JUKI DNU-1541 Engineer's Manual
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JUKI DNU-1541 Engineer's Manual

1-needle, unison feed, lockstitch machine (with safety mechanism)/(with automatic thread trimmer)
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1-Needle, Unison Feed, Lockstitch Machine
DNU-1541
1-Needle, Unison Feed, Lockstitch Machine
(with Safety Mechanism)
DNU-1541S
1-Needle, Unison Feed, Lockstitch Machine
(with Automatic Thread Trimmer)
DNU-1541-7
ENGINEER'S MANUAL
29353505
No.E349-01

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Summary of Contents for JUKI DNU-1541

  • Page 1 1-Needle, Unison Feed, Lockstitch Machine DNU-1541 1-Needle, Unison Feed, Lockstitch Machine (with Safety Mechanism) DNU-1541S 1-Needle, Unison Feed, Lockstitch Machine (with Automatic Thread Trimmer) DNU-1541-7 ENGINEER’S MANUAL 29353505 No.E349-01...
  • Page 2 PREFACE This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance of the machine. The Instruction Manual for this machine intended for the maintenance personnel and operators at an apparel factory contains operating instructions in detail. And this manual describes “Standard Adjustment”, Adjustment Procedures”, “Results of Improper Adjustment”, and other important information which are not covered in the Instruction Manual.

  • Page 3: Table Of Contents

    3) Parts list ............................38 (3) Installing the DL device ..................40 1) When installing the DL device to DNU-1541-7 after set-up of the machine (List A) ....40 2) Installing the pneumatic device components (List B) ..............40 3) Installing the 5-step switch (List C) ..................... 40...
  • Page 4 5. PORTION TO WHICH LOCKTITE IS APPLIED ........42 6. SELECTIVE PARTS AND CONSUMABLE PARTS ......43 7. ENGRAVED MARKER DOTS ON THE HANDWHEEL......44 8. LUBRICATION ROUTE DIAGRAM ............44 9. PNEUMATIC PIPING ................45 10. MACHINE HEAD WIRING (WITH THREAD TRIMMER ONLY) .... 46 (1) Connector coming from the machine head ............

  • Page 5: Specifications

    Lubrication Hook : automatic lubrication Others : Concentration tank type oil wick lubrication (excluding some parts) Lubricating oil JUKI New Defrix Oil No. 2 (equivalent to ISO VG32) Bed size 476.6 mm x 178 mm Free space for sewing 255 mm x 99 mm Size of handwheel V belt effective diameter : ø93.3 mm...

  • Page 6: Standard Adjustment

    2. STANDARD ADJUSTMENT (1) Needle entry position Standard Adjustment 8±0.2 mm Conditions • Needle bar at lowest dead point • Feed amount : 0 mm Top surface of throat plate (2) Longitudinal position of the feed dog Standard Adjustment Conditions •...
  • Page 7 Adjustment Procedures Results of Improper Adjustment 1. Set the stitch dial to “0”. ™ Stitch skipping or needle breakage will result. 2. Turn the handwheel to bring the needle bar to the lowest dead ™ Poorly tensed stitches will result. point of its stroke.

  • Page 8: Lateral Position Of The Feed Dog

    • Feed amount : 0 mm Adjust the position to almost A = B. a’ (4) Height of the feed dog Standard Adjustment Model Dimension A DNU-1541 0.8 to 0.9 mm DNU-1541S DNU-1541-7 0.4 to 0.5 mm Conditions • Feed amount : 0 mm...
  • Page 9 Adjustment Procedures Results of Improper Adjustment 1. Set the stitch dial to “0”. ™ S t i t c h s k i p p i n g o r t h r e a d 2. Turn the handwheel to bring the needle bar to the lowest dead breakage will result.

  • Page 10: Adjusting The Opener (Dnu-1541S)

    1 moves to front end (Diameter direction) Condition • Swing angle of opener is maximum. (6) Needle-to-hook timing Standard Adjustment Model Dimension A DNU-1541 56.55 mm DNU-1541S DNU-1541-7 58.55 mm 0.02 to 0.05 mm Conditions • Feed amount : 0 mm...
  • Page 11 0.2 mm (C) when needle bar 1 is raised by 2.15 ± 0.15 mm (B) from its lowest dead point. Then retighten the screw. (For DNU-1541-7, there is a marker line engraved on needle bar 1.) 3. Turn the handwheel to raise the needle bar by 2.15 ± 0.15 mm (B) from its lowest dead point.

  • Page 12: Lift Of The Presser Foot

    (7) Lift of the presser foot Standard Adjustment 1) Hand lifter Hand lifter Condition • State that the hand lifter is raised Top surface of throat plate 2) Knee lifter Condition • Lifting amount when the stopper screw of knee lifter spring hook comes in contact with the machine bed Top surface of throat plate...
  • Page 13 Adjustment Procedures Results of Improper Adjustment 1. Loosen setscrew 1 in the side cover located on the When the lifting amount is higher antioperator’s side of the machine arm and remove side cover than the specified value ™ The presser foot is held raised 2.

  • Page 14: Feed Motion

    1600 rpm 4 mm to less than 6.5 mm 1600 rpm Hinge screw ™ In case of DNU-1541-7, refer to “ 3. (2) Alternate vertical dial ”. Lower engraved marker line Standard of amount of alternate vertical movement • Upper engraved marker line : Approx. 5 mm •...
  • Page 15 Adjustment Procedures Results of Improper Adjustment 1) Amount of alternate vertical movement Increase the vertical stroke of the ™ In case of the machine without the thread trimmer walking foot in accordance with the 1. Loosen hinge screw nut 1 in the top feed rod. sewing products.

  • Page 16: Alternate Momentum

    Standard Adjustment 2) Alternate momentum Conditions • Feed amount : 0 mm • Amount of alternate vertical movement Top surface of feed dog Top surface of Top surface of throiat plate throat plate In case of the machine with thread trimmer In case of the machine without thread trimmer (9) Feed cam timing Standard Adjustment...
  • Page 17 Adjustment Procedures Results of Improper Adjustment 2) Alternate momentum Adjust the vertical stroke of the 1. Set the stitch dial to “0”. walking foot so that it is larger than that of the presser foot in accordance 2. Turn the handwheel to make sure that the amount of alternate vertical movement of walking foot 1 and presser foot 2 is with the sewing products.

  • Page 18: Top Feed Cam Timing

    Standard Adjustment 2) Top feed cam timing ™In case of DNU-1541 and DNU-1541S Main shaft Conditions • Feed amount : 6 mm • When needle and walking foot are lowered. Top feed cam rod To align To align ™In case of DNU-1541-7...
  • Page 19 Results of Improper Adjustment 2) Top feed cam timing ™ Pitch error at high or low speed ™In case of DNU-1541 and DNU-1541S is apt to occur. 1. Set the scale of stitch dial to “6”. 2. Adjust the amount of alternate vertical movement to the standard value.

  • Page 20: Needle Sway (Optional Selection Only Of Dnu-1541-7)

    (10) Needle sway (Optional selection only of DNU-1541-7) Standard Adjustment Horizontal feed shaft 20±0.5 mm Engraved marker line (11) Stitch length of normal/reverse feed Standard Adjustment Conditions • Feed amount : 6 mm Feed adjusting base Feed adjusting rod Notch...
  • Page 21 Adjustment Procedures Results of Improper Adjustment 1. Loosen hinge screw nut 1 in the horizontal feed rear arm. ™ Needle breakage or stitch 2. Move horizontal feed connecting rod 2 so that the distance skipping will result. from the center of the horizontal feed shaft to that of the hinge screw is 20 ±...

  • Page 22: Balancer (Dnu-1541, Dnu-1541S)

    (12) Balancer (DNU-1541, DNU-1541S) Standard Adjustment Condition : Needle bar is at the lowest dead point. To come in close contact Screw No. 1 with each other Top feed driving rod Main shaft intermediate bushing...
  • Page 23 Adjustment Procedures Results of Improper Adjustment 1. Turn the handwheel to bring the needle bar to the lowest point ™ Vibration is increased. of its stroke. 2. Set the screw No. 1 of balancer 1 so that it faces directly above and securely tighten the setscrews.

  • Page 24: Position Of The Reverse Feed Control Lever

    (13) Position of the reverse feed control lever Standard Adjustment ™ In case of DNU-1541-7 ™ In case of DNU-1541 and DNU-1541S Stitch dial To be almost flush Stitch dial Reverse feed control lever Feed Reverse feed lever shaft regulator...
  • Page 25 2. reverse feed stitching will be decreased. ™ In case of DNU-1541 and DNU-1541S When the position of the reverse 1. Set the stitch dial to “0”. feed control lever is high 2. At this time, loosen hexagon headed bolt 3 in the feed regulator ™...

  • Page 26: Safety Clutch (Dnu-1541S)

    (14) Safety clutch (DNU-1541S) Standard Adjustment (15) Lubrication Standard Adjustment Decrease Increase A sheet of paper...
  • Page 27 1. Remove the plug of lubricating hole of oil tank. When the amount of oil is short 2. Fill JUKI New Defrix Oil No. 2 up to line 2 of H (high) level ™ Loose stitches will result. from lubricating hole 1 of oil tank. Check the oil amount once ™...

  • Page 28: Standard Adjustment Of Thread Trimmer Components (Dnu-1541-7)

    3. STANDARD ADJUSTMENT OF THREAD TRIMMER COMPONENTS (DNU-1541-7) (1) Thread trimmer device Standard Adjustment 1) Cam follower 0.5 mm 2) Solenoid arm Conditions • Thread trimmer solenoid is at rest. 11 to 12 mm...
  • Page 29 Adjustment Procedures Results of Improper Adjustment 1. Raise cam follower 1 in the direction of the arrow mark. When the clearance is larger 2. Loosen stopper screw nut 4 and adjust by screwing amount ™ Stroke of the rotary knife is of stopper screw 5 so that a clearance of 0.5 mm is provided insufficient and double trimming between thread trimmer cam 2 and cam roller 3.

  • Page 30: Thread Trimmer Cam Timing

    Standard Adjustment 3) Thread trimmer cam timing Engraved marker dot Red engraved on machine arm marker dot Handwheel Conditions • Engraved marker dot on the handwheel is aligned with engraved marker dot on the machine arm. 4) Rotary knife and fixed knife Bed counter sinking Engraved marker Engraved marker line of...
  • Page 31 Adjustment Procedures Results of Improper Adjustment 1. Tilt cam driving bracket 2 in the direction of the arrow mark When the timing is retarded ™ Thread trimming action does not and make it come in contact with the periphery of thread trimmer cam 1.

  • Page 32: Alternate Vertical Dial

    Standard Adjustment ™ Installing position of the detection switch of the amount of alternate vertical movement Alternate vertical dial ™ Sewing speed of DNU-1541-7 Amount of alternate vertical Stitch length : Stitch length : movement of the walking foot and...
  • Page 33 Adjustment Procedures Results of Improper Adjustment 1. Turn the alternate vertical dial to adjust the scale “1” to the ™ Sewing speed may not change convex section on the top cover. even when turning the alternate 2. Loosen setscrew 1 in the alternate vertical dial and remove vertical dial.

  • Page 34: Adapting Sc-380 To Dnu-1541-7

    In case of “********* A” (in case there is “LU51” of the model LU-1510 is in the table of simplified setting value for JUKI sewing machine of SC-380) and in case of “*********” (in case there is no “LU51” of the model LU- 1510 in the table of simplified setting value for JUKI sewing machine of SC-380), the contents to be set are different.
  • Page 35 Function name Symbol Initial value Modified value Remarks Limitation of maximum speed 3) Thread trimming sequence (DNU-1541-7) Start of needle UP position detection (55˚) Needle UP position detection Start of needle DOWN position detection (215˚) Thread trimmer sol.

  • Page 36: Installation Of The Optional Parts

    4. INSTALLATION OF THE OPTIONAL PARTS (1) Automatic reverse feed device 2) Removing the reverse feed control lever 1) Removing the window plate (List of the parts to be removed) (List of the parts to be removed) Handwheel Window plate A Stitch dial 1.

  • Page 37: Installing The Reverse Feed Control Lever1. Reverse Feed Control Lever (List B)

    4) Installing the reverse feed control lever1. Reverse feed control lever (List B) Reverse feed control lever 1. Install reverse feed control lever spring bracket 1 with setscrew 2. 2. Install reverse feed control lever stopper 3 to the machine arm with setscrew 4. 3.

  • Page 38: Installing The Touch-Back Switch (List D)

    6) Installing the touch-back switch (List D) 1. Install touch-back switch 1 with switch installing plate setscrew 2 and switch installing plate washer 7) Installing the pneumatic components (List E) 1. Install pneumatic components (asm.) 1 onto the table with setscrews 2. Table 2.
  • Page 39 ™ Reverse feed link hinge screw components (List A) Note Part No. Name of part Q’ty NS6150430SP Reverse feed link hinge screw nut SD0800402TP Reverse feed link hinge screw ™ Reverse fedd control lever components (List B) Note Part No. Name of part Q’ty 22656003...

  • Page 40: Automatic Presser Foot Lifter

    (2) Automatic presser foot lifter 1) Installing the automatic presser foot lifter (List A) 1. Remove the side plate located on the anti-operator’s side of the machine arm. (Removing parts list) 2. Install two elbows !0 to automatic presser foot lifter cylinder 1. 3.

  • Page 41: Installing The Pneumatic Device Components

    2) Installing the pneumatic device components When installing the automatic presser foot lifter to DNU-1541 and DNU-1541S after set-up of the machine (List B) Refer to “4. (1)-7) Installing the pneumatic components”. When installing the automatic presser foot lifter to DNU-1541-7 after set-up of the machine (List C) 1.

  • Page 42: Parts List

    (Caution : These parts Nos. are the set parts Nos. of the parts from lists A to D.) Set Part No. Set name of part Q’ty Contents of set (List No.) Applicable model GAKA20010A0 Kit AK120A DNU-1541 GAKA20010B0 Kit AK120B DNU-1541S GAKA2300AA0 Kit AK123A DNU-1541-7 GAKA2300BA0 Kit AK123B ™...
  • Page 43 ™ Pneumatic device components (For DNU-1541 and DNU-1541S) (List B) Note Part No. Name of part Q’ty GAKA14010A0 Pneumatic components (asm.) SK3482500SC Setscrew ™ Pneumatic device components (For DNU-1541-7) (List C) Note Part No. Name of part Q’ty GAKA2301BA0 Pneumatic device B (asm.)

  • Page 44: Installing The Dl Device

    (3) Installing the DL device 1) When installing the DL device to DNU-1541-7 after set-up of the machine (List A) 1. Remove the window plate E located on the anti- operator’s side of the machine arm. (Removing parts list) 2. Attach elbow 2, muffler 3, cylinder connecting screw 4, alternate vertical link hinge screw 5 and nut 6 to jig cylinder 1.

  • Page 45: Parts List

    4) Parts list ™ Removing parts list Note Part No. Name of part Q’ty 21339601 Top feed stopper plate A 21339700 Top feed stopper plate 21437108 Window plate E ™ Attaching parts list ™ Set part No. of DL device Note Part No.

  • Page 46: Portion To Which Locktite Is Applied

    5. PORTION TO WHICH LOCKTITE IS APPLIED LOCKTITE has been applied to the following parts at the time of assembly at the factory. Avoid disassembling these parts to the most. When an assembly which includes the aforementioned parts has been forced to be disassembled, be sure to wash the LOCKTITE applied part using a paint thinner or the like, and reassemble it using LOCKTITE after removing any moisture from the mating faces.

  • Page 47: Selective Parts And Consumable Parts

    L = 57.4 mm (standard) Tension release bar 21348206 L = 57.9 mm Tension release bar 10321107 L = 58.5 mm ™ For DNU-1541 Nameof consumable part Part No. Remarks Needle MC372001600 SCHMETZ 135 X 17 Nm 160 Hook (asm.)

  • Page 48: Engraved Marker Dots On The Handwheel

    7. ENGRAVED MARKER DOTS ON THE HANDWHEEL Needle-up stop position at the time of reverse revolution to lift needle Thread trimming position Range of needle-up stop position (white) Adjustment of thread trimmer cam (red) Needle-down stop position (yellow) 8. LUBRICATION ROUTE DIAGRAM...

  • Page 49: Pneumatic Piping

    9. PNEUMATIC PIPING Name of cylinder Display No. Remarks Automatic reverse feed stitching Presser lifter Cylinder drawing side (AK type only) Presser lifter Cylinder pushing side (AK type only) (DL type only) Regulator...

  • Page 50: Machine Head Wiring (With Thread Trimmer Only)

    10. MACHINE HEAD WIRING (WITH THREAD TRIMMER ONLY) (1) Connector coming from the machine head ™ 12-pin connector ™ 6-pin connector Name of part Pin No. Remarks Name of part Pin No. Remarks Synchronizer SGND(Black) DL control switch G N D Synchronizer UDET(White) (Green and Black)

  • Page 51: Connector Coming From The Pneumatic Device

    (2) Connector coming from the pneumatic device ™ 2-pin connector Name of part Pin No. Pneumatic components(asm.) Part No. : 23105554 Solenoid valve 1 BT (+) (Red) Solenoid valve 1 BT (–) (Black) ™ 9-pin connector Name of part Pin No. Pneumatic device B(asm.) Pneumatic device C(asm.) Part No.

  • Page 52: Connector Coming From The Relay Cable (Inserting Side To The Control Box)

    (3) Connector coming from the relay cable (Inserting side to the control box) ™ 14-pin connector Pin No. Relay cable (asm.) : 21443957 Thread trimmer (–) (Red) 2P LED (–) (Black) Needle UP switch (Yellow) 2P switch (White) BT switch (Brown) BT (–) (Blue) Tension release (–) (Yellow) Thread trimmer (+) (Orange)

  • Page 53: Table Of Troubles And Corrective Measures

    11. TABLE OF TROUBLES AND CORRECTIVE MEASURES (1) With reagard to sewing Troubles Causes Checking Corrective measures Thread breakage Thread path, needle Check the sharp edge or Remove the sharp edges or burrs point, hook blade point or burr on the respective on the blade point of hook using i n n e r h o o k r e s t i n g parts.

  • Page 54: With Regard To Lubrication

    Troubles Causes Checking Corrective measures Loose stitches Bobbin thread is not Check the bobbin thread Correctly pass thread to the bobbin (Balloon stitches or isolated passed to the fork end of route. case. idling loop) bobbin case tension spring. Thread paths have been Check the finish of the Finish using a fine emery paper or poorly finished.

  • Page 55: With Regard To Thread Trimming

    (3) With regard to thread trimming Troubles Causes Checking Corrective measures One or several stitches Needle thread remaining Check the routing of T h r e a d t h e n e e d l e t h r e a d skip at the start of sewing.

  • Page 56: Others

    Troubles Causes Checking Corrective measures From the next page Thread remains uncut The blades of rotary knife Replsace the rotary knife or fixed after thread trimming. and fixed knife have knife with a new one. worn out or broken. C h e c k w h e t h e r a Refer to “3.

  • Page 57: Drawing Of The Table

    2 Installing position of stopper for drawer Style of tpe : Helvetica Reg. Condensed Thickness : 1.5 (on the reverse side) Condensed voided letters 3 JUKI logotype Thickness : 0.5 Thickness : 1.5 4 16 depth 30 Thickness : 0.8 5 Top surface C1.5...
  • Page 58 FAX : (81)3-3430-4909 • 4914 • 4984 The description covered in this engineer's manual is subject to change for improvement of the TELEX : J22967 commodity without notice. Copyright C 2001-2002 JUKI CORPORATION. All rights reserved throughout the world. 02 · 10 Printed in Japan (E)

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Dnu-1541sDnu-1541-7

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