JUKI LK-185 2-30 Engineer'S Manual Download Page 1

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From the library of: Superior Sewing Machine & Supply LLC

Summary of Contents for LK-185 2-30

Page 1: ...IES High Speed 1 Needle Cylinder Bed Lockstitch Bar Tacking Machines ENGINEER S MANUAL 19 k TOKYO JOKI INOUSTRIAL CO LTD FOREIGN TRADE BUSINESS DIV No IV 19 1983 7 From the library of Superior Sewing Machine Supply LLC ...

Page 2: ... at a garment factory contains detailed operating instructions This manual describes Standard Adjustment How to Adjust Effects of Adjustment and various other information which is not covered by the Instruction Book It is advisable to use the relevant Instruction Book and Parts Book together with this Engineer s Manual when carrying out the maintenance of the machine From the library of Superior S...

Page 3: ...19 Adjustment of the length of thread remaining on the needle 2i Adjustment of the thread take up spring 2i Adjustment of the belt tension 23 Adjustment of the bobbin winder 23 5 OTHER PRECAUTIONS 25 1 Configuration of the shuttle race ring 25 2 How toremove the backlash ofthe shuttle driver shaft 25 3 How toremove the backlash of the main shaft 25 4 How to remove the backlash between the worm and...

Page 4: ...ver fixed by nut Thread trimmingsystem Thread spreader Interlocked with main shaft Thread trimmer Interlocked with lifter Liftingsystem One pedal system Pedalpressure decreasing unit Standard Two pedal system Forfoot treadle type P option Wiper Interlocked with lifter Bobbin winder Driven by belt Drivingsystem 2 stage V belt speed reducingsystem Safety device One pedaldouble safety device Lubricat...

Page 5: ...From the library of Superior Sewing Machine Supply LLC ...

Page 6: ... Adjusting the lower deat point of the needle bar Adjusting the feed cam Adjusting the shuttle race spring Adjusting the needle and shuttle driver Adjusting the right and left work clamp feet Adjusting the auxiliary knife driving cam Adjusting the moving and counter knives Adjusting the length of thread remaining on the needle Adjusting the tension of the thread take up spring Note The solid lines...

Page 7: ...ke Note Perform this adjustment first before making any other adjustment Needle bar Needle bar bushing lower Upper marker line Fig 3 2 Adjustment of the feed cam Adjustment should be made so that the feed is completed when the needle point is 7 to 10 mm 9 32 25 64 above the throat plate surface It is advisable to make this adjustment during lateral feed 10 9 32 25 64 3 E3 Fig 4 Fig 5 From the libr...

Page 8: ...ng advances When the feed cam is turned in direction B the feed timing is delayed Fig 6 Caution Perform this adjustment first after the adjustment of the height of the needle bar Make sure to readjust stop motion regulating cam whenever the feed cam has been adjusted 4 Effects of Adjustment Improper adjustment will cause stitch skipping or thread breakage Whenit is adjusted to 7 mm 9 32 or so well...

Page 9: ...mer returning roller Driving plate 3 64 Stop motion cam Knife driving cam roller 0 0 5 1 64 Fig 9 Fig 8 4 Stop motion timing Perform adjustment to make the stop motion regulating cam roller drop from the low speed point of the stop motion regulatingcam onto the stop motion point at the moment the top surface of the stop motion hookaligns with the centerof the screw No 1 on the stop motion cam at t...

Page 10: ...ses Also the stop motion cam will interfere with the stop motion hook at the time of stop motion Fig 8 If the clearanceis adjusted to 3 mm 1 8 or more The pressure of spring will become too high when the machine mns at high speed often causing the machine to idle and stop It may alsolead to inadequate torque at the start of high speedrunning with consequent reduction in sewing speed Also the threa...

Page 11: ...ng plate 6 Adjustment of the starting lever stopper Bring the starting lever into contact with the stopper screw and make adjustment so that the starting lever when pulled will stop at the moment the clearance between the stop motion hook and the stop motion cam reaches 3 mm 1 8 refer to the previous clause 3 Starting lever To be in contact with stopper screw Fig 17 Stop motion hook 7 Stop inotion...

Page 12: ...ming may not synchronize with the motion of the needle bar often causing the machine to idle and stop Also the machine may fail to reach the high sewingspeed If A is smaller than 0 4 mm 1 64 while B is large than 0 4 An inadequate torque may be caused in low speed operation or heat may generated due to the contact between the changing pulley and the high speed pulley If A B C is larger than the sp...

Page 13: ...ork clamp foot lifting lever Safety plate S Down Fig 18 Fig 19 8 Position of the work clamp foot Tum the main shaft by hand and perform adjustment to equalize the both clearancesA between the needle and the work clamp feet in the longitudinal feed Alsomake equal the both clearancesB between the feed plates and the work clamp feet Feed bracket Feed plate Work clamp foot B B Fig 20 9 From the librar...

Page 14: ...the work clamp foot lifting lever will interfere with each other causing a stop motion failure If the clearance B is zero the machine can not be started If the clearance A is too large the wiper and the thread trimmer will be actuated before stop motion causing the wiper to interfere with the needle or the thread trimmer to cut the needle thread to remain on the needle too short with consequent sl...

Page 15: ...orkclamp feetis 17mm 43 64 L shaped wrench 1 7 10 Position of the wiper Fig 21 j r r A The clearance between the wiper and the needle should be 1 5 mm 1 16 or more at the time when the wiper passes by the needle point The needle is in stationary state at the time of stop motion o 1 5 1 16 j 1 czi Height of the work clamp feet Fig 22 11 From the library of Superior Sewing Machine Supply LLC ...

Page 16: ... 24 when making this adjustment Fig 23 Stop motion hook stop motion cam Fig 24 12 Effects of Adjustment If the work clamp feet are too high they will interfere with the wiper when the wiper is actuated Ifscrews aretoo low the feed bracket will interfere with the loweringshaft Point A If the clearance is smaller than 1 5 nun 1 16 The wiper will interfere with the needle point resulting in needle br...

Page 17: ...2 Position of the shuttle race spring The shuttle race spring should beevenly positioned laterally with respect to theneedle entry point and it should bepositioned longitudinally so that therear edge ofthe needle aUgns withcorner Aasshown below Note Presence of any scrathes on area B may cause breakage of the bobbin thread Grind and smooth out scratches If any Fig 26 13 From the library of Superio...

Page 18: ...on release bar 3 willcome off supporter when the work clamp feet begins to go up and consequently the work clamp feet fail to go up Also the tension discs will not be released If the projection of the tension release bar is larger than 4 mm The end of tension release bar 3 will hit the face cover when the work clamp feet go up producing a loud noise Also the thread will not be released at the time...

Page 19: ... 4 Clearance between the needle and the point of the shuttle Whenthe state is as described in 2 the clearance B between the needle and the point of the shuttle should be 0 05 to 0 1 mm 0 001 0 004 Fig 31 5 Clearance between the needle arid the shuttle race The clearance between the side face of the needle and the shuttle race should be 7 5 mm 19 64 Fig 32 1 Timing of the needle bar 2 Timing of the...

Page 20: ...djustment 1 and 2 Slightly reduce the height of the needle bar upper marker line for floppy material and on the contrary slightly increase the height for heavy weightmaterial to adjust the timing of the shuttle For prevention of stitch skipping 3 If the clearance is more than 0 mm the needle will be bent in the direction of the shuttle point causing scratches on the shuttle point and the needle On...

Page 21: ... large size bartacking 18th stitch for 28 stitch large size bartacking Fig 35 15 Adjustment of the auxiliary knife driving cam The clearance between the end ofthe auxiliary knife driving cam and roller D should be 0 3 to0 5 mm 0 0H 0 019 when roller fits intherecess oftheknife driving cam Changing pulley Knife driving cam S Fig 36 17 Auxiliary knife driving cam Roller 2 Roller 0 3 0 5 0 0110 019 D...

Page 22: ...nd make adjustment so that a clearance of 0 3 to 0 5 mm 0 011 0 019 is provided between the end of theauxiliary knife driving cam and roller 3 when roller fits in the recess of the knife driving cam 18 Effects of Adjustment Improperly positioned center of the work clamp foot would cause the needle to hit the work clamp foot leading to breakage of the needle If the clearance is extremely large the ...

Page 23: ...Fig 37 17 Height of the moving knife and the counter knife Moving knife Engagement of the needlehole guidewith the moving knife blade 0 15 mm 0 005 Counter knife Difference between the needle holeguide and the counterknife blade in height 0 1 to 0 15 mm 0 003 0 005 0 1 0 1 5 0 003 0 005 Counter knife Moving knife f r w 1 u i m ylT Tv 0 005 Needle hole Throatplate guide Fig 38 18 Tilt of the counte...

Page 24: ...mmed by the blade point of the counter knife when the moving knife pulls the threads and therefore the needle and bobbin threads will be trimmed too short If the clearance is greater than 0 5 mm 0 019 the thread remaining on the fabric after thread trimming will be longer If the moving knife is deflected to the counter knife the thread trimmer will be actuated at the time of stop motion or the thr...

Page 25: ...at of cotton thread Tension controller No 1 N Fig 40 20 Adjustment of the thread take up spring Stroke Should be adjusted so that the threadtake up spring moves approx 8 mm 5 16 from the horizontal of the L shaped thread guide Tension Make adjustment while checking the stitch performance The proper tension issuch thatthethread take up spring moves for thefull stroke inactual sewing operation Threa...

Page 26: ...insert ascrewdriver intotension controller No 2 2 to tum it foradjustment 2 Adjustingthe tension First securely tighten the setscrew then insert a screwdriver into tension controller No 2 to turn it for adjustment 22 Effects of Adjustment Insufficient length of the remain ing thread will cause the thread to slip off the needleat sewing start If the remaining thread is too long the needle thread wi...

Page 27: ... under an approx 1 kg pressure Driving pulley i Idler puller Motor pulley Fig 42 Fig 43 22 Adjustment of the bobbin winder The clearance between the bobbin windingwheeland the V belt should be about 3 mm 1 8 when the wheel is not winding a bobbin Brake 0 1 Vbelt Winding belt support Bobbin presser boss D _rj III i Fig 44 3 1 8 Fig 45 Fig 46 23 From the library of Superior Sewing Machine Supply LLC...

Page 28: ... while a bobbin is being wound To be in light contact 3 Ifa bobbin iswound unevenly loosen screw 0 andbend the bobbin winder to the right or left MBend to the left Bend to the right 4 To adjust the amount of thread to be wound round a bobbin loosen nut 2 and move back or forth the bobbin presser boss to make adjustment 24 Effects of Adjustment Excessive tension of the high speed belt will prevent ...

Page 29: ...nd check whether the hatched portion on the rear side measures 0 2 mm 0 007 x 8 mm 5 16 0 2 0 007 2 How to remove the backlash of the shuttle driver shaft Shuttle driver shaft Gearconnection 1 Fig 48 3 How to remove the backlash of the main shaft Screwdriver 0 Thrust collar Fig 49 25 t 8 5 16 n r Fig 47 From the library of Superior Sewing Machine Supply LLC ...

Page 30: ...3509153 Shuttle driver shaft gear connection A Standard o 13509252 Shuttle drivershaft gearconnection B 0 1 larger in dia o 13509351 Shuttle driver shaft gear connection C 0 2 larger in dia Tighten thrustsetscrews T and while twisting thecrank in the direction of arrow using a screwdriver or the like Setscrew T isthe first setscrew Tighten it so thatit fits to the fiat part of the main shaft Thepr...

Page 31: ... Worm gear D Crank rod Worm Fig 50 5 How to remove the backlash of the feed bracket Backlash of the feed cam roller Fig 74 or feed slide block Figs 73 and 74 would lead to lateral or longitudinal backlash of the feed bracket 27 From the library of Superior Sewing Machine Supply LLC ...

Page 32: ... readjust the stop motion timing and the feed cam 1 Replace the feed cam roller by one of the followings B250228000A Feed cam roller 69 5 0 005 B250228000B Feed cam roller 09 5 B250228000C Feed cam roller 09 5 _o So5 2 Replace the feed slide block by one of the followings 13516604 Feed slide block 12 0 009 13516703 Feed slide block 0 009 0 13516802 Feed slide block 0 018 0 009 28 Remarks An excess...

Page 33: ... main shaft 1 Remove the speed reducer 2 Remove the needle 3 Remove the stop motion lever 4 Loosen two setscrews Dof the counterweight and four setscrews of the worm 5 Loosen two setscrews 5 of the crank rod and remove the crank rod cover 6 Loosen and remove two set screws of the thrust collar 7 Loosen and remove setscrew 0 of the main shaft rear bushing Shuttle driver Thrust collar Fig 51 DO 8 Re...

Page 34: ...ap it gradually 30 Precautions in Assembly When reassembling the same gears put the mating faces of the gearsto their original position to prevent loud gear noise To assemble the main shaft place a covering piece on the end of knife driving cam and tap it gradually using a brass bar or the like to drive in the rear bushing of the main shaft Securely fit the end of setscrew intothe long groove ofth...

Page 35: ...ove low speed pulley adjusting shim 5 and pulley spacer 8 5 Loosen setscrew A and then setscrew B 0 tapered screw to remove low speed pulley shaft Q 6 Remove changing pulley 0 and low speed pulley spring 7 Loosen setscrew then loosen and remove setscrew large O tapered screw toremove high speed pulley 0 Assemble the unit by reversing the above disassembling procedure Fig 53 31 From the library of ...

Page 36: ...e changing pulley and also not to twist the pulley springs Caution Take care not to overtighten 0 otherwise It would be difficult to remove It later 35 kg cm Screw 4 The clearances between low speed pulley changing pulley and high speed pulley 0 should be about 0 4 mm 0 015 each Tieck that a contraction of about 1 mm is obtained when the part shown by an arrow in the figure below is pushed forcibl...

Page 37: ... can beremoved from stop motion cam 0 4 Stop motion cam pawl and safety stopper spring O can be removed by drawing out stop motion cam pin 0 Stop motion cam pin 0 is force fitted Assemble the high speed pulley asm by reversingthe above disassemblingprocedure D 5 Disassembling the changing pulley 1 Loosen and remove setscrew 0 ofthe changing pulley 2 Changing pulley shaft 0 comes offchanging pulley...

Page 38: ...reasing the number of adjusting shim D 0 1 mm 0 003 in thickness As the number of the adjusting shims is increased the clearance will grow smaller 4 To install ball bearing apply a thin coat of grease to the inner ring and push the outer ring to force fit it into the pulley At this time take care not to produce scratches on the end surface of the high speed pulley 5 Of the three setscrews for the ...

Page 39: ...em onto inner sleeve 0 Then install them so that the groove of the inner sleevefits to the pin of the pressure decreasingclutch latch 5 Apply Esso Temprex N3 toouter sleeve Cj and attach itsothatthe stopper pin ofthe outer sleeve comes incontact with theend ofclutch spring j 6 Apply Esso Temprex N3 toinput shaft O then attach needle bearings and Q and collar A O to the input shaft 7 Attach input s...

Page 40: ...to screw the spring onto the latch excessively otherwise the spring will be deformed Apply Esso Temprex N3 to the circumference of the screw Pay attention to the orientation of the spring 4 Groove of the inner sleeve Fin End of the spring 5 Bring the pin into contact with the end of the spring and turn the outer sleeve in the direction of arrow to attach it to the inner sleeve 36 Precautions in Di...

Page 41: ...aligning the tapered hole of the shaft with the tapered hole of the pressure decreasing clutch latch Fig 57 12 Tighten setscrew J 13 Attach spring suspension to work clamp foot lifting lever link T 14 Attach upper and lower work clamp foot lifting levers D towork clamp foot lifting lever link byhinge screw 3 15 Using setscrew A and setscrew B 5 attach lever latch A and lever latch B to work clamp ...

Page 42: ...rews A 0 and B 0 9 Apply grease to thepartsof hinge screw 3 andspring suspension 0 onto which the spring ishooked 38 Precuations in Disassembly When taking out the dowel pin be careful not to hit it reversely or else the head would be crashed and the dowel pin would not come out To draw out pressure decreasing shaft 5 draw out the dowel pin loosen setscrew and tap the shaft from direction A From t...

Page 43: ...sure decreasing unit frame 0 17 Fix eccentric pin 0 by setscrew 0 18 Inserting stopper screw 0 into pressure decreasing unit frame 0 fix itusing nut 0 19 Attach tension spring 8 to the work clamp foot lifting lever 20 Tighten sleeve thrust collar screw 8 of Fig 57 Fig 60 39 From the library of Superior Sewing Machine Supply LLC ...

Page 44: ... replace the clutch springor cut the springend on the pressure decreasing clutch latch ofFig 57 The reverse rotation preventinglatch should come in contact with the pressuredecreasing clutch by 1 4 to 3 4 at the point shown below 13 14 Outer sleeve The clearance between outer sleeve O orFig 57 andlatchAof work clamp footlifting lever g should be 0 5 mm 0 019 Adjust theclearance bystopper screw 0 5...

Page 45: ... motion lever End of stop link rod 3 Changing pulley Setscrews Setscrews of changing pulley Screw on the stop motion lever stud Fig 61 4 Throat plate Knife driving lever stud Knife driving lever stud Fig 64 Fig 63 Stop motion spring adjusting nut large i motion spring adjusting nut small Fig 62 5 Work clamp foot lifting lever Work clamp foot lifting lever latch Work clamp foot lifting Setscrew B l...

Page 46: ...to be filled with grease If a grease pump isnot available use a plasticoiler or an injector with its needle removed 1 Main shaft components 2 Pedal pressure decreasing unit compoments Hinge screw Bushing rear 1 411Inside of the pressure decreasing shaft Temprex N3 Bushing middle Fig 67 3 Speed reducer Inside of the main shaft Inner ring of the bearing Low speed pulley springs Sliding part of the c...

Page 47: ... and lateral feed components Feed regulator shaft Inside of the regulating arm shaft Fig 72 Groove in feed plate Pivot stud Lateral feed slide block Groove in lateral feed regulator I Longitudinal feed slide block Groove in longitudinal feed driving arm Longitudinal feed driving arm stud Lateral feed regulator stud Fig 74 Lateral feed driving arm shaft Fig 73 8 Knife driving cam components Knife d...

Page 48: ...y Part No Description Caution in installation 13503750 High speed clutch disc Refer to 6 Disassembling assembling procedures for replacement 13504402 Changing pulley 13504709 Low speed pulley B1215280000 Stop motion cam latch B1217280000 Stop motion cam latch driving spring 13520309 Changing pulley pressing plate Replace this part when the portion in contact with the ball has been depressed scarce...

Page 49: ...as shoes For higher tension of pressure spring Description Foot treadle type lifter for P Belt cover for P Pedal shaft asm for P Needle bar Needle bar thread guide Wiper Shuttle Shuttle race ring for 23 needle Needle hole guide without boss Needle hole guide with boss Thread take up spring Tension spring No 2 Large oscillating rock shaft Spring Part No 13545959 13546809 13547658 D1401L7VV00 D1405L...

Page 50: ...s Refer to the paragraph cover ing the stop motion reflating cam Worm Replace accord ing to number of stitches Refer to the paragraphs cover ing the worm and worm gear Worm gear Replace accord ing to number of stitches Refer to the paragraphs cover ing the worm and worm gear Modified to subclass machine Modification in which bartacking size is also changed Condition Change from standard machine De...

Page 51: ...f grease 8 A The stop rootion timing is wrong 19 AThe worm has no backlash H TIic crank rod ha ituck 9 C Tlic feed cim roller sticksagainst the feedcamgroove 5 A The clutch ha s worn 5 B Tlie clutch has grease on its surface 47 Corrective measures 1 Correct the position of tlie prctsineplate Rcfci lo Standard Adjustment 5 Correct the position of the startingicvetstopper Refer to Standard Adjustmen...

Page 52: ...ing is too late 7 3 The high speed clutch has grease on its surface 7 4 The pressing plate has been positioned improperly 8 I niebelt slips 8 2 The safety plate sticks 8 3 Failure with the pedal pressure decreasingunit 1 B Excessive torque due to maladjustment of the parts 1 A The tension of the low speed belt is not high enough i B The height of the work clamp foot is OTong 1 C Tlie work clamp fo...

Page 53: ...operly adjust the starting lever stopper Refer to Standard Adjustment adjusted improperly 6 Correctly adjust the starting lever stopper Refer to Standard Adjustment 6 Supply grease to the clutch spring j 2 AThe clutchspring has worn out 1 Replace the clutch spring Refer to Disas scmbliiig Assembling ftocedures 3 A The clutchspring has worn out Replace the clutch spring Refer to Disassembling A sse...

Page 54: ...e between the needle and the shuttle driver Refer to Standard Adjustment 13 Correct the feed cam timing Refer toStandard Adjustment 2 Remove the scratches orreplace the needle hole guide Correct the position of the work clamp foot Refer to Standard Adjustment 8 I Properly position the moving knife Refer to Standard Adjustment I6 Correct the timing and clearance between them Refer to Standard Adjus...

Page 55: ... B The moving knife does not engage with the counter knife propcily I C Tltc moving knife has an improper vertical backlash I D The tilt of the eountci knife is not correct 3 A The portion A of llic moving knife has a buir Thread is trimmed in improper shape and thread waste remains 51 Corrective measures Replace or properly attach the needle I Properly position the work clump foot Refer toStandar...

Page 56: ... 2 Is released 4 A The timing between the needle and the shuttle is bad 2 A The needle thread tension is not high enough 18 4 The needle thread stitches intersect with each other as illustrated below vwvw 19 1 Thread breaks due toheat generated 1 AThe sewing speed is too high L L Correct the timing and clearance between the needle and the shuttle Refer to Standard Adjustment 131 Correct the feed c...

Page 57: ...oles at time setup 4 8 5 2 hole 26 1A Spot facing depth 5 5i 30 1 A hole Make thishole onlywhenP type is used 30 1 A hole 51 A spot facing depth 5 a Mounting hole for oil drain funnel 564 Makethisholeat timeofsetup i 7a I200 471 172 62 130 B 4 72 28 3 8 A hole 4U 20 108 4 1 C c hole 2 r sod ft Table part No 13534102 Fullperiphery 1J 2 A Full periphery 10 8 From the library of Superior Sewing Machi...

Page 58: ...nel Make this hole at time of setup 3 8 ihole Funnel stopper mounting hole Make this hole at time of setup 12 00 471 SlOCil 30 1 hole Make this hole only when P type is used 3 Table part No 13545207 30 s I P v17 2 bore S 20 20 20 C oa 90 32 20 3 246 o Full 1 40_ j 2 Full peripheryX il periphery Top of Table 2 k i 4 0 2 Note All dlmsnsions are millimeter Not scale From the library of Superior Sewin...

Page 59: ... CO LTO Address Cable Telex Phone 23 3 Kabuki cho 1 chome Shinjuku ku Tokyo 160 Japan JUKI TOKYO J22967 232 2301 03 205 1188 1189 1190 c r JULY 1983 Printed in Japan T From the library of Superior Sewing Machine Supply LLC ...

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JUKI LK-185 2-30, Engineer'S Manual

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