JUKI HZL-G Series Service Manual
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JUKI HZL-G Series Service Manual

Computer sewing machine
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COMPuTER SEWInG MaCHInE
HZl-G Series
SERVICE Manual

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Summary of Contents for JUKI HZL-G Series

  • Page 1 COMPuTER SEWInG MaCHInE HZl-G Series SERVICE Manual...
  • Page 2 6-2 Adjusting the needle entry point ○ Remove the face cover. Adjustment procedure 1. Select the straight stitch using the pattern selecting button. Choose center needle position. 2. Assemble a needle #14 into the needle bar, loosen the setscrew in the eccentric collar and adjust the feed bar eccentric collar so that the needle meets the center of the needle slot in the throat plate when it reaches the top face of the throat plate by turning the hand wheel.

  • Page 3: Table Of Contents

    COnTEnTS [ 1] Specifications of HZL-G Series ............1 [ 2] Search by trouble (related to mechanical components) ..... 3 [ 3] Principal parts ..................4 [ 4] Disassembling the machine covers ............. 5 [ 5] PCB connection diagram ..............9 [ 6] Adjustment ................... 13 6-1 Adjusting the needle bar height ..............13 6-2 Adjusting the needle entry point ..............14 6-3 Feed dog height ....................14 6-4 Timing belt ......................15 6-5 Feed timing ....................... 15 6-6 Timing between the needle and the hook ............16 6-7 Clearance between the needle and the blade point of hook ......17 6-8 Position of the hook rotation stopper plate ............ 18 6-9 Adjusting the bobbin thread tension .............. 18 6-10 Adjusting the disk opening amount .............. 19 　　6-10-1 Adjusting the tension release adjusting plate ........19 　　6-10-2 Tension disk opening amount ............19 　　6-10-3 Base tension opening amount ............20 　　6-10-4 Adjusting the disk opening amount at the time of thread trimming 　 　　　　(HZL-G210) ....................21 6-11 Adjusting the needle thread tension ............. 21 6-12 Vertical position of the needle threading hook ..........22 6-13 Adjusting the presser foot lifting switch ............23 6-14 Adjusting the presser bar height ..............23 6-15 Motor belt ......................24 6-16 Automatic thread trimming (HZL-G210) ............25...

  • Page 4: 1] Specifications Of Hzl-G Series

    [1] Specifications of HZL-G Series (1) Power switch ･ 220-240V AC common to 50/60 Hz ･ 20V AC common to 60 Hz (2) Power consumption ･ 65 W (3) Dimensions and weight ･ Dimensions Main unit: 445 (width) x 20 (depth) x 290.5 (height) (mm) Case set: 50 (width) x 257 (depth) x 305 (height) (mm) ･...
  • Page 5 (7) Amount of feed ･ The amount of feed is changed in increments of 0.2 mm by the stitch length adjusting dial. (For the parallel parts of a buttonhole and satin stitches, the amount feed is changed in increments of 0. mm.) Default setting: 2.4 mm (for straight stitching) (8) Pattern selection ･...

  • Page 6: 2] Search By Trouble (Related To Mechanical Components)

    [2] Search by trouble (related to mechanical components) Phenomenon Item to be checked Faulty thread tension 6-8: Position of the hook rotation stopper plate 6-9: Adjusting the bobbin thread tension 6-0-2: Tension disk opening amount 6-0-3: Base tension opening amount 6-: Adjusting the needle thread tension Stitch skipping 6-: Adjusting the needle bar height...

  • Page 7: 3] Principal Parts

    [3] Principal parts Thread tension adjustment dial Spool cap (large) Speed controller Spool pin Bobbin winding shaft Face plate cover Needle up/down button LCD Screen Presser foot lifting lever Reverse stitch button Thread cutter Operational buttons Thread trimming button Start/stop button Auxiliary bed (accessory case) Drop feed knob...

  • Page 8: 4] Disassembling The Machine Covers

    [4] Disassembling the machine covers 1) Top cover ○ To remove the top cover, bow the hinge section of the right side of the cover. 2) Face cover ○ Remove setscrews from the cover. Then, remove the cover. 3) Throat plate ○...
  • Page 9 4) Spool cover ○ Remove setscrew from the thread tension cover. Remove the thread tension cover. ○ Remove setscrews from the spool cover. ○ Pull out the cable of bobbin winder motor from the microcomputer PCB. Loosen the setscrew of the grounding wire. Remove the grounding wire. ○...
  • Page 10 6) Bed cover ○ Remove setscrews from the rubber cushion of the bed cover. Remove setscrew from the bed cover. Remove setscrews from the metal plate. Remove the bed cover. 7) Upper cover of the free ○ Remove setscrew from the upper cover of the free arm. Remove the cover.
  • Page 11 9) Front panel ○ Remove setscrews from the front panel. ○ Put a thin screwdriver in the notch in the rising section under the arm and pry off the front panel and hook of the rear panel. ○ Opening the right side of the front panel in the direction of the arrow, tap section with your hand to remove hook located at the bed surface.

  • Page 12: 5] Pcb Connection Diagram

    [5] PCB connection diagram ・ Microcomputer PCB CN10 Connector Terminal Destination ON_HAND_LED_CIRCUIT_BOARD_2 (Not installed) BOBBIN_WINDING_MOTOR Bobbin winder switch Bobbin winder motor (+) (29V) Bobbin winder motor (-) OST SW Presser foot lifting switch BH_SW BHR SW BHS SW MAIN_SHAFT_DETECTION_CIRCUIT_BOARD Motor pulse FLASH MEMORY INTERFACE FOR FACTORY RESERVE (Not installed)
  • Page 13 Connector Terminal Destination CN0 POWER_SUPPLY_RELAY_LEAD_WIRE CN MAIN MOTOR MAIN MOTOR (+) (29V) MAIN MOTOR (-) CN2 THREAD_TRIMMING_STM 8.5Ω 8.5Ω CN3 FEED_STM 4.0Ω 4.0Ω CN4 NEEDLE_THROW_STM 5.0Ω 5.0Ω THREAD_TRIMMING_STM_ORIGINAL CN5 Detection signal _POINT_CIRCUIT_BOARD CN6 SW/SLIDE_VOLUME_CIRCUIT_BOARD LED G LED R Thread trimming/needle up/down switch Reverse stitch switch S/S switch...
  • Page 14 ・ Display PCB To be connected to CN19 of microcomputer PCB ・ Power PCB Connector No. Destination Check POWER SW AC input POWER_SUPPLY_RELAY_LEAD_WIRE -2PIN 29V, 4-5PIN GND(FG) –  –...
  • Page 15 ・ Connection block diagram – 2 –...

  • Page 16: 6] Adjustment

    [6] Adjustment 6-1 Adjusting the needle bar height ○ Remove the face cover. Adjustment value: ・ Distance from the bottom end of the pin inside needle bar surface to the top surface of the throat plate: 9 mm ・ When the needle is mounted, the needle eye tilts rightward by 2 degrees. Adjustment procedure .

  • Page 17: Feed Dog Height

    6-4 Timing belt ○ Remove the front panel and the microcomputer PCB. Adjustment procedure . Loosen the setscrew in the idler mounting base and loosen the timing belt. 2. Turn the hand wheel to bring the needle bar to its lowest dead point. 3.

  • Page 18: Timing Between The Needle And The Hook

    6-6 Timing between the needle and the hook ○ Remove the throat plate, the bed cover and the bottom cover of the free arm. Method for checking . Check to be sure that the needle entry point and needle bar height are correct. 2.

  • Page 19: Clearance Between The Needle And The Blade Point Of Hook

    6-7 Clearance between the needle and the blade point of hook ○ Remove the face cover and the throat plate. Adjustment procedure . Loosen screw . Adjust the clearance between the needle and the blade point of the hook to 0.02 to 0.07 mm by turning adjusting shaft 0.02 to 0.07 mm Adjusting the balance of the clearances at the right and left needle entry points...

  • Page 20: Position Of The Hook Rotation Stopper Plate

    6-8 Position of the hook rotation stopper plate ○ Remove the throat plate. Adjustment procedure . When the bobbin case holder is placed inside the rotating hook, loosen the setscrew and determine the longitudinal position of the rotation stopper plate so that the projection of the bobbin case holder and the leaf spring of the rotation stopper plate are located as illustrated in the enlarged partial view.

  • Page 21: Adjusting The Disk Opening Amount

    6-10 Adjusting the disk opening amount 6-10-1 Adjusting the thread tension release adjusting plate ○ Remove the face cover, the thread tension cover and the spool cover. Adjustment procedure . Raise the presser foot lifting lever. 2. Loosen the adjusting screw and adjust the thread tension release adjusting plate so that the top end of claw of the opening arm aligns with the marker dot on the thread releasing arm.

  • Page 22: Base Tension Opening Amount

    6-10-3 Base tension opening amount ○ Remove the face cover, the thread tension cover and the spool cover. Adjustment procedure . Raise the presser foot lifting lever. 2. Adjust the base tension opening amount to  mm by turning the base tension adjusting screw. Base tension adjusting screw Thread tension...

  • Page 23: Adjusting The Disk Opening Amount At The Time Of Thread Trimming (Hzl-G210)

    6-10-4 Adjusting the disk opening amount at the time of thread trimming (HZL-G210) Adjustment procedure . Lower the presser foot lifting lever. 2. Select No. 9 (meaning: tension release) of the service mode. 3. Loosen the locknut. Turn the adjusting nut to adjust the retracting amount of the thread tension releasing link plate so that the top end of claw of the opening arm is aligned with the marker dot on the thread tension releasing arm.

  • Page 24: Vertical Position Of The Needle Threading Hook

    6-12 Vertical position of the needle threading hook ○ Remove the frame cover. Adjustment procedure . Assemble a household HA x  needle # into the needle bar. 2. Turn the hand wheel to bring the needle bar near its highest dead point and stop the hand wheel when the needle bar reaches the location where the setscrew in the needle bar guide is visible.

  • Page 25: Adjusting The Presser Foot Lifting Switch

    6-13 Adjusting the presser foot lifting switch ○ Remove the face cover, the thread tension cover and the spool cover. Adjustment procedure . Loosen the adjusting screw of the presser foot lifting switch. Adjust the position of the presser foot lifting switch so that the sewing machine stops when the presser foot lever is raised by 5 mm or more while the machine is in operation.

  • Page 26: Motor Belt

    6-15 Motor belt ○ Remove the front panel. Adjustment procedure . Set the motor timing belt to the motor pulley and the motor shaft pulley. 2. Adjust the motor bracket so that the belt deflection amount becomes 6±1 mm when pressing the center of the belt with a force of 0.98 N.

  • Page 27: Automatic Thread Trimming (Hzl-G210)

    6-16 Automatic thread trimming (HZL-G210) 6-16-1 Lateral position of the thread trimming mechanism base Adjustment procedure . Turn the power switch OFF. Then, turn the power switch ON with the reverse stitch button and the thread trimming button held pressed simultaneously. 2.

  • Page 28: Phase Of The Catching Unit Driving Cam

    6-16-2 Phase of the catching unit driving cam ○ Carry out the adjustment with the power OFF. Adjustment procedure . Loosen setscrews 1 and 2 . 2. Turn the cam driving shaft in the direction of the arrow as shown in Fig. A, and the catching unit driving cam will rotate in the direction as shown in Fig.

  • Page 29: Replacing The Thread Trimming Blade

    6-16-3 Replacing the thread trimming blade Changing the thread trimming knife . Remove the throat plate. 2. Remove the setscrew of the thread trimming knife cover. Remove the thread trimming knife cover, the thread trimmer grasping unit and the thread trimming knife. 3.

  • Page 30: Longitudinal Feed

    6-17 Longitudinal feed Preparation for adjustment Turn OFF the power switch. Keep pressing both the reverse stitch button and thread trimming button simultaneously and turn ON the power switch. The service mode screen appears on the display. Select "No. 3" to change over the screen to the sewing pattern for adjusting darning. Adjustment procedure Sew a darning sewing pattern three times under the aforementioned sewing conditions.

  • Page 31: Buttonhole

    6-17 Buttonhole Adjustment procedure Lower the buttonholing lever to bring it in contact with the projecting part of the buttonholing foot. In this state, loosen the screws and adjust the buttonholing switch so that its standby-side contact point is placed at the center of the range of movement of the lever. The stitches at the beginning of sewing must be hidden under the bartacking part and circular part.

  • Page 32: Service Mode

    6-19 Service mode 6-19-1 Service mode screen [How to select the service mode] . Turn the power switch OFF. In this state, turn the power switch ON with the two buttons (see the description below) held pressed simultaneously. ・ HZL-G20: Reverse stitch button and thread trimming button ・...
  • Page 33 Item name Description Thread trimming condition can be checked. Perform thread trimming halfway by using the "OK" button THREAD TRIM CHECK From this condition, manually turn the main shaft to carry out the thread trimming sequence in order. Bring the disks to the floating condition. Tension release Operate the "OK"...
  • Page 34 SEWING MACHINERY BUSINESS UNIT 2-11-1, TSURUMAKI, TAMA-SHI, TOKYO, 206-8551, JAPAN PHONE : (81)42-357-2371 FAX : (81)42-357-2380 http://www.juki.com Copyright C 2011 JUKI CORPORATION. All rights reserved throughout the world. 40113428 2011/09...

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