment Counter knife position : The clearance between the counter knife and the needle hole guide is 0.5mm. Moving knife position : Before thread trimmer operation (standby state), the distance from the throat plate front end to the tip of the thread cutter lever (small) is 18.5mm.

• Page 27
  If the clearance is more than 2. The throat plate is the appropriate item for the 0.5mm, the residual thread length LK-1900A Series (40006721). after thread cutting operation be- comes longer beneath the work. Adjustment Procedures Results of Improper Adjustment o If the step is too small (0.25 ~…

• Page 28: Inclination Of The Blade Point Of The Counter Knife

  (17) Inclination of the blade point of the counter knife Standard Adjustment To cut the two threads (needle thread and, bobbin thread) uniformly, the blade face of the counter knife made to have an inclination of 0.2mm. 0.2mm 0.5mm (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…

• Page 29
  Results of Improper Adjustment Adjustment Procedures 1. If the thread on Side cannot be cut, grind Side . If the thread on o When less than 0.2mm Side cannot be cut, grind Side Thread on Side cannot be cut. o When more than 0.2mm (Caution) When grinding the side, make the angle more acuter than Thread on Side cannot be cut.

• Page 30: Second Thread Tension Connection / Disconnection

  (19) Second thread tension connection / disconnection Procedures of disassembling /assembling 1. Loosen the set screw 2. Remove the two set screw 3. Move the AT link unit (front) downwards (in the direction of the Arrow ), and pull out the pin block from the hole of the thread tension releasing pin of the second thread tension 4.

• Page 31
  Cautions for disassembly and reassembly 1. When pulling out the second thread tension , confirm that the pin block of the AT link unit (front) been displaced from the hole of the thread tension releasing pin . If this action is taken forcedly with the pin block left connected, this can be a cause of breaking the second thread tension 2.

• Page 32: At Unit Connection / Disconnection

  (20) AT unit connection / disconnection Procedures of disassembling /assembling 1. Remove the set screw of the AT link unit (front) and take out the second thread tension . ((19) Refer to “Second thread tension connection / disconnection.”) 2. Draw out the cotter pin from the pin block of the AT link unit (rear) .

• Page 33
  Cautions for disassembly and reassembly 1. When incorporating the AT solenoid unit , the solenoid cable should be laid beside the AT solenoid. If this solenoid cable is positioned in the vicinity of the AT link unit (rear) , this will be a cause of AT solenoid malfunction.

• Page 34: Position Of The Mechanical Origin

  (21) Position of the mechanical origin 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 (22) Adjusting the Y origin sensor Standard Adjustment –…

• Page 35
  Results of Improper Adjustment Adjustment Procedures 1. The position of the mechanical origin is shown in the illustration at o The maximum area cannot be left. secured. 2. In the horizontal direction, the needle hole center <center of the horizontal feed fulcrum shaft >…

• Page 36: Adjusting The X Origin Sensor

  (23) Adjusting the X origin sensor Standard Adjustment (24) Adjusting the wiper position Standard Adjustment Above 1.5mm – 32 –…

• Page 37
  Results of Improper Adjustment Adjustment Procedures 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 .

• Page 38: Adjusting The Wiper Spring (Lk-1903A Only)

  (25) Adjusting the wiper spring (LK-1903A only) Standard Adjustment (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 2.

• Page 39
  Results of Improper Adjustment Adjustment Procedures After thread cutting, the wiper spring is used to hold the needle thread with the aid of the wiper . Adjust the wiper spring and fix it with the set screw so that the intensity of the spring force becomes 30g (some- what stronger than that of the bobbin thread that is protruded from the bobbin case).

• Page 40: Installing The Feed Plate Support Plate

  (27) Installing the feed plate support plate Standard Adjustment Machine bed (28) Installation of the feeder bar rear cover Standard Adjustment The clearance between the feeder bar rear cover and the upper surface of the work feed presser bar about 1mm. When the feeder bar is moved in the direction of the arrow , there must be a clearance at the notch part…

• Page 41
  Adjustment Procedures Results of Improper Adjustment 1. Loosen the Y feed arm set screw o The feeding load becomes too much and this can be a cause of ⇒. 2. Push the Y feed shaft in the direction of the arrow feed error.

• Page 42: Adjustment Of The Bobbin Winder Driving Wheel Position

  (29) Adjustment of the bobbin winder driving wheel position Standard Adjustment The distance is 10mm between the measuring plane of the bobbin winder driving wheel and the cover mounting plane of the sewing machine frame 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…

• Page 43
  Adjustment Procedures Results of Improper Adjustment 1. Adjust the position of the bobbin winder driving wheel and fix it o If the distance of 10mm is insufficient, rubber ring wear may with two set screws occur in the bobbin winder unit. In addition, the bearing life may be reduced in the bobbin winder unit.

• Page 44: Adjustment Of The Hook Upper Spring Position

  (31) Adjustment of the hook upper spring position Standard Adjustment For the right and left positions, the needle center is made to coincide with the center of the groove width . For the front and rear positions, the needle rear end is made to coincide with the corner part (Caution) If Part is damaged, this is the cause of thread breakage, hangnail of thread, stain on B B B B B…

• Page 45
  Adjustment Procedures Results of Improper Adjustment 1. Remove the work feed bar, feed plate, and the throat plate. Make o If there is a front and rear displacement or a right and left adjustments with the screw displacement, needle thread (Caution) The right and left positions can also change during (10) biting may occur into the hook.

• Page 46: Shape Of The Shuttle Race Ring

  (33) Shape of the shuttle race ring Standard Adjustment If wear seems to be too much around the pointed tip of the inner hook, release the shuttle race ring confirm that the dimensions of the hatched area on the rear side are 0.3 x 8mm. (34) Adjustment of the thread take-up spring Standard Adjustment –…

• Page 47
  Results of Improper Adjustment Adjustment Procedures 1. If the dimensions of 0.3 x 8mm are not secured, retouching is re- quired with the aid of an oil stone. Dimension A Part No. Name of part Remarks (mm) Conforming to Specifications F 14103253 Shuttle race ring A and M as standard…

• Page 48: Needle Thread Clamp Device Connection / Diconnection

  (35) Needle thread clamp device connection/disconnection Procedures of disassembling 1. Remove the hinge 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.

• Page 49
  Procedures of assembling and adjustment procedures 1. Push the needle thread clamp device in the direction of A and fix it with the four set screws . Tighten the hinge screw 2. Turn on the power supply and press the key twice so that the needle thread clamp support plate complete is positioned at the far advanced end.

• Page 50: Adjusting The Needle Thread Clamp Sensor

  (36) Adjusting the needle thread clamp sensor Standard Adjustment When the needle thread clamp support plate complete is withdrawn by 3 to 4 pulses from the needle thread clamp position (Caution) 1., the clearance A toward the needle thread clamp device becomes 0.

• Page 51
  Adjustment Procedures Results of Improper Adjustment 1. Start the test mode CP-7. o If there are too many pulses used until the clearance A becomes 0, 2. Tread on the pedal for needle thread clamp device origin retrieval. this can be a cause of unthreading 3.

• Page 52: Adjusting The Needle Thread Clamp Notch

  (37) Adjusting the needle thread clamp notch Standard Adjustment 1. Needle thread clamp notch R position 1) When the needle thread clamp link complete is pushed in Direction A and Part B of the needle thread clamp support plate complete and the needle thread clamp device begins to open, the distance between the needle thread clamp device…

• Page 53
  Results of Improper Adjustment Adjustment Procedures 1. Needle thread clamp notch R adjustment o If the distance between the needle thread clamp device 1) Loosen the two set screws needle thread clamp base 2) Push the needle thread clamp link complete in Direction A so that comes to leager than 21mm, the distance between the needle thread clamp device…

• Page 54: Sub-Class Information

  4. Sub-class information (1) Models classified by button sizes (LK-1903A) Model name LK-1903A-301 LK-1903A-302 Optional For small buttons For medium-sized Button size classification For Extra-small button For large buttons (accessories) buttons Outside diameter that can be adjusted (mm) ø8~ø9 ø9~ø10 ø10~ø15 ø10~ø20 ø10~ø20…

• Page 55: Table Of Standard Patterns (Lk-1903A)

  (2) Table of Standard Patterns (LK-1903A) The number of stitches and the standard sewing lengths X and Y are as specified in the table below. Pattern Stitch Sewing thread Standard length Standard length Pattern Stitch Sewing thread Standard length Standard length sape (pcs.) X (mm)

• Page 56: Memory Switches

  5. Memory switches The sewing machine operation can be changed by changing the setting of the memory switch. (1) Memory switch start and change 1. When the key is pressed in the state that the sewing LED is turn off, the user level setting mode is assumed for the memory switches. When the key is continuously pressed for 6 seconds, the service level setting mode is assumed for the memory switches.

• Page 57: Table Of Memory Switch Functions

  (2) Table of memory switch functions Some initial values for shipment may change according to models. The contents are divided into two categories of user level (U) and service level (S). State when Indication Level Functions Setting range Remarks delivered Max sewing speed 400~3000rpm 3000…

• Page 58
  State when Indication Level Functions Setting range Remarks delivered Standard pedal, clamp switch position 50~200 When the setting value is increased, the amount of pedal tread becomes larger. Standard pedal, 2-step stroke switch 50~200 When the setting value is increased, the position amount of pedal tread becomes larger.
• Page 59
  State when Indication Level Functions Setting range Remarks deivered State of work clamp foot when 0: Work clamp foot goes up. machine stopped by temporary 1: Work clamp foot goes up stop command can be selected. with work clamp foot switch. 2: Lift of work clamp foot is prohibited.
• Page 60
  State when Indication Level Functions Setting range Remarks delivered XY feed forward / back speed 100~4000pps (Setting possible in the unit of 10pps) When the power supply is turned on, 0: Normal oautomatic preparation is possible 1: Automatic preparation is without pressing the READY key.

• Page 61: Test Mode

  6. Test mode When the test mode is started, it is possible to carry out maintenance and inspection. (1) Test mode start 1. When the key is continuously pressed for 3 seconds in the state that the sewing LED is turn off, the buzzer sounds and test mode start can be selected, with the user level setting mode of the memory switch kept effective.

• Page 62: Display Output Test

  (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. – 58 –…

• Page 63: Method Of Confirmation According To Each Test Program No

  (3) Method of confirmation according to each test program No. 1) CP-1 (Input signal check) It is possible to check the input conditions of the respective operation panel keys, pedal switches, and various sensors. Input No. display When the keys are pressed simultaneously, the input number is updated by +1.

• Page 64
  2) CP-2 (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 dis- played. 1. Preparation At first, press the key to start origin retrieval for needle thread clamp and work clamp foot/thread trimmer motors.
• Page 65
  4) CP-4 (Main motor rpm check) Used to set up the sewing machine rpm. Only the main motor is driven at the preset rpm and the actually measured rpm number is displayed. 1. Preparation At first, press the key to start origin retrieval for needle thread clamp and work clamp foot/thread trimmer motors.
• Page 66
  6) CP-6 (work clamp foot/thread trimmer motor/origin sensor check) Inching operation of the work clamp foot/thread trimmer motors, operation of origin retrieval, and the status of origin and thread trimmer sensors are displayed. 1. Preparation In the first place, the key is pressed to carry out origin retrieval of needle thread clamp.
• Page 67
  CP-8 (Software version display) The software versions of 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.

• Page 68: Miscellaneous

  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, CN1 : Power input ← Power switch noise reduction, and the detection of a momentary interruption In the signal-phase mode, the power supply is connected to…

• Page 69
  2) FLT-S board Single-phase 200V~240V Pulse generation is carried out for the purposes of power supply rectification, noise reduction, and the detection of a momentary interruption CN1: Power input ← Power switch S i n c e s i n g l e — p h a s e s p e c i f i c a t i o n s a r e adopted, the power supply is connected to Pins 4-5.
• Page 70
  3) SDC board The power supply is generated and error check is carried out. Main shaft control is effected, receiving the com- mands from the MAIN board. F1: 5A Time lag fuse For +85V F2: 3.15A Time lag fuse F4: 4A For +33V Fuse fixed to the board…
• Page 71
  4) LED3 for SDC board error check No. of LED3 flashes Error description Display of operation panel Remarks Turn on Dimly turn on in ordinary state Main shaft motor lock E007 Failure in revolving for 2 seconds Error in phase Z E303 Failure in phase Z detection Error in phases A and B…
• Page 72
  5) MAIN board Overall controls are carried out, such as pulse motor driving for shafts, control of active tension, etc., memory switch control, etc. CN32: For the SDC board CN34: For the panel CN38: For the INT board (head) U11: LK-1900 PROM 27C256 CN49: Temporary stop (for OP)
• Page 73
  6) INT board The INT board repeats the head sensor signals and transfers the head model data to the MAIN board. CN64: Presser bar lifter origin (black) CN62: X feed origin (red) CN66: Thread trimmer operation (red) CN63: Y feed origin (yellow) CN67: Fall switch (red) CN65: Needle thread clamp origin Needle thread clamp operation…
• Page 74
  7) PANEL board The PANEL board accommodates the display LEDs, switches, buzzer, etc. together with the control CPU. Switch 7-segment LED Face F CPU: IC socket mounted Face R Buzzer – 70 –…

• Page 75: Lk1900 Data Rom

  ROM 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 SDC board 2.

• Page 76: Table Of Standard Pattern Specifications

  (4) Table of standard pattern specifications 1900A 1901A 1902A Lengthwise Crosswise Number of stitches Pattern S, F, H, W S, H 1 (51) Large size bartacking Large size bartacking Large size bartacking Large size bartacking Large size bartacking Large size bartacking Large size bartacking Large size bartacking Large size bartacking…

• Page 77: Table Of Standard Patterns

  (5) Table of standard patterns Num- Num- Sewing size Sewing size (Note) 2 (Note) 2 ber of (mm) ber of (mm) No. of work Stitch diagram No. of work Stitch diagram Length- Length- Cross- Cross- stitches stitches clamp foot clamp foot wise wise wise…

• Page 78
  Sewing size Sewing size (mm) (mm) Stitch diagram Number of stitches Stitch diagram Number of stitches Length- Cross- Length- Cross- wise wise wise wise 20 2.5 25 2.5 25 2.5 30 2.5 30 2.5 30 2.5 ø8 ø12 (Note) 1. Patterns Nos. 41 to 46 are arranged for the optional presser bar (No.

• Page 79: Optional Features

  8. Optional features (1) Connection of PK-57 1. Connect PK-57 change cable with CN41 of MAIN circuit board 2. Connect the cord of PK-57 with the PK-57 change cable 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.

• Page 80: Table Of Optional Parts

  (2) Table of optional parts Name of parts Type Part No. Remarks Feed plate blank Without knurl/Processed 14120109 For the stitich size 30 x 20 With knurl/Processed 14120307 For the stitich size 30 x 20 t=1.2 Without knurl/stainless steel 14120505 t=0.8 For the stitich size 30 x 20…

• Page 81
  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 SM8040302TP – 77 –…

• Page 82: Table Of The Work Clamp Foot

  (3) Table of the work clamp foot No. of the work clamp foot 13518659 (asm.) 13548557 (asm.) 13542964 (asm.) Work clamp foot 14116107 14116404 14116800 14116305 14116206 (Without knurl) (Without knurl) Feed plate Sewing specification * Finger guard 13533104 Remarks Standard accessory Optional Spplied with F (foun-…

• Page 83
  No. of the work clamp foot 14137509 (Right) 13548151 (asm.) 13542451 (asm.) 13571955 (asm.) 13561360 (asm.) 14137608 (Left) Work clamp foot 13548003 13554803 14116602 14116503 14116909 14116701 14137707 ( Without knurl) ( Without knurl) ( Without knurl) ( Without knurl) Feed plate Sewing specification * Finger guard…

• Page 84: Maintenance

  9. Maintenance (1) Replacing the fuse The machine uses the following three fuses: For pulse motor power supply protection 5A (time-lag fuse) For solenoid and pulse motor power supply pro- tection 3.15A (time-lag fuse) For control power supply protection 2A (fast-blow type fuse) ↔…

• Page 85: Greasing Parts

  10g tube JUKI Part No.: 40006323 Juki Grease B — Used, in particular, for the specific areas with highly loaded parts. Important: this grease must be replenished at the specified intervals of period, according to “(5) Grease-up procedures for the specified position.”…

• Page 86: Parts To Which Grease Is Applied

  (4) Parts to which grease is applied 1) Presser bar lifter area Grease Grease Grease Grease Grease (Juki Grease A) Grease 2) Wiper area Grease Grease Grease – 82 –…

• Page 87
  3) Thread tension area Grease Grease 4) Thread trimmer area Grease (Juki Grease A) Grease (Juki Grease A) Grease – 83 –…
• Page 88
  5) Feed area Grease Grease Grease Grease Grease Grease Grease Grease Grease (Templex N2) – 84 –…
• Page 89
  6) Needle bar and main shaft area Grease (Juki Grease A) Grease Grease (Juki Grease A) (Juki Grease B) 7) Lower shaft area Grease (Juki Grease A) Grease (Juki Grease B) Grease (Juki Grease A) – 85 –…
• Page 90
  Needle thread clamp mechanism area Grease Grease Grease Grease Grease – 86 –…
• Page 91
  9) LK-1901A relations Grease Grease Grease Grease Grease Grease – 87 –…
• Page 92
  10) LK-1903A relations Grease Grease – 88 –…

• Page 93: Grease-Up Procedures For The Specified Position

  E220 or No. E221 will be displayed again. 2. For the replenishment of grease to the parts specified below, use the attached Juki Grease B (Part No. 40013640). If any grease other than the specified item is replenished, this can be a cause of destruction of parts.

• Page 94: Table Of Errors

  10. Table of errors Indication Name of error Description of error Corrective measure Remarks Machine lock error The main shaft of the sewing machine Turn OFF the power switch and remove does not rotate due to some troubles. the cause of troubles. Pattern No.

• Page 95
  Indication Name of error Description of error Corrective measure Remarks Z phase detection error Detection of the upper dead point of the Turn OFF the power switch and check whether sewing machine cannot be performed. CN14 of SDC circuit board is disconnected or loose.
• Page 96
  Indication Name of error Description of error Corrective measure Remarks Y origin retrieval error Y origin sensor does not change. Turn OFF the power switch and check whether CN63 of INT circuit board or CN43 of MAIN circuit board is discoonected or loose. Work clamp foot origin Work clamp foot origin sensor does not Turn OFF the power switch and check whether…

• Page 97: Troubles And Corrective Measures

  11. Troubles and corrective measures (1) Troubles and corrective measures (Mechanical parts) Trouble Cause (1) Cause (2) Check and corrective measures 1. Wiper cannot spread a thread 1-1) Interference between wiper 1-A) Wiper mounting position is Adjust the wiper position. and needle inadequate.

• Page 98
  Trouble Cause (1) Cause (2) Check and corrective measures From the previous page 3-5) Inadequate adjustment of the Adjust the X sensor position correctly. X sensor position 3-6) Inadequate adjustment of the Adjust position of the Y slit plate correctly. Y slit plate 4.

• Page 99: Sewing Conditions

  (2) Troubles and corrective measures (Sewing conditions) Trouble Cause (1) Cause (2) Check and corrective measures 1. Thread comes off at the start of 1-1) Stitch skipping at the 1st Decrease the sewing speed at the start of sewing. sewing stitch 1-A) Penetration registance of the Use a thinner needle.

• Page 100
  Trouble Cause (1) Cause (2) Check and corrective measures From the previous page 1-4) Material to be sewn is not Remove the slack of the material to be sewn. properly stretched. 1-5) Unstable needle thread clamp 5-A) Thread tends to be extended Increase the needle thread clamp needle number to or sliding efficiency is worse.
• Page 101
  Trouble Cause (1) Cause (2) Check and corrective measures 3. Stitch Skipping 3-1) Too much clearance between Adjust the clearance between needle and inner hook. the needle and the inner hook. 3-2) Inadequate timing adjustment Adjust timing for the needle and the inner hook. for the needle and the inner hook.
• Page 102
  Trouble Cause (1) Cause (2) Check and corrective measures From the previous page From the previous page 2-E) Thread take-up spring tension Adjust the thread take-up spring. is too low. 2-F) Length of the remaining Properly adjust the tension controller No. 1. needle thread is too long.
• Page 103
  Trouble Cause (1) Cause (2) Check and corrective measures 5. Thread breakage at the time of 5-1) Thread release timing is 1-A) Floating amount of the thread Adjust the amount of thread tension No. 2 floating. thread trimming. defective. tension disk No. 2 is small. 5-2) Thread spreading section of the Paying attention to the blade section, polish with moving knife has scratches.
• Page 104
  Trouble Cause (1) Cause (2) Check and corrective measures From the previous page 6-3) Moving knife does not spread 3-A) Initial position of the moving Adjust the initial position of the moving knife. threads. knife is maladjusted. 3-B) Thread trimmer cam position Adjust the thread trimmer cam position.
• Page 105
  Trouble Cause (1) Cause (2) Check and corrective measures From the previous page 7-7) Shape of the feed plate is 7-A) Material to be sewn is stiff and Raise the material to be sewn by means of the feed defective. closely contacted with the throat plate.
• Page 106
  Trouble Cause (1) Cause (2) Check and corrective measures 9. Thread chips generated in the 9-1) Long needle thread at the 1-A) The thread trimmer is used Needle thread clamp device OFF shuttle beginning of stitches for cutting. Adjust the needle thread length to 32 ~ 36mm Increase the sewing length to more than 10mm.

• Page 107: Electrical Components

  (3) Troubles and corrective measures (Electrical components) (Refer to “Block diagram A”) Trouble Cause (1) Cause (2) Check and corrective measures 1. No display at the operation panel 1-1) No supply of DC power. 1-A) AC power is not supplied. Examine if a power supply is available at the power switch.

• Page 108
  Trouble Cause (1) Cause (2) Check and corrective measures 4. Error E030 4-1) Displacement of the up 1-A) The stop position is inadequate. Try to turn the main shaft by hand. Check if there is Needle bar up position position any particular heavy load.
• Page 109
  Trouble Cause (1) Cause (2) Check and corrective measures 8. Error E306 8-1) Irregular motor rotations 1-A) There are irregularities in Check the mechanism and look for the section that Needle thread clamp sensor error the mechanism, such as is particularly overloaded or whether screws are overloading, etc.
• Page 110
  Trouble Cause (1) Cause (2) Check and corrective measures 12. Error E811 12-1) Excessive AC input voltage 1-A) There are variations or Check the AC input power line. Overvoltage error (More than 280V) unusual rise in the AC input LED3 on SDC board: Flashing power line.
• Page 111
  Trouble Cause (1) Cause (2) Check and corrective measures 17. Error E905 17-1) Heat sink temperature of the 1-A) Failing in cooling. Check whether electric box cooling is effective. Thermal error in SDC board SDC board has exceeded 85°C. Look for clogging around air suction holes and check LED3 on SDC board: Flashing the fan, etc.
• Page 112
  Trouble Cause (1) Cause (2) Check and corrective measures 20. Error E910 20-1) Irregular motor rotations 1-A) There are irregularities in Check the mechanism and look for the section that Work clamp foot origin retrieval the mechanism, such as is particularly overloaded or whether screws are error overloading, etc.
• Page 113
  Trouble Cause (1) Cause (2) Check and corrective measures 22. Error E914 22-1)Main shaft motor failing in 1-A) There are irregularities in the Check the mechanism and look for the section that Feed error normal rotations mechanism, such as is particularly overloaded or whether screws are overloading, etc.

• Page 114: Circuit Diagrams

  12. Circuit diagrams (1) Block diagram A – 111 –…

• Page 115
  (2) Power supply circuit diagram A – 112 –…

• Page 116: Power Supply Circuit Diagram A

  (3) Power supply circuit diagram B – 113 –…

• Page 117: Power Supply Circuit Diagram B

  (4) Power supply circuit diagram C – 114 –…

• Page 118
  (5) Servo motor circuit diagram – 115 –…

• Page 119: Servo Motor Circuit Diagram

  (6) Sensor – pedal VR circuit diagram – 116 –…

• Page 120: Main • Panel Board Circuit Diagram

  (7) MAIN • PANEL board circuit diagram – 117 –…

• Page 121: Motor • Solenoid Circuit Diagram

  (8) Motor • solenoid circuit diagram Thread trimmer Lifting the work clamp foot motor – 118 –…

• Page 122: Table Drawings

  4×2 drill depth 10 rear side (Table stand mounting holes) 8 drill Drawer stopper mounting position (1 position on rear side) 9 drill x20 depth Counterbore depth 17 JUKI logotype 2×2 drill depth 10 rear side (Power switch mounting holes) 4×8 drill 17 drill…

• Page 123: Table Type For Lateral Installation

  4×2 drill depth 10 rear side (Table stand mounting holes) Oil drain funnel mounting hole Drawer stopper mounting position (1 position on rear side) 3×7 drill, depth 6 JUKI logotype 17 drill 8 drill 28 drill 9 drill x20 depth Counterbore depth 17…

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