JUKI DP-2100 Engineer's Manual
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JUKI DP-2100 Engineer's Manual

JUKI DP-2100 Engineer's Manual

Computer-controlled dry-head, lockstitch, sleeve setting machine with multi-programming device
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Computer-controlled Dry-head, Lockstitch,
Sleeve Setting Machine
with Multi-programming Device
DP-2100
ENGINEER'S MANUAL
R
40018531
No.E363-00

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Summary of Contents for JUKI DP-2100

  • Page 1 Computer-controlled Dry-head, Lockstitch, Sleeve Setting Machine with Multi-programming Device DP-2100 ENGINEER’S MANUAL 40018531 No.E363-00...
  • 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 these machines 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 by the Instruction Manual.

  • Page 3: Table Of Contents

    CONTENTS 1. SPECIFICATIONS...................1 2. CONFIGURATION .................. 2 (1) Sewing machine main unit ................. 2 (2) Operation panel ....................3 3. STANDARD ADJUSTMENT ..............4 (1) Adjusting the height of the needle bar .............. 4 (2) Adjusting the needle and the hook ..............4 (3) Removing the main shaft motor and the coupling ...........
  • Page 4 6. INITIALIZING THE BACKUP DATA ............72 7. SEWING DATA LIST ................73 8. MEMORY SWITCH DATA LIST ..............76 9. ERROR CODE LIST ................82 10. TROUBLES AND CORRECTIVE MEASURES ........87 (1) Mechanical parts ....................87 (2) Electrical parts..................... 93 11.

  • Page 5: Specifications

    Data mirroring Possible Right/left alternate sewing Smart media Data record Exclusive grease : 23640204 (500g can) Grease JUKI grease A : 40006323 (tube of 10g) 106 Kg (head 65 Kg) Weight of complete set MC-650 Control box model 3-phase Single phase...

  • Page 6: Configuration

    2. CONFIGURATION (1) Sewing machine main unit 1 Sewing machine head 2 Operation panel 3 Control box 4 Auxiliary table (WORK TOP TABLE) 5 Power switch 6 Main pedal 7 Auxiliary pedal 8 Thread stand 9 Shirring release switch !0 Knee switch for step changeover −...

  • Page 7: Operation Panel

    (2) Operation panel (Front face) (Right side face) 1 Touch panel, LCD display section 2 Smart media slot card (Use with the lid closed.) 3 Slide switch (Unused • OFF) 4 Connector for RS-232C communication 5 Variable resistor for adjusting color LCD screen contrast 6 Connector for external input 7 Cable −...

  • Page 8: Standard Adjustment

    3. STANDARD ADJUSTMENT (1) Adjusting the height of the needle bar Standard Adjustment 1. Bring the needle bar to its lower dead point, and adjust so that the upper marker line engraved on the needle bar aligns with the bottom end face of the needle bar lower bushing. To align (2) Adjusting the needle and the hook Standard Adjustment...
  • Page 9 Adjustment Procedures Results of improper Adjustment ™ Stich skipping or thread breakage 1. Turn the handwheel by hand to bring the needle bar to its may occur. lower dead point. 2. Remove the plug of the face plate cover. 3. Loosen needle bar connection setscrew 1 to adjust the height.

  • Page 10: Removing The Main Shaft Motor And The Coupling

    (3)Removing the main shaft motor and the coupling Standard Adjustment 1. Clearance between main shaft motor 1 and coupling 2 has to be 0.5 mm. Screw No. 1 0.5mm Screw No. 1 Flat section − −...
  • Page 11 Adjustment Procedures Results of improper Adjustment ™ When setscrews 3 and 7 in 1. Loosen the respective setscrews in side plate 4, pulley 5 and the coupling are not adjusted to the pulley cover 6, and remove the respective parts. flat section of main shaft motor 1 2.

  • Page 12: Adjusting The Main Shaft Belt Tension

    (4) Adjusting the main shaft belt tension Standard Adjustment 1. Press in the direction of A with a load of 19.6 N (2 Kgf), and tighten setscrew 2. Main shaft belt (5) Adjusting the hook shaft belt tension Standard Adjustment 1.
  • Page 13 Adjustment Procedures Results of improper Adjustment ™ When belt tension is excessively 1. Loosen setscrew 2 in idler installing plate 1. low, the side where the belt is 2. Press idler installing plate 1 in the direction of arrow mark A loosened vibrates and noise with a load of 19.6 N (2 Kgf), and tighten setscrew 2.

  • Page 14: Adjusting The Feed Belt Tension

    (6) Adjusting the feed belt tension Standard Adjustment 1. Main feed belt Adjust so that main feed belt 9 sags 3 mm when it is pressed with a finger with a load of 1.3N (130 gf). 2. Auxiliary feed belt Adjust so that auxiliary feed belt !0 sags 3 mm when it is pressed with a finger with a load of 0.4N (40 gf).
  • Page 15 Adjustment Procedures Results of improper Adjustment ™ If the tension is not proper, shirring 1. Main feed belt trouble due to feed pitch error will (1) Remove 10 setscrews 8 in top feed covers A 1 and B 7. be caused. (2) Move tension adjustment plate L 2 to the right and left to adjust the tension.

  • Page 16: Adjusting The Height Of The Feed Foot Bar

    (7) Adjusting the height of the feed foot bar Standard Adjustment 1. Adjust the clearance between top and bottom feed belts to 0.1 mm. Be careful of parallel (8) Adjusting the height of the presser foot bar Standard Adjustment 1. Adjust the clearance between the bottom face of presser foot 4 and needle hole guide 7 to 0.1 mm.
  • Page 17 Adjustment Procedures Results of improper Adjustment ™ When the clearance is larger than 1. Height of the feed foot bar 0.1 mm, feed force is deteriorated. (1) Bring the needle bar to its upper dead point. ™ Clearance between top and bottom (2) Remove plug 1.

  • Page 18: Adjusting The Amount Of Alternate Vertical Movement

    (9) Adjusting the amount of alternate vertical movement Standard Adjustment 1. State of feed foot and presser foot at the time of delivery Cam rod position Top feed arm lowest position Amount of alternate vertical movement of feed foot 0.2 to 0.3 mm Clearance at lower dead point of feed foot 0.1mm Amount of alternate vertival movement of presser foot...
  • Page 19 Adjustment Procedures Results of improper Adjustment ™ When the clearance is widened, 1. Turn the handwheel and bring the needle bar to its lower dead feed force is deteriorated at high point. speed. 2. Adjust the position of cam rod 1 to the lowest position of top ™...

  • Page 20: Height Of The Presser Screw

    (10) Height of the presser screw Standard Adjustment 1. Adjust the height of top feed spring adjusting screw 1 to 30 ± 0.3 mm from the machined plane of frame. 2. Adjust the height of presser spring regulator 2 to 19 ± 0.3 mm from the top surface of spring base 3. (11) Assembling the guide plate Standard Adjustment 1.
  • Page 21 Adjustment Procedures Results of improper Adjustment ™ When the height is excessively 1. For the adjustment of top feed spring adjusting screw 1, loosen high, shortage of feed force occurs nuts 5, adjust the height to 30 ± 0.3 mm, and tighten nuts 5. and jumping at high speed occurs.

  • Page 22: Adjusting The Initial Position Of The Auto-Lifter

    (12) Adjusting the initial position of the auto-lifter Standard Adjustment 1. Adjust so that the clearance between the top surface of presser lifter link 1 and the bottom face of feed foot bar connection 2 is 0.1 to 0.3 mm at the upper dead point of the needle bar. (13) Adjusting the speed of the auto-lifter Standard Adjustment 1.
  • Page 23 Adjustment Procedures Results of improper Adjustment ™ When the clearance is excessively 1. Remove the side plate, and loosen setscrews 3 in stopper wide, a big noise occurs when the installing plate 4. auto-lifter goes up. 2. Move stopper installing plate 4 in the direction of the arrow mark, and adjust the clearance between presser lifter link 1 and feed foot bar connection 2 to 0.1 to 0.3 mm.

  • Page 24: Adjusting The Stroke Of The Auto-Lifter

    (14) Adjusting the stroke of the auto-lifter Standard Adjustment 1. Adjust so that the clearance between the bottom face of the top feed belt and the top surface of the bottom feed belt is 10 to 10.3 mm. (15) Adjusting the thread trimmer cam Standard Adjustment 1.
  • Page 25 Adjustment Procedures Results of improper Adjustment 1. Loosen nut 2 of link ball shaft 1 . ™ When the clearance is excessively 2. Turn link ball shaft 1 and tighten nut 2 when the specified wide, feed foot comes in contact value (10 to 10.3 mm) is reached.

  • Page 26: Adjusting The Initial Position Of The Moving Knife

    (16) Adjusting the initial position of the moving knife Standard Adjustment 1. The initial position of the moving knife is the position where marker dot 1 engraved on the hook shaft base aligns with V groove 2 on the moving knife base 3 . At this time, end 6 of the cam roller is higher by 1.7 mm than hook driving shaft center 7 .
  • Page 27 Adjustment Procedures Results of improper Adjustment ™ Thread handling trouble 1. Adjusting the engraved marker dot (1) Loosen clamp screw 4 in knife driving arm 5 , make The blade section of moving knife engraved marker dot 1 align with V groove 2 , and tighten does not fully pass the blade clamp screw 4 .

  • Page 28: Adjusting The Position Of The Moving Knife And The Counter Knife

    (18) Adjusting the position of the moving knife and the counter knife Standard Adjustment 1. Install moving knife 1 with setscrews 2 in the moving knife by making it come in contact with the moving knife base. 2. Install counter knife 4 together with knife pressure adjustment plate 5 with setscrew 3 in the counter knife.
  • Page 29 Adjustment Procedures Results of improper Adjustment 1. Adjust so that the blade section of the eye of moving knife 1 ™ When the parallel is not obtained, and the blade section of counter knife 4 come in contact with remaining of thread end will be caused.

  • Page 30: The Fixing Position Of The Main Feed Motor Pulley

    (20) The fixing position of the main feed motor pulley Standard Adjustment 1. Adjust the dimension from the end of the shaft of main feed motor 3 to the end of pulley 2 to 9 ± 0.2 mm. 9 ± 0.2 mm (21) The fixing position of the thrust collar of AT solenoid Standard Adjustment 1.
  • Page 31 Adjustment Procedures Results of improper Adjustment 1. Loosen setscrews 1 . ™ When the dimension is small, timing belt comes off pulley 2 . 2. Adjust the position of pulley 2 (dimension : 9 ± 0.2 mm). 3. Tighten setscrews 1 . ™...

  • Page 32: The Fixing Position Of The Thread Tension Shaft Collar

    (22) The fixing position of the thread tension shaft collar Standard Adjustment 1. Pull thread release pin adjustment collar 2 in the direction of B, and adjust so that the dimension from the end of thrust collar 3 to the main body of AT solenoid 4 to 1 ± 0.1 mm when thread tension disks 6 are fully closed.
  • Page 33 Adjustment Procedures Results of improper Adjustment 1. Loosen nut 1 . ™ When the dimension is large, 2. Loosen thread release pin adjustment collar 2 . needle thread tension is not 3. Insert a spacer 5 of 1 mm between thrust collar 3 and the main stabilized.

  • Page 34: Adjusting The Height Of The Auxiliary Feed Foot

    (24) Adjusting the height of the auxiliary feed foot Standard Adjustment 1. Make the clearance A between the bottom face of auxiliary feed belt 5 and the top surface of bottom feed belt 6 the same as that B between the bottom face of main feed belt 7 and the top surface of bottom feed belt 6 when needle bar 1 is in the position of its upper dead point.
  • Page 35 Adjustment Procedures Results of improper Adjustment 1. Bring needle bar 1 to the position of its upper dead point. ™ When dimension is large / 1. Material cannot be fed 2. Loosen nut 2 . straight. 3. Turn screw 3 , and adjust the height of auxiliary feed foot 4 . 2.

  • Page 36: Adjusting The Feed Eccentric Cam

    (26) Adjusting the feed eccentric cam Standard Adjustment 1. Adjust feed eccentric cam 2 so that screw No. 1 faces the center of hinge screw 4 in cam rod at the upper dead point of the needle bar. (27) Adjusting the assembly of the counter knife guard plate Standard Adjustment 1.
  • Page 37 Adjustment Procedures Results of improper Adjustment 1. Turn top feed arm cover 1 . ™ When timing is improper, troubles 2. Turn the handwheel and adjust the main shaft to the upper dead below will be caused. point of the needle bar. 1.

  • Page 38: Replacing Procedure Of The Top Feed Belt

    (28) Replacing procedure of the top feed belt (1/7) Procedures of disassembling / assembling − −...
  • Page 39 Caution in disassembling Caution in assembling 1. Loosen setscrew 1, and remove needle 2. 2. Remove setscrew 3, and remove presser foot 4. 3. Remove 10 setscrews 5, and remove cover A 6 and cover B 7. 4. Loosen setscrew 8 , move tension adjustment plate L 9 in the direction of A, and loosen the tension of main feed belt !2 and auxiliary feed belt !3 .
  • Page 40 (28) Replacing procedure of the top feed belt (2/7) Procedures of disassembling / assembling − −...
  • Page 41 Caution in disassembling Caution in assembling 6. Remove main feed belt !2 from the pulley. 7. Remove auxiliary feed belt !3 from the pulley. 8. Raise manual presser lifting lever !4 . 9. Remove setscrew !5 , and remove auxiliary feed foot !7 from feed foot bar !6 .
  • Page 42 (28) Replacing procedure of the top feed belt (3/7) Procedures of disassembling / assembling − −...
  • Page 43 Caution in disassembling Caution in assembling 10.Remove the old auxiliary feed belt !3 of auxiliary feed foot !7 , and replace it with the new auxiliary feed belt !3 . 11.Remove the old main feed belt !2 of feed foot !9 , and replace it with the new main feed belt !2 .
  • Page 44 (28) Replacing procedure of the top feed belt (4/7) Procedures of disassembling / assembling − −...
  • Page 45 Caution in disassembling Caution in assembling * When setting auxiliary feed belt !3 14.Set auxiliary feed belt !3 to the respective pulleys in order of to the pulley, do not twist or draw the numbers in the illustration on the left side. forcibly auxiliary feed belt !3 .
  • Page 46 (28) Replacing procedure of the top feed belt (5/7) Procedures of disassembling / assembling − −...
  • Page 47 Caution in disassembling Caution in assembling * For the details of adjusting the 17.Bring the needle bar to the position of its upper dead point, and tighten screw !5 after adjusting the height of feed foot !9 so that height of the feed foot, refer to the clearance between main feed belt !2 and bottom feed belt @0 0 "(23) Adjusting the height of the...
  • Page 48 (28) Replacing procedure of the top feed belt (6/7) Procedures of disassembling / assembling − −...
  • Page 49 Caution in disassembling Caution in assembling * For the details of adjusting the 20.Bring the needle bar to the position of its upper dead point, loosen nut @1 , turn screw @2 , and adjust so that the bottom face of auxiliary height of the auxiliary feed foot, feed belt !3 is as high as that of main feed belt !2 .
  • Page 50 (28) Replacing procedure of the top feed belt (7/7) Procedures of disassembling / assembling − −...
  • Page 51 Caution in disassembling Caution in assembling 23.Install needle 2 , and tighten setscrew 1 . 24.Tighten 10 setscrews 5 , and fix cover A 6 and cover B 7 . − −...

  • Page 52: Replacing Procedure Of The Bottom Feed Belt

    (29) Replacing procedure of the bottom feed belt Procedures of disassembling / assembling − −...
  • Page 53 Caution in disassembling Caution in assembling 1. Loosen cover setscrews 1 , 2 and 3 . 2. Remove throat plate auxiliary plate 4 , hook cover 5 , hook belt cover 6 , frame cover 7 and bottom feed cover 8 . 3.

  • Page 54: Parts To Be Greased

    4. PARTS TO BE GREASED (1) Periodically perform grease-up to the indicated sections below approximately every six months as a standard. (2) Apply the exclusive grease (500g can, Part No. :23640204 or tube containing 10g, Part No. : 40006323) to the sections for which lubrication is necessary excluding the lubricating sections. (3) Tighten the respective hinge screws excluding the auxiliary feed foot hinge screw with a tightening torque of 5.88±0.49N •...
  • Page 55 Presser vertical link Internal plane of belt roller (4) Tighten the auxiliary feed foot hinge screw with a tightening torque of 4.9±0.49N • m (50±5 kgf • cm). Auxiliary feed foot hinge screw − −...

  • Page 56: Set-Up Manual For Ip-200

    5. SET-UP MANUAL FOR IP-200 (1) Connecting procedure of operation panel with external vehicle It is possible for this operation panel to perform communication or input of signal with the external vehicle below other than the control box. 1. Smart media card 2.
  • Page 57 3) When the setting of the card is completed, close the smart media card cover. It is not possible to receeive or send the data with smart media card with the cover opened. For the operating procedure, refer to “USING COMMUNICATION FUNCTION” of the Instruction Manual. If the smart media card comes in contact with the cover and the cover is not closed, check the following matters.
  • Page 58 2. Communication by means of RS-232C Operation panel can give and take the data with the personal computer by using communication by means of RS-232C. For the cable to be connected, connect the reverse type 9-pin (female) to the operation panel side. Signal names of the operation panel are as follows.
  • Page 59 3. Input of signal by means of the connector for external input It is possible to input the signal from the outside. When the switch is connected, it is possible to use as the input of the production control information. For the details, refer to "Observing the production control information"...

  • Page 60: Re-Setup Of Operation Panel

    (2) Re-setup of operation panel When the case is as below, it is necessary to perform re-setup of the program of the operation panel. ™ When the operation panel is used as that for other model. ™ When version-up of the program is performed. The way of performing setup of the program from the smart media is shown below.
  • Page 61 Communication screen 2   6) Press key File selection screen   7) Press key and select the download program at display   8) Press key  . Communication screen 3   9) Press key <-<- Start of communication ->-> – 57 –...
  • Page 62 Screen during data deletion Screen 1 during data writing Screen 2 during data writing End screen If the screen below is displayed, quickly turn OFF the power and perform the set- up again after checking [Checking items] below. Data writing abnormal screen The procedure above completes the replacing work of application software.

  • Page 63: Re-Setup Of Main Program

    (3) Re-setup of main program When you have purchased the single unit of IP-200 operation panel, the smart media card is packed together. You can perform re-setup of the main program of MAIN circuit board on the control box side by using this smart media card.
  • Page 64 Communication screen 2   6) Press key File selection screen   7) Press key and select download program at display   8) Press key Communication screen 3   9) Press key <-<- Start of communication ->-> – 60 –...
  • Page 65 Screen during data writing Screen of end of data writing The procedure above completes the replacing work of application software. If the screen below is displayed, quickly turn OFF the power and perform the set- up again after checking [Checking items] below.
  • Page 66 2. When panel program does not match with main program and an error occurs Perform the work by the procedure below when replacing the main program in case trouble such as Error "E703", "E704", etc. occurs. 1) First, turn ON the power. Error screen (E703 or E704) is displayed after turning ON the power. 2) Insert the smart media card into the operation panel.
  • Page 67 Communication screen 2   6) Press key File selection screen   7) Prees key and select the download program at display   8) Press key Communication screen 3   9) Press key <-<- Start of communication ->-> – 63 –...
  • Page 68 Screen during data writing Screen of end of data writing The procedure above completes the replacing work of application software. If the screen below is displayed, quickly turn OFF the power and perform the set- up again after checking [Checking items] below.

  • Page 69: Re-Setup Of Servo Program

    (4) Re-setup of servo program Perform the work by the procedure below when rewriting the servo program in the same way of “Re-setup of main program”. 1. When main program matches with servo program Perform the work by the procedure below when making the servo program version-up by using the smart media card.
  • Page 70 Communication screen 2   6) Press key File selection screen   7) Press key and select the download program at display   8) Press key Communication screen 3   9) Press key <-<- Start of communication ->-> – 66 –...
  • Page 71 Screen during data writing Screen of end of data writing The procedure above completes the replacing work of application software. If the screen below is displayed, quickly turn OFF the power and perform the set- up again after checking [Checking items] below.
  • Page 72 2. When panel program does not match with main program and an error occurs Perform the work by the procedure below when replacing the main program in case trouble such as Error "E703", "E704", etc. occurs. 1) First, turn ON the power. Error screen (E703 or E704) is displayed after turning ON the power. 2) Insert the smart media card into the operation panel.
  • Page 73 Communication screen 2   5) Press key File selection screen   6) Press key and select the download program at display   7) Press key Communication screen 3   8) Press key <-<- Start of communication ->-> – 69 –...
  • Page 74 Screen during data writing Screen of end of data writing The procedure above completes the replacing work of application software. If the screen below is displayed, quickly turn OFF the power and perform the set- up again after checking [Checking items] below.

  • Page 75: When Using Smart Media Other Than That Which Has Been Packed Together

    (.bin) corresponding to the machine ¥¥ model of the aforementioned folder name. PROG DP2100 Make the folder name the machine model name. The example above is in case of DP-2100. However, do not put "-" (hyphen) of the machine model name. – 71 –...

  • Page 76: Initializing The Backup Data

    6. INITIALIZING THE BACKUP DATA Perform the work in the order of the procedures below in order to return the backup data which are memorized in the sewing machine to the status at the time of delivery. 1) Press down shirring release switch 1, press down knee switch for step changeover 2, and turn ON power switch 3 with auxiliary pedal 4 depressed.

  • Page 77: Sewing Data List

    7. SEWING DATA LIST This list is the list of sewing data to set for every pattern. "Semi-automatic selection and fully-automatic selection" Item Setting range Edit unit Initial display Selection of gents and ladies (Fully-automatic only) – – – – – – Gents Select from two kinds of gents and ladies.
  • Page 78 Setting range Edit unit Initial display Item Compensation shirring amount setting Number of Number of stitches to increase/decrease the stitches of shirring amount immediately after changing compensation 1 stitch 0 stitch over the step and the shirring amount are set. 0 to 15 Compensation shirring...
  • Page 79 "Manual selection" Initial display Item Setting range Edit unit Auxiliary pedal motion selection – – – – – – Interlocking The motion is selected from two kinds of step mode and mode interlocking mode. : Step mode : Interlocking mode Auxiliary feed mode selection –...

  • Page 80: Memory Switch Data List

    8. MEMORY SWITCH DATA LIST 1) Level 1 Memory switch data (level 1) are the motion data that the sewing machine has in common and the data that operate on all sewing patterns in common. Item Setting range Edit unit Initial display Reverse stitching at the sewing start selection –...
  • Page 81 Item Setting range Edit unit Initial display Compensation tension mode selection – – – – – – Manual Select from among manual (numerical value), manual (level) (numerical and automatic. value) : Numerical value : Level : Automatic For setting procedure of the manual (numerical value), refer to "Explanation of compensation tension (numerical value)"...
  • Page 82 Setting range Edit unit Initial display Item Knee switch use selection – – – – – – Whether knee switch for step changeover is used or not is selected. : Unused : Use – – – – – – Shirring amount interlock function at the time of change corrected of pitch selection Whether shirring amount set to each step at the time of...
  • Page 83 Item Setting range Edit unit Initial display Flicker reduction function setting 0 to 8 This function is set when hand lamp flickers. 0 : Without flicker reduction function 1 : Less effective / 8 : more effective Rotation start pedal stroke setting 1.0 to 5.0 0.1mm 3.0mm...
  • Page 84 Setting range Edit unit Initial display Item Reverse stitching at the sewing start A/M changeover – – – – – – Speed by function selection manual Designation of sewing speed of reverse stitching at the operation sewing start is selected. : In accordance with the speed by manual operation of pedal or the like : In accordance with the speed set by...
  • Page 85 Item Setting range Edit unit Initial display Top feed amount compensation value –1.0 to 1.0 0.1mm setting Compensation value of set value and actual value of top feed amount is set. Thread tension curve selection – – – – – – Standard Inclination of thread tension curve is selected.

  • Page 86: Error Code List

    9. ERROR CODE LIST Pictograph Description of error Error code How to recover Place of recovery E000 Contact of initialization of main shaft Turn OFF the EEP-ROM of MAIN p.c.b. power. When data is not written in EEP-ROM or data is broken, data is automatically initialized and the initialization is informed.
  • Page 87 Description of error Error code Pictograph How to recover Place of recovery Read error P o s s i b l e t o Previous screen E012 Data read from external media cannot be recover by reset. performed. P o s s i b l e t o E013 Write error Previous screen...
  • Page 88 Error code Pictograph Description of error Place of recovery How to recover Abnormality of control Turn OFF the E702 CPU performed processing other than power. supposed. Panel is connected to the machine other Possible to E703 than supposed. (Machine type error) rewrite program When machine type code of system is after pressing...
  • Page 89 Pictograph Description of error Error code How to recover Place of recovery Overvoltage Turn OFF the E811 When power overvoltage signal (OVL) which power. is output when input power is 280V or more is detected. Turn OFF the Low voltage E813 power.
  • Page 90 Error code Description of error How to recover Place of recovery Pictograph CPLD reading abnormality Turn OFF the E941 When input signal from CPLD is read twice power. and they do not agree with each other even when trying 10 ms or more when turning ON the power.

  • Page 91: Troubles And Corrective Measures

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  • Page 108: Circuit Diagram

    11. CIRCUIT DIAGRAM (1) Block diagram (1/2) PART No. DESCRIPTION ASSEMBLED PLACE REMARKS 40008173 CONTROL BOX A ASM. CONTROL BOX A (3-PHASE : JAPAN, JUS) 40017733 CONTROL BOX B ASM. B (SINGLE PHASE : GENERAL EXPORT) 40017734 CONTROL BOX C ASM. C (SINGLE PHASE : CE TYPE) 40008187 MAIN P.C.B.

  • Page 109: Block Diagram (2/2)

    (1) Block diagram (2/2) 1 CONTROL BOX ASM. (A TYPE) CONTROL BOX ASM. (B TYPE) CONTROL BOX ASM. (C TYPE) @3 HEAD RELAY !8 IP-200 C ASM. CN104 CORD 1 ASM. #3 AT SOLENOID THREAD OPERATION PANEL TENSION CN34 #4 OPTIONAL CN105 SWITCH ASM.

  • Page 110: Head And Table/Stand Circuit Diagram

    (2) Head and table/stand circuit diagram MAIN P.C.B. PEDAL SENSOR CN36 CN53 CN104 AT SOLENOID WHITE SHIRRING RELEASE WHITE 13.8Ω WHITE SGND SOL_ACT– SHIELD CN105 MONITOR SOL_ACT+ AUXILIARY PEDAL SENSOR CN62 WHITE BLACK SGND CN54 SHIRRING RELEASE SHIELD KNEE SWITCH STEP CHANGEOVER CN52 CN107...

  • Page 111: Main And Panel Circuit Diagram

    (3) Main and panel circuit diagram PANEL P.C.B. MAIN P.C.B. CN34 CN100 TXD (N) TXD [N] RXD (N) RXD [N] RTS (N) RTS[N] CTS (N) CTS [N] CLK (N) CLK [N] S_RES (N) SYS_RESET [N] PWR_F PWRF [N] SL_VR +24V +24V −...

  • Page 112: Power Source A Circuit Diagram

    (4) Power source A circuit diagram FLT - T P.C.B. PWR P.C.B. MAIN P.C.B. POWER SWITCH CONNECTION TO 200V CN59 CN13 BLUE OCRS_N +33V GREEN GREEN PURPLE +24V +33VRTN BLACK BLACK power ORANGE +24V +33V WHITE WHITE ORANGE +33V source HEATP AC200-240V +48V...

  • Page 113: Power Source B Circuit Diagram

    (5) Power source B circuit diagram PWR P.C.B. MAIN P.C.B. POWER SWITCH FLT - S P.C.B. CN13 CN59 BLUE GREEN/ GREEN/ +33V OCRS_N YELLOW YELLOW PURPLE power +33VRTN +24V BROWN BROWN ORANGE +24V +33V source LIGHT BLUE LIGHT BLUE ORANGE HEATP +33V AC200-240V...

  • Page 114: Power Source C Circuit Diagram

    (6) Power source C circuit diagram PWR P.C.B. MAIN P.C.B. POWER SWITCH FLT - S P.C.B. CN13 CN59 BLUE GREEN/ GREEN/ OCRS_N +33V YELLOW YELLOW PURPLE +24V +33VRTN power BROWN BROWN ORANGE +24V +33V LIGHT BLUE LIGHT BLUE source ORANGE +33V HEATP AC200-240V...

  • Page 115: Motor Circuit Diagram

    (7) Motor circuit diagram PWR P.C.B. MAIN P.C.B. BOX FAN MOTOR CN56 CN23 M1M_A +24V ORANGE TOP FEED M1M_B +24VRTN YELLOW MOTOR M1M_C +24VRTN BLUE R = 0.93 Ω / 1 ø M1M_D BLACK M1M_E FAN MOTOR IN BOX CN24 +24V +24VRTN M2M_A...

  • Page 116: Servo Motor Circuit Diagram

    (8) Servo motor circuit diagram SDC P.C.B. AC SERVO MOTOR CN21 SHIELD WHITE (DRAIN WIRE) SGND BLACK ORANGE BLUE PURPLE ENCODER LIGHT BLUE PINK SDET YELLOW R = 1.29 Ω CN38 BLACK WHITE GREEN/YELLOW − − − −...

  • Page 117: Various Printed Wiring Boards

    12. VARIOUS PRINTED WIRING BOARDS (1) FLT-T p.c.b. (2) FLT-S p.c.b. 3-phase 200V~240V Single-phase 200V~240V Single-phase 200V~240V Pulse generation is carried out for the purposes of power supply rectification, Pulse generation is carried out for the purposes of power supply rectification, noise reduction, and the detection of a momentary interruption noise reduction, and the detection of a momentary interruption CN1 : Power input , Power switch...

  • Page 118: Pwr P.c.b

    (3) PWR p.c.b. (4) MAIN p.c.b. This p.c.b. performs generation of power, check of power and drive of main motor. This p.c.b. performs the whole control such as control of feed stepping motor, control of main motor, control of active tension, memory switches, etc. CN44 Power +5V, CN34...

  • Page 119: Panel P.c.b

    (5) PANEL p.c.b. (6) DATA p.c.b. This p.c.b. performs input of operation, creation of sewing data, change of various setting of memory switches, This p.c.b. records the data which are specific to the machine head such as compensation value of active storing of various data, writing, communication with external equipment, etc.

  • Page 120: Drawing Of The Table

    A 4 x ø3.4 on the bottom surface, depth 20 (Drill a hole at the time of set-up.) ø11 ø7 B JUKI logotype C Jointless at the joining of slant section D ø24 drilled hole ø19 E ø18 drilled hole ø3.5...

  • Page 121: Work Top Table

    250 ± 250 ± 14.5 34 ± 34 ± Z - Z (1:1) (6 places) ø4 A 4 x 6.6 drill B 8 x 6.6 drill, depth 17, spot facing depth 2 ø8 C JUKI logotype 90˚ − − − −...

  • Page 122: Edge Stopper A

    (3) Edge Stopper A Part No. : 40013087 275 ± 275 ± 3 x ø 2.5 depth 14 − − − −...

  • Page 123: Edge Stopper B

    (4) Edge Stopper B Part No. : 40013088 250 ± 250 ± 3 x ø 2.5 depth 14 − − − −...
  • Page 124 ＊ The description covered in this engineer's manual is subject to change for improvement of the TELEX : J22967 commodity without notice. Copyright C 2004 JUKI CORPORATION. All rights reserved throughout the world. 04 · 02 Printed in Japan (E)

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