Computer-controlled, Cycle Machine With Input Function ...suporte.silmaq.com.br/JUKI/Manuais JUKI/Engineer Manual...17 Lubricating oil JUKI NEW Defrix oil No. 2 (equivalent to ISO

40110357No.E400-00

ENGINEER’S MANUAL

Computer-controlled, Cycle MachineWith Input Function

AMS-224EN Series

®

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.

It is advisable to use the 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 section under which the most basic adjustment value

is described and on the latter section the “Results of Improper Adjustment” under which stitching errors and

troubles arising from mechanical failures and “How To Adjust” are described.

i

CONTENTS

1. Specifications .....................................................................................................................1

2. Configuration......................................................................................................................2(1) Names of main unit ..................................................................................................................................................... 2

(2) IP-420 operation panel ............................................................................................................................................... 3

3. Standard adjustment .........................................................................................................4(1) Adjustment of the installing height of the throat plate auxiliary cover .............................................................. 4

(2) Adjustment of the feed base auxiliary cover rail X ............................................................................................... 6

(3) Adjustment of the X movement top cover ............................................................................................................. 6

(4) Main shaft connection/disconnection .................................................................................................................... 8

(5) Removal of main shaft motor and coupling ........................................................................................................ 10

(6) Connection/disconnection of the hook driving shaft and backlash removing procedure ............................. 12

(7) Adjustment of main shaft belt tension ................................................................................................................. 14

(8) Adjustment of intermediate presser cam ............................................................................................................ 16

(9) Adjustment of intermediate presser bar .............................................................................................................. 16

(10) Intermediate presser variable connection /disconnection ................................................................................. 18

(11) Intermediate presser variable adjustments ......................................................................................................... 20

(12) Intermediate presser drive arm ............................................................................................................................. 22

(13) Oscillator gear positioning .................................................................................................................................... 24

(14) Adjustment of hook oil amount ............................................................................................................................ 24

(15) Shuttle connection / disconnection and oil wick piping .................................................................................... 26

(16) Adjusting the height of the needle bar ................................................................................................................. 28

(17) Hook adjustment .................................................................................................................................................... 30

(18) Thread trimmer presser lifter cam connection/disconnection .......................................................................... 32

(19) Thread trimmer and presser origin sensor adjustment ..................................................................................... 32

(20) Adjustment of the moving knife and counter knife position ............................................................................. 34

(21) Floating amount of the thread tension disk ........................................................................................................ 34

(22) Second thread tension connection / disconnection ........................................................................................... 36

(23) AT unit connection / disconnection ..................................................................................................................... 38

(24) Wiper adjustment ................................................................................................................................................... 40

(25) Backlash adjustment for the X motor .................................................................................................................. 42

(26) Backlash adjustment for the Y motor ................................................................................................................... 42

(27) Tension adjustment for the X timing belt ............................................................................................................. 44

(28) Tension adjustment for the Y timing belt ............................................................................................................. 46

(29) How to remove rattles from the Y drive shaft ...................................................................................................... 48

(30) Phase adjustment for the Y timing belt ................................................................................................................ 48

(31) Adjustment of the X-Y mechanism ....................................................................................................................... 50

(32) Pressure adjustment for the side plate bearing .................................................................................................. 52

(33) Initial length of the presser cylinder .................................................................................................................... 54

(34) Adjustment of the speed controller ...................................................................................................................... 56

(35) Adjustment of the pressure reducer .................................................................................................................... 58

(36) Making the origin setting gauge ........................................................................................................................... 60

(37) Adjusting the X origin sensor ............................................................................................................................... 60

(38) Adjusting the Y origin sensor ............................................................................................................................... 62

(39) Adjustment of the bobbin winder driving wheel position .................................................................................. 64

(40) Adjusting the bobbin winder amount ................................................................................................................... 64

(41) Adjustment of the shuttle upper spring and lower thread holder position ...................................................... 66

(42) Shuttle felt ............................................................................................................................................................... 66

(43) Shape of the inner hook presser .......................................................................................................................... 68

(44) Adjustment of thread take-up spring ................................................................................................................... 68

(45) Needle thread clamp device connection/disconnection .................................................................................... 70

(46) Adjusting the needle thread clamp notch ............................................................................................................ 72

(47) Adjusting the needle thread clamp sensor .......................................................................................................... 74

(48) Installation/removal of encoder ............................................................................................................................ 76

ii

4. Memory switch ..................................................................................................................78(1) Start and change .................................................................................................................................................... 78

(2) Function list ............................................................................................................................................................ 79

5. Supplemental remarks of each function number and explanation of each function ...........................................................................................96

(1) Feeding frame operational sequence setup ........................................................................................................ 96

(2) Fixed refuge position setup ................................................................................................................................ 100

(3) Bank function setup ............................................................................................................................................. 101

(4) Port I/O setup ........................................................................................................................................................ 104

(5) Simplified program setup .................................................................................................................................... 115

(6) Version display ..................................................................................................................................................... 128

(7) Keylock setup ....................................................................................................................................................... 129

(8) Customize function setting of key lock ............................................................................................................. 131

(9) Communication screens of the maintenance personnel level (Program rewrite) ......................................... 138

(10) Information screen at the maintenance personnel level .................................................................................. 142

(11) Test sewing function ........................................................................................................................................... 144

6. Test mode.......................................................................................................................147

7. Printed wiring board and dip switch ...........................................................................163(1) Various printed wiring boards ............................................................................................................................ 163

(2) Dipswitch setup .................................................................................................................................................... 171

8. Table of exchanging gauge parts according to sewing specifications andneedle size used............................................................................................................172

9. Option list ......................................................................................................................173(1) Method of pedal switch cable set connections ................................................................................................. 176

10. Maintenance ..................................................................................................................178(1) Replacing the fuse ............................................................................................................................................... 178

(2) Changing the voltage specification .................................................................................................................... 179

(3) Application of grease and locktight ................................................................................................................... 180

(4) Parts to which grease • Locktight is applied ..................................................................................................... 181

(5) Replenishing the designated places with grease ............................................................................................. 189

11. Error code list ................................................................................................................192

12. Message list ...................................................................................................................200

13. Troubles and corrective measures ..............................................................................205(1) Mechanical parts .................................................................................................................................................. 205

(2) Sewing conditions ............................................................................................................................................... 209

(3) Electrical components ......................................................................................................................................... 217

14. Circuit diagrams ............................................................................................................229(1) Block diagram ...................................................................................................................................................... 229

(2) Power supply circuit diagram A ......................................................................................................................... 230

(3) Power supply circuit diagram B ......................................................................................................................... 231

(4) Power supply circuit diagram C ......................................................................................................................... 232

(5) Servo motor circuit diagram ............................................................................................................................... 233

(6) Sensor-pedal circuit diagram .............................................................................................................................. 234

(7) MAIN•PANEL board circuit diagram ................................................................................................................... 235

(8) Motor•solenoid circuit diagram .......................................................................................................................... 236

(9) Air circuit diagram ............................................................................................................................................... 237

15. Drawing of the table ......................................................................................................238

iii

– 1 –

1. Specifications

(Caution) 1. Grease type, refer to 10.-(3) Application of grease and Locktight

No. Application

AMS-224EN-HS/AMS-224EN-GB

Sub-class 4530 6030

1 Sewing area X-Direction (right, left) 450mm; Y-Direction (forward, backward) 300mm X-Direction (right, left) 600mm; Y-Direction (forward, backward) 300mm

2 Max. sewing speed 2500sti/min (when sewing pitch is 3mm or less)

3 Stitch length 0.1 to 12.7mm (Min. resolution : 0.05mm)

4 Feed motion of feeding frame intermittent feed (2-shaft drive by stepping motor)

5 Needle bar stroke 41.2mm

6 Needle H type: DP x17#18 (135 x 17 Nm 110), G type: DP x 17#23 (135 x 17Nm260)

7 Method to lift feeding frame Air

8 Feeding frame shape Right and left united

9 Lift of feeding frame Standard 25mm, Max. 30mm

10 Intermediate presser stroke Standard 4mm (0 to 10mm)

11 Lift of intermediate presser 20mm

12 Standard 0 to 3.5mm (Max. 0 to 7.0mm)

13 Needle thread clamp device With

14 Needle thread tension Active tension (electronic thread tension control mechanism)

15 Hook 2-fold semi-rotary hook

16 Lubrication Frame: Grease, hook part and hook driving shaft box: Minute-quantity lubrication (tank type)

17 Lubricating oil JUKI NEW Defrix oil No. 2 (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)1.

• Machine : Max. 999 patterns (Max. 50,000 stitches/1pattern)/Approx. max. 500,000 stitches19 Memory of pattern data • External media : Max. 999 patterns (Max. 50,000 stitches/1pattern)/Approx. max.50million stitches

(CF and 256M)

20 Temporary stop facility Used to stop machine operation during a stitching cycle.

21 Enlarging/Reducing Allows a pattern to be enlarged or reduced on the X axis Y axis independently when sewing a pattern.function 1% to 400% times (0.1% steps)

22 Enlarging/Reducing Pattern enlargement / reduction can be done by increasing / decreasing either stitch length or the number of stitches.method (When the pattern button is selected, the function available is only the adjustment of stitch length.)

23 Sewing speed limitations 200 to 2,500 sti/min (Scale : 100 sti/min steps)

24 Pattern selector facility Pattern No. selection method

25 Up/Down method (0 to 9,999)

26 Bobbin thread counter Up/Down method (0 to 9,999)

27 Memory back-up In case of a power interruption, the pattern being used will automatically be stored in memory.

The needle position before sewing cycle can be set in the desired position.(This setting is also stored in the memory.)

29 Sewing machine moto Servo motor

W: 1,703mm L: 1,370mm H: 1,200mm W: 1,923mm L: 1,370mm H: 1,200mm(Excluding thread stand) (Excluding thread stand)

31 Weight (gross weight) 401kg 410kg

32 Power consumption 550VA

33 Working temperature/humidity Temperature: 5°C to 35°C, Humidity: 35 to 85% (no condensation)

1-phase 100V to 120V, 3-phase 200V to 240V, 1-phase 200V to 240VRating ±10%, 50/60Hz

35 Air pressure used Standard: 0.5 to 0.55MPa, Max. 0.55MPa

36 Air consumption 1.8dm3/min (ANR)

37 Needle highest position stop facility After the completion if sewing, the needle can be brought up to its highest position.

Model name

Item

34 Supply voltage/frequency

Pattern selector facility(Sewing counter)

28 2nd origin setting facility

30 External dimensions

Intermediate presserDOWN position variable

– 2 –

2. Configuration(1) Names of main unit

Machine head

Wiper switch

Temporary stop switch

Feeding frame

Intermediate presser

Thread stand

Operation panel (IP-420F)

Power switch (Also used as an emergency stop switch)

Control box

Foot pedal

Air regulator

– 3 –

(2) IP-420 operation panel

(Front view) (Right side view)

Touch panel • LCD display section

READY key → Changeover of the data input screen and the sewing screen can beperformed.

INFORMATION key → Changeover of the data input screen and the information screen canbe performed.

COMMUNICATION key → Changeover of the data input screen and the communication screencan be performed.

MODE key → Changeover of the data input screen and the mode changeover screenwhich performs various detail settings can be performed.

Contrast control

Brightness control

CompactFlash (TM) eject button

CompactFlash (TM) slot

Cover detection switch (Not used for IP-420)

Connector for external switch

Connector for control-box connection

– 4 –

Standard Adjustment

3. Standard adjustment

(1) Adjustment of the installing height of the throat plate auxiliary cover

3.7 to

3.9m

m

!13

3

3

2

2

Within 0.3mm

3

2

1

!0

8

3

2

!2

!3

45

3

6

7

45

7 79 9 9

– 5 –

Adjustment Procedures

1. Move the cloth feed base to the rear and place throat plate auxiliary cover (asm.) 3 from between lower plate 1 and throat plate 2.

At this time, be careful not to bend lower plate 1.2. Temporarilyfixthroatplateauxiliarycover(asm.)3 with

throat plate auxiliary cover support setscrews 5 and washers 4.

3. Temporarilyfixthroatplateauxiliarycoversupport6 to the machine bed with setscrews (M6) 7.

4. Fix throat plate auxiliary cover (asm.) 3 on the machine bed with two counter-sunk screws 8.

5. Insert spacer !3 between cloth feed base cover !0 and throat plate auxiliary cover (asm.) 3andfixitwithsetscrew!2.

6. Move the cloth feed base to the left front, move up and down throat plate auxiliary cover (asm.) 3 so that a distance of 3.7 to 3.9 mm is provided between the bottom surface of lower plate installing base !1 and the top surface of throat plate auxiliary cover (asm.) 3,andfixsetscrews7.

7. Move the cloth feed base to the right front of the center front and perform the same work.

8. At this time, check to be sure that throat plate auxiliary cover (asm.) 3 is located higher than throat plate 2 and the differ-ence in height between them is 0.3 mm or less.

9. Fix throat plate auxiliary cover setscrew 5.10. Referring to the caution below, perform positioning of the

throat plate auxiliary cover (asm.) 3. When the positioning is not performed enough, perform the positioning after loosening once throat plate auxiliary cover setscrew 5 and throat plate auxiliary cover base setscrews 9.

Results of Improper Adjustment

○ The lower plate 1 is caught by the stepped section of throat plate 2 and throat plate auxiliary cover (asm.) 3.

Such an awkward condition results in shape deformation.

○ A bend is caused in the lower plate 1.

○ A problem of contact is caused with lower plate mounting plate !1 and throat plate auxiliary cover (asm.) 3.

– 6 –

(2) Adjustment of the feed base auxiliary cover rail X

(3) Adjustment of the X movement top cover

11

Standard Adjustment

1

2

1

4

3

3

4

X

2

Standard Adjustment

1

1

7

2 5 6

32

4AB

– 7 –


○ If the clearance is smaller thanthespecifiedvalue,Xmovement top cover asm. 3 and X movement bottom cover 4 can break or de-velop moving torque, causing stitch shape deformation.

○ If the clearance is larger than thespecifiedvalue,noisewillbe produced.

○ If the clearance is smaller thanthespecifiedvalue,Xmovement top cover asm. 3 and X movement bottom cover 4 can break or de-velop moving torque, causing stitch shape deformation.

○ If the clearance is larger than thespecifiedvalue,noisewillbe produced.


45301. Loosen 32 setscrews 1.2. Tighten setscrews 1 (16 pcs.) with feed base auxiliary cover

rail X 2 locating this side of the operator pressed in the direc-tion of the arrow.

3. Position feed base auxiliary cover rail X 2 locating far side of the operator at the location where both X movement top cover asm. 3 and X movement bottom cover 4 respectively have a clearance of 1.5 to 2 mm in which they can move in the longi-tudinaldirection.Then,fixtherailwithsetscrews1 (16 pcs.).

60301. Loosen 40 setscrews 1.2. Tighten setscrews 1 (20 pcs) with feed base auxiliary cover

rail X 2 locating this side of the operator pressed in the direc-tion of the arrow.

3. Position feed base auxiliary cover rail X 2 locating far side of the operator at the location where 1.5 to 2 mm movable clear-ance is provided between X movement top cover asm 3 and X movement bottom cover asm 4andfixitwithsetscrews1 (20 pcs.).

Adjustment Procedures Results of Improper Adjustment

○ If there is any rattling, this can be a cause of noise.

○ If the rattling condition is removed extremely, this can be a cause of abrasion devel-oped in the X movement top cover 3.

1. Loosen 8 setscrews 1.2. Press feed base auxiliary cover rail Y 2 in direction A and X

movement top cover 3 in direction B to sandwich guide rail nail 4 between them to eliminate the play.

On this occasion, tentatively tighten setscrews 1 (8 pcs.) to move X movement base 7 backward and forward so as to eliminate a play uniformly.

3. Securely tighten setscrews 1(8pcs.)tofixtheXmovementbase.

4. Fix auxiliary cover holder 5 with setscrews 6 (4 pcs.) with pressed against the machined surface of the X movement base.

– 8 –

Procedures of disassembling

(4) Main shaft connection/disconnection

1. Loosen the setscrew 2 securing the main shaft counterbalance 1, and remove the taper screw 3.2. Loosen 2 setscrews 4 (through the screwdriver hole A), 2 setscrews 5, and 2 setscrews 6. On this occasion, loosen No. 2 setscrew first, and completely remove No. 1 setscrew from the flat

part of the main shaft 7.3. Remove the main shaft motor 8. Refer to “3.-(5) Removal of the main shaft motor and coupling”.4. Loosen setscrews !0 (4 pcs.) in main shaft sprocket !1.5. Loosen 2 setscrews !2.6. Loosen setscrews !4 (2 pcs.) and two setscrews !5.7. Loosen Idler adjustment screw !3.8. Pull out the main shaft 7 in the direction of Arrow C.

3

Main shaft taper hole

127

!3

!6

Timing belt

Machined surface of bed

Chamfered part of the hook driving shaft

1 4

Screwdriver hole A

No. 1 setscrew

@2!2

!5 !7

@0

7

!4

!4!8

@1

!2!54

No. 2 setscrew

89

Engraved point on the main shaft

6

6

!9

5

5

!0

No. 2 setscrew

No. 1 setscrew

!1

F

E

C

Machined surface of arm

D

– 9 –

Procedures of assembling

1. Mount main shaft 7 in the frame, while fitting main shaft sprocket !1, bobbin winder driving wheel !8, hand pulley gear A !7, intermediate presser eccentric cam @2 and counterbalance 1 on the main shaft in the written order.

2. Tighten the taper screw 3 into the taper hole of the main shaft 7, and tighten the setscrew 2 to se-cure the main shaft counterbalance 1.

3. Lightly press the main shaft counterbalance 1 in the direction of Arrow D and the middle metal !9 in the direction of Arrow E, and tighten 2 setscrews 5.

(Tighten No. 1 setscrew so that it touches the flat part of the main shaft 7. Then, tighten No. 2 set-screw. Same procedure hereafter)

4. Tighten 2 setscrews 4 and 2 setscrews 6. (Make sure that No. 1 setscrew touches the flat part of the main shaft 7.)

5. Mount the main shaft motor 8 and coupling 9. Refer to “3.-(5) Removal of main shaft motor and coupling”.6. Secure the eccentric cam of the intermediate presser @2 with 2 setscrews !2. Refer to “3.-(8) Adjust-

ment of intermediate presser cam”.7. Press the hand pulley @1 in the direction of Arrow F to engage the hand pulley gear A !7 with the

hand pulley gear B @0, and secure them with 2 setscrews !5.8. Secure the bobbin winding drive wheel !8 with 2 setscrews !4. Refer to “3.-(39) Adjustment of the

bobbin winder driving wheel position”.9. Insert main/hook-driving shafts phase matching shaft !6 through the hole in the side-face machined

surface of the bed from the chamfered side of the hook driving shaft.10. Turn main shaft 7 until the position where the center of the engraved point (upper dead point of the

needle bar) on the main shaft is aligned with the machined end face of the arm is reached. Then, secure the main shaft with setscrew !0.

* Make sure that no torque is applied by rotating the main shaft 7.

(Caution) If the center of the engraved point on the main shaft is not aligned with the machined end face of the arm, needle breakage or stitching failure can occur.

– 10 –


(5) Removal of main shaft motor and coupling

1. For removal of the main shaft motor with the coupling, Loosen 2 setscrews 5 on the main shaft side of the coupling 2, and remove 4 setscrews 4 secur-

ing the motor.2. For removal of the coupling 2 from the main shaft motor 3, loosen 2 setscrews 6 on the main

shaft motor side.

(Caution) The screw (hole) that can be seen first is No. 1 setscrew 6 when the main shaft 1 is turned in the forward direction A. For loosening, loosen No. 2 setscrew first, and for tightening, tighten No. 1 setscrew 6 first.

3

6 No. 1 setscrew

0.7mm

21

8

A

4

3

7

5 No. 2 setscrew

5 No. 1 setscrew

– 11 –


1. For mounting the main shaft motor with the coupling,(1) Tighten 4 setscrews 4 that securing the motor, and tighten 2 setscrews 5 on the main shaft side of

the coupling 2.(2) The cords 7 of the main shaft motor 3 should be positioned in the lateral direction.

2. For connecting the coupling to the main shaft motor,(1) Provide a clearance of 0.7 mm between the coupling 2 and main shaft motor 3.(2) Apply No. 1 setscrew 5 of the coupling 2 to the flat section 8 of the main shaft motor 3, the main

shaft 1 and secure it.

3. For engaging the coupling,(1) Position the setscrew 6 (No. 1 setscrew) on the main shaft motor side between 2 setscrews 5 on

the main shaft side, and engage the coupling.

– 12 –

Procedures of disassembling / assembling

(6) Connection/disconnection of the hook driving shaft and backlash removing procedure

1

!2

Timing belt

Machined surface of bed

!1

!0

Engraved point on the main shaft

!3

!6

3

Flush

!5

6

5

4

2

B A

C

Timing belt

7

!7 8 !4

9!8

Hook driving shaft gear Oscillator gear

B

Chamfered part of the hook driving shaft

– 13 –

Procedures of disassembling / assembling

Removing the hook driving shaft1. Loosen idler adjusting screws 1 (2 pcs.).2. Loosen gear box setscrews !3 (4 pcs.).3. Remove cover setscrews 2 (6 pcs.) to open the cover.4. Loosen setscrews, 3, 4, 5, 6, 7, 8 and 9. Pull out the hook driving shaft in the direction of ar-

row A.

Assembling the hook driving shaft1. Fit all parts (!5 and !6) on the hook driving shaft. Insert the hook driving shaft in the direction of the

arrow C until its top face becomes flush with the end face of the bushing. 2. Align No. 1 screws of 3, 4, 5, 7 and 9 with the flat face of the hook driving shaft and tighten

them. Then, tighten No. 2 screws.3. Slide the gear box in the direction of the arrow B to obtain a backlash between the hook driving shaft

gear and oscillator gear. Then, tighten gear box setscrews !3 (4 pcs.).4. Orienting the chamfered rear-end face of the hook driving shaft toward the machined hole in the side

face of the bed, insert main/hook-driving shafts phase matching shaft !2 into the hook driving shaft.5. Loosen main-shaft sprocket setscrews !0 (4 pcs.). Turn main shaft !1 until the center of the en-

graved point on the main shaft is aligned with the machined end face of the arm (the upper dead point of the needle bar is reached when the center of the engraved point on the main shaft is aligned with the machined end face of the arm). Then, tighten setscrews 8, !4 and !0.

At this time, press hook driving shaft sprocket !8 against hook driving shaft intermediate bushing !7 to reduce the thrust play to zero.

(Caution) 1. When the end face of the bushing and end face of the hook driving shaft are not flush, main/hook-driving shaft phase matching shaft !2 cannot be inserted into the hook driving shaft.

2. When the gear box is not positioned horizontally with respect to the hook driving shaft gear, the gears will come in single-sided contact with each other, causing abrasion, break and torque.

3. When the engraved line is not aligned with the machine end face of the arm, stitching failures can occur.

4. When the aforementioned backlash is too large or too small, wear on or break-age of the gear, the main motor seizure or inconsistent stitching can be caused.

– 14 –

(7) Adjustment of main shaft belt tension

Standard Adjustment

Timing belt

1

2

2

5

6 A

B

Bearing section

C

Measuring tool

D

34

Bearing section

– 15 –


1. Shift idler linkage 1totherightandfixitbyfullytighteningfoursetscrews 2.

(Tightening torque: 4.5 to 5.5 Nm)2. Atthistime,fitthebearingsectionofidlerlinkage1 into outside

of the timing belt.3. Put spring 3 on spring peg 4 to tense the timing belt.4. Set the belt tension by sliding idler adjusting screws 5 and 6

in A (to increase) or B (to decrease). 5. Insert a measuring tool through hole C and bring it to the

measuring point (center of the main shaft timing belt). Tap the arrowed part D and measure the belt tension.

Belt tension gauge U-507 (UNITTA) Tension for assembly : 175 ± 30 N Unit mass : M = 4.0 g/m (length) x mm (width) Belt width : W = 25.0 mm Span length : S = 260.0 mm6. Fully tighten idler adjusting screw 5. (Tightening toque: 4.5 to 5.5

Nm)7. Fully tighten idler adjusting screw 6. (Tightening toque: 4.5 to 5.5

Nm)8. Afterfinaltighteningtheadjustingscrews,re-checkthebeltten-

sion.

– 16 –

Standard Adjustment

(8) Adjustment of intermediate presser cam

Standard Adjustment

(9) Adjustment of intermediate presser bar

3

2

1 1

2

3

Align

Align

13.5

mm

1

2

3

– 17 –

1. Adjust the thrusting distance of the intermediate presser bar 1 to 13.5 mm, and tighten the setscrew 2 after ensuring that the needle passes through the center of the intermediate pressure.

(Caution) Be aware that the tightening pressure of the set-screw 2 should be from 2.16 to 2.75 N•m (22 to 28 kgf•cm).


○ An excessive thrusting distance of the intermediate presser bar 1 may dam-age the intermediate presser spring or cause poor presser lifting.

○ Excessive tightening pressure may deform the intermediate pressure bar 1 or intermedi-ate presser bar connecting 3 resulting in malfunction.

1. Align the edge of the intermediate presser cam 1 with the center of the engraved point on the main shaft 2, align the engraved line on the intermediate presser cam 1 with the engraved point on the main shaft 2, and tighten the setscrew 3.


○ Stitch skipping and poor tense stitch may occur.

– 18 –


(10) Intermediate presser variable connection/disconnection

1. Remove the presser adjusting screw 1. Then, remove the intermediate presser spring 2 and the guide shaft.2. Remove the intermediate presser auxiliary spring 3.3. Remove the stepscrews 4 and 6.4. Remove the stepscrew 7.5. Remove the stepscrew 8, and then the intermediate presser variable plate 9 and the variable plate

spacer !0.6. Remove the stepscrew !1, and then the intermediate presser variable link !2. (At that time, insert a hexagonal wrench through the arm screw hole A and apply it to the setscrew

!3 as a means of turn stop for the intermediate presser variable arm @3.)7. Loosen 2 each of the setscrews !4, !5, and !6. At that time, the second screw should be loosened first. The first screw of the setscrew should be

removed, completely separate from the flat part of the intermediate presser variable shaft @2.8. After the intermediate presser variable arm @3 and the intermediate presser variable shaft @2 have

been pulled out in the direction of the Arrow B, loosen the setscrew !3 and pull out the intermediate presser variable shaft @2 from the intermediate presser variable arm @3.

At that time, both of the setscrews !3 should be separated completely from the flat parts (2 posi-tions) of the intermediate presser variable shaft @2.

9. Loosen the 2 setscrews !8 and remove the trailing gear @4, he intermediate presser motor installing base @5, and the intermediate presser motor @6.

10. Loosen 2 each of the setscrews !9, @0, @1 and @7. At that time, the second screws of the setscrews !9 and @0 should be loosened first. The first screw of the set-

screw should be removed, completely separate from the flat part of the intermediate presser lifting shaft @8.11. Remove the E ring @9 and pull out the intermediate presser lifting shaft @8 in the direction of the Ar-

row C.

@2

@3

#0

#4

@3 @2 #3#1!4 !5 #0#4 @2 !6 @4!8@5

@6

!8!9

#6

#7@8

@1@9

@0

@7#5

!7

BE

0.5m

m

D

G

HC

229.5mm

Fig J Right above

45°

4.4mm

#2

1

3

6

4

2

!2

!1

!3

A

!3 89

7!0

27.0

mm

5

– 19 –

1. Fix the intermediate presser variable shaft @2 to the intermediate presser variable arm @3 by means of the 2 setscrews !3 so that the length of the shaft section becomes 229.5mm.

(Both setscrews !3 should be adjusted level to the intermediate presser variable shaft @2.)2. Insert the washer #3, thrust bearing #2, thrust collar #1, and the drive bevel gear #0 in the intermedi-

ate presser variable shaft @2 in this order, and mount this assembly on the frame.3. Pressing the intermediate presser variable arm @3 in the direction of the Arrow E, secure a proper

thrust by pressing the thrust collar #1 in the direction of the Arrow D and tighten the two setscrews !4. (Tighten the first screw first so that it is fixed level to the intermediate presser variable shaft @2. Then, tighten the second screw. To be done in the same manner hereafter.)

(Caution) If there is rattle in the variable shaft @2 of the intermediate presser in the forward and backward directions, this can be a cause of intermediate presser step-out. Be careful when you try to fix the thrust collar #1.

4. Adjust the distance to 4.4mm between the thrust collar #1 and the drive bevel gear #0. Tighten the first screw of the setscrew !5 and fasten the trailing bevel gear @4 with the setscrew !6.

(Tightened till the completion of intermediate presser sensor adjustment)5. When the intermediate presser motor @6 is fixed to the intermediate presser motor installing base

@5, tentatively fix it to the frame with 2 setscrews !8. Turn the trailing bevel gear @4 and adjust the intermediate presser motor asm. to the position where the amount of backlash becomes zero. Since then, tighten 2 setscrews !8.

6. Insert the sensor slit 5, intermediate presser lifting cam #7, thrust collar #6, and the wave washer #5 in the intermediate presser lifting shaft @8 in this order, and pass this assembly through the frame. Mount the E ring @9 on the intermediate presser lifting shaft @8.

7. Pressing the intermediate presser lifting shaft @8 in the direction of the Arrow C, press the thrust col-lar #6 in the direction of the Arrow G and tighten the two setscrews @7.

8. Fix the intermediate presser lifting cam #7 by means of the 2 setscrews @0 so that the clearance be-comes 0.5mm between both end planes of the intermediate presser lifting cam #0 and the intermedi-ate presser lifting link !7.

9. Turn the intermediate presser variable shaft @2 and the intermediate presser lifting shaft @8 so that the trailing bevel gear #4 and the drive bevel gear #0 are positioned as shown in Fig. J. Since then, fix them by means of the 2 setscrews !9 while the trailing bevel gear #4 is pressed in the direction of the Arrow G (in order to reduce the backlash to zero).

10. Press the sensor slit 5 in the direction of the Arrow C and turn the setscrew @1 so that its H comes in the section toward the setscrew @0 of the intermediate presser lifting cam #7. Then, fix H of the setscrew @1 tentatively.

11. According to adjustments of intermediate presser variable as described in 3-(11), make adjustments of intermediate presser variable and fasten the setscrews of the drive bevel gear #0 and the sensor slit 5.

12. Using the stepscrew !1, mount the intermediate presser variable link !2 on the intermediate presser variable arm @3.

13. Using the stepscrew 8, mount the intermediate presser variable plate 9 and the variable plate spacer !0.

14. Mount the stepscrews 4 and 6.15. Using the stepscrew 7, mount the intermediate presser variable link !2 on the intermediate presser

variable plate 9.16. Mount the intermediate presser auxiliary spring 3.17. Mount the intermediate presser spring 2 and the guide shaft from above the frame. Then, mount

the presser adjusting screw 1. (27.0mm from the upper plane of the arm to that of the presser adjusting screw 1)


– 20 –

Standard Adjustment

(11) Intermediate presser variable adjustments

Start the test mode I10 (IP-420). When is pressed twice after the completion of origin retrieval,

there is coincidence between the center of left hole C in the arm and the second screws 9 of the intermediate presser movable arm 8.

2

3 4

1

89

C

C

BA7 6

5

2

!0

4

!2!1 D

– 21 –

1. Start the Test Mode I10 (IP-420).2. Tread on the start pedal for origin retrieval, and make adjust-

ments by turning the sensor slit 4 so that the lines combining the center of the intermediate presser lifting shaft 1, the stan-dard hole of the intermediate presser lifting cam 2, and the center of the cam follower 3 become almost a straight line.

3. Press of the panel three times. Loosen the first screw

7 of the drive bevel gear 6 of the intermediate presser vari-able shaft 5.

Take out the drive bevel gear 6 from the flat part of the inter-mediate presser variable shaft 5 and move it in the direction of the Arrow A.

4. Using the [+] key or the [–] key, turn the intermediate presser variable shaft 5 until the second screw 9 of the intermediate presser variable arm 8 settles in the center of the arm’s left-side hole C. (Insert a hexagonal wrench to adjust positioning so that the arm comes in the center of backlash deflection.)

5. Turn the intermediate presser lifting shaft 1 so that the sec-ond screw !0 of the intermediate presser lifting cam 2 comes just above. Press the drive bevel gear 6 of the intermediate presser variable shaft 5 in the direction of the Arrow B to fix it.

6. After the completion of second origin retrieval, press of

the panel twice to secure the [timing adjustment position]. In this case, confirm that the second screw 9 of the intermedi-ate presser variable arm 8 is positioned in the center of the arm’s left-side hole C or below it. (If the screw seems to have been positioned above the center, return to Step 4 and repeat the above-mentioned adjustments.)

7. If the second screw 9 of the intermediate presser variable arm 8 is not positioned in the center (or lower), loosen the setscrew !1 of the sensor slit 4 and turn this sensor slit 4 in the direction of the Arrow D for fine adjustments.

8. Make origin retrieval and confirm that the the cam follower 3 is located in the parallel section of the intermediate presser lifting cam 2. When the condition has been found normal, fasten the setscrew 7 of the drive bevel gear 6 and the set-screw !1 of the sensor slit 4 regularly.

(Caution) For the prevention of the sensor !2 from destruc-tion, make origin retrieval after confirming that the slit of the sensor slit 4 is positioned in the center of the sensor !2.


○ There will be a displacement between the variable value of

rewol resserp etaidemretni ehtposition and the panel setup value.

○ If there is no cam follower 3 in the parallel section of the intermediate presser lifting cam 2 at the time of origin retrieval, stepping out may oc-cur in the intermediate presser motor, thus causing defective stitches, generation of sound from the face plate section, and destruction of parts.

○ If adjustments of backlash are insufficient for the drive bevel gear 6, stepping out may oc-cur in the intermediate presser motor, thus causing defective stitches, generation of sound from the face plate section, and destruction of parts. .

– 22 –

Standard Adjustment

(12) Intermediate presser drive arm

※ Refer to Instruction Manual, 4-7. Intermediate presser height.

4

2

6Intermediate presser bar

App

rox

3.6m

m

5

Close contact

1

3

– 23 –

1. Turn ON the power supply and set the height of the interme-diate presser 4 to 0mm. Turn OFF the power supply in the state that the intermediate presser 4 has been lowered.

2. Loosen the intermediate presser stroke adjusting screw 1.3. Turn the pulley and move the needle bar to the lower dead

point. When the intermediate presser 4 is lifted and the intermedi-

ate presser stroke adjusting screw 1 is moved to the right orleft,confirmthattheintermediatepresseradjustingarm3 is positioned not to move vertically and that the intermedi-ate presser positioning link 5 keeps a close contact with the arm. In this state, tighten the setscrew 2 of the intermediate presser drive arm.

(The clearance is approximately 3.6mm between the inter-mediate presser needle bar connection and the intermediate presser bar metal 6.)

4. After the setscrew 2hasbeentightened,confirmthatthereis no backlash in the intermediate presser adjusting arm 3 in the forward and backward directions.

5. Finally, make adjustments of the intermediate presser stroke. (Refer to Instruction Manual #. MAINTENANCE OF SAWING

MACHINE, 1-5. Adjusting the vertical stroke of the intermedi-ate presser.)


○ If there is no clearance, there will be interference between the intermediate presser bar metal 6 and the intermediate presser needle bar connec-tion during sewing machine operation, and this will gener-ate abnormal sound as a result.

○ If there is too much clear-ance, there will be interfer-ence between the intermedi-ate presser adjusting arm and the arm 3 during sewing machine operation, thus gen-erating abnormal sound as a result.

○ If there is too much or too less clearance, the lower dead-point height of the intermediate presser 4 may be changed as a result of intermediate presser stroke adjustments.

– 24 –

Standard Adjustment

(13) Oscillator gear positioning

Standard Adjustment

(14) Adjustment of hook oil amount

4

3

2

1

A

2

3

1

4

2.4mm

5

4

3

4

3

Hook side

6

– 25 –

1. Loosen two setscrews 1 and one setscrew 2 of oscillator gear 3.

2. Loosen four setscrews 5 of gear box 6 to detach oscillator gear 3 from hook driving shaft gear 4.

3. Turn the hook driving shaft to the position where hook driving shaft gear 4 does not slip off from oscillator gear 3. (The gearsareflushwitheachother.)

4. In the state as described in 3, tighten two setscrews 1 in the flatsurfaceoftheoscillatorgearfirst,andonesetscrew2, providing a clearance of 2.4 mm between the inside machined surface of gear box 6 and oscillator gear 3.

5. Adjust the backlash according to [(6) Removal/installation of the hook driving shaft and backlash removing procedure].

6. After adjustment of the backlash, let the hook driving shaft rotate to verify that no torque variation is observed.


○ When the clearance of 2.4 mm is not provided, gear abrasion or breakage can be caused.

1. Loosen the setscrew 1 and remove it.2. When the adjusting screw 2 is tightened, the quantity of oil

can be regulated for the lubrication pipe left 4.3. After adjustments, tighten the setscrew 1tofixit.(Cautions) 1. In the state of standard shipment, hook lu-

brication reducer 3 is positioned so that it is lightly tightened and adjusting screw 2 is return-loosened by 1.5 turns.

2. When reducing the oil amount, the hook lu-brication reducer should not be fully tight-ened up at a time. Tighten hook lubrication reducer 3 slightly at a time at about a half-day intervals checking how the oil amount is reduced. Excessive reduction of oil can be a cause of hook wear.


○ If the amount of hook lubri-cant is reduced too much, this can be a cause of fric-tional wear of the hook race plane or lock-up.

– 26 –


(15) Shuttle connection / disconnection and oil wick piping

1. Remove seven setscrews 1 from the pipe holder. Remove lubrication pipes 9, !0, !4 and !5, and waste oil pipes !1 and !6 from clamps !2 and !3.

2. Remove lubrication pipes 9, !0, !4 and !5 which have been inserted in oil tank 2 from the tank.3. Loosen setscrew 3 to take out driver 4.4. Loosen setscrew 5.5. Remove setscrew 6 to pull out shuttle race adjust shaft 7.6. Pull shuttle race 8 toward the operator to take it out.

4

3

8

To the waste oil receiver

To the arm oil tank (for lubricating the gear box)

To the arm oil tank (for lubricating the hook)

9

!0

!4

!5

!31

!3

6

7

5

1 1

!3

1!4 !5

!6

!1

!2

1

!09

2

!5

!49!0

1!3

– 27 –


1. Pass two lubrication pipes 9 and !0 and waste-oil drain pipe !1 through the frame and mount shuttle race 8.

2. Hold lubrication pipe !0 with pipe holder !2 and fix them with setscrew 1. At this time, make sure that lubrication pipe !0 comes in contact neither with the thread clamp con-

nector link nor the hook driving shaft.3. Clamp lubrication pipes 9, !0, !4 and !5 and waste-oil drain pipes !1 and !6 by means of clamp !3.

Fix them with setscrew 1.4. Insert two combinations of lubrication pipes, 9 and !0, and !4 and !5 into oil tank 2. 5. Clamp waste-oil drain pipes !1 and !6 with clamp !3 and fix them with setscrew 1.6. Insert waste-oil drain pipes !1 and !6 into the waste-oil receiver. 7. Fix shuttle race 8 and mount driver 4 with setscrew 3. [Refer to (17) Hook adjustment.]

– 28 –

Standard Adjustment

(16) Adjusting the height of the needle bar

5 : Marker line for DP x 56 : Marker line for DP x 17 (with needle count higher than #22)7 : Marker line for DP x 17 (with needle count lower than #22)

1

2

1

4 3

6

7

5

– 29 –

* Turn ON the power once, and turn OFF the power again after making the intermediate presser in the lowered state.

1. Bring the needle bar 1 down to the lowest position, loosen the needle bar connection screw 2 and align the upper en-graved line 3 on the needle bar with the bottom end of the needle bar lower bushing 4.

2. Change the adjusting position according to needle sizes.(Caution) Be sure that torque is even after adjustment.


– 30 –

Standard Adjustment

(17) Hook adjustment

3

6

DP x 17 needle(of which needlecount is lower

than #22) is used.

DP x 17 needle(of which needlecount is higher

than #22) is used.

4 : Marker line for DP x 5 needle5 : Marker line for DP x 17 needle (with needle count higher

than #22)6 : Marker line for DP x 17 needle (with needle count lower than

#22)

5

1

4

When a DP x 5needle is used

3

2

3

2

3

2

!0 !1 9

!1!2

!0

!2

!4

!3

0mm

0mm

9

!2!4

!2!4

!3

!5

87

!2

!3

0.5mm

A

b

D

C

0.05 to 0.1mm

7.5mm

– 31 –

* Turn ON the power once, and turn OFF the power again after making the intermediate presser in the lowered state.

1. Turn hand wheel by hand to ascend the needle bar 1. Adjust so that lower marker line 2 on the ascending needle

bar aligns with the bottom end of the needle bar bushing lower 3.

2. Loosen setscrew 9 in the driver. Drawing bobbin case open-ing lover hook !0 toward you, open it to the right and left until bobbin case opening lover !1 comes off.

(Caution) At this time be careful not to let inner hook !2 come off and fall.

3. Refer to 5. below and make tentative adjustments of timing for the inner hook !2.

4. Turn the pulley by hand and make adjustments for the needle location block of the driver !4 by bending it in the direction of Arrow A so that the clearance b attains 0mm to 0.5mm be-tween the needle tip and the lowest end of the needle location block of the driver !4 when the needle tip of the inner hook !2 is protruded by 0.5mm from the right end of the needle !3.

5. Make an adjustment so that the blade point of the inner hook !2 is aligned with the center of the needle !3, and that the clearance between the front end of the driver !4 and the needle !3 is 0 mm because the front end of the driver !4 receives the needle to prevent needle bending. Then, tighten the setscrew 9 securing the driver.

6. Make adjustments so that the clearance (C) in the revolving direction attains 0.3mm to 0.6mm between the inner hook !2 and the driver !4 by bending the inner hook holder block (re-verse side of the needle location block) of the driver !4 in the direction of the arrow (D).

(Caution) Make sure not to damage the shuttle !5 race plane while making adjustment of the driver !4.

7. Loosen the setscrew 7 securing the shuttle !5, and adjust the frontrear position of the shuttle by rotating the shuttle adjusting shaft 8 so that the clearance between the needle !3 and the blade point of the inner hook !2 becomes 0.05 to 0.1 mm.

8. After adjusting the front-rear position of the shuttle !5, set the clearance between the needle !3 and the shuttle !5 to 7.5 mm by adjusting the rotating direction, and tighten the setscrew 7 securing the shuttle.


○ Stitching failure and needle breakage can occur.

– 32 –


(18) Thread trimmer presser lifter cam connection/disconnection

1. Loosen 2 setscrews 2 securing the presser lifter and thread trimmer cam (hereafter called “cam”) 1.2. Loosen the 2 setscrews 4 and remove the sensor slit 3.3. Remove the 4 setscrews 5 and take out the presser lifting motor 6 in the direction of the arrow. In

some cases, the bearing 7 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 7.

At that time, the cam 1 may come down. Handle it with care, not to damage it.

Standard Adjustment

(19) Thread trimmer and presser origin sensor adjustment

At the time of origin retrieval (Start Switch ON) in the test mode I07 (IP-420), the reference holes A and B of the sewing machine frame come in coincidence with the reference hole C each of the thread trim-ming and presser lifter cam 1.

6 8

5

4

3

1 2

7

A

B

A

2

3

5

A

5

D

2

3

C4

1

E

– 33 –


1. Apply a proper amount of grease (Juki Grease A) to the grooved cam block of the cam 1, the pe-ripheral cam block, and the rollers of the presser lifter link and the thread trimmer link 8. Refer to “10.-(4) Parts to which grease • Locktight is applied o TENSION RELEASE & THREAD TRIMMER MECHANISM COMPONENTS.”

2. While the cam 1 is being inserted in the shaft of the presser lifting motor 6, mount the assembly on the sewing machine frame and tighten the four setscrews 5. The insertion of the cam should be done gently in order not to hurt the bearing 7.

3. Adjust the position of the cam 1 so that Clearance A of 0.5 to 0.7mm is secured between the cam 1 and the thread trimmer link 8. Since then, fix the cam 1 with 2 setscrews 2. (Adjust the screw to the flat parts on both ends of the shaft.)

4. Mount the sensor slit 3 with the 2 setscrews 4 so that the end plane of the motor shaft can ap-proximately coincide with that of the sensor slit 3. (Join the flat section for installation.)

* Confirm that the slit plate of the sensor slit 3 does not interfere with the presser bar lifter sensor.5. Refer to “3.-(19) Thread trimmer and presser origin sensor adjustment” and make sensor adjust-

ments.

1. Start the test mode I07 (IP-420).2. Tread on the pedal for the retrieval of the thread trimmer and

presser bar lifter (cam) origin.3. Make sure that the standard holes ( A and B ) of the thread

trimming motor stand are aligned with the standard hole C of the thread trimmer and presser lifter cam 1 using a bar 4.

4. If the standard hole C of the thread trimmer and presser lifter cam 1 is too high ( E direction), loosen the setscrew 2 and move the sensor mounting plate 3 upward ( E direction) and secure it.

If the standard hole C of the thread trimmer and presser lifter cam 1 is too low ( D direction), loosen the setscrew 2 and move the sensor mounting plate 3 downward ( D direction) and secure it.

After securing the sensor mounting plate , conduct origin retrieval by pressing the pedal to make sure that the standard holes are aligned.

5. Repeat the above steps 2 to 4 until the coincidence is confirmed.(Caution) Tighten the setscrew 2 after confirming that there

is no interference between the sensor slit plate 5 and the sensor.


○ If the standard holes are not aligned, the thread trimming timing error occurs and de-fective thread trimming and unthreading at the beginning of sewing may be caused.

– 34 –

Standard Adjustment

(20) Adjustment of the moving knife and counter knife position

Counter knife position : The clearance between the counter knife 5 and the needle hole guide 6 is 1.0mm.

Moving knife position : Before thread trimmer operation (standby state), the distance from the throat plate 4 front end to the tip of the thread cutter lever (small) 7 is 18.5mm.

However, there shall be a proper clearance toward the moving knife tip during needle thread clamp and feed forward.

Standard Adjustment

(21) Floating amount of the thread tension disk

When the sewing machine power supply is turned off (AT solenoid 1 is OFF), the gap between AT thread tension disk 7 is 0.6 to 1mm.

415

6

1.0mm

2

1

4

73

56

18.5mm

There shall be aclearance

18.5mm

73

6

4

8

5

0.6 to 1mm

8 5

AB

4 mm or less1

2

Close contact

– 35 –

1. Counter knife position Loosen the counter knife setscrew 1 to adjust the position.2. Moving knife position Loosen the screw 2 to adjust the position.


○ If the clearance is less than 1.0mm, thread may be cut by the counter knife 5 blade when the thread is pulled with the moving knife 3. In this case, upper and lower threads are cut into short pieces.

○ If the clearance is more than 1.0mm, the residual thread length after thread cutting operation becomes longer beneath the work.

1. Turn off the power supply and look for any close contact be-tween the AT solenoid 1 and the thrust collar 2.

2. Loosen the three setscrews 3 and remove the thread tension cap 4.

3. Hold the tension releasing pin adjust collar 5 not to let it ro-tate, and loosen the nut 6.

4. Turn the tension releasing pin adjust collar 5 and adjust the gap between the thread tension disk 7. (Adjustment of thread tensiondiscfloating)

5. Hold the tension releasing pin adjust collar 5 and tighten the nut 6.

Mount the thread tension cap 4 by means of the setscrew 3.6. Turn on the power supply and set up the thread tension. Con-

firmthatthethreadtensiondisk7 are closed.(Caution) When the tension releasing pin adjusting collar 5

is rotated, the thread section should not be en-gaged with the incomplete thread section of the thread tension releasing pin 8. (The thrusting distance of the thread tension releasing pin should be 4 mm or less from the tension releasing pin 8 adjusting collar 5.)

* If the amount of disc floating cannot be adjusted properly under the condition that the thrusting distance is 4 mm or less, loosen the setscrew 3 and adjust the AT link unit (front) in the right-left direction.

Refer to “3.- (23) AT unit connection/disconnec-tion”.


○ Iftheamountofdiscfloat-ing is too less, the residual thread length can be changed or shortened when the thread is thick.

○ Iftheamountofdiscfloat-ing is too much, the thread tension discs 7 cannot close completely and normal thread tension may fail to be chosen. This can be a cause of imperfect sewing.

○ If the thread section of the tension releasing pin adjust-ing collar 5 is engaged with the incomplete thread section of the thread tension releas-ing pin 8, the thread tension releasing pin 8 may be dam-aged.

– 36 –


(22) Second thread tension connection / disconnection

1. Loosen the setscrew 2.2. Remove 3 setscrews 3 and take out the thread tension cap 1.3. Remove the nut 5 and the tension releasing pin adjusting collar 6. Then take out the thread ten-

sion disc pressing plate 9 and three thread tension disc return springs !0.4. Pull out the second thread tension 4 to remove it. (Arrow A )5. For reassembly, follow the steps of 4. to 1. above.

1

2

13

5

A

6!0

9

4

78

!1

– 37 –


1. When mounting thread tension controller No. 2 4, check first that the hole in tension releasing pin 7 fits over pin block 8 of AT link unit (front) !1. If you try to forcibly mount thread tension control-ler No. 2 4 when the pin does not fit in the hole, tension releasing pin 7 can break or malfunction can be caused. After completion of mounting of the thread tension controller No. 2, make adjust-ments described in (21) Floating amount of the tension disk and in (44) Adjustment of thread take-up spring; 1) Stroke adjustments.

– 38 –


(23) AT unit connection / disconnection

1. Remove the setscrew 2 of the AT link unit (front) 1 and take out the second thread tension 3. (3.- (21) Refer to “Second thread tension connection / disconnection.”)

2. Draw out the cotter pin 7 from the pin block 5 of the AT link unit (rear) 4. Be careful not to drop the washer 8 at that time.

3. Lift the AT joint block 9 of the AT unit upward to remove the block from the pin block 5 of the AT link unit (rear) 4.

4. Draw out the AT link unit (front) 1 from the plane side (in the direction of the arrow E ) and remove it.5. Remove the 2 setscrews !0 and take out the AT solenoid unit !1.6. For reassembly, follow the steps of 5. to 1. above.

21

E

3

Close contact

6

!1

!0F

– 39 –


1. For incorporating the AT solenoid unit !1 into the system, run the solenoid cable !2 from the rear of the AT solenoid unit to the rear end of the machine arm.

2. The center-to-center distance between the AT joints 9 of the AT connector rod !3 is 699.5 mm. When the AT joints 9 are disassembled or assembled, make sure that the center-to-center distance

is correct, and that the front and rear of the AT joints 9 are parallel. Failure to observe this may cause AT malfunction resulting in incorrect thread tension.

(When the AT joint 9 is turned 4 times, the feed move amount comes to attain 2mm.)3. For the pin block of the AT link unit (rear) 4, use the pin block 5. The wrong pin position may cause AT malfunction resulting in incorrect thread tension.4. After completion of all assembly work, make sure that the thrust collar 6 closely contacts with the

AT solenoid unit !1. If there is a clearance between them, loosen 2 setscrews !0 and move the AT solenoid unit !1 to the rear (Arrow F ) and secure it again.* If the above-mentioned center-to-center distance is great between the AT joints 9, the clear-

ance will be opened wider.

9 !39

(652mm)

Secure parallelism between plane and plane.

699.5mm

98

7

4

Close contact

!2

6

!15

– 40 –

(24) Wiper adjustment

(Caution) The intermediate presser supplied as standard accessory is available up to 5 mmmaterial thickness. However, the intermediate presser cannot be used for the materialthickness of 3mm since the wiper cannot pass the space between the tip of needleand the intermediate presser .Turn OFF the wiper switch in case of 3mm material thickness or more.Otherwise, set the memory switch U105 at 1 so that the wiper can operate in thelowering phase of the intermediate presser .

A

Throat plate top surfaceHeight ofIntermediatePresser

1mm

or m

ore

10mm15° to 20°

V letter

1. When lowering the intermediate presser at the stop position after thread trimming (needle height fromthe top surface of throat plate is 17.7 mm.) and pressing wiper link section A , adjust the clearancebetween the center of needle and the inside of V letter of the wiper to 10 mm.

2. Press wiper link section A on the way and when the wiper has come to the underside of needle, adjustthe clearance to 1 mm or more.

3. The opening angle of the top end of the wiper is 15° to 20°.

Center of needle

Standard Adjustment

Wiper shaft cap

1mm

or m

ore

– 41 –

1. Turn OFF the power after stopping the thread trimming, or turn ONthe threading switch and lower the intermediate presser .

(Caution) As for the height of needle when adjusting the wiper, set the height when the sewing machine stopped af-

ter trimming the thread actually.2. In the state of the above item 2. , loosen setscrew and adjust the

clearance toward the tip of the needle, the clearance toward the in-termediate presser , and the opening angle (15˚ to 20˚). Then tightensetscrew .

3. In the state of the above item 2. , adjust the clearances between thewiper and needle tip and between the wiper and intermediatepresser after loosening the setscrew . Then, adjust the openingangle (15° to 20°) and tighten the setscrew .

4. Push wiper link section A to the last and loosen setscrew .5. In the state of the above item 4. , adjust the longitudinal (10 mm) and

lateral positions of the wiper . Then tighten setscrew .(Caution) After the modification of the needle bar height, needle

size (boldness), and intermediate presser height, adjustthe wiper , without fail.* Length of the needle can change according to the

needle tip shape and needle size (boldness).

o If the clearance between the wiper and needle is too small, the

wiper comes in contact with theneedle due to uneven stopposition of the main shaft, causingneedle breakage.

o If the clearance between the wiperand needle is excessive,

the wiper comes in contact withthe intermediate presser andthe wiper will damage the inter-mediate presser . Also, the in-termediate presser can not goup. (intermediate presser step-out)

o If a clearance of 10 mm betweenthe inside of V letter of the wiper

and the center of needle ismistakenly set, the wiper fails tospread the thread.

o Similarly, If the center of needledoes not align with the V letter ofthe wiper , the wiper fails tospread the thread.

o If the opening angle of the wiper is excessive, thread sweeping

failure will occur.


– 42 –

Standard Adjustment

(25) Backlash adjustment for the X motor

Standard Adjustment

(26) Backlash adjustment for the Y motor

1 1

2

4

3

7

8

5

Flat section

5

6

Flat section

1

4

Y drive gear thrust bearing

37.5

to 3

7.6m

m

– 43 –

1. Loosen four setscrews 1.2. Press the X-feed stepping motor in the direction of the arrow

to reduce the backlash to zero.3. Tighten four setscrews 1.


○ If there is any backlash, needle entry accuracy is lowered. This can also be a cause of feed error.

○ Too much pressing may re-sult in an increase in the feed load, thus causing feed error.

1. Remove 4 setscrews 2 and take out the Y feed stepping mo-tor 4.

2. Confirmthatdistanceiskept37.5to37.6mmbetweenthetipof the Y drive bevel gear 5 and the spigot joint of the Y feed stepping motor 4.

If this distance is not secured, loosen 2 setscrews 1 to re-move the Y drive bevel gear 5 and adjust the number of teeth of the Y drive bevel gear spacer 6.

(The spacer thickness is 0.1mm. Usually, two pieces are used.)

(Caution) When tightening the setscrews 1, try to join the flat section of the shaft of the Y feed stepping mo-tor 4 with the position of the setscrew 1. At that time, confirm that the Y drive bevel gear 5 does not move in the axial direction.

3. Install the Y feed stepping motor 4 on the bed.4. Press the Y trailing gear 7 in the direction of the arrow to

reduce the backlash to zero and tighten 2 setscrews 3. At thattime,jointheflatsectionoftheYdriveshaft8 with the position of the setscrew 3.


○ If there is any backlash, needle entry accuracy is lowered. This can also be a cause of feed error.

○ Too much pressing may re-sult in an increase in the feed load, thus causing feed error.

– 44 –

Standard Adjustment

(27) Tension adjustment for the X timing belt

In case of 4530

In case of 6030

AB

AB

2.5m

m

9.8N

3

4

2

15

3

4

2

15

– 45 –


○ If the tension is too much, this can cause destruction in the X timing belt 4.

○ If the tension is too less, this can be a cause of feed error.


1. Move the X movement base 3 to left side.2. Move the X movement base 3 forward and backward, and let

the right side hole of the bed coincide with the position of the adjusting screw 1.

3. Loosen 3 setscrews 2.4. Turn the adjusting screw 1 to secure a warp of 2.5mm at the

load point when a load of 9.8N (1kg) is applied to the center of the X timing belt 4 by means of a spring balance.

Turning adjusting screw 1 in direction A reduces the warp, and turning it in direction B increases the warp.

5. Tighten the setscrew 2 and check the amount of warp again.

(Reference) Adjustment of X-belt tension (factory-adjusted)1. Shift X movement base 3 to the leftmost position as observed

from you. 2. Placing the measuring tool against the measuring point (center

of X timing belt 4), tap the arrowed part to measure the ten-sion.

Belt tension gauge U-507 (UNITTA) Tension for assembly: 550 ± 10 N Unit mass : M = 4.0 g/m (length) x mm (width) Belt width : W = 40.0 mm Span length : S = 517.0 mm (4530) 667.0 mm (6030)3. Loosen setscrew 2. Turn adjusting screw 1 to adjust the ten-

sion.4. When the correct tension is obtained, fully tighten setscrew 2

and tighten nut 5. (Tightening toque: 4 to 4.5 Nm)5. After adjustment, move X movement base 3 to the right and

left to check that X timing belt 4 moves at the center of the sprocket.

– 46 –

Standard Adjustment

(28) Tension adjustment for the Y timing belt

1.5m

m

9.8N

3

4

4

1

1

2

A

B

– 47 –

1. Move the X movement base 3 to the extreme inner part.2. Loosen 8 setscrews 1.3. Turn the adjusting screw 2 to secure a warp of 1.5mm at the

load point when a load of 9.8N (1kg) is applied to the center of the Y timing belt 4 by means of a spring balance.

Turning adjusting screw 2 in direction A reduces the warp, and turning it in direction B increases the warp.

4. Tighten the setscrew 1 and check the amount of warp again.

(Reference) Adjustment of X-belt tension (factory-adjusted)1. Press X movement base 3 forward, as observed from you,

until it will go no further.2. Placing the measuring tool against the measuring point (center

of Y timing belt 4), tap the arrowed part to measure the ten-sion.

Belt tension gauge U-507 (UNITTA) Tension for assembly : 450 ± 10 N Unit mass : M = 4.0 g/m (length) x mm (width) Belt width : W = 40.0 mm Span length : S = 378.0 mm (4530, 6030)3. Loosen four setscrews 1 respectively. Turn adjusting screw

2 to adjust the Y belt tension.4. When the correct tension is obtained, fully tighten setscrew 1. (Tightening torque: 5.5 to 6.5 Nm)5. After adjustment, move X movement base 3 to the right and

left to check that Y timing belt 4 moves at the center of the sprocket.


○ If the tension is too much, this can cause destruction in the Y timing belt 4.

○ If the tension is too less, this can be a cause of feed error.

○ When there is a difference in tension between the right and left belts, the belt deteriora-tion and faulty feed can be caused.

– 48 –

Standard Adjustment

(29) How to remove rattles from the Y drive shaft

Standard Adjustment

(30) Phase adjustment for the Y timing belt

Bed

Making flush end-to-end

4

Flat section

1

Y timing belt

3

A

45

Flat section

1

2

7

6

8

Flat section

3

1

4

2

5

1

4

5

– 49 –

1. Loosen two setscrews 2.2. Making the left end face of Y drive shaft 3flushwiththeend

face of bushing 4, tighten setscrew No. 1 1intheflatsectionof Y drive shaft 3.

3. Tighten two setscrews No. 2 5 in the bushing.4. Pressing Y drive shaft 3inthedirectionofthearrowA,fit

thrust collar 6 closely against bearing 7 and tighten two set-screws 8.

(Caution) 1. Check to be sure that there is no axial play in Y drive shaft 3.

2. Check to be sure that torque is neither exces-sive nor inconsistent when rotating Y drive shaft 3.


○ If there is any rattling, this can be a cause of feed error.

○ When play exists in Y drive shaft 3 or torque is exces-sive or inconsistent, accuracy in the needle entry position can be reduced.

1. Loosen 4 setscrews 1.2. Move the X movement base 2 forward and backward two or

three times.3. Tighten 4 setscrews 1.* When the Y timing belt 3 is adjusted, phase adjustments of

this Y timing belt 3 should be carried out, without fail.(Caution) When Y timing belt 3 sticks on Y-belt holder

mounting plate 4, phase cannot be adjusted by moving Y movement base 5 backward and for-ward.


○ Incorrect phase matching can be a cause of feed error.

– 50 –

Standard Adjustment

(31) Adjustment of the X-Y mechanism

216m

m13

6mm

136m

m

96mm!3

!1

2

2

1

6

Butt

Butt

8

!4

!2

Rear end face

Rear end face

Rear-end machined surface of bedMachined surface

Butt

7

Make adjustments to the dimensions specified below.

4

5

9

!0

Machined surface of bed Machined surface of bed

• • • !6 (7 pcs.) • • • 3 (7 pcs.) • • • !5 (7 pcs.) • • • !7 (7 pcs.)

• • • @0 (4 pcs.) • • • !8 (4 pcs.) • • • !9 (4 pcs.) • • • @1 (4 pcs.)

!6

3

!5

!7

@0

!8

!9

@1

– 51 –

Installing the Y-LM guide1. Pressing Y-LM guide A 4 against the machined surface of the

bed, tighten seven setscrews 3.2. Adjust the distance between Y-LM guides A 4 and B 5 to

216 mm, the distance between Y-LM guides A 4 and C 9 to 136 mm and the distance between Y-LM guides B 5 and D !0 to 136 mm, and secure parallelism of the guides.

3. Fix Y-LM guides B 5, C 9 and D !0 with setscrews !5, !6 and !7 (7 pieces each).

Installing the X-LM guide1. Pressing X-LM guide A 8 against the machined surface of X

movement base 7, tighten eight setscrews 2.2. Adjust the distance between X-LM guides A 8 and B 6 to

96 mm, and secure parallelism of the guides. Tighten eight setscrews 1.

3. Pressing Y movement bases !1 and !2 against X-LM guide 8, bring the rear end faces of Y movement bases !1 and !2 into parallelism with the read-end machined surface of the bed. Fix the Y movement base and the bed respectively with four setscrews !8 and !9.

4. Pressing Y movement base !3 and !4 against X-LM guide A 8, tighten the base and guide respectively with four setscrews @0 and @1.


○ If no parallelism is secured, this can be a cause of feed error.

○ If no parallelism is secured, needle entry accuracy will be lowered.

– 52 –

Standard Adjustment

(32) Pressure adjustment for the slide plate bearing

Move work clamp foot bed slide 4 up and down until bed slide bearing 6 comes in contact with spring pin 7. Startup torque (slippage torque) after the aforementioned moment should be 0.98 to 7.84 N (100 to 800 g).

2

2

1

4

3

Machined surface

The thinner side should be positioned toward the front.

The thinner side should be positioned toward the front.

6

5

5

7 7

7

7

77

– 53 –

1. Pressing work clamp foot slide B 3 against the machined surfaceofthefeedbracket,fixtheslidewithsetscrew1.

2. Temporarily tighten setscrew 2.3. Pressurize work clamp foot slide B 5 by lightly tapping it

from its outer side face with a plastic hammer or the like. At this time, be careful to pressurize work clamp foot plate 4 by moving it up and down to prevent inconsistent torque.

4. Tighten setscrew 2. (Caution) 1. Tightening setscrew 2 changes the pressure

applied to foot slide bearing 6. After you have tightened setscrew 2, check

that the slippage torque is correct.


○ If normal pressure is not ap-plied, vertical movement of the presser cannot be ac-complished normally.

○ If normal pressure is not ap-plied, rattling will be gener-ated and accuracy will be lowered.

○ Wear of foot slide bearing 6 can occur.

– 54 –

Standard Adjustment

(33) Initial length of the presser cylinder

When the shaft section of the presser cylinder 3 assumes a state of maximum suction, the center-to-center distance is 119.5 ± 0.3mm between the ø5 hole 4 of the presser cylinder 3 and the ø5 hole 5 of the cylinder knuckle.

3

4

15

2

119.5±0.3mm

– 55 –

1. Tighten the nut 1.2. Turn the cylinder knuckle 2 and adjust the center-to-center

distance to 119.5 ± 0.3mm.3. Securelyfixthenut1.


○ If the distance is greater than 119.5 ± 0.3mm, the feed-ing frame cannot attain the maximum rising distance of 30mm.

○ If the distance is too less than 119.5 ± 0.3mm, the feeding frame cannot come down completely. As a result, the material cloth cannot be held tight and displacement of materials can occur.

– 56 –

Standard Adjustment

(34) Adjustment of the speed controller

Standard adjusting value of the speed controller for the presser cylinder1. Loosen the nut 1 and once turn the knob 2 fully in Direction A. Then, turn this knob in Direction B

by one turn and tighten the nut 1.

1

2

For presser cylinder (right)

For presser cylinder (left)

AB

– 57 –

Make adjustments according to the standard adjusting values.○ To increase the vertical presser speed, turn the knob 2 in

Direction B.○ To decrease the vertical presser speed, turn the knob 2 in

Direction A.


○ Too much noise is generated when the presser is lowered.

○ The presser does not rise.

– 58 –

Standard Adjustment

(35) Adjustment of the pressure reducer

Standard adjusting value of the pressure reducer for the presser cylinder (left)1. Loosen the nut 1 and turn the knob 2 to adjust the air pressure so that it is reduced to 0.23 to

0.25Mpa. Then, tighten the nut 1.Standard adjusting value of the pressure reducer for the presser cylinder (right)1. Check to be sure that the pressure reducer for work clamp cylinder (right) 3 is reduced to 0.23 to

0.25 Mpa. When the pressure does not fall within the aforementioned range, check a torque of the operating unit of the feed bracket and properly re-adjust to correct the malfunction.

1

2

3

0.23 to 0.25Mpa

AB

– 59 –

Make adjustments according to the standard adjusting values.○ To decrease the pressure, turn knob 2 in direction B.○ To increase the pressure, turn knob 2 in direction A.


○ The presser cannot be low-ered by hand.

– 60 –

Standard Adjustment

(36) Making the origin setting gauge

Standard Adjustment

(37) Adjusting the X origin sensor

When the feed is in the mechanical origin, align the tip of the needle with the lateral position of the en-graved dot of the origin.

A

B

3 2

1

D

C

10m

m

10m

m

10m

m

10m

m

Engraved marker of origin (common for 4530/6030)

539mm (4530) / 689mm (6030)

295m

m

5 drill 7.6 x 90°Depth of counterbore 2.5 (four locations)

Rear face

Rear face

1

– 61 –


1. Start the test mode I06 (IP-420).2. When the star pedal is depressed, the feed moves to the me-

chanical origin and stops.3. Lower the needle and check the right and left displacement

based on the engraved marking of the origin.4. When the engraved marking of the origin is found to be dis-

placed in Direction A from the needle tip, loosen the 2 set-screws 2 and adjust the sensor mounting plate 1 in Direction C. After adjustments, tighten the 2 setscrews 2.

5. When the engraved marking of the origin is found to be dis-placed in Direction B from the needle tip, loosen the 2 set-screws 2 and adjust the sensor mounting plate 1 in Direction D. After adjustments, tighten the 2 setscrews 2.

(Caution) 1. After the adjustment, check to be sure that the slit plate does not interfere with sensor 3.

2. After the adjustment of the origin, move the feed in the X ± direction to verify that the origin does not depart from the engraved line.


○ When the origin departs from the correct position, inter-changeability of patterns be-tween sewing machine units will be lost.

No. Part No. Part name Q’ty

1 40051769Feeding frame support shaft bearing

2

2 B2560220000 Feeding frame support shaft 2

3 SM8050412TP Setscrew for support shaft 2

4 SM1040870TP Setscrew for shaft bearing 4

1. Prepare an origin adjustment gauge 1 as illustrated in the sketch. Mount the following parts to the gauge.


※ Wheninstallingoriginadjustmentgauge1 on the feed arm, check to be sure that there is no lateral play in the gauge.

– 62 –

Standard Adjustment

(38) Adjusting the Y origin sensor

When the feed is in the mechanical origin, align the tip of the needle with the longitudinal position of the engraved dot of the origin.

A B

2

2

1

Sensor Y

D

C

– 63 –

1. Start the test mode I06 (IP-420).2. When the pedal is trodden on, the feed moves to the mechani-

cal origin and then stops.3. Lower the needle and check the front-rear displacement from

the engraved marking of the origin.4. When the engraved marking of the origin is found to be dis-

placed in Direction A from the needle tip, adjust the sensor mounting plate 1 in Direction C. (Loosen the sets

Documents

Computer-controlled, Cycle Machine With Input Function ...suporte.silmaq.com.br/JUKI/Manuais JUKI/Engineer Manual...17 Lubricating oil JUKI NEW Defrix oil No. 2 (equivalent to ISO