JUKI APW-895 Engineer'S Manual Download

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40052509

No.E375-00

ENGINEER’S MANUAL

Lockstitch, Automatic Welting Machine

APW-895

(Parallel Pocket with Flap Sewing)

Summary of Contents for APW-895

Page 1: ...40052509 No E375 00 ENGINEER S MANUAL Lockstitch Automatic Welting Machine APW 895 Parallel Pocket with Flap Sewing ...

Page 2: ...n which are not covered in the Instruction Manual It is advisable to use the Input Instruction Manual relevant Instruction Manual and Parts List together with this Engineer s Manual when carrying out the maintenance of these machines 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 form...

Page 3: ...justment the bobbin thread remaining amount detection 25 20 Lower shaft area 27 2 Unit and related sections 29 1 Binder adjustments 29 2 Clamp foot operation 35 3 Tension adjustment of clamp foot feed belt 37 4 Stop position adjustment for forward end or backward end of clamp foot feed 37 5 Positioning adjustment of welting patch folding plate 39 6 Adjustment of parallelism of welting patch foldin...

Page 4: ...n the control box and installation position 137 2 Function of boards in the operation panel IP 310 and installation position 137 3 Function of INT board relay board and installation position 138 4 Function of PMDC board optional component and installation position 138 2 Replacement of part 139 1 Replacement of fuses 139 2 Replace the board 139 3 Description of dip switches 143 1 MAIN board dip swi...

Page 5: ...11 Air circuit diagram 202 12 Circuit diagrams 203 1 Block diagram 203 2 Connection diagram 204 1 Diagram 1 204 2 Diagram 2 205 3 Diagram 3 206 4 Diagram 4 207 ...

Page 6: ...13 Control By a micro computer Machine operation is automatically stopped if the cloth feed mechanism error detector the needle thread breakage detector or anu of the various safety devices is actuated 15 Lubricating oil JUKI New Defrix Oil No 1 equivalent to ISO VG7 16 Grease 1 JUKI Grease A 2 JUKI Grease B 17 Operating air pressure Standard 0 5MPa 18 Air consumption 40dm3 min ANR Dimensions of W...

Page 7: ...ker unit Optional G Sewing machine head H Electric control unit Control panel I Operation panel J Power switch K Temporary stop switch With this machine consisting of the aforementioned 11 units you can do desired welting work simply by setting materials garment body interlining piece welting patch etc in place and operating the switches on the operation panel In addition when temporary stop switc...

Page 8: ...3 Standard Adjustment 1 Machine head 1 How to change the timing belt 3 Flat in front Arm inner diameter Up dead position No 1 screw Flat Flat 0 5mm Arm hole Driving Standard Adjustment Parts no 40029049 ...

Page 9: ...e inner diameter of the arm apply a sealant of medium or higher strength and drive the rear bearing until it stops in the interior 12 Tighten two setscrews from the armhole There is no flat section 13 Join the flat section of the main shaft with the first screw of the pulley and mount the pulley At that time the clearance should be about 0 5mm between the pulley and the arm 14 Turn the pulley and ...

Page 10: ...needle bar height 5 3 Front or rear adjustment of needle bar rocking base Lower dead point marker of needle bar Blindstitch marker of hook blade tip Eccentricity Origin position Standard Adjustment Standard Adjustment ...

Page 11: ...at plate 3 If the needle motion is not uniform insert a tool from the hole on the top surface of machine arm and loosen the needle bar rocking arm setscrew for adjustments 4 In the case of eccentricity to the left confirm whether the sensor slit is located in the edge position of the sensor 5 In the case of deflection loosen the sensor slit setscrew or the sensor setscrew for adjustments For fine ...

Page 12: ... position for needle thread trimming unit 7 5mm 30 to 32mm Clearance 5 Adjustment of needle thread trimmer sharpness 6 Replacement of needle thread knife Same surface Standard Adjustment Standard Adjustment Standard Adjustment ...

Page 13: ...dle thread clamp is more than 2 9N 300g both right and left In the case when this force is not secured select an adequate spacer The spacer has four types of thickness 0 2mm 0 4mm 0 6mm and 0 8mm 1 Loosen the setscrew and remove the pin Then the moving knife can be pulled off downwards 2 Install a new moving knife and insert the pin At that time the pin should be held almost in the same plane of t...

Page 14: ...7 Adjusting the bobbin thread trimming knife 9 A B Standard Adjustment ...

Page 15: ...oat plate and the bobbin thread trimming knife are joined in the same plane 3 Loosen the setscrew of the right bobbin thread trimmer and make adjustments so that the upper surfaces of the throat plate and the bobbin thread trimming knife are joined in the same plane Caution Be aware that the bobbin thread trimming knife should be below the top surface of the throat plate 4 Push the bobbin thread t...

Page 16: ...8 Height adjustment of center knife 11 9 Adjustment of center knife link Knife bar connection Screw hole 0 to 0 3mm Tightening screw hole Level Metal Standard Adjustment Standard Adjustment ...

Page 17: ...trated 12 1 Remove the four set screws and remove the face plate 2 Confirm that Link A is maintained level at the lower dead point of the center knife 3 If the horizontality of Link A is not secured insert a tool from the tightening screw hole and loosen the driving arm tightening screw Where Link A is maintained level tighten the driving arm tightening screw again At that time the driving arm sho...

Page 18: ...motion stop 13 11 Timing adjustment of needle and hook Protruded Coincidence of shaft centers 1 3 0 2mm Blade point 3 5mm Withdrawn Lifting position Needle Blade point 0 to 0 05mm 0 to 0 03mm Standard Adjustment Standard Adjustment ...

Page 19: ... At that time the clearance between the needle side surface and the hook holder shall be 0 to 0 05mm the clearance between the needle side surface and the blade point shall be 0 to 0 03mm and the distance between the upper end of the needle hole and the blade point shall be 1 3 0 2mm 2 Adjustment of hook timing 1 Loosen three setscrews of small gears located on the hook shaft and turn the hook Whe...

Page 20: ...12 Adjustment of clearance between needle and hook 13 Installing and removing of hook 14 Opener adjustment 15 0 2 to 0 3mm Standard Adjustment ...

Page 21: ...ce then remove the hook Installing of the hook 1 Reassembly can be carried out in the reverse order for disassembly Caution 1 When the hook is installed confirm that the washer is inserted in between the hook shaft lower metal and the hook shaft small gear 2 When mounting the throat plate turn the inner hook by hand so that its embossed part is entered in the groove of the throat plate Since then ...

Page 22: ...15 Wiper adjustment 17 A B C D E F 5 1mm 21 1mm Standard Adjustment 1 mm 0 0 5 ...

Page 23: ...troke adjustments tighten the fixing nut of the wiper stopper and fix the wiper stopper Caution If the stroke is changed the clearance is also changed between wiper s lower end surface C and the head section D when the wiper cylinder is returned Therefore loosen the wiper unit setscrew to adjust the unit overall so that the clearance between wiper s lower end surface E and the head section F attai...

Page 24: ...of hook oil amount Minimum Maximum Oil splashed Plunger To the hook shaft base To oil tank 2 Cleaning of the filter section 3 Setting for hook oil amount check B A H C D F G E Standard Adjustment Oil amount decreases Oil amount increases ...

Page 25: ...pper to take out the tube and the joint 3 After the removal of dust attached to the net area of the joint recover the initial state 3 Setting for hook oil amount check 1 Display the check program menu screen When the key is kept pressed for 3 seconds a check program button A is displayed in the screen When this button is pressed the check program menu screen is displayed 2 IO1 head aging mode Pres...

Page 26: ...hanging the amount of motion for the thread take up spring Stroke 14 2mm 2 When changing the strength of the thread take up spring Thread take up spring tension 1mm 0 25N 25g Standard Adjustment Thread take up spring tension 1mm 0 25N 25g Stroke 14 2mm ...

Page 27: ...ution When the second thread tension setscrews left and right are loosened the amount of disk floating may become change Check 18 Adjustment of floating amount of the thread tension disk again 2 When changing the strength of the thread take up spring 1 When changing the strength of the right thread take up spring turning the spring shaft to the right causes the strength to increase and turning it ...

Page 28: ...18 Adjustment of floating amount of the thread tension disk 23 A B Same surface Standard Adjustment ...

Page 29: ...linder and take out the disk floating unit 2 Loosen the fixing nut of the disk floating cylinder and move the disk floating cylinder in the direction of the arrow Adjustment of the disk floating cylinder o Moving it in Direction A causes the amount of disk floating to increase o Moving it in Direction B causes the amount of disk floating to decrease Reassembly can be carried out in the reverse ord...

Page 30: ...dicator OFF stability display Lit in green Orange unlit ON stability display Lit in green and orange Both unlit or lighting in orange only indicates an unstable condition B 1 Sensor lateral direction 2 Adjustment of the sensor lateral direction 3 Method of sensor check A Standard Adjustment ...

Page 31: ... 3 Set a bobbin case in the inner hook and slowly pull out the thread until the bobbin reflector seal taps the sensor s optical axis section When the sensor is actuated at that time and the sensor indicator light is lit in orange this is the sign for the completion of adjustments 4 To confirm whether the sensor performs detection assuredly even when the bobbin case is moved to the right and left a...

Page 32: ...20 Lower shaft area 27 Plunger groove A B A B L R 1 Adjustment of the lower shaft gear 2 Replacement of the lower shaft Standard Adjustment Mounting direction of the spacer B Hook shaft base ...

Page 33: ...in a set Set part No 40044641 2 The lower shaft face and the gear face have their appropriate directions of assembly Conform to the assembly diagram When plunger groove is positioned downwards o the engraved marking L of the left side lower shaft gear comes to lower side as the lower shaft gear is seen from Direction A o the engraved marking R of the right side lower shaft gear comes to lower side...

Page 34: ...r cylinder begins to be driven and the binder lowers to the section between the right and left clamp foot After the completion of sewing and corner knife actuation the binder is raised at the end of backward return by the return action of the air cylinder until its original position is recovered Standard Adjustment ...

Page 35: ...he lock base Since then deflect the entire slide base in the direction of the arrow around the center of the pivot shaft in order to secure the parallelism between side face of the slide base and that of the machine head After parallelism adjustments tighten the fixing screw assuredly Adjustment Procedures Results of Improper Adjustment ...

Page 36: ...1 2 Adjustment of binder fall position Binder Sewing table When the stitch width is 10mm 0 5 to 1 0mm Sewing machine needle Binder fulcrum shaft 5 0 5mm BINDER_FITING_BASE Standard Adjustment 10mm 5mm 5mm ...

Page 37: ... line loosen the setscrew securing the binder mounting base and the screw securing the thrust collar and adjust the position of the binder in the right left direction After adjustments let the thrust collar contact the binder mounting base and tighten the respective screws and 4 The dimension from the needle settle position to the rear end of the welting patch scale shall be approximately 5 0 5mm ...

Page 38: ... 33 3 Adjustment of concentricity between 4 Adjustment of binder levelness pocket bag scale and needle center 0 5 to 1 0mm 0 1 to 0 6mm 5 Adjustment of materials guide Standard Adjustment 1mm 1mm ...

Page 39: ...tality tighten the fixing screw securely 4 For the adjustment of clearance 1mm between the lower face of the welting patch scale and the upper face of the sewing table try to turn the cylinder sahft as illustrated Loosen the lock nut and turn the cylinder shaft in the direction of tightening the shaft onto the cylinder joint to let the welting patch scale rise or in the direction of loosening the ...

Page 40: ...lamp foot operation 35 Unilateral bilateral welt changeover cylinder Unilateral bilateral welt changeover cylinder Slide base Folding cylinder Folding cylinder Flap presser Flap presser Standard Adjustment ...

Page 41: ...left side clamp foot cylinder is actuated the left side clamp foot lowers to complete the garment body clamp 2 In the case of flap sewing set the right or left flap material and tread on the pedal switch Then the flap presser cylinder is actuated to clamp the flap in the specified position Adjustment Procedures Results of Improper Adjustment ...

Page 42: ...clamp foot feed 37 Backward end position 155mm 315mm Needle center Forward end position 80mm 220mm 15mm 30mm For origin sensing For step out sensing 10 2 0 98N 9 4mm Standard Adjustment 3 Tension adjustment of clamp foot feed belt 4 Stop position adjustment for forward end or backward end of clamp foot feed ...

Page 43: ...s illustrated o For the clamp foot forward end the garment body clamp tip shall be positioned 315mm from the needle center o For the clamp foot forward end the garment body clamp tip shall be positioned 155mm from the needle center 2 When the origin detection sensor is ON the clamp foot advances by 30mm and then stops 3 If the dimensions are not as shown in the figure loosen the lock nut and turn ...

Page 44: ...elism of welting patch folding 39 Position of 220mm movement 1 5 to 2 0mm 1 5 to 2 0mm Sewing machine needle Left folding plate Right folding plate Standard Adjustment 5 Positioning adjustment of welting patch folding plate 6 Adjustment of the parallelism of welting patch folding ...

Page 45: ...f the arrow for adjustments 6 Adjustment of the parallelism of welting patch folding 1 When it is moved by 220mm from the clamp foot forward end the difference between the needle center and the folding end face shall be 0 15mm or less 2 If the parallelism is not secured loosen the setscrew for adjustments Adjustment Procedures Results of Improper Adjustment ...

Page 46: ...ent of parallelism of right and left garment body clamp and welting patch scale 41 1 3 0 2mm 1 3 0 2mm Standard Adjustment 7 Positioning adjustment of right and left garment body clamp 8 Adjustment of parallelism of right and left garment body clamp and welting patch scale ...

Page 47: ...Adjustment of parallelism of right and left garment body clamp and welting patch scale 1 When it is moved by 220mm from the clamp foot forward end the difference between the welting patch scale and the end face of the left garment body clamp and right garment body clamp shall be 0 15mm or less 2 If the parallelism is not secured loosen the fixing screw for adjustment by lowering the serge back cla...

Page 48: ... 11 Positioning adjustment of flap scale and flap stopper 43 Top surface of sewing table Garment body clamp 25 1mm 6 5 0 5mm Standard Adjustment 9 Adjustment of released presser height 10 Positioning adjustment of the flap presser 11 Positioning adjustment of flap scale and flap stopper ...

Page 49: ...tion of the flap presserr For this adjustment however never fail to adjust the parallelism for the folding plate and the flap presser 11 Positioning adjustment of flap scale and flap stopper 1 In conjunction with the flap length loosen the setscrew of the flap scale for adjustment 2 The flap stoppers A and B used to set up the flap materials shall be mainly adjusted by loosening the setscrew accor...

Page 50: ...fe B position of sewing start moves to the position that is proportionate to the preset sewing length 2 At the end of movement the moving side corner knife B and the fixed side corner knife C position of sewing end begin to be raised by the respective elevator air cylinders D and E to cut the material A B C D E Standard Adjustment ...

Page 51: ...stment draw out the corner knife unit before adjustments 2 After completion of the adjustment be sure to conduct the tests sufficiently to ensure that no defective cutting occurs before regular operation Adjustment Procedures Results of Improper Adjustment ...

Page 52: ...orner knife 14 Tension adjustment of corner knife feeding belt 47 5 0 5mm 4 4mm 4 6 0 6N Oblong hole Standard Adjustment Drive side pulley 13 Height adjustment of corner knife 14 Tension adjustment of corner knife feeding belt ...

Page 53: ...elt 1 Loosen the fixing screw and the lock nut and move the follower side pulley along the oblong hole of the base By moving the adjusting screw forward and backward the follower side pulley can be moved 2 When a pressing force of 4 6 0 6N is applied to the center of the pulley exert a tension to a degree where a deflection of 4 4mm is caused 3 After adjustments tighten the fixing screw and the lo...

Page 54: ...5 1mm B 1mm 145 1mm A 1mm Needle center Counter corner knife Moving corner knife Origin sensing photo switch Origin detector plat G Gauge size mm 8 10 12 14 16 18 20 A Assemblying dimensions mm 131 5 130 130 126 9 125 3 123 8 122 4 B Assemblying dimensions mm 31 9 35 35 41 2 44 3 47 4 50 Standard Adjustment ...

Page 55: ... secured even after the adjustment by loosening the setscrew try to loosen the setscrew for another adjustment 3 If the dimension of the moving corner knife cannot be secured even after the adjustment by loosening the setscrew try to loosen the fixing screw and shift the switch mounting bracket for adjustment Adjustment Procedures Results of Improper Adjustment ...

Page 56: ... Movement of 220mm Locus of corner knife movement A deflection of 0 0 5mm per movement of 220mm Needle center Sewing machine needle Normal Stitch 0 to 1 0mm 0 2 to 1 2mm Failure Stitch Standard Adjustment 16 Centering adjustment of corner knife 17 Adjustment of corner knife right and left bends ...

Page 57: ...parallel to the needle center Fine adjustments can be made by loosening the lock nut and shifting the adjusting screw forward and backward 2 Shift the guide plate to make the positioning pin enter the hole and tighten the fixing screw 3 Loosen the fixing screw and make adjustments by shifting the switch bracket so that the corner knife unit opening sensor switch can detect the presence of opening ...

Page 58: ...f parallel sewin 19 Fine adjustments for stitches 53 Approx 25mm G Corner knife Blade tip G Needle width Knife holder groove section Standard Adjustment 18 Adjustment of parallel sewin 19 Fine adjustments for stitches ...

Page 59: ...rection of the arrow and fix it After completion of the setting described above perform trial sewing with use of sewing material 19 Fine adjustments for stitches 1 To adjust the cut section length loosen the eccentric pin and move the corner knife in the direction of the arrow Caution During the above mentioned moving adjustments the blade tip section should be positioned where it is covered 2 For...

Page 60: ...20 Pedal and related sections 55 A B Standard Adjustment B A ...

Page 61: ...of the pedal lever 3 The plunger ball only is allowed to be protruded from the end face of the pedal lever 2 Adjustment of the pedal lever support plate 1 To prevent the pedal lever from rattling in the direction of the arrow loosen the pedal lever support plate setscrew and move the pedal lever support plate in the direction of the arrow for adjustment Caution 1 A pedal return error may occur if ...

Page 62: ...ewing machine needle Vertical laser beam 80mm Vertical laser beam Wiring for the marking light Parallelism not secured Deviation in right and left directions From the rear side of the marking light 2 Adjustment of the light value of the marking light Fig A Fig B Sewing machine needle Standard Adjustment Sewing machine needle ...

Page 63: ...ght B for adjustment o If the vertical laser beam has deviated in the right or left direction See Fig B loosen the hinge screw and adjust the marking light B by turning it around the center of the hinge screw o If the radiation range 300mm from the needle center of the vertical laser beam is not secured loosen the setscrew and turn the marking light B for adjustment around the center of the fixed ...

Page 64: ... 3 Optional sections 1 SA 117 dart stretcher unit 59 1 Installation A B 2 Adjustment Standard Adjustment ...

Page 65: ... on the base by means of two setscrews 2 Insert the tube in Joint A and the tube in Joint B 2 Adjustment 1 Loosen and adjust the adjusting screw until the darts holding rubber fits the sewing table hole Adjustment Procedures Results of Improper Adjustment ...

Page 66: ... 61 1 Installation of the shim bracket 2 SA 118 shim unit Standard Adjustment ...

Page 67: ...linder bushing 40034468 into the pocket bag clamp guide plate 4 Secure the cylinder to the frame with the 2 screws 5 Secure the cylinder PA160152900 to the interlining clamp cylinder bracket 40034471 with the screw and nut Secure the cylinder cover to the cylinder with the 2 screws Mount the speed controller on the cylinder 6 Secure the cylinder to the suction base with the 2 screws 7 Secure the i...

Page 68: ... 63 Adjustment of interlining clamp parallelism Standard Adjustment ...

Page 69: ...ve and connect the cable 11 Secure the shim guide 40034442 to the sewing table shim specific type with the 8 screws SS5090210SP Adjustment of interlining clamp parallelism 1 If the parallelism between the interlining clamp and clamp foot is not established loosen the screw and adjust the parallelism 2 If the parallelism between the interlining clamp and the top surface of the table is not establis...

Page 70: ...3 SA 119 suction unit 65 Standard Adjustment ...

Page 71: ...d fasten it with the setscrews 8 pcs 3 Fasten the hose mounting plates 2 pcs to the main body frame by means of the setscrews 4 pcs 4 Pinch the hose by means of the hose holders 2 pcs and fix it to the main body frame with the setscrews 4 pcs 5 Enter the hose in the cable clamps 2 pcs and fasten it to the hose mounting plates 2 pcs mounted in the step 3 above using the setscrews 2 pcs Adjustment P...

Page 72: ... 67 Section A Standard Adjustment ...

Page 73: ... spacer in the T shaped joint and fasten the hose by means of the hose band 10 This work shall be done both on the right and left 11 Insert the pipe spacer in the T shaped joint and fasten the hose by means of the hose band 12 Pinch the T shaped joint by means of the clamp and fasten it to the stud connector plate by means of the setscrew 13 Install the solenoid valve connectors and the air piping...

Page 74: ... 69 Section A Standard Adjustment Section B ...

Page 75: ...ion changeover 1 Suction changeover is carried out by reducing the hole section B of the filter box 2 Confirm that the hole section B of the filter box is exactly closed when the stopper rubber of the changeover cylinder is moved in the direction of the arrow 3 The suction force is weakened if the hole section B of the filter box is not closed completely Filter cleaning Periodically clean the filt...

Page 76: ...4 SA 120 automatic interlining feeder unit 71 1 Installation of the automatic interlining feeder unit Bed Clearance 2 Installation of the guide plate Standard Adjustment Parallelism need be secured ...

Page 77: ...se by means of two setscrews 3 At the time of installation the automatic interlining feeder unit shall be installed in parallel to the suction base 2 Installation of the guide plate 1 Fix the material guides A and B by means of two setscrews 2 The clearance between the material guides A and B shall be arranged so that it permits the passage of material cloth Adjustment Procedures Results of Improp...

Page 78: ...n of the interlining roll guide Interlining roll Plug Release Roller release cylinder Interlining cut cylinder Cut Feed 4 Air tube piping Interliningl feed cylinder Standard Adjustment Speed controller Speed controller ...

Page 79: ... guide 1 Adjust the interlining guide and the thrust collar so that the interlining interlining roll can be pulled out straightforward 4 Air tube piping 1 Make air tube wiring as illustrated Adjustment Procedures Results of Improper Adjustment ...

Page 80: ...it 75 1 Adjustment of pattern matching marking light position 150mm 55mm Sewing machine needle Rear horizontal lines for pattern matching Vertical lines for pattern matching Front horizontal lines for pattern matching 150mm Standard Adjustment ...

Page 81: ...marking light A around the center of the hinge screw for adjustment 2 For rear horizontal lines loosen the setscrew and turn the marking light B for adjustment 2 Adjustment of vertical lines 1 For vertical lines and sewing machine center parallelism loosen the setscrew and turn the marking light C for adjustment 2 To adjust the vertical line lighting position loosen the setscrew and turn the marki...

Page 82: ...s For cord passing holes Power cord Green yellow wire The earth wire of the power cord shall be fixed to the mounting plate Green yellow wires only shall be folded back toward the outside Prevention of wire pulling out shall be provided by means of cable clip bands Black wire White wire 2 Suction switch mounting Installation of the switch on the suction motor Standard Adjustment Green yellow wires...

Page 83: ...ons 2 Installation of the suction switch 1 Fix the power switch to the switch mounting plate by means of the setscrew Switch wiring 1 Provide wiring inside the power switch according to the instructions in the illustration Installation of the switch on the suction motor 1 Install the suction switch set on the suction motor mounting plate by means of the setscrew Adjustment Procedures Results of Im...

Page 84: ... 79 3 Installation of the suction motor 4 Installation of the suction pipe 5 Suction pipe fixing 6 Suction wiring A B Standard Adjustment ...

Page 85: ... pipe on the blower joint A section by means of the hose bands 2 The suction pipe is connected to the filter box Install this pipe on the blower joint B section by means of the hose bands 5 Suction pipe fixing 1 Pinch the suction pipe with the cable clip bands and fix it by means of the setscrew 6 Suction wiring 1 Fix the switch wiring by means of cable clips and the setscrews as illustrated Adjus...

Page 86: ...7 SP 46 clamp bar stacker unit 81 1 Installation of the clamp bar stacker 30 5mm A 2 Stacker support plate and stacker positioning bolt positions 3 Stacker unit assembly Standard Adjustment ...

Page 87: ...the stacker base are separated by 30 5mm as illustrated 2 Stacker support plate and stacker positioning bolt positions 1 Temporarily fasten the stacker positioning bolt with the frame nut 2 Temporarily fasten the stacker support plate with the setscrews and the washers in 4 positions 3 Stacker unit assembly 1 Insert the stacker unit in the mounting hole A of the stacker base Adjustment Procedures ...

Page 88: ...n of the air pipe and the cable Sewing table end face Parallel Parallel Top surface of sewing table 5 Adjustment of parallelism between wipe out bar and sewing table end face A Parallel Parallel Standard Adjustment 1 1 ...

Page 89: ...in Section A 5 Adjustment of parallelism between wipe out bar and sewing table end face 1 If no parallelism is secured from above loosen the stacker positioning bolt for adjustment 2 If no parallelism is secured from the side loosen the setscrew to move the stacker support plate for adjustment Adjustment Procedures Results of Improper Adjustment ...

Page 90: ... 85 6 Adjustment of stacker hinge length 7 Adjustment of stacker close open sensor position 8 Installation of the safety bar A Standard Adjustment ...

Page 91: ...er close open sensor so that it is exactly turned ON when it comes in contact with the stacker positioning bolt 2 Loosen the setscrew that is used to fix the stacker close open sensor and move it in the direction of the arrow for adjustment 8 Installation of the safety bar 1 Insert the safety bar in the safety bar clamp and insert the rotary shaft from Section A 2 Loosen the setscrew of the safety...

Page 92: ... 87 9 Auxiliary table and cushion assembly and position adjustments 10 Clamp bar cord fixing 11 Overall stacker position check A Standard Adjustment ...

Page 93: ...on of interference 10 Clamp bar cord fixing 1 Use the cable clip bands for fixing so that the stacker cords and air pipes are not pinched when the stacker as a whole is swiveled 11 Overall stacker position check 1 Confirm that no interference is present at each part and Section A when the stacker is actuated or the stacker unit is swiveled Adjustment Procedures Results of Improper Adjustment ...

Page 94: ... 89 12 Adjustment of clamp base position 167 2 5mm 13 Adjustment of second clamp bar position 83 2 5mm 369mm 367mm 105 2 5mm 20 2 5mm Standard Adjustment ...

Page 95: ...in the state that the cylinder rod is protruded 13 Adjustment of second clamp bar position 1 Adjust the 2nd clamp bar position to set the distance between the clamp bar and stacker base E to 105 2 5 mm in the Y axis and 20 2 5 mm in the X axis 2 Loosen the 2nd clamp bar drive cylinder rod fixing nut rotate the 2nd clamp bar drive cylinder rod and move the rod in the arrow direction to make adjustm...

Page 96: ... 91 14 Adjustment of first clamp bar position 24 2 5mm 5 2 5mm A 15 Adjustment of material wipe out bar position Standard Adjustment 202mm ...

Page 97: ...goal dimension is 202mm in the state that the cylinder is withdrawn 15 Adjustment of material wipe out bar position 1 djust the material wipe out bar by loosening the setscrew to secure the illustrated dimension and move the material wipe out bar in the direction of the arrow so that the second clamp bar and the material wipe out bar are positioned in parallel to each other In addition loosen the ...

Page 98: ... 93 16 Adjustment of clamp stacker unit position 220mm 47mm 33 2 5mm A Sewing table B 17 Adjustment of clamp base cylinder air pressure Standard Adjustment ...

Page 99: ... stacker unit fixing screw so that a dimension of 220mm can be secured between the end face of the sewing table and that of the clamp base cushion 17 Adjustment of clamp base cylinder air pressure 1 Lower the regulator knob in the direction of Section A and turn it for adjustment until a clamp base cylinder air pressure of 0 4MPa can be secured After the completion of adjustment raise the regulato...

Page 100: ...8 SP 47 roller stacker unit 95 1 Adjustment of roller stacker setup 0 5mm Shaft flatness 2 Right left adjustment of the rubber roller Standard Adjustment 3 Adjustment of backlash ...

Page 101: ...ft adjustment of the rubber roller 1 There is a screw in the flat part of the shaft inside the rubber roller When this screw is loosened the rubber roller can be moved to the right and left 2 According to the material length move the rubber roller and tighten the screw 3 Adjustment of backlash 1 Loosen three setscrews and take out the gearbox lid 2 The worm gear is directly coupled with the motor ...

Page 102: ...reen and the mode changeover screen which performs various detail settings can be performed Media card slot Close the cover for use Connector for RS 232C communication Variable resistor for adjusting Contrasr of the screen can be adjusted Adjust it as you contrast of colored LCD screen like Connector for external input Media removing lever Front Right side 97 MODE CHANGEOVER key INFORMATION key Ca...

Page 103: ... desire to change 98 2 Memory switch 1 Changing procedure of the memory switch data 1 Display the memory switch data list screen Press MODE CHANGE OVER key and the memory switch button A is displayed When this button is pressed the memory switch data list screen A is displayed A B C Memory switch data list screen Screen A ...

Page 104: ... at sewing end 0 to 99 9 0mm Feeding length of automatic interlining supplying device at sewing end is set It is possible to set only when automatic interlining supplying 0 1mm device is used Thread trimming timing Thread trimming timing after sewing is selected from Standard Medium Longest and length of thread at sewing end is adjusted Standard 0 Medium 1 Longest 2 When and zipper device are moun...

Page 105: ...memory switch Sewing speed under the low speed mode 1000 to 2500 1500rpm Number of revolutions of condensation and back tuck sewing sections is set It is limited by sewing speed under the high speed mode 100rpm It is possible to set only when sewing speed setting selection is set to memory switch Soft start 1st stitch 500 to 2500 500rpm Number of revolutions of first stitch at sewing start is limi...

Page 106: ...ght and left are simultaneously actuated Folding plate motion mode Return No return of folding plate when corner knife projects is selected Return No return Prohibition of binder reduced pressure rise Binder reduced pressure rise Yes No is set up at the time of vacant feed Yes No Standing pedal continuous depressing timer effective ineffective change over Effective ineffective of standing pedal co...

Page 107: ...ing is only the irradiation position of marking light Actual sewing position is the flap end position detected by the flap sensor Number of stitches of grease up Number of stitches of sewing machine motion after replenishing grease is indicated When pressing CLEAR button number of stitches is cleared to 0 Be sure to clear after replenishing grease Language selection No selection Language to be ind...

Page 108: ... of solenoid valve corner knife separate drive is set Non mounting Mounting Pedal operation mode change over Mode to be used for foot pedal is set 7 step pedal mode 1 shot pedal mode Excess rate of center knife cutting 300 to 500 350 Excess rate in terns of the speed of revolution of center knife can be set 1 Setting on intermittent feed prohibition Perform not perform intermittent feed sewing is ...

Page 109: ...rn data performs setting of speed of sewing machine Memory switch Pattern data Selection of reflecting tape check mode ON OFF of reflecting tape check mode is set When On is set the clap foot is automatically comes lowered with the first clamp foot advance motion after turning ON the power and deterioration check of reflecting tape is performed Clamp foot is automatically lowered Be sure to use th...

Page 110: ...ht origin compensation just under 500 to 500 0pulse Origin of marking light motor is compensated Origin is in the sate that it irradiates light just under and located at the position of 230mm from needle 1pulse Marking light origin compensation needle side 500 to 500 0pulse Position of needle side from origin of marking light motor is compensated Light irradiation position 80mm from needle 1pulse ...

Page 111: ...ng Long type selection It is set when using long type clamp foot Standard Standard clamp mounting Sewing size 220mm Long Long clamp mounting Sewing size 250mm Endiless zipper device mounting not mounting is set When using ong type clamp foot endless zipper device does not work Not mounting Mounting Ready made zipper device mounting not mouting is set When using long type clamp foot ready made zipp...

Page 112: ...ation of your sewing machine B Panel program version C Main program version D Main shaft program version Pressing the cancel button E closes the version information screen and calls up the mode screen 2 To display the detail screen Press the detail screen button F to call up the panel program detail screen G Module H RVL I Checksum Pressing the cancel button J closes the detail screen and calls up...

Page 113: ...vated 2 To select keylock and activate it Select the keylock activation button B on the keylock setting screen and press Then the keylock setting screen closes and keylock becomes activated 3 After closing the mode screen and calling up the data input screen After closing the mode screen and calling up the data input screen PICT C indicating that keylock is acti vated appears on the right of the p...

Page 114: ... for the maintenance personnel level Each data type is as specified below Data name Pict Extension Contents of data Adjustment data Model name 00XXX MSW Data of the memory switches 1 and 2 Example APW00001 MSW All sewing machine data Model name 00XXX MSP All data maintained by the sewing machine Example APW00001 MSP Panel program data AP RVL 6 digits HED Program data and display data of the panel ...

Page 115: ...l level is displayed 3 Program rewriting 1 Selection of the data type When the data classification button C is pressed in a communication screen of the maintenance per sonnel level the data selection screen is displayed In this state select the panel program data D 2 Selection of a file When the file selection button E is pressed in a communication screen the file selection screen is displayed Pre...

Page 116: ...been completed If any data writing error screen should be displayed im mediately turn off the power supply and check the check ing items specified below Then take the setup actions again Checking items 1 Did you open the media cover in the middle of data communication from the media card 2 Data of the media card are incorrect or there is no data file 3 The contact point of the media card is contam...

Page 117: ...iguration should be established with a personal computer Information about the method of media card formatting is obtainable from the Instruction Manual VI 15 How to Use the Communication Functions Route directory PROG APW895 MTxxxxxx prg Servo program MAxxxxxx prg Main program APxxxxxx Panel program APxxxxxx hed APxxxxxx p01 AMxxxxxx i01 AMxxxxxx i10 AMxxxxxx i11 AMxxxxxx i12 AMxxxxxx i13 AMxxxxx...

Page 118: ...ll up the error history screen Press the error history button B on the informa tion screen to call up the error history screen The error history screen shows the error history of your sewing machine C Chronological recording number D Error code E Cumulative energizing time during error hour Pressing the cancel button G closes the error history screen and calls up the information screen 3 To displa...

Page 119: ...anges from blue to or ange and there are 5 buttons 2 To display cumulative operating information Press the cumulative operating information button A on the information screen to call up the cumu lative operating information screen The following 4 items are indicated on the cumula tive operating information screen B Cumulative operating time hour C Cumulative thread trimming count D Cumulative ener...

Page 120: ...am 1 Display the check program menu screen When the key is kept pressed for 3 seconds the check program button A is displayed on the screen When this button is pressed the check program menu screen is displayed 115 A ...

Page 121: ...oration Check deterioration if any in the reflection seal for flap detection which is stuck to the folding plate Stacker adjustments Perate only the stacker independently Unit aging Repeat sewing operation Input check Check the sensor input state Output check Check the solenoid valve output Touch panel correction Correct the touch panel and button display positions LCD check LCD dot defect check C...

Page 122: ...en and display the head aging screen A A D B C G E F B Set up the head rpm value C Set up the revolving time D Set up the stop time E In interlinkage with the sewing machine select whether the center knife can be driven F Set up the head run stop operation G Returned to the menu Effective only in the middle of stoppage ...

Page 123: ...rogram menu screen and display the center knife check screen B Set up the rpm value of the center knife motor C Make center knife rise lower changeover D Start the revolution of the center knife motor E Returned to the check program menu Effective only in the middle of stoppage A B C D E ...

Page 124: ... flap sensor adjusting position Adjust the flap sensor spot so that it coincides with the marking light radiating position 2 Select the right and left sensors with B when fine adjustments are needed for the flap sensor position Move the marking light with C and adjust the flap sensor spot so that it coincides with the marking light radiating position Adjust the flap sensor spot so that it coincide...

Page 125: ... large presser begins to advance at a low speed In this phase detect reflection of the reflection seal by means of the flap sensor Display the result of detection at C If no deterioration is detected an OK sign is indicated If any deterioration is detected an NG sign is indicated In the case of NG pressing the C causes the large presser to move to the place of deterioration With D the check progra...

Page 126: ... A of the check program menu screen and display the stacker adjustment screen When the B is pressed the stacker preset by optional setup is actuated Use Stacker Timer 1 for the pattern that is selected at present With C the check program menu screen is recovered A B C ...

Page 127: ...pressed the repeated sewing operation is performed for the pattern that is selected at present When the C is pressed no unit aging is carried out but the check program menu screen is recovered Caution 1 Be careful that pressing the B results in automatic sewing operation 2 To stop the aging operation press the temporary stop SW A C B ...

Page 128: ...atus is displayed A B C D If there is any change in the input status the panel buzzer sounds and the screen simultaneously changes as illustrated at left The connector name and the input name are displayed at B C A color change takes place where there has been a change To finish input check press the D to move to the check program menu screen ...

Page 129: ...d breakage detection left IN33 CN63A 2 TRD SNS R Thread breakage detection right IN35 CN65A 3 CLOTH SNS Material sensor IN36 CN66A 3 CP FER Step out detection of clamp foot IN38 CN68A 1 B OPN SNS Binder opening detection IN39 CN69A 1 WELT SW Changeover SW of welting patch specifications IN40 CN70A 1 W CP GEND Bottom end detection of welting patch clamp IN41 CN71A 3 B DSNS Binder upper detection IN...

Page 130: ... L Swing detection left of flap supply IN74 CN74B 3 FPSPLY SDET R Swing detection right of flap supply IN79 CN79B 1 CN KN SDSENS Lower detection of fixed side corner knife IN80 CN80B 1 CN KN SDUENS Upper detection of fixed side corner knife IN81 CN81B 1 CN KN MDSENS Lower detection of moving side corner knife IN82 CN82B 1 CN KN MDUENS Upper detection of moving side corner knife IN83 CN83B 13 STK O...

Page 131: ...finished and the check program menu screen is recovered When the button is pressed the output status ON OFF can be changed Caution Be careful that the knife and others may operate according to the output type For reference Maintain the output state until the check program is finished In the case of sensor check etc you can use IO7 input check immediately 126 ...

Page 132: ...der fall 14 Binder rise 15 Rise in binder s reduced pressure 16 Interlining presser 17 Darts stretcher 18 Thread release 19 Disk rise 20 Vacuum 21 Bobbin thread detection blow 22 Needle thread trimmer 23 Bobbin thread trimme 24 Center knife 25 Fixed side corner knife elevator 26 Moving side corner knife elevator 27 Marking light turn off 28 Roller rise 29 Interlining feeder release 30 Interlining ...

Page 133: ...essed the touch panel correction screen is displayed 2 Pressing the bottom left position Press the red circle C located at the bottom left of the screen To complete correction press the can cel button B 3 Pressing the bottom right position Press the red circle D located at the bottom right of the screen To complete correction press the can cel button B 128 ...

Page 134: ...reen To complete correction press the cancel button B 6 Data saving When all the four points have been pressed the cor rection data are saved At that time the Power OFF Prohibition screen is displayed The power supply must not be turned off while the above mentioned screen is displayed If the power supply is carelessly turned off no cor rection data are saved After data saving the check program sc...

Page 135: ...e LCD check screen is displayed 2 Confirmation of LCD dot missing The LCD check screen is displayed only in one color In this state the LCD should be checked to freedom from dot missing After this confirmation press a proper position on the screen The LCD check screen is closed and the check program screen is displayed A ...

Page 136: ... button flap holding operation setup is carried out With the E button a menu is recovered Similarly as for the welt type setup screen the large presser advances when the pedal is trodden on in this screen and ordinary set operation becomes possible At that time however the binder does not rise and lower The large presser retreats when you perform the starting operation that is preset by pedal oper...

Page 137: ...on A of the check program menu screen and display the binder elevation screen With the B button the binder is raised With the C button the binder is lowered With the D button the binder s reduced pressure is raised With the E button a menu is recovered A B C E D ...

Page 138: ...ree 10 degrees max With the C button the upper stop angle is decreased by one degree 10 degrees minimum With the D button a menu is recovered With the E button setting is canceled and a menu is recovered A D B C E F After the parameters have been set up turn OFF the power supply once and turn it ON again When the reset button F is pressed in the screen at left it moves above the needle In this sta...

Page 139: ...e of the pedal sensor in the present state of pedal treading on within the data range of 0 to 99 In the first place in the state that the pedal is reversely trodden on press the reverse tread on input button D The voltage value at that time is then entered in E Then press the free input button F in the pedal free state The voltage value at that time is then entered in G In the similar manner make ...

Page 140: ... pedal adjustments One shot pedal means that each time the pedal is trodden on the pedal step is advanced Unlike the 7 step pedal the status is retained even when the foot is separated from the pedal To return the step reverse foot action is taken A B Select the B one shot pedal with K54 Pedal operation mode change over ...

Page 141: ...nge of 0 to 99 In the first place in the state that the pedal is reversely trodden on press the reverse tread on input button F The voltage value at that time is then entered in G Then press the free input button H in the pedal free state The voltage value at that time is then entered in I In the similar manner make the setting of step J for step advancement Reference 1 When the F G H buttons are ...

Page 142: ...a new board to make it possible to perform data transfer SDC board asm Machine s main shaft servomotor is controlled DC source voltage is also generated Fuses for control power supply protection are installed FLT board asm AC input source rectification and noise elimination are carried out This board comes in two types single phase specification and single phase three phase specification 2 Functio...

Page 143: ... line to each I O equipment unit INT board A asm upper side Used to relay the I O signals of the switches and sensors installed mainly on the tabletop INT board B asm lower side Used to relay the I O signals of the switches and sensors installed mainly on the table bottom as well as the parts related to the machine head 4 Function of PMDC board optional component and installation position 1 Instal...

Page 144: ...nting position refer to 2 2 Replacement of SDC board 2 Replace the board 1 Replacement of MAIN board This board is provided with a memory device EEPROM that stores the adjusting data singular to the machine and also the operation setup data This memory device can be out of order due to a problem in the board However since precious data are stored there it is recommended to transfer this memory dev...

Page 145: ...f order errors will occur mainly in the control source voltage and the main shaft motor of the sewing machine Two replaceable fuses are installed for power source protection When replacing the fuses refer to 2 Replacement of parts 1 Replacement of fuses F1 F2 ...

Page 146: ...ard and the MAIN board can be defective at the same time Note that there are two types of boards according to the power specifications 40000046 Single phase 200V FLT board asm Caution The setup procedures shall conform to the input source voltage specifications for 100V 200V source changeover terminals 40000056 Single phase 100V 3 phase 200V FLT board asm ...

Page 147: ...rmal or there will be lack of torque Make all settings again because all the dip switches are set at OFF if the replacing board is a newly purchased item Dip switch setting should conform to 3 Dip switches 4 Dip switches of the PMDC board Make the resetting of the dip switches SW1 1 only is set at OFF and SW1 2 to 4 are at ON ...

Page 148: ...te and unnecessary to be modified Caution The setup values at the time of shipment are based on the ON condition for 1 and 2 and OFF condition for 3 and 4 4 PMDC board dip switch For roller stacker The dip switch on the PMDC board is used as a functional changeover switch No modification shall be carried out after shipment because all adjustments and other settings are definite and unnecessary to ...

Page 149: ...ed to the AC power and the wire of green yellow is connected to the earth system In single phase operation the wire of Red need not be connected Both ends should be cut off at the root of the cord When a 3 phase AC 200 240V power supply is used make power code plug connections such that the wires of Black White and Red are connected to the AC power and the wire of green yellow is connected to the ...

Page 150: ... IN 29 Photo sensor for marking light 2nd origin INT CN75A IN 45 Air cylinder sensor for clamp origin INT CN83B IN 92 Air cylinder sensor for material wiper origin INT CN83B IN 90 Micro switch for stacker opening detection INT CN83B IN 83 Reflex optical sensor left for bobbin thread remaining amount detection INT CN64B IN 64 Reflex optical sensor right for bobbin thread remaining amount detection ...

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Page 156: ...the machine bed cover turn the oil can and discharge the collected waste oil Inside of the hook oil cover 1 Periodically remove cloth chips and dust accumulated inside the hook oil cover o Raise the sewing machine and loosen the setscrews 5 positions to take out the oil cover 2 Cleaning of the hook shaft base o Clean inside of the hook oil cover ...

Page 157: ...10g tube JUKI Part No 40006323 500g IE 22 JUKI Part No 23640204 2 JUKI Grease B Used in particular for the specific areas with highly loaded parts Important this grease must be replenished at the specified intervals of period according to 4 Grease up procedures for the specified position 10g tube JUKI Part No 40013640 3 Method of greasing If no grease pump is available fill a plastic oiler with gr...

Page 158: ... 153 3 Spots where grease adhesive agents are used EXTERIORS A JUKI Grease A A A ...

Page 159: ... 154 MAIN SHAFT THREAD TAKE UP LEVER COMPONENTS A JUKI Grease A G Three Bond 1373N A A G A A A G A A G A ...

Page 160: ... 155 NEEDLE THREAD TRIMMER COMPONENTS A JUKI Grease A C Locktight 242 A A C A ...

Page 161: ... 156 THREAD TENSION WIPER COMPONENTS A JUKI Grease A A A ...

Page 162: ... 157 LOWER THREAD COMPONENTS A A C A A A C A JUKI Grease A C Locktight 242 A ...

Page 163: ... 158 CENTER KNIFE COMPONENTS A A A A A C A A A C C A A JUKI Grease A C Locktight 242 ...

Page 164: ... 159 LOWER SHAFT COMPONENTS A JUKI Grease A G Three Bond 1373N G A A A A ...

Page 165: ... 160 HOOK DRIVING SHAFT LEFT COMPONENTS A JUKI Grease A A A A A A ...

Page 166: ... 161 HOOK DRIVING SHAFT RIGHT COMPONENTS A JUKI Grease A A A A A A ...

Page 167: ... 162 BACK TUCK COMPONENTS A JUKI Grease A G Three Bond 1373N G A ...

Page 168: ... 163 CLAMP FOOT UNIT 1 B B B C B B B B C B JUKI Grease B C Locktight 242 ...

Page 169: ... 164 CLAMP FOOT UNIT 2 B JUKI Grease B C Locktight 242 B B B B B C B B B ...

Page 170: ... 165 CLAMP FOOT UNIT 3 B JUKI Grease B C Locktight 242 B C B B B B B B ...

Page 171: ... 166 CLAMP FOOT FEED UNIT B JUKI Grease B D Locktight 243 D D B B B ...

Page 172: ... 167 CONER KNIF UNIT B JUKI Grease B D Locktight 243 E Locktight 277 F Locktight 641 G Three Bond 1373N CORNER KNIF COMPONENTS B JUKI Grease B B B B B B G F D B B B B B B B B B E ...

Page 173: ... 168 BINDER UNIT B JUKI Grease B D Locktight 243 D B B B B B B ...

Page 174: ... 169 MARKING LIGHT UNIT D B D B F B B JUKI Grease B D Locktight 243 F Locktight 641 ...

Page 175: ... 170 FRAME AND COVER COMPONENTS 1 B JUKI Grease B G Three Bond 1373N H Cemedyne Super X Clear G H B ...

Page 176: ... 171 FRAME AND COVER COMPONENTS 2 B JUKI Grease B B ...

Page 177: ... 172 FLAP PATTERN MATCHING MARKING LIGHT UNIT SA 121 B JUKI Grease B PEDAL SWITCH COMPONENTS B JUKI GreaseB B B B ...

Page 178: ... 173 CLAMP BAR STACKER UNIT SP 46 B JUKI Grease B G Three Bond 1373N B B B B B B B B B B B B B G B B B B G B B G B B B B ...

Page 179: ... 174 B JUKI Grease B G Three Bond 1373N AUTOMATIC INTERLINING FEEDER UNIT SA 120 B B G B B G ...

Page 180: ... 175 ROLLER STACKER UNIT SP 47 B JUKI Grease B G Three Bond 1373N B B B B B G B G G B B ...

Page 181: ... operation to 0 with CLEAR button When the machine has been continuously used up to 48 million stitches grease up error E221 is displayed on the panel In this case even when RESET button is pressed and the error screen is released the sewing after that cannot be performed Be sure to call Memory switch U245 and set the number of stitches of to 0 with CLEAR button after performing replen shment of g...

Page 182: ... that air is not supplied Apply grease to the metal so as to infiltrate the inside A 3 Replenishment of grease to the needle bar section Apply Juki Grease A to the thread take up lever needle bar upper section needle bar lower section needle bar and needle bar 4 Remove the rubber cap and apply new grease to the inside of the hole after removing old grease adhered to the inside of hole A Then cover...

Page 183: ...6155 o Corner knife Part Nos 16607301 and 16607400 Sharpness s deter orated and sewing quality s influenced unless it is periodically replaced o Reflecting tape Part No 40039942 Accuracy of detection of flap is deteriorated and sewing quality is influenced unless it is periodically replaced o Garment body clamp rubber Part No 40034825 o Flap presser rubber Part No 40034826 Pressing of material is ...

Page 184: ...ossible to Media is not inserted re start after reset E012 Read error Possible to Data read from media cannot be performed re start after reset E013 Write error Possible to Data write from media cannot be performed re start after reset E015 Format error Possible to Formatting of media cannot be performed re start after reset E016 External media capacity over Possible to Capacity of media is short ...

Page 185: ...reakage detection error Possible to When thread breakage is detected re start after reset A201 Needle replacing time warning Possible to When number of stitches of operation is reached to number of re start after stitches of needle replacement that is set from the panel reset A202 Cleaning time warning Possible to When operation time of the sewing machine is reached to the re start after cleaning ...

Page 186: ...ormed E366 Center knife does not lower Possible to re start after reset E367 Corner knife cannot be entered Possible to re start after reset E368 Zipper has run out Possible to re start after reset E369 Roller stacker lower does not detect Possible to re start after reset E370 Roller stacker upper sensor is gone past Possible to re start after reset E371 Clamp bar stacker material presser sensor i...

Page 187: ...tion Possible to re start after reset E379 Roller stacker lift sensor cannot detect Possible to re start after reset E380 Flap sensor cannot receive light Possible to re start after reset E381 Flap rear end cannot be detected forced stop Possible to Error is displayed after end of sewing re start after reset E382 Flap dust detection error Possible to re start after reset E383 Flap front end cannot...

Page 188: ...or Automatic Material remains after end of stacker operation recovery by sensor input E391 ST material presser lift detection error Automatic recovery by sensor input E392 ST material sweeper origin detection error Automatic recovery by sensor input E393 Binder bottom detection error Automatic recovery by sensor input E394 Binder top detection error Automatic recovery by sensor input E398 Corner k...

Page 189: ...ated No Does not exist in medai or server recover with CANCEL button E435 Out of input range error Possible to When numeral that is set with ten key exceeds the setting range re start after reset E484 Zipper attaching data cannot be sewn Possible to re start after reset E485 Data other than zipper attaching data cannot be sewn Possible to re start after reset E486 Flap sewing data can not be sewn ...

Page 190: ... sewing start sewing end over Possible to When sewing length is shorter than the total of length os each re start after condensation back tuck at sewing start and sewing end reset E496 Condensation at sewing end length over Possible to When condensation pitch X number of stitches exceeds 15 0mm re start after reset E497 Back tuck at sewing end length over Possible to When back tuck pitch X number ...

Page 191: ...tion sensor is Turn OFF the defective power When hole sensor of sewing machine motor position sensor is defective E733 Reverse rotation of main shaft motor Turn OFF the When the sewing machine motor rotates in the reverse direction power E802 Power momentary cut detection Turn OFF the When input power is momentarily cut power E811 Over voltage of power error Turn OFF the When input power is more t...

Page 192: ... MAIN CPU and main Turn OFF the shaft CPU power When abnormality occurs in data communication E917 Communication abnormality between operation panel and Possible to personal computer re start after When abnormality occurs in data communication reset E918 MAIN circuit board heat sink temperature abnormality Turn OFF the Turn ON the power again after taking time power E943 Defective EEP ROM of MAIN ...

Page 193: ...r E987 Back tuck motor origin retrieval error Possible to re start after reset E998 Corner knife stepping motor origin retrieval error Possible to re start after reset E999 Marking light motor origin retrieval error Possible to re start after reset 188 ...

Page 194: ...o 0 3 mm the inner hook guide and inner Refer to the description of opener adjustment hook 1 4 Inadequate hook mounting 4 A Interference between the Adjust the clearance between the needle and the blade needle and the blade point point of the hook Refer to adjustment of the hook of the hook nd needle 4 B Inappropriate timing for the Adjust the timing between the needle and the blade needle and hoo...

Page 195: ... between the needle and hook 2 B Excessive contact between Adjust the clearance between the needle and needle the needle and needle guide holder Refer to adjustment of the timing between the needle and hook 3 3 Misalignment of the needle bar Adjust the position of the needle bar rocking base in rocking base in the front rear the front rear direction Refer to alignment of the direction needle bar r...

Page 196: ...to adjustment of the binder levelness 5 Needle breakage 5 1 Interference between the needle Adjust the clearance between the needle and the blade and the blade point of the hook point of the hook Refer to adjustment of the hook and needle 5 2 Excessive contact between Adjust the timing between the needle and hook the needle and needle guide Refer to adjustment of the hook and needle 5 3 Interferen...

Page 197: ...take up spring 6 4 Excessive winding tension of Adjust the winding tension the bobbin thread 6 5 Uneven feeding tension of 5 A Thread chips caught between Remove thread chips the bobbin thread the bobbin and inner hook 5 B Deformed bobbin resulting in Replace the bobbin with new one non smooth movement 7 Excessive puckering 7 1 Excessive tension of the Reduce the tension of the needle bobbin threa...

Page 198: ...with new one body or welting patch entirely 1 B Defective installation of Install the center knife properly center knife Refer to adjustment of the center knife 10 2 Too thick needle or blunt tip Use a thinner needle Replace the needle with new of the needle one 11 Needle thread untrimmed 11 1 Malfunction of the needle 1 A Defective installation of the Install the needle thread trimmer properly th...

Page 199: ... mechanism to the needle 2 Different welting widths between 2 1 Defective clearance between Adjust the clearance Refer to adjustment of the front and rear the binder and garment body binder mechanism clamp 2 2 Uneven presser movement Adjust the position Refer to adjustment of the with respect to the binder binder mechanism 3 Displacement of welting patch 3 1 Defective positions of the front 1 A Di...

Page 200: ...n Refer to adjustment of the needle thread trimming knife at lowering thread trimming unit 5 Slack flap lining 5 1 Defective pressure of the flap 1 A Insufficient pressure of the flap Adjust the position Refer to adjustment of the clamp presser presser foot mechanism 6 No core material feeder from the 6 1 Defective clearance of the guide 1 A Excessive clearance Adjust the position of the automatic...

Page 201: ...d path Replace the needle thread breakage detection sensor Check the connectors CN62 and CN63 of the lower INT board Part No 40043997 Sensor assembly L Check whether the IN32 and IN33 signals are transmitted and the sensor Part No 40043996 Sensor assembly R appropriately functions Check the main shaft motor because the semilunar pate is integrated into Replace the main shaft motor the motor Part N...

Page 202: ...ck the connectors CN60 and CN61 of the lower INT board Check whether the IN60 and IN61 signals are transmitted and the sensor appropriately functions Check the connector CN79 of the lower INT board Replace the cylinder sensor Part No 40044627 Sensor E386 Check whether the IN79 signal is transmitted and the sensor appropriately Part No 40023214 Cylinder functions Check the connector CN80 of the low...

Page 203: ...ning detection micro switch E399 Binder opening detection error Check whether the IN83 signal is transmitted and the switch appropriately Part No 40044001 Switch functions E702 CPU haywire detection Replace the MAIN board if this occurs frequently Replace the MAIN board Part No 40025270 MAIN board Connection of the panel to the machine other than supposed Check the version with reference to the sy...

Page 204: ...oot step out detection sensor E985 Clamp foot motor step out error Check the connector CN66 of the upper INT board Part No HD00057000A Sensor Check whether the IN36 signal is transmitted and the sensor appropriately functions Check whether dust is stacked between the sensors Clamp foot pulse motor origin Check the connector CN77 of the upper INT board Replace the clamp foot origin photosensor retr...

Page 205: ... panel disabled Or a different switch responds Key operation sound is not generated Replace the IP 310 operation panel Part No 40052016 Check whether the cable is connected appropriately between the IP panel and MAIN board The power switch of the vacuum system Check the power supply voltage of the motor drive Replace the vacuum motor Part No G6951172CA0 automatically turned off Check whether the m...

Page 206: ... 201 MEMO ...

Page 207: ...4 2 Œ 18037408 WIRE MARK 25 2 18038000 WIRE MARK 31 2 18038109 WIRE MARK 32 2 No Part No Part Name Q ty Â 18038307 WIRE MARK 34 6 18038802 WIRE MARK 39 2 Á 18038901 WIRE MARK 40 2 18039008 WIRE MARK 41 2 18039107 WIRE MARK 42 6 Ø 18039305 WIRE MARK 44 2 18039404 WIRE MARK 45 2 Å PV150104000 5 PORT SOKENOID VALVE 12 Í 40044631 PLUG 4 9 Î PV920004000 BLANKING PLATE ASSY 3 Ï BT0400251EB URETHANE HUSE...

Page 208: ... corner knife opening 6 Photo sensor for back tack motor origin Pluse motor for back tack needle throwing CN338 3 CN238 40043993 40043990 CN38 7 Photo sensor for corner knife opening origin CN202 3 40043975 CN37 8 4 CN201 Pulse motor for marking light movement 6 Photo sensor for marking light motor origin CN204 3 CN203 40043979 CN36 7 50 CN45 Solenoid valve for center knife elevator 2 2 Solenoid v...

Page 209: ...1 204 Main shaft servo motor of the sewing machine Servo motor encoder Fan motor Clamp foot driving pluse motor Power switch Power switch Signal phase specification power supply connection 3 phase specification power supply connection ...

Page 210: ...on GND INT PCB A CN29 1 2 3 4 5 6 7 8 9 60A 1 61A 1 62A 1 63A 1 64A 2 65A 2 66A 2 67A 2 68A 3 69 A3 70A 3 71A 3 72A 1 73A 1 74A 1 75A 1 76A 2 77A 2 78A 2 79A 2 80A 3 81A 3 THBr1 THBr2 AIRV A1 AIRV A2 AIRV A3 AIRV A4 AIRV A5 24V AIRV A6 24V AIRV A7 24V AIRV A8 24V AIRV A9 ST SEN GND 5VLDP PCBA1 PCBA2 MAIN PCB 2 4 CN138 1 2 24V Vacuum solenoid valve RSTSIG 4_3B 11 12 13 14 CN166 3 2 5V Sensor for cl...

Page 211: ... opening detection switch GND GND Stacker origin sensor Stacker origin sensor GND 24V Spare solenod valve output Spare solenod valve output INT PCB B CN32 1 2 24V 24V 5V 3 4 5V 5 GND 6 GND 7 GND 8 GND 24V 24V 5V 5V GND GND GND GND 9 SIG1 SIG2 SIG3 SIG4 SIG5 SIG6 SIG7 SIG8 SIG9 SIG10 SIG11 SIG12 SIG13 SIG14 SIG15 SIG16 SIG17 SIG18 SIG19 SIG20 SIG21 SIG22 SIG23 SIG24 SIG25 SIG26 SIG27 SIG28 SIG29 SI...

Page 212: ... 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V AIRV32 AIRV33 AIRV34 AIRV35 AIRV36 AIRV37 AIRV38 AIRV39 AIRV40 AIRV41 AIRV42 J78 1 2 AIRSW 24V GND 3 4 NC Air pressure detecting switch CN54 1 2 24VD 24VRTN CN53 1 2 24VD 24VRTN DC motor for lower bobbin winder CN45 1 2 AV10 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 2...

Page 213: ...an E This manual uses environment friendly soyink The environmental management system to promote and conduct 1the technological and technical research the development and design of the products in which the environmental impact is consid ered 2the conservation of the energy and resources and the recycling in the research development design distribution sale and mainte nance service of the industri...

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