LK-1942ZA5050 - Sewing machine JUKI - Free user manual and instructions

USER MANUAL LK-1942ZA5050 JUKI

For the sewing machine, automatic machine and ancillary devices (hereinafter collectively referred to as "machine"), it is inevitable to conduct sewing work near moving parts of the machine. This means that there is always a possibility of unintentionally coming in contact with the moving parts. Operators who actually operate the machine and maintenance personnel who are involved in maintenance and repair of the machine are strongly recommended to carefully read to fully understand the following SAFETY PRECAUTIONS before using/maintaining the machine. The content of the SAFETY PRECAUTIONS includes items which

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Precautions to be taken so as to use the LK-1941, LK-1942 more safely

1. To avoid electrical shock hazards, neither open the cover of the electrical box for the

motor nor touch the components mounted inside the electrical box.

2. After changing the pattern, make sure the needle entry point. If the pattern is

protruded from the work clamp feet, the needle will interfere with the work clamp feet during sewing, and it is dangerous due to the needle breakage or the like.

1. So as to prevent possible accidents caused by abrupt start of the sewing machine,

depress the start switch after ascertaining that there is no interfering thing under the needle when winding the bobbin thread.

2. When changing the pattern, turning ON the ready switch or turning ON the work clamp

foot switch, the work clamp feet automatically come down. So, never place your fi ngers under the work clamp feet to prevent possible accidents caused by abrupt start of the sewing machine. During operation, be careful not to allow your fi ngers to come close to the work clamp feet.

3. Keep your hands away from the feeding frame when turning the power off while the

sewing machine is in operation, since the feeding frame goes up at that time.

4. Be careful of handling this product so as not to pour water or oil, shock by dropping,

and the like since this product is a precision instrument.

5. This is a Class A product. In a domestic environment this product may cause radio in-

terference, in which case the user may be required to make corrective actions.ENGLISH

Safety devices and warning labels Power switch This is a switch for discon- necting the power unit of the sewing machine from the power supply. Power switch (EU type) This switch is used for discon- necting the power unit of the sewing machine from the power supply. It is also used as the emergency stop switch. Selection of the power switch Use the IEC60204-1-compliant power switch with rated cur- rent of 20 A or more and short-circuit breaking capac- ity of 120 A or more, which has the operating section in red against the yellow back- ground. In addition, be aware that the safety devices such as the "eye protection cover" and "fi nger guard" are sometimes omitted in the sketches, illustrations and fi gures in- cluded in the Instruction Manual for the explanation's sake. In the practical use, never remove those safety devices. CAUTION Electrical-shock danger label (EU type) (Refer to "Elec- trical- shock danger label" on page i.) In order to pro- tect against electrical shock, safety precau- tions to be taken to avoid danger are written on this label. Eye protection cover This is a cover for protecting eyes from being injured by a broken needle. Finger guard This is a cover for preventing contact between fi ngers and the needle. Motor cover This is a cover for preventing contact be- tween the motor and magnet and the human body. Warning label (Refer to the warn- ing la- bel on page i.) The label gives the minimum precautions to be taken when oper- ating the sewing machine. Warning label against pinching This label warns that fin- gers or other parts of hu- man body can be pinched in the thread take-up lever. Warning label against pinching This label indicates that there is a risk of pinch- ing hands between the machine head and the feed bracket. Warning label against pinching This label warns that hands can be pinched under the sewing ma- chine. Thread take-up lever cover This is a cover for preventing contact between the human body and the thread take-up lever.vii DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY We hereby declare that the sewing machine (sewing head) described below ;

1. Must not be put into service until the machinery to which it is incorporated has been declared in

conformity with the provisions of the Directive 2006/42/EC, and

2. Conforms to the essential requirements of the Directive 2006/42/EC, described in the technical

3. To be prepared with the above technical documentation compiled in accordance with part B of

4. Also to conform to the RoHS Directive 2011/65/EU

5. Relevant information on which should be transmitted in response to a reasoned request by the

4. How to take out the sewing products when the thread cutting failure has occured (for Z type only) .... 37

2) Max. sewing speed : ＊ 2,200 sti/min (When sewing pitch is less than 3 mm.)

3) Stitch length : 0.1 to 10.0 mm (adjustable in 0.1 mm step)

4) Feed motion of work clamp foot : Intermittent feed (2-shaft drive by stepping motor)

5) Needle bar stroke : 41.2 mm

6) Needle : DP x 17, DP x 5 (DP x 17 is attached at the time of delivery.)

7) Lift of feeding frame : 18 mm (standard) Max. 25 mm

8) Hook : Full-rotary three-fold capacity hook

9) Intermediate presser stroke : 4 mm (standard) (Adjustable in the range of 0 and 4 to 10 mm)

10) Lift of intermediate presser : 18 mm (For LK-1942 only)

11) Lubricating oil : New Defrix Oil No. 2 (supplied by oiler)

12) Data recording : EEP-ROM (32k byte)

13) Enlarging/Reducing facility : Allows a pattern to be enlarged or reduced on the X axis and Y

axis independently when sewing a pattern Scale : 20% to 200% (1% step)

14) Enlarging/Reducing method : Pattern enlargement / reduction can be done by increasing/

decreasing the stitch length

15) Temporary stop function : Used to stop machine operation during a stitching cycle.

17) Max. sewing speed limitation : The max. sewing speed can be set limited to any value within

a range of 200 to 2,200 sti/min using the up/down key. (100 sti/min steps)

18) Pattern selection : 1 to 99 patterns can be selected by specifying the desired

19) Bobbin thread counter : Tells the time to replace the bobbin by the bobbin thread

counter. (Max. 9,999 pcs.)

20) Production counter : Displays the number of pieces of production by the production

counter. (Max. 9,999 pcs.)

21) Memory back-up : In case of a power interruption, the pattern being used will

automatically be stored in memory.

(Use the standard table and stand.)

27) Operating humidity range : 35% to 85% (No dew condensation)

31) Needle bar reverse rotation stop function : After the completion of sewing, the needle can be stopped in its upper position by rotating the needle bar in the reverse direction. ＊ Reduce the max. sewing speed in accordance with the sewing conditions. ＊ To select and use either the bobbin thread counter or the production counter.

Equivalent continuous emission sound pressure level (L

) at the workstation : A-weighted value of 79.5 dB; (Includes KpA = 2.5 dB); according to ISO 10821- C.6.3 -ISO 11204 GR2 at 2,200 sti/min.2

1. Names of main unit

• Needle threaddrawing device(For G and Ztypes only) Air regulator
• Pedal switch 1st step : Feeding frame switch. 2nd step : Start switch• Needle thread breakage detecting plate• Wiper switch• Temporary stop switch• Intermediate presser (for LK-1942 only)• Feeding frame• Machine head• Thread stand• Operation box• Control box• Power switchPower switch( EU type)3 ENGLISH

2. Names of switches on the control box

Heat cutter temperature (For Z type only)

• Selection key : Every time this key is pressed, the selection will be made as follows.

2) Connect the pedal with 4 the pedal switch using the chain !2.

3) Securely fix the respective power cables with the staples.

4) Securely fix oil drain 7 on the table 1, and screw oil receiver 8.

5) Set cushion rubber 5 on oil pan 6, and fit oil pan 6 to the holes of the table hinges (4 places) 9. Then

fix oil pan 6 at 4 places with wood screws.6) Close the center portion of oil pan 6 with the rubber plug after screwing it.

7) Strike head support bar !0 in the hole of table !1.

and is for 1-pedal type only.2. Installation of and is for Z type only.

To prevent possible accidents caused by the fall of the sewing machine, perform the work by two personsor more when the machine is moved.ReferenceReferenceReference5 ENGLISH (2) Connecting the power source cord

• Voltage specifications Table Brown Brown Brown Light blue Light blue Light blue Green/Yellow Green/Yellow Control box Green/Yellow Plug Power source cord Power switch GND AC200 V AC220 V AC230 V AC240 V Table Black Brown Black Light blue Red White White Green Green/Yellow Green Red Control box Power source cord Plug Power switch GND AC200 V AC220 V AC240 V AC380 V AC400 V AC415 V Voltage indication seal Power source specifications are indicated on the voltage indication seal. Connect the cord in accordance with the specifications. Specification Voltage Specification Voltage indication seal indication seal Three phase 200V 3ø 200V Three phase 220V 3ø 220V Three phase 240V 3ø 240V Single phase 200V 1ø 200V Three phase 380V 3ø 380V Single phase 220V 1ø 220V Three phase 400V 3ø 400V Single phase 230V/240V 1ø 240V Three phase 415V 3ø 415V

• Connecting single phase 200V, 220V, 230V and 240V

1. Never use under the wrong voltage and phase.

2. When changing the voltage to be used :

Refer to the item “Changing the voltage between 100 and 240V” for the following specifications. 1 ø200V, 1 ø220V, 1 ø240V, 3 ø200V, 3 ø220V and 3 ø240V Refer to the item “Changing the voltage between 220 and 415V” for the following specifications. 3 ø220V, 3 ø240V, 3 ø380V, 3 ø400V, and 3 ø415V6 (3) Power switch Black Table Brown Black Plug Green/Yellow Control box Light blue Green/Yellow Black Ampere set value 200V 220V 230V 240V 380V 400V 415V 3.2A3,2A 2.4A2,4A7 ENGLISH Changing the voltage between 220V and 415V When the voltage from 220V to 415V is supplied, following voltages can be used by changing the terminal board. Line color (White) Line color (Black) Line color (Blue) Input voltage Terminal board No.

(4) Changing the voltage Changing the voltage between 100 and 240V When the voltage of 100V or 200V is supplied, following voltages can be used by changing the terminal board. Line color (White) Line color (Blue) Input voltage Remarks Terminal board No.

200V When voltage of 100V, 110V or 120V is used, it is necessary to connect the voltage change cord (Part No. M90215800A0) to J32 connector mounted on the POWER circuit board. When voltage of 200V, 220V , 230V or 240V is used, do not install J32 connector. If the setting of J32 connector is mistaken, the control box is likely to be broken.8 Terminal board This side POWER circuit board Power transformer J32 SDC circuit board The white and black lines are fixed. Change the blue line position in accordance with the voltage used. White Black Red Purple Black Brown Orange 0 V 220 V 380 V 415 V 220 V 240 V 400 V White Black Blue Transformer POWER circuit board Change the blue line position in accordance with the voltage used. Transformer White Brown Orange Gray Black Red Purple 0 V 110 V 200 V 240 V 100 V 120 V 220 V White Blue POWER circuit board 100 to 200V 220 to 415V9 ENGLISH (6) Setting the safety switch The safety switch is provided so that the sewing machine does not rotate when it is tilted for maintenance or inspection. Properly set the switch at the correct position when installing the sewing machine. (If the switch is not set to the correct position, the sewing machine cannot be operated.)

1) Loosen two setscrews 1.

2) Lower safety switch 2 to the bottom.

3) Tighten two setscrews 1.

(5) Fixing the sewing machine main unit Fit hinge rubber 1 to the hinge shaft ,and fix the sewing machine main unit. Hold section A w hen moving the sewing machine. In addition, do not hold motor portion

To prevent possible accidents caused bythe fall of the sewing machine, performthe work by two persons or more whenthe machine is moved.

B10 (7) Installing the motor cover Install motor cover 1 to the sewing machine main unit using the screws set in the cover.

(8) Installing the operation box Pass operation box cable 1 into table hole 2, and fix the operation box.

• 1-pedal J18 MAIN circuit board J1811 ENGLISH (10) Connecting the cords Perform the connection of the cords as shown in the figure below. Bundle CN2 and CN7 together with other cords using cable band B so that they do not come in contact with Y feed shaft A. Pass the cords of J12, 14, 15, 59 and through the cord clamp A located on the upper side of the inside of the control box and the cords of J17, 18 and (26 ) through the cord clamp B. Bundle J2, 8 and FG using the cable band.

1. Bend and clamp J17 and J18 cords as shown in the figure above.

2. Remove the fan motor cord from the clamp when opening the cover.

In addtion, wind the cord on the clamp when attaching the cover. One-pedal Operation box Pressure switch J18

Position of MAIN circuit board connectors

1) Remove four screws A and remove the heater unit cover.

2) Pass the cables and connect them to terminal board 1 and 2 as shown in the figure below.

(Be careful that the cable does not come in contact with Y feed shaft B.)

CN2 From the hot wire plate

J46 J87 B14 (13) Connecting the air hose

1) Cut the air tube supplied with the machine in an

appropriate length, and connect solenoid vsalve 1 with air regulator 2.

2) Connect the air source hose using one-touch joint 3 and

hose band 4 supplied with the machine.

3) Open air cock 5 and adjust the air pressure to 0.5 to

} by pulling up and turning adjustment knob 6 of the air regulator while observing air pressure gauge 7.

4) Turn knob 8 located in front of the air regulator using a

small screwdriver and adjust the pressure switch to 0.4 MPa {4 kgf/cm

(12) Managing the cord

1) In the state that the sewing machine is tilted, connect the cords, and bundle them with clip band 1 as

shown in the figure.

2) Fix the cords with cords setting plate 2 in the state that the cords slacken as shown in the figure.

When you tilt the sewing machine, make sure that the sewing machine head support bar is placed on the table. Slack

(15) Installing the thread stand

1) Assemble the thread stand, and set it in the

hole in the top right corner of the machine table.

2) Tighten locknut 1 to fix the thread stand.

3) When ceiling wiring is possible, pass the power

cord through spool rest rod 2.

(14) Installing the eye protection cover

Be sure to attach this cover to protect the eyes from the disperse of needle breakage. Be sure to install and use eye protection cover 1.16 (16) Installing the auxiliary throat plate cover

1) Install the auxiliary throat plate cover support

2 to auxiliary throat plate cover 1 using setscrew 3 (L=6) and washer 4.

2) Install the cover on the machine arm using

attaching screw 5(L=8). Adjust so that the auxiliary throat plate cover should be almost levelled with the throat plate. If there is a difference in height, the feed plate may be caught with the auxiliary throat plate cover. (17) Attaching the bolt for transportation When transporting the sewing machine, fix the sewing machine main unit with the bolt for transportation.

When tilting/raising the sewing machine head, perform the work so as not to allow your fingers tobe caught in the machine. In addition, to avoid possible accidents caused by abrupt start of themachine, turn OFF the power to the machine before starting the work. When tilting the sewing machine head, tilt the head gently until head support rod 1 comes in contact with the head.

1. Make sure that head support rod

is attached to the machine table before tilting the sewing machine head.

2. When the sewing machine head

is tilted, feeding frame

moves to the left side by itself and interferes with the intermediate presser or the like. As a result, it will be the cause of breakage. Remove the aforementioned component in advance, or fix feed plate

to throat plate support cover

with tape or the like, and tilt the sewing machine head.

3. When tilting the sewing machine

head while holding motor cover

and throat plate support cover

, the covers may be bent. Be sure to tilt the sewing machine head while holding the main unit of the sewing machine.

4. Be sure to tilt the sewing machine

head on a flat place to prevent it from falling.18

1) Once a day, fill oil from oil hole 1 on the machine

head up to the red mark in the center of oil gauge

2) Apply one drop of oil to hook race 3 part to spread

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of thesewing machine.19 ENGLISH

3) Remove the top cover, and apply oil to front bushing

4 and intermediate bushing 5. Be sure to perform the above 2) and

3) steps when the machine is first

installed, or when it is run after a long period of disuse.

2. Attaching the needle

Loosen setscrew 1 and hold needle 2 with the long groove facing toward you. Then fully insert it into the hole in the needle bar, and tighten setscrew 1.

1. If the stitches are made as shown

in A, attach the needle facing to the direction B to a small extent.

2. If the wiper interferes with the

needle, turn the hand pulley and slightly lower the needle bar, or turn the air cock 4of the filter regulator and expel the air. When using the needle other than the one supplied at the time of delivery, it may be necessary to replace the hook. See the table of the gauge parts on P62.

Font bushing Intermediate bushing

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

When threading through the needle, perform following operation to lower the intermediate presser and the feeding frame.

1) Press key on the operation box to light up

2) Press key and the intermediate presser and

the feeding frame come down.

3) After threading through the needle, press again

key, and the intermediate presser and the feeding frame return to their home positions. Pull out the thread by approximately 4 cm from the needle after threading through the needle.

Do not place your fingers or any thing under the presser since there is a danger of damage of your fingers or hands caused by being caught in the presser, needle, etc. G type, Z type Normal When the needle thread remaining on the needleafter thread trimming is short due to theresistance of thread path. (when using coatingthread, net for thread on thread stand, etc.) To make one turn21 ENGLISH

1) Open hook cover 1.

3) When installing the bobbin case, fully insert it into

the shuttle shaft, and close the latch. If it is not fully inserted, bobbin case 2 may slip off during sewing.

5. Installing the bobbin

1) Set the bobbin 1 into bobbin case 2 in the

direction shown in the figure.

2) Pass the thread through thread slit 3 of bobbin

case 2, and pull the thread as it is. By so doing, the thread will pass under the tension spring and be pulled out from thread hole 4.

3) Pass the thread through bobbin thread guide 5,

and pull out the thread by 3 cm from the bobbin thread guide. If the bobbin is installed in the bobbin case orienting the reverse direction, the bobbin thread pulling out will result in an inconsistent state.

4. Installing and removing the bobbin case

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

6. Adjusting the thread tension

If thread tension controller No. 1 1 is turned clockwise, the length of remaining thread on the needle after thread trimming will be shorter. If it is turned counterclockwise, the length will be longer. Shorten the length to such an extent that the thread is not slipped off. Adjust the needle thread tension with thread tension controller No. 2 2, and bobbin thread with 3. It is not necessary to normally adjust auxiliary thread tension 4 attached to G and Z types. However, turn it counterclockwise to decrease the thread tension when needle thread slips out of thread guide wheel 5 and the thread guide wheel does not stably turn.

7. Adjusting the thread take-up spring

The standard stroke of thread take-up spring 1 is 6 to 8 mm, and adjust the tension in accordance with needle thread tension.

1) Adjusting the stroke

Loosen setscrew 2, and turn the whole of thread tension 3.

2) Adjusting the pressure

Insert a screwdriver into the slit of thread tension rod 4 and turn it while setscrew 2 is held tightened.

3) When the stroke of thread take-up spring is

changed, adjust the thread breakage detector plate referring to Page 43. G and Z types H type Short Long Short Long G and Z types H type

8. Adjusting the height of the intermediate presser (for LK-1942 only)

1) Lower the intermediate presser 2. (Refer to “3.

Threading the machine head”.)

2) Turn the handwheel to lower intermediate presser

2 to its lowest position.

3) Loosen setscrew 1 and adjust the height of

intermediate presser 2 so that the clearance provided between the intermediate presser and the cloth is approximately 0.5 mm.

9. Adjusting the intermediate presser stroke (for LK-1942 only)

9-1. Adjusting the intermediate presser stroke to 4 to 10 mm

1) Remove the machine arm side cover.

2) Loosen setscrew 1 and move it in the direction

of arrow for adjustment.

3) If moving in the direction of A, the stroke will be

decreased. (Min. 4 mm) If moving in the direction of B, the stroke will be increased. (Max. 10 mm) The nut may be removed if setscrew 1 is excessively loosened. So, be careful. Loosen setscrew 1 by a half turn to properly adjust the stroke.24 9-2. Adjusting the intermediate presser stroke to 0 mm

1) Set the intermediate presser stroke to the minimum

3) Remove setscrew 1, invert intermediate presser

stopper 2, and attach it again with setscrew 1.

Set each item following the procedure described below. (1) Turn ON the power switch Pattern No. of the item selection lights up, and the pattern No. is indicated on the data display. (2) Setting of the pattern No.

2) Press the or key to indicate Pattern No.

1 to 99 on the display. In case the pattern is not prepared, indicate the service pattern No. 51 to 53 inputted beforehand at the time of delivery. For LK-1941, the intermediate presser is not provided. Prepare the presser in accordance with the sewing pattern. Switch design on the control box may be different from each other in accordance with the models. Setting of the pattern No. Setting of the X scale Setting of the Y scale Setting of the max. sewing speed limitation Setting of the heat cutter temperature (For Z type only) Service pattern No. Shape □ 50x30 mm P=3.0 P=3.0 ø30 P=3.0 P=3.5 ø30 Sewing cannot be performed since this No. is for the pattern for adjusting the amount of oil in the hook. (See P. 45.)26 Setting of the Y scale

1) Press the key to indicate the item “Y Scale”.

2) Press the or key to set the scale in the

range of 20% to 200%. Enlargement/reduction is a mode of enlargement/reduction of stitch length. When enlargement/reduction is performed, the number of stitches is fixed and the stitch length varies. (3) Setting of the scale Setting of the X scale

1) Press the key to indicate the item “X Scale”.

or key to set the scale in the range of 20% to 200%. (4) Setting of the max. sewing speed limitation

the display. (Setting of 400 sti/min) (5) Setting of the heat cutter temperature (For Z type only)

on the display. (Setting of level 3)

• Hot wire plate is a consumable part.

• Level “3” of the heat cutter temperature is the standard set value. The higher the level is raised, the more the thread trimming performance is improved. However, when the level is raised more than necessary, damage or deterioration of the service life of the hot wire plate may occur. When thread trimming failure occurs at the standard setting value, perform the proper action referring to “( -5. Troubles and corrective measures (sewing conditions) ”.27 ENGLISH (6) Finish of setting

2) The feeding frame comes down and moves. Then,

after it has been raised, the sewing LED lights up, and the sewing is ready. ※ If the key is pressed, you can make sure the set value of the respective items again. Use after checking the pattern No. Press the sewing ready switch while No. other than the service pattern is indicated on the display, and the error No. E-1 will be shown. At this time, set again the pattern No. which has been registered. SEWING 2.Checking the contour of a sewing pattern

1) Depress the pedal switch to the first step to descend

frame will move by one stitch. Keeping the key held pressed, the feeding frame will move continuously.

3) If the key is pressed, the needle point will return

to the starting position, and the feeding frame will go up. If the feed is fed by one stitch, detach your foot from the pedal.

• Make sure without fail of the contour of the sewing pattern after selection of the sewing pattern. If the sewing pattern extends outside the work clamp feet, the needle will interfere with the work clamp feet during sewing, causing dangerous troubles including needle breakage.

• When checking the sewing pattern, do not depress the pedal switch up to the second step. Sewing starts if the pedal switch is depressed up the second step.28 Start 2-step PK pedal

1) Set a workpiece on the feeding frame section.

2) Depress the pedal A, the feeding frame will come down. If depressing the pedal again, the feeding frame

3) Depress the pedal B, and the sewing machine will start sewing.

4) After the sewing machine completes the sewing, the feeding frame will return to the home place, and go

up. In case of the Z type, the feeding frame performs the movement which is not commanded by the pattern data when trimming thread. However, it is not abnormal. When 2-step PK pedal is used Feeding frame End of sewing

For without AW device 1-pedal type

1) Set a workpiece on the feeding frame section.

2) Depress the pedal switch up to the first step, and

the feeding frame will come down. If you detach your foot from the pedal switch, the feeding frame will go up.

3) Depress the pedal switch up to the second step

after lowering the feeding frame, and the sewing machine will start the sewing.

4) After the sewing machine completes the sewing,

the feeding frame will return to the home place, and go up. 1-pedal type For with AW device B A

1) Press the key. (The sewing LED will go off.)

3) Set the items of 1–(2) to (5). For further steps,

return to the steps of “2. Checking the contour of a sewing pattern”. 5.Temporarily stopping the sewing machine You can temporarily stop the sewing machine during sewing or sewing pattern shape checking procedure. 5-1 How to temporarily stop the sewing machine Press temporary stop switch 1 while the sewing machine is running. The sewing machine stops, and “E5” will be indicated on the operation box. 5-2. Re-starting (re-sewing)

1) Press the temporary stop switch twice or press

key to make the thread trimming. ( It is not necessary to do so when the needle thread is not tied with the cloth such as jump feed or the like, or continuing the sewing as it is.)

2) Press or key to return the needle point to

the starting position or desired position. ( It is not necessary to do so when re-starting the sewing from the same position.)

3) Re-starting can be made by depressing the pedal

The sewing machine makes a revolution and the needle goes up and comes down. So, never place your fingers or any other thing under the needle.30

6. Winding the bobbin thread

6-1. To wind a bobbin while the sewing machine is performing sewing Thread the bobbin winder and wind the thread onto the bobbin as illustrated in the figure. 6-2. To wind a bobbin independently

1) Press the key to select the item “Bobbin

winder”. If the “Sewing LED” is lit up, the selection cannot be made.

2) Press the key, and the feeding frame come

down. Immediately after the power is ON, key is not valid. Press key after setting the pattern once.

3) Depress the start switch, and the bobbin winder

will start to wind the bobbin.

4) Press the temporary stop switch, depress again

the start switch, or press any one of the switches on the operation box, and the bobbin winder will stop.

5) Press the key to release it.

While the bobbin winder winds a bobbin, the feeding frame does not move but the needle bar moves, So, do not place your fingers or any obstacle under the needle.31 ENGLISH

Sewing speed (sti/min) Denim 8 pcs. 2,000 to 2,200 Denim 12 pcs. 1,500 to 1,800 Synthetic leather 1,500 to 1,800 Leather 1,500 to 1,800 Seat belt 1,000 to 1,200

6-3. Adjustment of the bobbin thread winder components (1) Adjusting the bobbin winder thread tension

1) Loosen nut 1, and adjust the height so that the

clearance between the bobbin thread guide and the top cover should be approximately 5 mm.

2) If the bobbin thread is wound like A, the height

should be higher than 5 mm. If it is like B, the height should be lower than 5 mm. (2) Adjusting the winding amount of the bobbin thread

1) If the winding amount of the bobbin thread is

excessive, loosen setscrew 1, and move bobbin thread winder lever 2 in the direction A. Then fix it.

2) If the winding amount of the bobbin thread is small,

loosen setscrew1, and move bobbin thread winder lever 2 in the direction B. Then fix it.

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of thesewing machine.Bobbin thread guideTop coverBobbin threadBobbin ※ To prevent the thread breakage due to the needle heat, set the sewing speed referring to the left-hand table in accordance with the sewing conditions.

7. Cautions in operation

(1) When threading and the sewing machine is switched ON, in case the thread tension disk is closed, sew the desired sewing pattern. After thread trimming, the thread tension disk will open. (2) When the error indicator lamp lights up, be sure to check the cause of trouble and take a proper corrective measure. (3) Do not draw, by hand, the material being sewn during sewing. Doing so will cause the needle shift from the correct position. If the needle moves from the correct position, press the key two times. This will return the needle to the normal origin. ClosedOpened Reference for the sewing speed to be applied32 (1) Registration to the pattern key Setting example : Register following setting to the P1. Pattern No. 52 X Scale rate : 50% Y Scale rate : 80% Max. sewing speed limitation : 2,000 sti/min.

1) Pressing the key, turn ON the power switch.

3) Press the key to indicate the Pattern No.

Set the pattern No. to Pattern No. “ ” using the or key.

4) Performing the same operation as that in the step 3), set X Scale

rate to “50%”, Y Scale rate to “80%” and Max. sewing speed limitation to “2,000 sti/min”.

5) Press the key to finalize the registration.

keys at the step 2), and perform the steps 3) to 5).

6) When the registration has been completed, turn OFF the power switch, and again turn ON the power

switch. Then, the sewing machine can be used as usual.

keys) If the patterns (No. 1 to 99) which have been already registered are registered in P1 to P7, the pattern calling can be made by one-touch without performing the selection by the pattern No. scrolling. ※ When selecting P4, P5, P6 or P7, the selection can be made by the combination of

keys.33 ENGLISH (2) Sewing operation Operation example : After performing sewing with the contents of the registered P1, perform sewing with the contents of P3.

1) Turn ON the power switch.

3) Press the key, and when the sewing LED lights

up, the work clamp foot goes up after it has moved.

4) Check the contour of the sewing pattern.

(Refer to the item “Checking the contour of a sewing pattern”.)

6) After the completion of sewing, press the

key. Then the work clamp foot will move to the sewing start point after the origin retrieval. (The P keys can operate the pattern chage by one-touch even when the sewing LED is lighting up.)

7) Perform the above items 4) and 5).

※ The P1 to P7 can be indicated on the display when selecting the pattern by pressing the or key.

• 0 to 99 ←→ P1 to P7 ← P1 to P7 which have not been registered are not indicated.

By arranging in the order of use of the pattern keys (P1 to P7) which have been already registered and registering in the C1, C2 and C3, the sewing pattern will change in the order every time the sewing machine finishes the sewing. ※ The maximum 15 pattern combinations of P1 to P7 can be registered in the C1, C2 or C3. (1) Registration of the combination Setting example : Combine in the order of P1, P2, P3, and register them in the C1.

and keys, turn ON the power switch.

5) Press the key to finalize the registration.

6) Turn OFF the power switch, and again turn ON the power switch. The

sewing machine can be used as usual. ※ 1. At the operation of the step 1), if the power switch is ON, pressing the

key and the key, in case of the

key, the registration can be made in the C2. In case of the

key, the registration can be made in the C3. ※ 2. Simultaneously press the

keys to set the P4 to P7. ※ 3. 10 to 15 showing the order will be indicated A to F. The sewing patterns which have not been registered in the pattern keys (P1 to P7) can not be combined.35 ENGLISH (2) Sewing operation Operation example : Perform sewing with the contents of the registered C1.

1) Turn ON the power switch.

2) Set the pattern No. to “ ” using the or

key. Scroll as follows :

• 0 to 99 ←→ P1 to P7 ←→ C1 to C3 ← ※ P1 to P7 and C1 to C3 which have not been registered are not indicated.

3) Press the key. When the sewing LED lights

up, the feeding frame will go up after having moved.

4) If the contour of the pattern is acceptable, the

5) Every time the sewing is finished, the step is made

according to the combination. After completing one cycle of sewing, the step returns to the first step. The sewing can be made repeatedly. ※ 1. When you desire to return the pattern to the previous one or step to the next one during sewing, press the or key in a state that the sewing LED lights up. The indication of the pattern No. will change, and the feeding frame will move to the sewing start point. ※ 2. If the contents of P1 to P7 are changed after registration of C1 to C3, the contents of P1 to P7 used in C1 to C3 will change. So, be careful. ※ 3. Make sure of the contour of the pattern for each of the patterns. (Refer to the item “%-2. Checking the contour of a sewing pattern”.) SEWING36

3. Performing sewing using the “bobbin thread counter”

The production counter can be used as the bobbin thread counter. In case a same sewing pattern is sewn in repitition, the sewing machine will stop sewing when the number of times (the specified number) that can be sewn with a bobbin is reached. The bobbin thread counter is of the subtracting method. The counter at the time of delivery is set to the production counter (adding method). If it is used as the bobbin thread counter, it is necessary to change the memory switch. AW-2 type cannot function. (Refer to the item “*. HOW TO USE THE MEMORY SWITCH”.)

1) While the sewing LED goes off, press the

key to indicate the “Counter” .

2) Then press the or key, and set the

specified number of times that can be sewn with a bobbin.

3) Every time the sewing machine finishes a sewing

cycle, counting-down is made by one.

4) When the sewing machine finishes the specified

number of times, the sewing machine does not start even if depressing the pedal.

5) Replace the bobbin with a new one, and press the

6) Repeat the steps of procedure from the steps 3) to

4. How to take out the sewing products when the thread cutting

failure has occured (for Z type only) Thread is cut and the sewing product can be taken out by reheating the hot wire plate when needle thread or bobbin thread is not cut at the time of completion of sewing. Thread is not cut even when the hot wire plate is reheated according to the cause of thread cutting failure.

1) Pull the sewing product in the direction of A and

take the slack of the thread in the state of completion of sewing (state that the sewing LED is lit up and the feeding frame is raised).

2) When the temporary stop switch is pressed, the

hot wire plate is heated and the thread is cut. Once the operation is performed, re- operation cannot be performed for five seconds. A38

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of thesewing machine.

2. Adjusting the needle-to-shuttle relation

1. Adjusting the height of the needle bar

Bring needle bar 1 to the lowest position of its stroke. Loosen needle bar connection screw 2 and adjust so that upper marker line 4 engraved on the needle bar aligns with the bottom end of needle bar bushing, lower 3. After the adjustment, make sure that there is no uneven torque. ※ When stitch skipping occurs in accordance with the sewing conditions, adjust the height of the needle bar so as to lower it by 0.5 to 1 mm from the needle bar engraved line 4. A : Engraved line for DP x 5B : Engraved line for DP x 17 #18 to #25C : Engraved line for DP x 17 #26Upper engraved line

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of thesewing machine.

2) Remove setscrew 1 and remove inner hook

stopper 2. Further, loosen right and left setscrews 3 and remove oil shield plate 4. At this time, do not try to forcibly remove the oil shield plate. Turn the handwheel and remove it at the position near to the up-stop position of the handwheel.

3) Loosen setscrew 8 and move the hook to adjust

so that the blade point of the hook is aligned with the center of the needle. Adjusting the clearance provided between the needle and the hook (Perform this adjustment together with the aforementioned adjustment.) Turn the handwheel and loosen setscrew 8 to adjust so that the clearance of 0.03 to 0.1 mm is provided between the needle and blade point 9 of the hook when the blade point of the hook is aligned with the center of the needle.

1) Turn the handwheel by hand in the direction of

normal rotation. When needle bar 5has gone up, adjust so that lower marker line 6 engraved on the needle bar aligns with the bottom end of the needle bar bushing 7, lower. Turn the needle guard section of the inner hook to the lower side so that the inner hook does not come in contact with the needle. Relation between needle and engraved lines When DPx5 is used.

When DPx17 #18 to #25 is used. When DPx17 #26 is used. Installing the inner hook stopper

1) Fit the projection at the top end of inner hook

stopper 1 to the groove on the inner hook, and install setscrews 2.

2) There is a slight play between inner hook stopper

1 and setscrews 2 in the direction of arrow mark A (lateral direction). Making the projection of inner hook stopper 1 come in contact with the groove on the throat plate, fix the inner hook stopper with setscrews 2 so that the setscrews are positioned approximately in the center of the play. Groove on inner hook Groove on throat plate A40 Kinds and application of the hook There are four kinds of hooks for LK-1940 Series. It is necessary to use the hook properly in accordance with the needle size and sewing conditions. Use a suitable hook referring to "Correspondence table of needle size" and "Correspondence table of sewing conditions" described below. In addition, the needle sticking (needle stuck into needle thread or needle stuck into bobbin thread) occurs due to the kind of thread or stitching direction. Then "hangnail", "thread breakage", or "stitch skipping", may occur. In this case, such problem can be solved by making the needle tip round as an emergency measure. However, when replacing the needle with the ball-point one, refer to the table below since the needle guard amount may be changed. [Correspondence table of needle size] (Symbols, H, G, and Z in the table denote the combination of the types at the time of delivery.) ORGAN needle (standard needle point) ORGAN needle (ball-point) SCHMETZ needle (standard needle point) ○ : Perform the hook adjustment with the standard engraved line. ● : Perform the hook adjustment with the sub engraved line. [Correspondence table of the sewing conditions] The combination of the different kinds of outer and inner hooks can be used under the special sewing conditions. (Example) Baloon stitch occurs when the lubricating hook D is used under the conditions of ORGAN needle #24 + (plus) cotton thread -> Use the outer hook only of lubricating hook A or B. Standard engraved line Needle size Kind of hook Lubricating hook A (14436554) H ○○ ○ Lubricating hook B (14436703)

#110 (18) #120( 19) #125 (20) #130 (21) #140 (22) #160 (23) #180 (24) #200 (25) Sub engraved line Sewing conditions When baloon stitches frequently occur due to violent movement of thread at the time of passing the hook in case of thin thread or cotton thread. When thick thread is used and thread tightness is required. Lubrication hook A (14436554) Lubrication hook B (14436703) Lubrication hook C (14436307) Lubrication hook D (14436158) Feature of hook Thread path presser is long. Thread path presser is short.41 ENGLISH

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of thesewing machine.

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of thesewing machine.

3. Adjusting the height of the feeding frame

1) Loosen setscrew 2 located in feed bracket 1.

Move cloth presser hook 3 in the direction B to increase the height.

2) After adjusting the height, securely tighten

4. Adjusting the rising amount of the thread tension disk

1) Remove the top cover. Make sure that tension

release pin 3 rides on tension release notch 4.

2) If the pin does not ride on the notch, push cam

follower 5 by hand to the e direction, and rotate the main shaft in the correct direction to make a state as illustrated in the figure.

3) Under the state as illustrated in the figure, loosen

setscrew 2 in the tension release adjusting arm. By moving tension release adjusting arm 1 to the left or right the rising amount of the thread tension disk will change. H type : Adjust the rising amount of the thread tension No. 2 to 0.8 to 1.0 mm. G and Z types : Adjust the rising amount of the auxiliary thread tension so that the thread guide wheel is lightly turned by hand.

4) For the G and Z types, further, adjust the rising

amount of the thread tension No. 2. Loosen nut 6 and turn clockwise the whole thread tension to increase the amount and counterclockwise to decrease the amount. Adjust the rising amount to

If the rising amount is insufficient, the length of the remaining thread after thread trimming will be not stable. If the rising amount is excessive, after releasing the rising of the thread tension disk, the disk closing will be defective. Widen(Tension release link)Narrow (Thread tension disk) G and Z typesAuxiliavythreadtensionThread guide wheelH typeThread tension No.2Thread tension No.242

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

5. The moving knife and counter knife

(1) Position of the moving knife (Common to H, G and hot wire types)

1) Remove the arm cover, and push cam follower 1in

the direction of the arrow mark A to enter it into thread trimmer cam 2.

2) Turn hand pulley 3 to rotate the main shaft in the

direction of normal rotation and move moving knife 4 to the front end of its travel while cam follower 1 is entered into thread trimmer cam 2.

3) Loosen adjustment screw 5 and move thread

trimming lever (small) 6 in the direction of the arrow mark to adjust so that the distance from the left end of the throat plate to the top end of moving knife 4 is 18.9 mm. In case of the hot wire type, when the aforementioned dimension is larger than specified one, the length of needle thread remaining on the needle after thread trimming may be excessively short. Throat plate 18.9mm43 ENGLISH H type G type Dimension A 0.8 to 1 mm 1.4 to 1.6 mm

(2) Position of the counter knife Adsjusting procedure for H type and G type

1) Select dimension A, clearance provided between

needle hole guide 1 and counter knife 2 from the table below in accordance with the type you desire, loosen setscrews 3 and move counter knife 2to djust the position. At this time, provide a clearance of 0.3 to 0.5 mm between the throat plate and counter knife 2. If dimension A is small, needle thread or bobbin thread may be too short.

2) Dimension B, difference in height between the

counter knife and needle hole guide 1 is as shown in the table below. When this dimension is not proper, bend the top end of the counter knife to adjust the dimension. If dimension B is large, needle thread or bobbin thread may be too short. Adjusting procedure for the hot wire type

1) Loosen setscrew 6 and move hot wire base 7 to adjust so

that a clearance of 0.5 mm is provided between needle hole guide 4 and hot wire plate 5 both in the longitudinal and lateral directions.

2) Check whether hot wire plate 5 and insulation

sheet 8 come in close contact with each other. If not, loosen setscrews 9 and move hot wire plate 5 to adjust. (When setscrews 9 are loosened, perform again the work of step 1).)

1. After adjusting the clearance, check

with the tester or the like that there is no electrical continuity in hot wire plate 5, needle hole guide 4 and the throat plate. If there is an electrical continuity, temperature will not rise and deterioration of sharpness or cause of trouble wll result.

2. Adjust the tightening torque of

setscrew 6 to 98 to 147 N

Adjust the tightening torque of setscrews9 to 48 to 98 N

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

6. Thread breakage detector plate

1) Adjust so that thread breakage detector plate 1 is

always in contact with thread take-up spring 2 in the absence of needle thread. (Slack : approx. 0.5 mm)

2) Whenever the stroke of thread take-up spring 2

has been changed, be sure to readjust thread breakage detector plate 1 . To make this adjustment, loosen screw 3. Adjust so that thread breakage detector plate 1 does not touch any adjacent metallic parts other than thread take-up spring 2.45 ENGLISH

7. Adjusting the amount of oil in the hook

Remove rubber cap 1, turn clockwise adjustment screw 2 to decrease the amount of oil in the hook, and counterclockwise to increase the amount of oil in the hook. Adjust the amount of oil when the followings occur. a. Decrease the amount of oil in the hook when oil in the oil tank on the machine bed side decreases quickly. b. Decrease the amount of oil in the hook when oil splashes from the hook are many and oil leaks from the hook cover. c. Increase the amount of oil in the hook when the hook noise is large. d. Increase the amount of oil in the hook when pulling up of needle thread is deteriorated due to the shortage of lubrication. After performing the adjustment, be sure to operate the sewing machine with the pattern No. 60 for checking the amount of oil in the hook to check the amount of oil.

1) Remove oil shield plate . (See p.38.)

2) Remove the needle.

3) Insert a sheet of paper between thread breakage

detector plate 1 and thread take-up spring 2for insulation.

4) Allow a sheet of paper in approximate 30 mm

square to come near the position of approximately 10 mm in the side direction of the hook, and operate the sewing machine with the pattern No. 60. (Set the number of rotations to the maximum one.)

5) After performing operation of one cycle, confirm

the amount of oil through the oil mark adhered to the paper3. The amount of oil in the hook does not change immediately after the adjustment. Be sure to check the amount after operating the sewing machine for approximately 10 minutes. Paper46

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

8. Cleaning the filter

Clean the filter 2 of the control box fan once every week.

1) Pull the screen kit 1 in the direction of the arrow

2) Wash the filter 2 under running water.

3) Reinstall the filter 2 and the screen kit 1.

9. Draining waste oil

When polyethylene oiler 1 becomes filled with oil, remove it and drain the oil.47 ENGLISH

To prevent possible accidents caused by electric shock, turn OFF the power, open the control box cover after a lapse of five minutes, and replace the fuse with a new one with the specified capacity.48

Pressing key and key, turn ON the power switch. The display gives the indication of the memory switch and the sewing machine operation can be changed.

2. Example of the memory switch setting

(1) Setting of max. sewing speed limitation Example of setting : Setting the max. sewing speed limitation to 1,800 sti/min.

1) After the memory switch has started, press the or key to indicate

2) Press the key to light up the sewing LED.

3) Indicate “1800” using the key.

4) After setting, register using the key.

(2) Setting the soft start speed at the sewing start The speed of the first stitch to the fifth stitch at the sewing start can be changed in a unit of 100 sti/min. For the max. sewing speed, the memory switch NO. 01 (setting the sewing speed limitation) has priority. Example of setting : The speed is changed as follows : 1st stitch 200 → 400 sti/min, 2nd stitch 600 → 900 sti/min

1) After the memory switch has started, press the or key to

indicate “ ” on the display.

2) Press the key to light up the sewing LED.

(The 1st stitch, 200 sti/min, will be indicated.)

3) Press the key to indicate “ ”.

(400 sti/min is set.)

(The 2nd stitch, 600 sti/min will be indicated.)

5) Press the key to indicate “ ”.

(900 sti/min is set.)

6) After setting, register using the key.

State when delivered Setting range 1st stitch 200 200 to 900 2nd stitch 600 200 to 2,200 3rd stitch 1,000 200 to 2,200 4th stitch 2,200 200 to 2,200 5th stitch 2,200 200 to 2,200 Unit [sti/min]49 ENGLISH

(3) Setting the counter operation Example of setting : The production counter (adding method) can be changed to the bobbin thread counter (subtracting counter).

1) After the memory switch has started, press the or key to

indicate “ ” on the display.

2) Press the key to light up the sewing LED.

4) After setting, register using the key.

(4) Setting the pedal specifications This function is set when changing the pedal specification is changed. Example of setting : the standard 1-pedal specification is changed to the 2-step pedal (optional) specification.

1) After the memory switch has started, press the or key to

indicate “ ” on the display.

2) Press the key to light up the sewing LED.

4) After setting, register using the key.

※ After setting the memory switch, turn OFF the power switch once, and turn ON again. Then, the sewing machine starts running in accordance with the setting made by the memory switches.50 NOTE) Display Remarks

3. Table of functions of the memory switch

Note) Contents of the memory switch may vary in accordance with the system ROM revision. (The following contents are in case of "005D".) Start of feed can be set by the angle of main shaft. Function Setting of the max. sewing speed limitation (in a unit of 100 sti/min) Starting speed of 1st to 5th stitch at the sewing start is set in a unit of 100 sti/min This function sets whether or not the calling of the service pattern data is acceptable. This function sets the indication of change of pattern No, X/Y scale rate, max. sewing speed limitation and heat cutter temperature, and whether or not the change is acceptable. (Prevention of maloperation) Setting of the counter operation Production counter : Adding counter Bobbin thread counter : Subtracting counter This function sets the needle bar stop position. Under the needle-up stop mode, the machine rotates in the reverse direction from the upper stop position and stops. This function sets the base point of enlargement/ reduction. This function selects whether or not to execute the origin retrieval after the completion of the sewing. (When performing sewing with the normal pattern No. or P1 to P7.) This function selects whether or not to execute the origin retrieval after the completion of the sewing. (When performing sewing with the combined pattern.) This function selects the pedal specifications. This function selects whether or not the wiper operates. This function selects the temporary stop switch input. (When the panel reset is selected, temporary stop input is effective only during sewing operation. This function selects the feed timing. Setting to 1 or 0 will be more effective when the thread is not well-tightened. This function selects whether or not the thread breakage detection function is provided. (This function detects at 8 stitches of the start of sewing, and at 3 stitches on the way.) Setting range 200 to 2,200 sti/min 1st stitch : 200 to 900 2nd stitch : 200 to 2,200 3rd stitch : 200 to 2,200 4th stitch : 200 to 2,200 5th stitch : 200 to 2,200 Pattern Nos. 1 to 64 can be set individually. 0 : Calling ineffective 1 : Calling effective 0 : OFF 1 : ON (key-lock) 0 : Adding 1 : Subtracting 0 : Upper stop position H, G types 53˚ Z type 40˚ 1 : Upper dead point stop 22˚ 0 : Origin 1 : Sewing start point 0 : Ineffective 1 : Effective 0 : Ineffective 1 : Effective 0 : 1-pedal 1 : 2-step pedal 2 : 1-pedal (PK-57) 3 : 3-step pedal (priority to the right) 4 : 3-step pedal (priority to the left) 5 : 3-step pedal (no priority) 0 : Ineffective 1 : Effective 0 : Ineffective 1 : Panel reset key 2 : Switch on the machine head 0 : 161˚ Slow 1 : 149˚ 2 : 137˚ 3 : 125˚ 4 : 113˚ 5 : 101˚ Fast 0 : Ineffective 1 : Effective 2 : Not adjusted State when delivered 2,200 sti/min 1 : 200 sti/min 2 : 600 sti/min 3 : 1000 sti/min 4 : 2,200 sti/min 5 : 2,200 sti/min No. 51 : 1 No. 60 : 1 No. 52 : 1 No. 53 : 1 No. 54 : 1

Nos. 1 to 30 mount the bartacking patterns of LK-1900. Note) When material is excessively thick, there is a danger of needle breakage if the timing is slow, So, be careful. Do not use the setting “2”.51 ENGLISH Display Remarks For LK-1942 only Automatic shift of Y=-12 mm imme-diately after the origin retrieval When performing basting, optional thread tension disk raising solenoid is required. (Setting of memory switch No. 28-1 : for H type only) In either case, connect to J59 of MAIN circuit board. (Cannot be used simultaneously) Setting 1 :P95 output Setting 2 :P99 output (See the table corresponding to solenoid valve of the optional parts list.) When it is set to "1", the cloth can be taken out instantly since the presser goes up immediately after the thread trimming. Even when it is set to ineffective, it is effective at the time of temporary stop or the like. For heat cutter type only Set toe the effective when the straight line movement is not possible due to the limitation of the shape of presser or the like. Function Wiper sweeping position is set. This function selects whether or not the air pressure detection is provided. When the work clamp foot of AMS-206, the origin is compensated. This function selects the basting mode. Pattern sewing data is read to "jump feed" and curved point to "sewing" respectively and the function is actuated. This function selects whether or not thread tension disk No. 2 rising function (optional for H type) or thread drawing function (G and Z types) is provided. This function selects the thread tension controller No.

This function selects whether all inverting commands of the pattern data are effective or optional inverting points only are effective. This function selects timing of presser lifting after completion of sewing. This function is not used with LK-1941/42. Do not change the setting. This function selects whether or not the needle cooler output is provided. This function selects whether or not the thread trimming command control of the pattern data is effective. This function selects whether or not the thread trimming device control is effective. This function sets the control of the delay timing from heat cutter output OFF to wiper ON. Set the value to a larger one whenever the thick thread is used.(Setting is possible in a unit of 50 ms.) This function selects whether or not the optional thread clamp device control is effective. This function sets the guide cylinder OFF timing of the optional thread clamp device by the number of stitches from the start of sewing. This function selects the speed of revolution of the bobbin winder. Selection of the return route to the sewing start point When the effective is set, the machine returns to the sewing start point through the route tracing reversely the sewing pattern. Setting range 0 : Wiper sweeps above the intermediate presser. 1 : Wiper sweeps below the intermediate presser. 0 : Ineffective 1 : Effective 0 : Without compensation 1 : With compensation 0 : Normal 1 : Basting 0 : Ineffective 1 : Disk rising 2 : Thread drawing 0 : Ineffective 1 : All inverting points 2 : Optional inverting points only 0 : Presser goes up after thread trimming and returning to the origin. 1: Presser goes up immediately after thread trimming.

(1) Pattern input device Pattern can be inputted by using the handy programming device, PGM-7, or PGM-20. (2) Data ROM for sewing pattern Turn OFF the power before inserting/ drawing out the ROM or changing- over the switch.

1) Data ROM is incorporated in U32 on the MAIN

circuit board. ™ When creating a pattern with the PGM-7, confirm that this ROM is incorporated. (The pattern which has been created is recorded in this ROM.) ROM part No. : HLO11940000 (EEP-ROM 58C256) ™ Write in this ROM as well when creating a pattern with the PGM-20.

2) When using the Data ROM (EEP-ROM 58C65) for

AMS-206, turn OFF DIP switch SW1-1. In addition, when using the presser of AMS-206, change the setting of the memory switch No. 26 to adjust the sewing position. Be sure to check the setting of DIP switch when replacing the Data ROM. If the setting is mistaken, correct data could not be read and E-1, E-2, or E- 8 may appear. (3) Table of interchangeability of Data ROM (part) of LK-1941/42 Data ROM System ROM Dip Switch53 ENGLISH (4) Making the sewing pattern

1) Receding position of the feeding frame (application of the 2nd origin)

Therer is a case where the feeding frame is slanted and the material is hard to be set in accordance with the material. In this case, it is easier to set the material if the 2nd origin is set to near-by the center of the feeding frame.

2) When using the feeding frame blank

In case where the lift of the feeding frame is high, the feeding frame is likely to come in contact with the intermediate presser. In this case, it is recommended to set receding position of the presser (2nd origin) described in item 1) and to make a recess for the intermediate presser in the feeding frame blank.

3) Position of the thread trimming

1) Do not enter the thread trimming data in the

slant section if possible. There may be a case where the thread is not trimmed.

2) When entering the thread trimming control, set

the pitch of the last stitch to 2 mm or more. The input device is necessary when creating the sewing pattern. Start End Center of the feeding frame Setting the cloth Recess for intermediate presser Position of starting sewwing 2nd origin Position of starting sewwing

By changing DIP SW1 1, DIP SW2 2, and SLIDE SW3 3 mounted on the control box, the setting can be changed as described in the following table.

• Perform the change of the DIP SW and SLIDE SW after turning OFF the power switch.

• Do not turn ON the switch not used yet.

SW1-1 SW1-2 SW1-3SW1-4(unused)Set valueOFF OFF OFF OFF (State of delivery)ON OFF OFF OFF 1OFF ON OFF OFF 2ON ON OFF OFF 3OFF OFF ON OFF 4ON OFF ON OFF 5OFF ON ON OFF 6ON ON ON OFF 7Function Change of needle bar stop height (It is possible to set ±7 stages by combination of the set value of DIP SW1-1 to -3 and the code setting of DIP SW2-1.) Needle tip height at the time of UP stopThe height depends on the set value of DIP switch SW2-1 2.DIP SW2-1ON/Needle stop position - highOFF/Needle stop position - lowFunction ON OFF State of deliverySW2-1Selection of needle bar UP stop position codeHigh Low OFFSW2-2Thread trimming speed setting250sti/min 400sti/min ONSW2-3 Unused - - OFFSW2-4 Unused - - OFFSW2-5 Unused - - OFFSW2-6 Unused - - OFFSW2-7 Unused - - OFFSW2-8 Unused - - OFFFunction State of deliveryUnused 3 side ON 1DIP SW1 2DIP SW2 3SLIDE SW355 ENGLISH

1) Remove the standard pedal cord from J18

connector on the MAIN circuit board.

2) Enter the 2-step PK pedal cord into the control box,

connect it with the 2-step pedal connecting cord asm.1, and connect it with J26 connector on the MAIN circuit board. Tighten with a screw the ground cable as illustrated in the figure. 2-step PK pedal : Part No. M85905130AA 2-step pedal connecting cord asm. : Part No. M90315800A0

• Memory switch No. 10-1 (2) Connection of the PK-57

1) Remove the standard pedal cord from J18

connector on the MAIN circuit board, and connect PK-57 change cable 1.

2) Connect the cord of PK-57 with J71 of PK-57

change cable 1 at the rear face of the control box. Then, clamp two places with adhesive clamp 2. Also, tighten with a screw the PK-57 ground cable as illustrated in the figure. PK-57 : Part No. GPK570010B0 PK-57 change cable : Part No. M90135900A0 Adhesive clamp : Part No. E96076030000 (2 pcs.)

• Memory switch No. 10-2

※ When using the optional pedal, refer to “ 2-(4) Setting the pedal specifications ” described in the item of

(1) Connection of the 2-step pedal

1) Remove the standard pedal cord from J18

connector on the MAIN circuit board.

2) Enter the 2-step pedal cord into the control box

and connect it with J26 connector on the MAIN circuit board. 2-step pedal : Part No. M85205800A0

• Memory switch No. 10-156 (4) Connection of the 3-step pedal

1) Remove the standard pedal cord from J18

connector on the MAIN circuit board.

2) Insert the 3-step pedal cord into the control box

and connect it to J26 connector of the MAIN circuit board. 3-step pedal : Part No. M85215800A0

• Memory switch Nos. 10-3 to -5 (5) Connection of the 3-step PK pedal

1) Remove the standard pedal cord from J18

connector on the MAIN circuit board.

2) Enter the 3-step PK pedal cord into the control box,

connect it with change cable asm. 1, and connect it with J26 connector on the MAIN circuit board. (Refer to the table below for the connection.) 3-step PK pedal : Part No. GPK470010AB Change cable : Part No. M90255800A0

J18 J26 Either J18 or J26 of MAIN circuit board can be used for the pedal. Be careful when the optional pedal is used since the machine may fail to work if both connectors are simultaneously connected. PK-47 Relay cord Signal name P1 P101 Feeding frame 1 P2 P102 Feeding frame 2 P3 P103 Feeding frame 3 - P104 Not used P4 P105 Start57 ENGLISH

4. Table of error indication

Caution : Refer to the Instruction Manual for AW-2D when any error other than the aforementioned ones is displayed with the sew ing machine provided with AW-2D. Remarks The service pattern is registered inSYSTEM ROM.If the setting of SW1-1 is differentfrom Data ROM, reading becomesunstable.If the setting of SW1-1 is differentfrom Data ROM, reading becomesunstable. Corrective measure Check the pattern No.• Check the scale rate and sewing pitch.• Make sure of setting of SW1-1.Turn the hand pulley, and return the needle bar to the upper position.Press the reset switch and check the pattern and scale rate.• Re-sewing by retreat of the feed → start• Thread trimming action using the temporary stop switch or reset• Return-to-origin action by reset after thread trimming action Turn OFF the power switch and raise the machine head. Check the safety switch.• Turn OFF the power switch, and remove the cause of trouble.• Check the power source voltage.• Turn OFF the power switch and remove the cause.• Check the mounting of EEP-ROM(contact failure, direction of mounting, etc.).• Check the setting of SW1-1.• Retreat of the feed after threading and re-sewing• Return-to-origin action by reset• Turn OFF the power switch and remove the cause.(Contact failure, disconnection of cord, or trouble of circuit boardis considered.)Turn OFF the power switch, and check the air pressure.• Turn OFF the power switch.• Defective memory (Replace the MAIN circuit board.)• Turn OFF the power switch.• Defective MAIN circuit board(Replace the MAIN circuit board.)Turn OFF the power switch, and check whether the fan filter is clogged,and the power source voltage. Turn ON the power after the temperaturehas dropped properly. Description The specified pattern No. has not been registeredin the data ROM.• The sewing pitch is beyond 10 mm.• Data ROM which is used is different from settingof DIP switch.The needle bar is shifted from the upper position.The sewing area is beyond the limit.Stop on the way while the sewing machine isrunning.Safety switch is turned OFF.(When the sewing machine head is tilted or the like.)The main shaft of the sewing machine does notrotate due to some troubles.The pattern data reading from the data ROM cannotbe made.The needle thread has been broken during sewing.Communication with the PGM-7 cannot beperformed due to some troubles.The air pressure is dropped.The data writing to the memory for the back-upcannot be made.MAIN circuit board is uncontrollable due to sometroubles.Temperature in the control box is abnormally high. Name of error Pattern No. errorEnlargement errorPattern reading errorNeedle bar upper position errorSewing area overStop on the waySafety switch errorMachine lock errorAbnormal voltage errorPattern data errorNeedle thread breakage detectionerrorPGM-7 communication errorAir pressure drop errorMemory write-in errorTime-out errorOverheat error Error indication58

5. Troubles and corrective measures (sewing conditions)

Corrective measures ™ Adjust the clearance between the needle and the shuttle to 0.05 to 0.1 mm. ™ Set soft-start sewing at the start of bartacking. ™ Change the pitch at the start of sewing. (Increase or decrease.) ™ Increase the rising amount of the disk of thread tension controller No. 2. ™ Increase the rising amount of the disk of auxiliary thread tension. ™ Increase the tension of the thread take-up spring, or decrease the tension of the thread tension controller No. 1. ™ Increase the clearance between the needle hole guide and the counter knife. (Knife type) ™ Lower the counter knife. (Knife type) ™ Adjust the position of the moving knife. (Hot wire type) ™ Decrease the tension of the bobbin thread. ™ Increase the clearance between the needle hole guide and the counter knife. (Knife type) ™ Lower the counter knife. (Knife type) ™ Take it out and remove the scratches using a fine whetstone or buff. ™ Buff or replace it. ™ Use a hook suitable for the needle count number. ™ Reduce the needle thread tension. ™ Reduce the tension. ™ Use silicone oil. ™ Use the needle cooler. ™ Use an oval needle hole guide. ™ Use the ball-point needle. ™ Replace the bent needle. ™ Replace it with a thicker needle according to the material. ™ Make the feeding timing fast.

Enter thread trimming at the proper position. ™ Correct the position of the moving knife. ™ Correct the timing between the needle and the shuttle. ™ Increase the pitch of the last stitch. ™ Replace the counter knife. ™ Increase the bend of the counter knife. ™ Make the setting high. ™ Adjust the position of the hot wire plate. ™ Correct the positions of the needle and shuttle. ™ Correct the positions of the needle and shuttle. ™ Replace the bent needle. ™ Increase the needle thread tension. ™ Delay the feed timing. ™ Increase the tension of the thread tension controller No. 1. ™ When making a pattern, set the sewing pitch at the start and end of sewing to 1 mm or less. Trouble

1. The needle thread

slips off at the start of bar-tacking.

2. Thread often breaks

or synthetic fiber thread splits finely.

5. Stitch skipping often

6. The needle thread

comes out on the wrong side of the material.

When synthetic fiber thread is used, at the start or end of sewing, needle thread rises or remaining of needle thread is excessive. Cause 1 Stitches are slipped at the start. 2 The needle thread remaining on the needle after thread trimming is too short. 3 The bobbin thread is too short. 1 The hook or the inner hook stopper has scratches. 2 The needle hole guide has scratches. 3 Partial catch of thread by hook due to needle deflection 4 The needle thread tension is too high. 5 The tension of the thread take-up spring is too high. 6 The synthetic fiber thread melts due to heat generated on the needle. 7 Thread breakage due to partial catch of thread by hook when sewing seat belt 8 Needle stitcks in fabric yarn. 1 The needle is bent. 2 The needle is too thin for the material. 3 Feed timming is excessively slow. 1 Position of thread trimming is improper. 2 The moving knife has been improperly positioned. 3 The last stitch is skipped. 4 Pitch at the last stitch is too small. (Knife type) 1 The counter knife is dull. 2 The difference in level between the needle hole guide and the counter knife is not enough. (Hot wire type) 1 Temperature setting is too low. 2 The hot wire plate comes in contact with the needle hole guide. 1 The motions of the needle and shuttle are not properly synchronized. 2 The clearance between the needle and shuttle is too large. 3 The needle is bent. 1 The needle thread tension is not high enough.

The needle thread after thread trimming is too long. 1 In case of synthetic fiber thread, the thread is harder than other threads and penetration resistance to material is small. Page

t = 1.2 Remarks Name of Parts Type Without knurl/Without processed With knurl/Without processed Solid type feeding frame/with knurl Solid type feeding frame/without knurl Separate type feeding frame/ without knurl Separate type feeding frame/with knurl Separate type feeding frame/with knurl Part No.

Needle cooler asm. Thread tension controller No. 3 Thread clamp device Table corresponding to the solenoid valve output In csse of the optional device for which the solenoid valve is used, connect the solenoid valve to MAIN circuit board referring to the figure on the right side. MAIN circuit board J17 Solenoid valve relay cable asm.

P,J79 Red Black Red Black Red Black Red Black Red Black Red Black Red Black Red Black Red Black White Black Solenoid valve cable asm. P,J80P,J78 Solenoid valve P91 Feeding frame (Right) Wiper switch Pressure sensor P92 Feeding frame (Left) P93 Intermediate presser P94 Needle cooler P95 Thread tension No.3 (1) P96 Thread clamp guide P97 Wiper P98 Thread clamp wire P99 Thread tension No. 3 (2)61 ENGLISH Remarks Knurl is coarser than that of the normal feed plate blank and effective for preventing materials from slipping. In addition, positioning of belt can be performed by using the feed plate guide. This is the guide for determining the position when sewing belt. This guide is used as a set together with 14444202, feed plate blank for belt and feeding frame blanks for belt (14444004 and 14444103). Knurl is coarser than that of the normal feeding frame blank and effective for preventing materials from slipping. Wiper waiting position is reverse to the normal position. This is used when the sewing product interferes with the wiper. (It is necessary to change connection in the air piping drawing.) This wiper lightly retains needle thread in order to prevent needle thread at the start of sewing from being caught under the presser. Be sure to replace the wiper base as a set when using the reverse sweeping wiper or the wiper for retaining thread. Name of Parts Solid type work clamp foot compl. Feed plate blank for belt Feed plate guide Feeding frame blank for belt Wiper Type With knurl/Without processed Separate type feeding frame, right/ with knurl/without processed Separate type feeding frame, left/ with knurl/without processed Reverse sweeping wiper Wiper for retaining thread Wiper base Part No.

7. Table of the gauge parts

Name of Parts Type A=3.0 B=4.0 For knife type thread trimming A=4.0 B=5.0 For knife type thread trimming A=3 x 4.4 Oval B=5.0 For hot wire type thread trimming A=2.0 B=3.0 For knife type thread trimming A=2.3 B=3.3 For knife type thread trimming A=3 x 4.4 Oval B=5.0 For knife type thread trimming A=3.0 B=4.0 For hot wire type thread trimming A=4.0 B=5.0 For hot wire thread trimming A=3.5 B=5.5 C=39.0 A=2.2 B=3.6 C=39.0 Lubricating hook A Hook gib is long. Lubricating hook B Hook gib is long. Lubricating hook C Hook gib is short. Lubricating hook D Hook gib is short. Part No.

Remarks Standard for H type Standard for G type For Z type (for seat belt) for seat belt Standard for G type Standard for H type Standard for H type Can be used up to needle size #18 to #20. (In case of ORGAN needle) Optional Can be used up to needle size #21 to #23. (In case of ORGAN needle) Standard for G type Can be used up to needle size #21 to #23. (In case of ORGAN needle) Standard for Z type Can be used up to needle size #24 to #26. (In case of ORGAN needle) Hook63 ENGLISH

Drilled hole 28Drilled hole 17Drilled hole 16

: Drawer stopper installing position (One place on the rear side)

: 4 places on the rear side-heater unit installing hole 4-drilled hole 2, 10 deep

: 2 places on the rear side-clamp installing hole 2-drilled hole 2, 10 deep

: JUKI logotype (by printing supplied by JUKI)

: Oil-drain funnel installing hole (Drill at the time of set-up)

: Drilled hole 30, 51 spot face, 16 deep

: 2 places on the rear side-pedal switch installing hole 2-drilled hole 2, 10 deep

: 3-drilled hole 2, 10 deep

: 4-drilled hole 7, 14 spot face, 7.5 deep

: 4-drilled hole 2, 10 deep

: 2 places on the rear side-power switch installing hole 2-drilled hole 2, 10 deep64

Table for the machine provided with AW device

• Dimensions and specifications which are not indicated are the same as those of the drawing of table on the previous page.

National ○ Z Exportation

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4) After setting, register using the

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SW2-2 SW2-3 SW2-4 SW2-5 SW2-6 SW2-7 SW2-8

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࣓ഃሸሎᄢçّႍЮඇ֬ୄಿè Please do not hesitate to contact our distributors or agents in your area for further information when necessary.