JUKI LU-2800 Series Engineer'S Manual Download

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Adjustment procedures

Results of Improper adjustment

1. Loosen hinge screw

❶

of the vertical feed rod.

2. Move the boss section

of the vertical feed cam rod

❷

adjust the momentum.

3. After the adjustment, tighten hinge screw

❶

of the vertical feed

rod.

Summary of Contents for LU-2800 Series

Page 1: ...40133310 No E407 03 ENGINEER S MANUAL Unison feed Lockstitch Machine with Vertical axis Large Hook LU 2800 Series LU 2810 2810 7 2860 2860 7 LU 2810 6 2860 6 2828 6 2828 7 LU 2818 7 2868 7 ...

Page 2: ...nd other important information which are not covered in the Instruction Manual When carrying out the maintenance work on the sewing machine be sure to refer also to the Instruction Manual and the Parts List In addition for the motor for the sewing machine with thread trimmer refer to the separate Instruction Manual or This manual gives the Standard Adjustment on the former page under which the mos...

Page 3: ...needle changing bobbin changing or oiling and cleaning Electrical shock danger label DANGER This indication is given where there is an immediate danger of death or serous injury if the person in charge or any third party mishandles the machine or does not avoid the dangerous situation when operating or maintaining the machine WARNING This indication is given where there is a potentiality for death...

Page 4: ...death JUKI assumes no responsibility for damages or personal injury or death resulting from the machine which has been modified or altered Education and training 1 In order to prevent accident resulting from unfamiliarity with the machine the machine has to be used only by the operator who has been trained educated by the employer with respect to the machine oper ation and how to operate the machi...

Page 5: ...arth cable in order to prevent accident caused by earth leakage IV Motor 1 Be sure to use the specified rated motor JUKI genuine product in order to prevent accident caused by burnout 2 If a commercially available clutch motor is used with the machine be sure to select one with an entan glement preventive pulley cover in order to protect against being entangled by the V belt Before operation 1 Be ...

Page 6: ...nt that can result in personal injury or death 9 Be sure to periodically clean up the air vent of the fan and inspect the area around the wiring in order to prevent fire accident of the motor 10 In order to prevent accidents resulting in personal injury or death adjustments have to be carried out within the instructions described in this Engineer s Manual and in the Instruction Manual by the perso...

Page 7: ... to protect against accident that can result in personal injury In addition be sure to select appropriate tools 3 In prevention of accident that can result in personal injury make sure after the completion of adjust ment work that neither screws nor nuts are loosened or come in contact with other parts 4 Turn OFF the power before starting the work in order to protect against accident that can resu...

Page 8: ...ine parts when replacing any of the machine parts JUKI assumes no responsibility for any accident caused by any part other than JUKI genuine one In addition in the event you cannot replace parts within the specified range immediately stop the re placement work and ask JUKI or distributor in your area for replacement of the parts 8 If the fuse has blown be sure to turn the power off and eliminate t...

Page 9: ...specified After the completion of assembly work be sure to check that screws and nuts are not loosened before starting test run 6 In prevention of accident that can result in personal injury make sure after the completion of adjust ment work that neither screws nor nuts are loosened or come in contact with other parts 7 Make sure after the completion of replacement work that neither connectors nor...

Page 10: ...ur work and disconnect the power plug from the receptacle so as to ensure safety 4 If the machine is suddenly moved from a cold place to a warm place dew condensa tion may be observed In this case turn ON the power to the machine after you have confirmed that there is no danger of water drops in the machine 5 To prevent fires periodically draw out the power plug from the plug socket and clean the ...

Page 11: ...normal rotation of the machine is counterclockwise as observed from the pulley side Take care not to allow the machine to rotate in the reverse direction Never operate the machine unless the machine head and the oil tank have been filled with oil For a test run remove the bobbin and the needle thread For the first month decrease the sewing speed and run the sewing machine at a speed of 80 or less ...

Page 12: ... feed adjustment 62 1 LU 2810 6 2810 7 2860 6 2860 7 62 2 LU 2828 6 2828 7 64 3 LU 2818 7 2868 7 66 22 Replacing the motor 70 23 Adjusting the condensation stitch LU 2828 6 2828 7 72 24 Condensation cylinder LU 2818 7 2868 7 72 3 Portion to which LOCKTITE is applied 74 4 Selective parts and consumable parts 75 5 Applying grease 77 1 Applying grease 77 2 Greasing points 77 1 Needle bar rocking base...

Page 13: ...Link thread take up 14 Needle bar stroke 40 mm 15 Amount of the alternate vertical movement 1 mm to 9 mm 6 5 mm at the time of delivery 2 Alternate vertical dial adjustment type 16 Hook Full rotary vertical axis 2 fold hook Latch type 17 Feed mechanism Box feed 18 Top and bottom feed actuation mechanism Timing belt 19 Thread trimming method Cam driven scissors type 20 Lubrication Automatic lubrica...

Page 14: ...ead take up 14 Needle bar stroke 40 mm 15 Amount of the alternate vertical movement 1 mm to 9 mm 6 5 mm at the time of delivery 2 Alternate vertical dial adjustment type 16 Hook Full rotary vertical axis 2 fold hook Latch type 17 Feed mechanism Box feed 18 Top and bottom feed actuation mechanism Timing belt 19 Thread trimming method Cam driven scissors type 20 Lubrication Automatic lubrication by ...

Page 15: ... to changeover of single double tension 17 Hook Full rotary vertical axis 2 7 fold hook Latch type 18 Feed mechanism Box feed 19 Top and bottom feed actuation mechanism Timing belt 20 Thread trimming method Cam driven scissors type 21 Lubrication Automatic lubrication by oil tank with oil gauge 22 Lubricating oil JUKI New Defrix Oil No 1 equivalent to ISO standard VG7 or JUKI MACHINE OIL No 7 23 B...

Page 16: ... accidents caused by abrupt start of the sewing machine Standard adjustment Model Dimension E mm Gauge type LU 2810 7 5 0 1 Standard gauge type LU 2810 6 LU 2810 7 LU 2860 LU 2860 6 LU 2860 7 Conditions Needle bar at lowest dead point Feed amount 0 mm Height of feed dog 0 5 to 0 6 mm Highest position E Top surface of In case of 2 needle ...

Page 17: ...imension E then securely tighten clamping screw of the needle bar rock ing link 8 Loosen clamping screw left of the feed base arm 9 Move the feed base to adjust so that needle enters the center of the needle hole in feed dog Then securely tighten clamping screw left of the feed base arm a a 10 Perform the adjustment work of step 1 to 2 11 Tighten clamping screw right of the feed base arm 12 Check ...

Page 18: ...ustment Model group Model Dimension E mm Gauge type Z LU 2810 5 7 0 2 Europe gauge type LU 2810 6 LU 2810 7 LU 2860 LU 2860 6 LU 2860 7 Y LU 2828 6 LU 2828 7 X LU 2818 7 9 8 0 1 LU 2868 7 Conditions Needle bar at lowest dead point Feed amount 0 mm Height of feed dog 0 5 to 0 6 mm Highest position E Operator s side In case of 2 needle E Top surface of Model group Z Y Model group X ...

Page 19: ...mping screw of the needle bar rocking link a a Model group X 6 Loosen clamping screw of the needle bar rocking link 7 In the state that the presser foot is raised adjust the clearance between presser bar and walking bar to dimension E then securely tighten clamping screw of the needle bar rock ing link 8 Loosen clamping screw left of the feed base arm 9 Move the feed base to adjust so that needle ...

Page 20: ...ork so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment A Top surface of Model Dimension A mm LU 2810 0 5 to 0 6 LU 2810 6 LU 2810 7 LU 2860 LU 2860 6 LU 2860 7 LU 2828 6 LU 2828 7 LU 2818 7 LU 2868 7 Conditions Feed amount 0 mm Height of feed dog maximum Model Dimension A mm LU 2810 1 0 1 LU 2810 6 1 5 0 1 LU 2810 7 LU 2860 1 0 1 LU 2860 6 1 5 0 1 LU 2860 7...

Page 21: ...og comes in con tact with the knife and the knife and the feed dog may be damaged When the height of the feed dog is lower than the specified value o Stitch pitch becomes smaller than the scale of the feed dial o Feed force will be deteriorated Adjustment procedures Results of Improper adjustment 1 Loosen two setscrews of the hook 2 Draw out hook in the direction of the arrow 3 Loosen four setscre...

Page 22: ...ance of opener Model Dimension A mm LU 2810 0 7 to 0 9 LU 2810 6 LU 2810 7 LU 2860 0 9 to 1 1 LU 2860 6 LU 2860 7 LU 2828 6 0 7 to 0 9 LU 2828 7 LU 2818 7 LU 2868 7 0 9 to 1 1 Conditions When the opener comes nearest to the protruding portion of bobbin case Press the inner hook stopper against the groove in the throat plate B C A 2 needle Shorter remaining thread type 1 needle ...

Page 23: ...ner arm LU 2860 2860 6 2860 7 2828 6 2828 7 2818 7 2868 7 1 Turn the handwheel in its normal rotational direction to bring that opener comes nearest to the protruding portion of bob bin case 2 Turn inner hook in the direction of the arrow until inner hook stopper B is pressed against the groove in throat plate 3 Loosen two setscrews of the opener sleeve Adjust the clearance between the opener and ...

Page 24: ...NING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 2 Opener timing To be in contact To be in contact 2 needle 1 needle ...

Page 25: ... and the center G of inner hook and the base H of blade point of hook are aligned linearly when the needle bar has gone up and the opener comes nearest to the protruding portion of bobbin case Then tighten setscrew of the opener cam It can be said that opener is in the closest position to the hook in a certain phase angle range interval Press opener cam against lower shaft gear immediately before ...

Page 26: ...05 to 0 2 LU 2810 6 LU 2810 7 LU 2860 LU 2860 6 LU 2860 7 LU 2828 6 LU 2828 7 LU 2818 7 LU 2868 7 Conditions Feed amount 0 mm Needl bar rises from the lowest dead point of its stroke Model Dimension F mm Dimension G mm LU 2810SS 56 8 LU 2810AS 54 8 LU 2810S6 58 8 LU 2810A6 56 8 LU 2810S7 58 8 LU 2810A7 56 8 LU 2860SS 54 1 LU 2860AS 54 2 LU 2860S6 56 1 LU 2860A6 56 2 LU 2860S7 56 1 LU 2860A7 56 2 L...

Page 27: ...yelet 5 Align the largest scale mark of the standard stitch dial with the marker dot on the machine arm Check to be sure that blade point of the hook does not come in contact with the needle Caution The operation panel could come in contact with the thread stand when tilting the ma chine head To protect the relevant parts from contact shift the thread stand to a position at which the thread stand ...

Page 28: ...esser foot WARNING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 1 Hand lifter Conditions State that the hand lifter is raised 10 mm ...

Page 29: ...ilitate adjustment 5 In the state as described in the aforementioned step 4 bring hand lifter A and B into the state as illustrated in the figure and tighten clamping screw of the hand lifter A 6 Remove the 10 mm thick thing placed between the top surface of throat plate and the under surface of presser foot 7 Attach the motor cover 8 Attach the face plate When the lifting amount is higher than th...

Page 30: ...o prevent accidents caused by abrupt start of the sewing machine Standard adjustment 2 Knee lifter Without thread trimmer only Conditions Lifting amount when stopper screw of knee lifter rotation arm comes in contact with mahcine bed Knee lifter rotating arm 20 mm ...

Page 31: ...ove ment is set at 6 5 mm or more adjust that the height from the top surface of throat plate to the under surface of presser foot is 16 0 5 mm Step 7 to 8 is standard gauge type only Caution 1 Check to be sure that parts of the knee lifter mechanism does not come in contact with the frame and other parts around it when the knee lifter link C is positioned horizontally If the knee lifter link C co...

Page 32: ...med while the power is ON never touch the switches other than the necessary one so as to prevent accidents caused by the malfunction of switches Standard adjustment 3 Automatic presser foot lifter Machine with thread trimmer only 20 mm ...

Page 33: ... 3 5 Remove the 20 mm thick thing placed between the top surface of throat plate and the under surface of presser foot 6 Attach rubber cap from the rear face of the machine arm Caution For the standard gauge type machine the walking foot interferes with the needle bar when the amount of the alternating vertical movement of the walking foot and the presser foot is set at 6 5 mm or more To use the m...

Page 34: ...og is rised Model group Model Timing Z LU 2810 Needle bat at lowest dead point LU 2810 6 LU 2810 7 LU 2860 LU 2860 6 LU 2860 7 Y LU 2828 6 Position where needle is aligned with blade point of hook Hook adjustment position LU 2828 7 X LU 2818 7 LU 2868 7 Top end of needle top surface of throat plate and top surface of feed dog are aligned Model group Z Center of needle eyelet top surface of throat ...

Page 35: ...tion written on the left page 5 Tighten two setscrews of the vertical feed cam Standard 1 In case of model group Z When three points of top end of the needle top surface of the throat plate and top surface of feed dog are aligned with one another the setscrew No 1 of the vertical feed cam faces almost right below for the sewing machine 2 In case of model group Y When three points of center of need...

Page 36: ...ace of throat plate Top surface of throat plate Top surface of feed dog Model group Model Z LU 2810 LU 2810 6 LU 2810 7 LU 2860 LU 2860 6 LU 2860 7 Y LU 2828 6 LU 2828 7 X LU 2818 7 LU 2868 7 Top end of needle top surface of throat plate under surface of walking foot and top surface of feed dog are aligned Model group Z Center of needle eyelet top surface of throat plate under surface of walking f...

Page 37: ...tscrews of the top cover to remove the top cover 4 Loosen two setscrews of the top feed cam 5 Turn the top feed cam so that the needle the throat plate the walking foot and the feed dog are in the position written on the left page 6 Tighten two setscrews of the top feed cam 7 Attach the top cover Standard In case of model group Z When four points of top end of the needle top surface of the throat ...

Page 38: ...OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment Anti operator s side Operator s side C A B Center of elongate hole A Bottom feed amount is decreased B Bottom feed amount is increased ...

Page 39: ... s side and the throat plate at the position so that the needle is away from the feed dog Dimension C Standard gauge 4 0 2 mm Europe gauge 3 0 2 mm Standard When Adjust the position of hinge screw nut of the horizontal feed rear arm in the direction of arrow A the bottom feed amount is decreased When Ad just the position of hinge screw nut of the hori zontal feed rear arm in the direction of arrow...

Page 40: ...NING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment o Except for LU 2828 6 2828 7 o In case of LU 2828 6 2828 7 Conditions Feed amount 6 mm A B Notched part C D ...

Page 41: ... 1 Set the stitch dial to 6 2 Loosen three setscrews from rear side of the machine arm and remove the cylinder unit 3 Loosen setscrew of the feed adjusting base support shaft 4 Turn the feed adjusting base support shaft to adjust the stitch length o Direction C Reverse feed pitch is increased o Direction D Normal feed pitch is increased 5 After the adjustment securely tighten setscrew of the feed ...

Page 42: ...ING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment o In case of LU 2810 6 2810 7 2860 6 2860 7 2828 6 2828 7 2818 7 2868 7 o In case of LU 2810 2860 B A B 0 1 to 0 5mm ...

Page 43: ...o that a clear ance between the reverse feed lever plate and the stopper part B of machine arm is 0 1 to 0 5 mm Then tighten clamping screw of the feed adjusting pin support arm Caution Check that the reverse feed control lever does not interfere with the machine bed or machine arm when the stitch dial is set to the maximum When the position of the reverse feed control lever is low o Reverse feed ...

Page 44: ...ety clutch WARNING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 6 N m 1 2 3 25 N m 13 23 N m Standard of release pressure ...

Page 45: ...e ma chine bed strongly turn the handwheel in the reverse direction of rotation 3 Resetting procedure completes when the handwheel cannot be turned with click o Adjusting the working torque of the safety clutch 1 Tilt the machine head 2 Loosen setscrew located at the periphery of lower shaft sprocket wheel and turn release pressure adjusting pin to adjust the release torque After the adjustment ti...

Page 46: ...the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment o Except for LU 2828 6 2828 7 o In case of LU 2828 6 2828 7 Operator s side Operator s side Operator s side ...

Page 47: ...rame top feed changing base and connecting link 4 Evenly and securely tighten two setscrews of balancer o In case of LU 2828 6 2828 7 1 Loosen setscrews of the top cover to remove the top cover 2 Turn the handwheel to bring the thread take up lever to the upper dead point of its stroke 3 Place the balancer in the position shown in the figure At this time make a clearance so that the balancer do no...

Page 48: ...d cylinder WARNING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment o LU 2810 7 2860 7 o LU 2810 6 2860 6 2828 6 8 0 5 mm 12 mm 52 mm ...

Page 49: ... the feed adjusting link rod and the cylinder rod is 12 mm 2 Set the stitch dial to the maximum 3 Extend the cylinder rod up to the maximum At this time the clearance between the feed adjusting link rod and the cylinder rod is about 52 mm 4 Depress the reverse feed control lever and tighten clamping screw of the feed adjusting link arm Caution Before tightening clamping screw of the feed ad justin...

Page 50: ... 38 WARNING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment o LU 2828 7 o LU 2818 7 2868 7 6 0 5 mm 5 mm ...

Page 51: ...that a clearance between the nut and the cylinder connecting screw is 6 0 5 mm 3 Securely tighten the nut o LU 2818 7 2868 7 1 Loosen the nut 2 Adjust so that a clearance between the nut and the knuckle joint is 5 mm 3 Securely tighten the nut o Stitch lengths of the reverse feed may not be obtained ...

Page 52: ...k so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment A sheet of paper G C D B A LU 2810 2810 6 2810 7 2828 6 2828 7 2818 7 F E LU 2860 2860 6 2860 7 2868 7 H G Except for LU 2818 7 and 2868 7 Only for LU 2818 7 and 2868 7 Max Min ...

Page 53: ...approximately five seconds as shown in a sheet of paper Reference In the case the oil quantity in the hook cannot be adjusted to the proper quantity it should be ad justed by loosening nut and turning oil quantity adjustment screw The oil quantity in the hook is increased by turning the oil quantity adjustment screw counterclock wise C or is decreased by turning it clockwise D Also check to be sur...

Page 54: ...Standard adjustment 1 Position of the counter knife and the clamp spring 37 0 1 mm A LU 2818 7 34 5 0 1 mm 3 7 0 1 mm B Mounting groove of the slide plate To be in contact 37 0 1 mm A LU 2868 7 34 5 0 1 mm 37 0 1 mm A LU 2868 7 34 5 0 1 mm 3 7 0 1 mm B 3 7 0 1 mm B Mounting groove of the slide plate Mounting groove of the slide plate To be in contact To be in contact 1 needle 2 needle ...

Page 55: ... it press against the step difference of the counter knife base and adjust the distance to 3 7 0 1 mm B 4 Tighten setscrews 1 needle 2 positions 2 needle 4 posi tions of the clamp spring Caution When the position of counter knife and clamp spring is moved re adjust the position of counter knife base and the knife pressure When dimension A is larger o Length of bobbin thread clamp is shortened and ...

Page 56: ...work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 2 Position of the counter knife base 1 2 to 1 5 mm C 1 2 to 1 5 mm C 1 2 to 1 5 mm C 1 needle 2 needle A To be in contact To be in contact LU 2818 7 2868 7 ...

Page 57: ...stance from the throat plate to the counter knife is 1 2 to 1 5 mm C then tighten setscrews 1 needle 2 positions 2 needle 4 posi tions of the counter knife base Caution When the counter knife base is moved re adjust the knife pressure When dimension C is larger o Knife pressure is increased As a result motor stop will be caused o Setting taking out bobbin cannot be performed o Counter knife base i...

Page 58: ...prevent accidents caused by abrupt start of the sewing machine Standard adjustment 3 Vertical position of the moving knife Model Dimension D mm LU 2810 6 0 3 to 0 4 LU 2810 7 LU 2860 6 0 1 to 0 3 LU 2860 7 LU 2818 7 0 05 to 0 15 LU 2868 7 Adjust at the center part D ...

Page 59: ...en setscrews of the moving knife shaft thrust collar 4 Tighten clamping screw of the moving knife driving arm so that there is no thrust play at the moving knife shaft Caution Adjust the height of moving knife at the center part of moving knife When the clearance is larger o Clamp failure of needle thread and bobbin thread occurs When the clearance is smaller o Moving knife interferes with the inn...

Page 60: ...ork so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 4 Thread trimmer cam timing Conditions Two marker dots on the handwheel aligns with marker line on the motor cover B A Most advanced position of moving knife ...

Page 61: ...the thread trimmer cam Caution Check that the edge of thread trimmer cam comes in close contact with the edge of lower shaft set col lar When thread trimming timing is retarded o Thread trimming action does not complete even at the needle up stop position As a result de fective thread trimming will be caused When thread trimming timing is advanced o Defective thread trimming will be caused o Lengt...

Page 62: ... Standard adjustment 5 Position of the thread trimmer cam 6 Adjusting the knife pressure o Knife pressure o Initial position 0 1 0 05 mm Model Dimension E mm LU 2810 6 6 to 7 LU 2810 7 LU 2860 6 8 to 9 LU 2860 7 LU 2818 7 LU 2868 7 Model Dimension F mm LU 2810 6 2 0 5 LU 2810 7 LU 2860 6 0 0 5 LU 2860 7 LU 2818 7 LU 2868 7 F E ...

Page 63: ...sed by the clamp pressure So adjust the knife pressure in the state that the clamp pres sure is not applied to the knife 3 Tighten setscrews of the moving knife Caution Operate the sewing machine with the knife pressure minimized to such an extent that both needle and bobbin threads can be trimmed o Initial position 1 Loosen clamping screw of the moving knife driving arm 2 Adjust so that the dista...

Page 64: ...rting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 1 Adjusting the moving knife the counter knife and the bobbin thread clamp B 37 8 mm B Adjusting the counter knife position Adjusting the moving knife position 0 2 to 0 4 mm A 0 02 to 0 1 mm 1 0 to 2 0 mm ...

Page 65: ...ing the moving knife position 1 Adjust so that a clearance of 0 2 to 0 4 mm is provided be tween inner hook stopper A and moving knife Then fix the moving knife by tightening screws 2 Adjust so that a clearance of 1 0 to 2 0 mm is provided be tween the top end of moving knife and that of counter knife when the moving knife is in its return end the moving knife is in the standby state Then fix the ...

Page 66: ... to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 2 Adjusting the thread trimmer cam timing Adjusting the knife pressure Adjusting the bobbin thread clamp position Adjusting the bobbin thread clamp pressure 0 05 to 0 2 mm C D ...

Page 67: ...arm and the moving knife Adjusting the bobbin thread clamp pressure 1 Loosen screw Adjust the clamp pressure by turning the cramp arm in the direction of the arrow Adjust the clamp pressure so that the bobbin thread comes off at the pressure of 0 3 N 2 Adjusting the thread trimmer cam timing 1 Bring the moving knife to its front end At this time position the thread trimming cam so that the two mar...

Page 68: ...0 sti min 3 mm to less than 4 mm 2 400 sti min 2 000 sti min 1 800 sti min 4 mm to less than 5 mm 2 000 sti min 2 000 sti min 1 800 sti min 5 mm to less than 9 mm 1 800 sti min 1 800 sti min 1 800 sti min LU 2868 7 Less than 3 mm 2 700 sti min 2 000 sti min 1 800 sti min 3 mm to less than 4 mm 2 400 sti min 2 000 sti min 1 800 sti min 4 mm to less than 5 mm 2 000 sti min 2 000 sti min 1 800 sti mi...

Page 69: ... distance between the detection switch of the amount of alter nate vertical movement to the alternate vertical dial is 0 to 0 4 mm 4 Then tighten installing screws of the detection switch of the amount of alternate vertical movement Caution When the position of the detection switch of the amount of alternate vertical movement is changed check whether the relation between the alternate ver tical di...

Page 70: ...used by the malfunction of switches Standard adjustment The DL device is a device for maximizing the amount of alternate vertical movement when it is placed in ON When the cylinder is turned ON to maximize the amount of alternate vertical movement tighten clamping screw with the alternate vertical adjusting pin pressed against the dial cam plane DL switch ...

Page 71: ...oper adjustment 1 Set the alternate vertical dial to 9 2 Loosen clamping screw of the alternate vertical cylinder arm 3 Operate the DL device by 6 operations switch or knee switch 4 Tighten clamping screw of the alternate vertical cylinder arm ...

Page 72: ...t accidents caused by abrupt start of the sewing machine Standard adjustment Standard adjustment value is the location where the momentum is minimized Fix hinge screw of the vertical feed rod in the slot so that it is positioned at the farthest from the vertical feed shaft A Momentum increase Momentum decrease ...

Page 73: ...es Results of Improper adjustment 1 Loosen hinge screw of the vertical feed rod 2 Move the boss section A of the vertical feed cam rod to adjust the momentum 3 After the adjustment tighten hinge screw of the vertical feed rod ...

Page 74: ...N never touch the switches other than the necessary one so as to prevent accidents caused by the malfunction of switches Standard adjustment 1 LU 2810 6 2810 7 2860 6 2860 7 Zero point alignment for 2P feed adjustment Forward reverse stitch length of 2P feed adjustment Fig A Fig B ...

Page 75: ...stopper 3 Turn ON the 2P switch 4 Lower the reverse feed control lever to align the cam section 0 point position of the 2P feed adjusting base with the 2P feed adjusting pin Fig B 5 Turning the handwheel check to be sure that the stitch length is zero 0 This shows that the zero point alignment of the 2P feed adjustment has been correctly carried out Forward reverse stitch length of 2P feed adjustm...

Page 76: ...N never touch the switches other than the necessary one so as to prevent accidents caused by the malfunction of switches Standard adjustment 2 LU 2828 6 2828 7 Zero point alignment for 2P feed adjustment Forward reverse stitch length of 2P feed adjustment A B ...

Page 77: ...wer the reverse feed control lever to align the cam section 0 point position of the 2P feed adjusting base with the 2P feed adjusting pin Fig B 5 Turning the handwheel check to be sure that the stitch length is zero 0 This shows that the zero point alignment of the 2P feed adjustment has been correctly carried out Forward reverse stitch length of 2P feed adjustment 1 Loosen two setscrews of the fe...

Page 78: ...ile the power is ON never touch the switches other than the necessary one so as to prevent accidents caused by the malfunction of switches Standard adjustment 3 LU 2818 7 2868 7 Zero point alignment for 2P feed adjustment Contact Fig A Fig B ...

Page 79: ... align the cam section zero point position of the feed adjusting base B with the feed adjusting pin Fig B In that state tighten clamping screws of the feed adjusting pin support arm B 9 Turn the hexagonal shaft to clockwise until a light resistance is felt so that the feed adjusting dial screw is in contact with the feed adjusting base B 10 Attach the feed dial cover B using three setscrews of the...

Page 80: ...med while the power is ON never touch the switches other than the necessary one so as to prevent accidents caused by the malfunction of switches Standard adjustment Forward reverse stitch pitch of 2P feed adjustment Contact Fig A Fig B ...

Page 81: ...of the feed adjusting pin support arm B Be careful to loosen too much At this time fix the feed adjusting pin support arm B so that it does not move out of position 3 Slightly tilt the reverse feed lever and tighten clamping screws of the feed adjusting pin support arm B 4 Return to step 1 check forward reverse stitch length 5 Return to standard pitch Turn OFF the 2P switch loosen clamping screws ...

Page 82: ...NING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment Screw No 1 Screw No 2 Screw No 1 Screw No 1 Screw No 2 Screw No 2 Code portion Timing belt ...

Page 83: ...er of screw No 2 screw No 1 flat section the set screw to remove the hub R from the motor 8 Replace motor with a new one 9 And later perform re assembling in the reverse order Caution 1 Secure the clearance between the hub R and the motor is 0 65 mm 2 Attach so that the handwheel and the motor code is not come in contact with each other 3 Attach so that the handwheel and the motor cover is not com...

Page 84: ...ork so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment 24 Condensation cylinder LU 2818 7 2868 7 WARNING Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine Standard adjustment Contact 5 2 0 5 mm 1 2 3 4 ...

Page 85: ...tch Caution If the condensation amount is excessively small the material can be torn depending on the type of seam to cause stitch skipping This can cause a thread trimming failure Adjustment procedures Results of Improper adjustment 1 Set the stitch dial to 1 5 2 Loosen clamping screw of the condensation arm 3 Make cylinder retract the most At this time manually lower the reverse feed lever to pl...

Page 86: ... or the like to help remove the part No Portion to which LOCKTITE is applied Part No LOCKTITE No Remarks 1 Setscrew of coupling SM8050812TP LOCKTITE 243 2 Setscrew of handwheel SM6054502TN LOCKTITE 243 Only LU 2810 6 and 2860 6 No 1 No 2 Setscrews of coupling LOCKTITE applied Coupling Setscrews of handwheel LOCKTITE applied Handwheel A Handwheel A 1st setscrew 2nd setscrew A Caution When an assemb...

Page 87: ... 2818 7 2868 7 Feed rod pin C 40149127 Shaft diameter ø7 993 to ø7 998 mm LU 2828 6 2828 7 LU 2818 7 2868 7 Feed rod pin D 40149128 Shaft diameter ø7 989 to ø7 994 mm LU 2828 6 2828 7 LU 2818 7 2868 7 Moving knife spacer t 0 4 40147932 t 0 35 to 0 45 mm LU 2828 6 2828 7 Moving knife spacer t 0 5 40147933 t 0 45 to 0 55 mm LU 2828 6 2828 7 Moving knife spacer t 0 6 40147934 t 0 55 to 0 65 mm LU 282...

Page 88: ... LU 2828 6 2828 7 40147985 LU 2818 7 2868 7 Bobbin 21334800 Aluminum bobbin with knurl LU 2810 2810 7 LU 2810 6 2860 6 LU 2860 2860 7 40147913 LU 2828 6 2828 7 LU 2818 7 2868 7 Moving knife 21389200 LU 2810 7 2810 6 40132434 LU 2860 7 2860 6 40147938 LU 2828 6 2828 7 40147940 LU 2818 7 2868 7 Counter knife 21389309 LU 2810 7 2860 7 LU 2810 6 2860 6 LU 2818 7 2868 7 40135498 LU 2828 6 2828 7 Clamp ...

Page 89: ...s alarming is heard a grease up action has to be taken Caution 1 Never feed oil to the grease up spots 2 It must be noted that too much grease application may result in grease leakage from the thread take up lever cover section or the needle bar Exclusive grease Part No Part name 40006323 JUKI grease A 2 Greasing points 1 Needle bar rocking base 1 Remove face plate 2 Remove rubber plugs 3 Fill gre...

Page 90: ...et felt clamp to alternate vertical change base and fix it with setscrews of felt clamp 7 Attach two return springs of alternate vertical change base 8 Attach top cover 3 Horizontal feed change base 1 Remove rear cover 2 Loosen setscrews of felt clamp to remove felt clamp 3 Apply JUKI grease A to felt 4 Apply JUKI grease A to sliding surfaces of horizontal feed change base and feed conversion link...

Page 91: ...cation drawing Indicating the points where grease is applied at shipment JUKI Grease A Part No 40006323 10g tube or 23640204 100g tube Unirex N3 Part No 13525506 10g tube Barch L1002 1 MAIN SHAFT THREAD TAKE UP LEVER COMPONENTS ...

Page 92: ... 80 2 NEEDLE BAR COMPONENTS ...

Page 93: ... 81 3 HOOK OPENNER COMPONENTS ...

Page 94: ... 82 4 UPPER FEED COMPONENTS ...

Page 95: ... 83 5 HAND LIFTER AUTO LIFTER COMPONENTS 6 KNEE LIFTER COMPONENTS FOR LU 2810 2860 ...

Page 96: ... 84 7 LOWER FEED COMPONENTS ...

Page 97: ... 85 LOWER FEED COMPONENTS FOR LU 2828 6 2828 7 ...

Page 98: ... 86 8 FEED ADJUST COMPONENTS ...

Page 99: ... 87 FEED ADJUST COMPONENTS FOR LU 2828 6 2828 7 ...

Page 100: ... 88 FEED ADJUST COMPONENTS FOR LU 2818 7 2868 7 ...

Page 101: ... 89 9 DL COMPONENTS FOR LU 2810 6 2810 7 2860 6 2860 7 10 AUTO BT COMPONENTS FOR LU 2810 7 2860 7 ...

Page 102: ... 90 AUTO BT COMPONENTS FOR LU 2810 6 2860 6 2828 6 AUTO BT COMPONENTS FOR LU 2828 7 ...

Page 103: ... 91 AUTO BT COMPONENTS FOR LU 2818 7 2868 7 ...

Page 104: ... 92 11 THREAD TRIMMING COMPONENTS FOR LU 2810 6 2810 7 2860 6 2860 7 2828 6 2828 7 2818 7 2868 7 ...

Page 105: ... 93 THREAD TRIMMING COMPONENTS FOR LU 2828 6 2828 7 ...

Page 106: ... 94 12 THREAD TENSION COMPONENTS FOR LU 2810 2810 6 2810 7 2828 6 2828 7 2818 7 ...

Page 107: ... 95 13 THREAD TENSION COMPONENTS FOR LU 2860 2860 6 2860 7 2868 7 ...

Page 108: ... 96 14 TENSION RELEASE COMPONENTS FOR LU 2810 6 2810 7 2860 6 2860 7 2828 6 2828 7 2818 7 2868 7 ...

Page 109: ... 97 15 BOBBIN WINDER COMPONENTS ...

Page 110: ... 98 16 CONDENSE COMPONENTS FOR LU 2818 7 2868 7 ...

Page 111: ... Engraved marker dots on the handwheel for the machine with thread trimmer only UP stop position One marker dot Adjustment of thread trimmer cam Two marker dots Adjustment of opener timing Three marker dots ...

Page 112: ...n switch 10 6 operation switch Fall detection sensor 11 6 operation switch 12 6 operation switch GND 13 6 operation switch GND 14 15 6 operation switch Alternate vertical movement state monitor output 16 6 operation switch Automatic reverse feed stitch ing cancellation state monitor output 17 6 operation switch Needle up down correction operation output 18 6 operation switch 2 pitch state output 1...

Page 113: ...860 6 1 Wiring diagram Details of the connectors wired to the machine head are as described below Refer to 2 Details of connectors on the next page for details of connectors to and layout of the pins Tension release solenoid upper side Tension release solenoid lower side Alternate up down limit switch Reverse feed switch 6 operation switch Thread trimming solenoid right side Thread trimming soleno...

Page 114: ...ector pin number Connector 5 4 3 2 1 10 9 7 6 Pin No Part name Color of cable Remarks 1 Alternate up down limit switch lower side White 2 Alternate up down limit switch upper side Red 3 Alternate up down limit switch lower side Black GND 4 Alternate up down limit switch upper side Green GND When connecting the connectors to the control box prepare a junction cord using the below stated connector p...

Page 115: ...V connector is connected to this switch the LED burnout can occur 2 6 operation switch Orange black dot 1 SW1 DLSW 3 Gray red dot 1 SW2 Automatic reverse feed prohibition switch 4 6 operation switch Gray black dot 1 SW3 One stitch correction switch 5 6 operation switch White red dot 1 SW4 Pitch changeover switch 6 6 operation switch White black dot 1 SW5 Thread tension changeover switch 7 6 operat...

Page 116: ...Solenoid valve CN155 Black 2 pitch cylinder 6 7 Solenoid valve CN151 Red 24V 8 Solenoid valve CN152 Red 24V 9 Solenoid valve CN153 Red 24V 10 11 Solenoid valve CN155 Red 24V 12 When connecting the connectors to the control box prepare a junction cord using the below stated connector pin ter minal Part number of the target connector HK034620120 MOLEX 5559 12P Part number of the target pin terminal ...

Page 117: ...D 13 14 15 6 operation switch Alternate vertical movement state monitor output 16 6 operation switch Automatic reverse feed stitch ing cancellation state monitor output 17 6 operation switch Needle up down correction operation output 18 6 operation switch 2 pitch state output 19 6 operation switch Tension increasing state mon itor output 20 6 operation switch Thread clamp solenoid en able disable ...

Page 118: ...id valve 24V 4 LU 2828 6 1 Wiring diagram Details of the connectors wired to the machine head are as described below Refer to 2 Details of connectors on the next page for details of connectors to 1 and layout of the pins CN158 4P connector Alternate up down limit switch lower side Alternate up down limit switch upper side 1 CN37A 2P connector Thread clamp solenoid junction cord Tension release sol...

Page 119: ...nector pin number Connector 5 4 3 2 1 10 9 7 6 Pin No Part name Color of cable Remarks 1 Alternate up down limit switch lower side White 2 Alternate up down limit switch upper side Red 3 Alternate up down limit switch lower side Black GND 4 Alternate up down limit switch upper side Green GND When connecting the connectors to the control box prepare a junction cord using the below stated connector ...

Page 120: ...peration switch Orange black dot 1 SW1 DLSW 3 6 operation switch Gray red dot 1 SW2 Automatic reverse feed prohibition switch 4 6 operation switch Gray black dot 1 SW3 One stitch correction switch 5 6 operation switch White red dot 1 SW4 Pitch changeover switch 6 6 operation switch White black dot 1 SW5 Thread tension changeover switch 7 6 operation switch Yellow red dot 1 SW6 Thread clamp switch ...

Page 121: ...g the below stated connector pin ter minal Part number of the target connector HK034620120 MOLEX 5559 12P Part number of the target pin terminal HK034630000 MOLEX 5558TL 2 1 4 3 5 6 8 7 10 9 11 12 CN37 2P connector Thread clamp solenoid Pin No Part name Color of cable Remarks 1 Thread clamp solenoid Blue 2 Thread clamp solenoid Blue Power supply 27 V When connecting the connectors to the control b...

Page 122: ...Fall detection sensor 11 6 operation switch 12 6 operation switch GND 13 14 15 6 operation switch Alternate vertical movement state monitor output 16 6 operation switch Automatic reverse feed stitch ing cancellation state monitor output 17 6 operation switch Needle up down correction operation output 18 6 operation switch 2 pitch state output 19 6 operation switch Tension increasing state mon itor...

Page 123: ...ead trimmer solenoid right side 27V 10 Thread release solenoid upper side 27V 11 Thread trimmer solenoid left side 27V 12 13 Reverse feed switch 14 o CN102 12P connector Pin No Part name Remarks 1 Solenoid valve Presser lifting cylinder 2 Solenoid valve Reverse feed cylinder 3 Solenoid valve Alternate vertical movement cyl inder 4 Solenoid valve Short stitch Condensation stitch 5 Solenoid valve 2 ...

Page 124: ...e thread tension is too high Adjust the needle thread tension 2 2 Needle comes in contact with the blade point of hook 2 A Check the clearance Refer to 2 6 Needle to hook timing 2 3 Clearance of opener is too large 3 A Check the clearance Decrease the clearance Refer to 2 5 Adjusting the opener 2 4 Amount of oil in the hook is insuffi cient 4 A Check the amount of oil in the hook Adjust the amount...

Page 125: ...se the tension of of the thread take up spring and increase the stroke of the spring 3 3 Feed timing is not proper Refer to 2 8 Feed adjustment 3 4 Timing between the needle and the hook is excessively advanced or retarded 4 A Check the specified dimension Refer to 2 6 Needle to hook timing 3 5 Thread melts due to needle heat Decrease the sewing speed Use silicon oil Refer to below 3 6 Amount of o...

Page 126: ... the needle bar Refer to 2 6 Needle to hook timing 4 5 Blade point of the hook is blunt 5 A Check the blade point of the hook Correct the blade point of the hook or replace the hook with a new one 4 6 Improper type of needle is used Replace the needle with one which is thicker than the current needle by one count 4 7 Hook needle guard is not unctioned 7 A Check the functional amount of the needle ...

Page 127: ... top divid ed type Use the optional walking foot and presser foot 5 5 Height of the feed dog is too high 5 A Compare the height with the standard value Refer to 2 3 Height of the feed dog Lower the height by 0 2 mm than the standard value 5 6 Feed timing is excessively advanced Retard the feed timing 5 7 Hard to slip thread is used Use silicon oil Refer to below Use separately available parts belo...

Page 128: ...7 3 Bobbin fails to move smoothly 3 A Check the change of bobbin thread tension Replace the bobbin or the hook with new ones 7 4 Bobbin thread tension is too low Increase the tension of the bobbin thread 7 5 Bobbin has been wound too tight or too weak 5 A Check the state of bobbin wind ing Decrease or increase the tension applied to the bobbin winder 7 6 Direction of setting bobbin is reverse 6 A ...

Page 129: ...ere are scratches on the moving knife and the hook Polish with buff or replace the part with a new one 1 F Presser foot drops from cloth at the time of thread trimming Perform thread trimming on cloth 1 2 Bobbin thread is not clamped 2 A Position of the clamp spring Refer to 2 16 1 Position of the counter knife and the clamp spring 2 B Pressure of the clamp spring is too low Refer to 2 16 1 Positi...

Page 130: ...ng the knife pressure and 2 16 1 2 and 3 Position of the moving knife and Position of the counter knife 1 B The blades of moving knife and counter knife have worn out or broken Replace the moving knife and counter knife with new ones 1 C Pressure of the counter knife is insuffi cient Refer to 2 16 6 Adjusting the knife pressure 1 D Presser foot drops from cloth at the time of thread trimming Perfo...

Page 131: ... cam timing 3 G Thread is not cut sharply Refer to causes Thread cannot be trimmed and Thread remains uncut after trimming 3 4 Needle thread is not caught 4 A Stitch skipping at the last stitch Refer to 2 6 Needle to hook timing 4 B Check the thread trimmer cam timing Refer to 2 16 4 Thread trimmer cam timing 4 C Top end of the moving knife is broken or has burrs Replace the moving knife with a ne...

Page 132: ...16 4 Thread trimmer cam timing Replace the thread trimmer solenoid with a new one 6 D Presser foot drops from cloth at the time of thread trimming Perform thread trimming on cloth 4 Thread slips off the needle eyelet simultaneously with thread trimming 4 1 Thread tension given by the tension controller No 1 is too high Decrease the thread tension given by the tension controller No 1 4 2 Thread tak...

Page 133: ...ead guide to the needle thread presser 40034675 supplied with the unit and turn OFF the needle thread clamp changeover switch Only LU 2828 6 and 2828 7 6 Faulty intertwining of the needle thread and bobbin thread at the beginning of sewing 6 1 Bobbin thread clamp pressure is high Decrease the bobbin thread clamp pressure 7 Thread is not cut sharply 7 1 Bobbin thread tension is too low Increase the...

Page 134: ...lt the remaining needle thread is left on the right side of the sewing product 11 1 The thread clamp releases the needle thread while the operator is taking out the sewing product from the sewing machine with the presser foot lifted In this case the needle thread is drawn together with the sewing product Change the thread clamp ON retention time while the presser foot is being lifted and the sewin...

Page 135: ...ubrication Circulation Oil tank Oil regulating valve Pump To oil pan Oil filter Oil filter Distributor To hook shaft gear To hook To oil pan To oil tank To oil tank Details of pump To distributor Details of distributor To pump To oil regulating valve To oil tank To hook shaft gear ...

Page 136: ...ubrication Circulation Oil tank Pump To oil pan Oil filter Oil filter Distributor A Distributor right Distributor left To hook shaft gear right To hook shaft gear left Joint A Joint C Joint B To left hook To right hook Distributor left Distributor right Details of distributors left and right To pump To distributor A To right hook To left hook Joint A Joint B ...

Page 137: ...20 Drill a hole at the time of set up B Installing position of drawer stopper on the bottom surface C ø16 depth 25 D ø17 drilled hole E 3 ø13 drilled hole F 2 ø3 5 depth 10 G 2 ø3 5 depth 10 H 8 ø2 7 on the bottom surface depth 6 Drill a hole at the time of set up Y Y 2 locations V V 2 locations U U 2 locations W W 3 locations X X Z Z T T ...

Page 138: ... of set up B Installing position of drawer stopper on the bottom surface C ø16 depth 25 D ø17 drilled hole E 3 ø13 drilled hole F 2 ø3 5 depth 10 G 2 ø3 5 depth 10 H 8 ø2 7 on the bottom surface depth 6 Drill a hole at the time of set up I ø20 drilled hole Y Y 2 locations V V 2 locations U U 2 locations W W 3 locations P P X X Z Z T T ...

Page 139: ... 2 R 2 R 101 5 193 220 15 5 0 5 1200 1 6 0 5 2 3 13 0 5 0 50 1 202 5 50 80 52 5 4 R8 4 R8 4 R8 18 20 0 5 0 Ø26 14 5 0 5 0 25 40 362 100 14 9 80 8 5 24 75 21 0 5 0 50 116 55 27 5 22 5 175 535 35 70 90 2 40 50 25 205 390 15 104 29 0 5 29 0 5 21 5 8 60 30 8 5 Ø 40 Ø 40 Ø 8 R A B D C E F G H I J Part No 40139494 A 4 ø3 4 on the bottom surface depth 20 Drill a hole at the time of set up B Installing po...

Page 140: ...0 R 8 R 8 R 8 R 8 R 242 5 R 242 5 R 10 R 1 0 R 20 5 R 8 R 8 R 8 R 8 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 1 0 R 2 R 30 R 30 R 20 2 R 2 R 331 1200 20 5 0 5 50 50 13 5 2 3 1 8 193 101 5 90 217 2 10 35 29 0 5 29 0 5 40 50 13 5 535 22 5 149 15 390 25 24 120 80 80 18 75 362 100 40 28 50 Ø8 5 20 0 5 0 21 Ø26 8 5 25 24 171 5 30 40 Ø 40 Ø 0 5 0 0 5 0 0 5 0 1 0 5 0 5 0 W U U V V Y Y Z Z Z Z Y Y X X X X V V U U 2ヶ所...

Page 141: ...7 5 R 10 R 10 R 10 R 3 0 R 30 R 3 0 R 20 R 22 5 R 10 R 10 R 2 R 2 R 2 R 2 R 2 R 2 R 20 5 R 10 R 2 0 R R10 10 R 30 R 242 5 R 120 1200 101 5 193 220 2 0 5 0 5 2 3 20 5 0 5 1 50 13 5 50 80 8 5 55 116 25 40 Ø26 362 18 80 8 5 20 0 5 0 21 100 24 75 50 8 175 390 40 2 22 5 535 29 0 5 29 0 5 8 50 15 24 25 40 Ø 40 Ø 30 Ø8 5 Ø8 5 0 5 0 0 5 0 0 5 0 1 0 5 Q R R R R Y Y V V U U U 2ヶ所 W W W W W V V U U Y Y V V U...

Page 142: ......

Page 143: ... 206 8551 JAPAN PHONE 81 42 357 2371 FAX 81 42 357 2274 http www juki com An environmental management system to promote and conduct the following 1 Eco friendly development of products and technologies 2 Green procurement and green purchasing 3 Energy conservation reduction in carbon dioxide emissions 4 Resource saving reduction of papers purchased etc 5 Reduction and recycling of waste in the act...

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JUKI LU-2800 Series, Engineer'S Manual

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