Juki DNU-1541s Service Manual /Engineer`s Manual
Contents
1. 24 1 Thread trimmer device 24 1 Cam follower 24 2 Solenoid arm 24 3 Thread trimmer cam timing 26 4 Rotary knife and fixed knife 26 2 Alternate vertical dial 28 3 Adapting SC 380 to DNU 1541 7 30 4 INSTALLATION OF THE OPTIONAL PARTS 32 1 Automatic reverse feed device 32 1 Removing the window plate List of the parts to be removed 32 2 Removing the reverse feed control lever List of the parts to be removed 32 3 Installing the reverse feed link hinge screw List A2. 32 4 Installing the reverse feed control lever1 Reverse feed control lever List B 33 5 Installing the automatic reverse feed device List C 33 6 Installing the touch back switch List D 34 7 Installing the pneumatic components List E 34 8 Parts list 34 2 Automatic presser foot lifter 36 1 Installing the automatic presser foot lifter List A 36 2 Installing the pneumatic device components 37 3 Parts list 38 3 Installing the DL device 40 1 When installing the DL device to DNU 1541 7 after set up of the machine List A 40 2
3. 10 1 Amount of alternate vertical movement 10 2 Alternate momentum 12 9 Feed cam timing 12 1 Horizontal feed cam timing 12 2 Top feed cam timing 14 10 Needle sway Optional selection only of DNU 1541 7 16 11 Stitch length of normal reverse feed 16 12 Balancer DNU 1541 DNU 1541S 18 13 Position of the reverse feed control lever 20 14 Safety clutch DNU 1541S 22 15 Lubrication 22 3 STANDARD ADJUSTMENT OF THREAD TRIMMER COMPONENTS DNU 1541 7
4. 50 3 With regard to thread trimming 51 4 Others 52 12 DRAWING OF THE TABLE 53 1 1 SPECIFICATIONS No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Item Model Model name Application Sewing speed Needle Thread possible to be sewn Thread possible to be trimmed Stitch length Presser foot lift Stitch length adjusting mechanism Reverse stitch selection method Thread take up Needle bar stroke Alternate foot stroke Hook Feed mechanism Top and bottom feed actuation mechanism Thread trimming mechanism Lubrication Lubricating oil Bed size Free space for sewing Size of handwheel Motor Specifications DNU 1541 1 needle unison feed lockstitch machine DNU 1541S 1 needle unison feed lockstitch machine with safety mechanism For heavy weight materials Max 2 500 rpm SCHMETZ 135 X 17 Nm 125 to 180 Standard Nm 160 30 to 5 Max 9 mm normal reverse feed Hand lifter 9 mm Knee lifter 16 mm By dial Lever type Slide thread take up 36 mm 2 5 mm to 6 5 mm Slot adjusting type Horizontal axis 2 fold hook Ellipse feed By timing belt Hook autom
5. Adjustment Procedures Results of Improper Adjustment 1 Raise cam follower 1 in the direction of the arrow mark 2 Loosen stopper screw nut 4 and adjust by screwing amount of stopper screw 5 so that a clearance of 0 5 mm is provided between thread trimmer cam 2 and cam roller 3 3 Taking care not to move stopper screw 5 tighten stopper screw nut 4 Cam follower return spring 8 Adjust the cam follower so that it returns with the minimum force which is required 1 Loosen two setscrews 6 of the spring rack 2 Turn spring rack 7 to adjust the return force of the spring 3 Taking care not to move spring rack 7 tighten setscrews 1 Loosen clamping screw 3 in the solenoid arm 2 Adjust solenoid arm 4 so that protruding amount of thread trimmer driving shaft 1 in terms of the edge of thread trimmer base 2 is 11 to 12 mm 3 Tighten clamping screw 3 in the solenoid arm When the protruding amount is high Cam follower dose not come in contact with the thread trimmer cam and thread trimmer machanism may not work When the protruding amount is low Cam follwer comes in contact and contact noise occurs Cam roller or thread trimmer cam may be broken When the clearance is larger Stroke of the rotary knife is insufficient and double trimming will result When the clearance is smaller When the thread trimmer works the cam roller comes in contact with the side face of the thread trimmer cam and threa
6. Black 7 Tension release White 8 Thread trimmer White 9 10 Earth Green Yellow 11 12 GND White 13 BT White 14 Tension release White Name of part Pin No Remarks 5 string switch 1 DL Brown 5 string switch 2 BT Red 5 string switch 3 BT Orange 5 string switch 4 DL Yellow 5 string switch 5 FL Pink 5 string switch 6 FL Gray 5 string switch 7 2P White 5 string switch 8 2P 24V Black 5 string switch 9 47 2 Connector coming from the pneumatic device 2 pin connector 9 pin connector Name of part Pin No Pneumatic components asm Part No 23105554 Solenoid valve 1 1 BT Red Solenoid valve 1 2 BT Black Name of part Pin No Pneumatic device B asm Pneumatic device C asm Part No GAKA2301BA0 Part No GAKA2301CA0 Solenoid valve 1 1 BT Red BT DL Red Solenoid valve 1 2 BT Black BT Black Solenoid valve 1 4 DL White Solenoid valve 2 5 AK Red AK Red Solenoid valve 2 6 AK Black AK Black 48 Pin No Relay cable asm 21443957 1 GND Yellow 2 DL switch 1 Red 3 DL LED Yellow DL Black 4 5 DL switch 2 Orange 6 DL switch Orange 7 8 LED Blue 9 10 11 12 13 ABT switch Red 14 15 15 pin
7. 3 6 9 8 7 1 a Red Black White Red Black Solenoid valve B CN1 1 CN1 4 CN1 2 CN1 5 CN1 6 41 4 Parts list Removing parts list DL device components List A Attaching parts list Set part No of DL device 5 step switch components List C Part No 21339601 21339700 21437108 No 1 2 3 Note Name of part Top feed stopper plate A Top feed stopper plate Window plate E Q ty 1 1 1 Part No GDL21000DA0 No Note Name of part Kit DL 21D Q ty 1 Part No PA320200101 PJ304065102 PX015101000 21438403 SD0600403TP NM6080721SE 21437207 SM6044002TP 21438106 21438601 SS6111610SP 21438502 SD0600452TP 21438205 21438700 SS4110815SP No 1 2 3 4 5 6 7 8 9 0 1 2 3 4 7 8 Note Name of part Jig cylinder Elbow Muffler Cylinder connecting screw Alternate vertical link hinge screw Nut Window plate F Jig cylinder setscrew Top feed stopper plate B Alternate vertical link spacer Setscrew Alternate vertical link Hinge screw Top feed stopper plate Alternate vertical link support Setscrew Q ty 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 2 Part No 21442553 SS7110840SP No 1 2 Note Name of part 5 step switch asm 5 step switc
8. 36 2 Automatic presser foot lifter 1 Installing the automatic presser foot lifter List A 1 Remove the side plate located on the anti operator s side of the machine arm Removing parts list 2 Install two elbows 0 to automatic presser foot lifter cylinder 1 3 Install cylinder connecting screw 3 to the presser foot lifter cylinder For the standard adjust the distance from the end face of piston rod of the presser foot lifter cylinder to the end face of cylinder connecting screw to 24 mm and tighten nut 4 4 Tighten cylinder stay front 1 and presser foot lifter cylinder stay rear 2 to the presser foot lifter cylinder with cylinder installing screw 2 5 Install the presser foot lifter cylinder which has been assembled at the above step 4 to to the machine arm with cylinder stay installing screw 3 6 Assemble automatic presser foot lifter lever B 7 with automatic presser foot lifter lever A 6 Insert automatic presser foot lifter lever shaft 9 into the holes of both levers and tighten with hexagon headed bolt 8 7 Install automatic presser foot lifter lever A which has been assembled at the above step 6 to the machine arm with automatic presser foot lifter lever shaft 9 Groove of automatic presser foot lifter lever B 7 enters hinge screw 5 attached to cylinder connecting screw 3 8 Install pneumatic components 9 Insert the air hose and check the operation When actuating the automatic presser foot lifter make su
9. Reverse feed control lever interferes with the machine bed and the stitch length of the reverse feed stitching will be decreased When the position of the reverse feed control lever is high Reverse feed control lever interferes with the stopper or the machine arm and stitch length of the normal feed stitching will be decreased 22 Standard Adjustment Standard Adjustment 15 Lubrication 14 Safety clutch DNU 1541S 1 2 1 2 3 4 5 A B Decrease Increase A sheet of paper 23 Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment The safety clutch functions when an excessive load is applied to the hook driving shaft or the like during sewing When the safety clutch functions the hook will not rotate even if turning the handwheel and the hook driving shaft sprocket wheel only will run idle since the power is not transmitted to the hook driving shaft Resetting procedure 1 Checking the moving part of the sewing machine and look for and remove the cause which the safety clutch has functioned 2 Pressing push button 1 located on the top surface of the machine bed strongly turn the handwheel in the reverse direction of rotation 3 Resetting procedure completes when the handwheel cannot be turned with click Adjusting the working torque of the safety clutch 1 Tilt the machine head 2 Turn worki
10. 1 DNU 1541 2 GAKA20010B0 Kit AK120B 1 DNU 1541S 3 GAKA2300AA0 Kit AK123A 1 DNU 1541 7 4 GAKA2300BA0 Kit AK123B 1 39 Pneumatic device components For DNU 1541 7 List C Part No GAKA14010A0 SK3482500SC No 1 2 Note Name of part Pneumatic components asm Setscrew Q ty 1 4 Pneumatic device components For DNU 1541 and DNU 1541S List B Part No GAKA14040C0 SK3514000SC No 1 2 Note Name of part Presser foot lifter knee switch B asm Wood screw Q ty 1 2 Kit A Knee lifter switch List D Part No GAKA2301BA0 GAKA2304000 SK3482501SE SK3415001SE No 1 2 3 4 Note Name of part Pneumatic device B asm Regulator installing plate Wood screw Wood screw Q ty 1 1 2 2 40 3 Installing the DL device 1 When installing the DL device to DNU 1541 7 after set up of the machine List A 1 Remove the window plate E located on the anti operator s side of the machine arm Removing parts list 2 Attach elbow 2 muffler 3 cylinder connecting screw 4 alternate vertical link hinge screw 5 and nut 6 to jig cylinder 1 3 Attach the cylinder which has been assembled at the above step 2 to window plate F 7 and tighten it with jig cylinder setscrew 8 4 Remove the top feed stopper plate A attached to alternate vertica
11. BT1 BT2 BT3 Initial value OFF OFF C 2 5 Modified value ON ON 1 0 2 Function name Max speed when speed is limited VC 2 speed inflection point 1 VC 2 speed inflection point 2 Remarks Symbol VL1 VP1 VP2 Initial value 86 56 71 Modified value 80 60 67 Function name Limitation of maximum speed Remarks Symbol LHH Initial value 41 Modified value 31 Start of needle UP position detection 55 Needle UP position detection Start of needle DOWN position detection 215 Thread trimmer sol Thread release sol 32 4 INSTALLATION OF THE OPTIONAL PARTS 1 Automatic reverse feed device 4 5 1 2 3 1 2 3 4 5 6 7 8 9 8 0 1 1 Removing the window plate List of the parts to be removed 1 Loosen setscrew 1 in the window plate B located at anti operator s side of the machine arm 2 Remove window plate B 2 3 Remove window plate packing B 3 Handwheel Window plate A 2 Removing the reverse feed control lever List of the parts to be removed 1 Loosen the respective setscrews in the belt cover and remove the belt cover 2 Remove two setscrews 4 in the reverse feed control lever 3 Remove reverse feed control lever 5 Stitch dial 3 Installing the reverse feed link hinge screw List A 1 Remove feed driving rocker tension spring 1 2 Loosen felt presser setscrews 2 and remove felt presser 3
12. IFA ON and OB OT4 3 D mode selection D setting of improving the quality of tacking alignment 2 In case the manufacturing No Mfg No is 1 Select LU 22 0 LU2S from the table of simplified setting value for JUKI sewing machine Select program mode 1 A B Caution Do not select LU2v The alternate vertical movement amount device does not work normally with LU2v 2 Change the parameters below For the selection of each program mode from the normal mode and the details of functions refer to the Engineer s Manual for the SC 380 1 Normal mode slow start OFF ON 2 P mode selection setting of number of rotations of the machine head used stopping angle etc Function name Thread trimming mode Presser lifter output duty Remarks Symbol TR FUD Initial value PRG MF Modified value J1 FL Function name Change over of input signal function Remarks Needle lifting signal Presser lifting signal Caution 1 Cancel signal Refer to Caution 2 Symbol ID I2 I7 IF OB Initial value TL U no F W Modified value U F BTL no no Function name No of stitch compensation for tacking Remarks End tacking OFF compensation Symbol BT3 Initial value 1 Modified value 2 Function name Max speed Start tacking speed End tacking speed Medium speed No of stitches of slow start Reverse revolution angle Needle DO
13. movement of the walking foot and presser foot Less than 2 5 mm 2 5 mm to less than 4 mm 4 mm to less than 4 75 mm 4 75 mm to less than 6 5 mm Stitch length 6 mm or less 3000 rpm 2400 rpm 2000 rpm 1800 rpm Stitch length More than 6 mm and 9 mm or less 2000 rpm 2000 rpm 2000 rpm 1800 rpm Sewing speed of DNU 1541 7 Scale of alternate vertical dial 1 to 2 5 2 625 to 4 4 125 to 4 75 4 875 to 6 5 Switch upper Red and green lines OFF OFF ON ON Switch lower White and black lines OFF ON ON OFF 29 Adjustment Procedures Results of Improper Adjustment 1 Turn the alternate vertical dial to adjust the scale 1 to the convex section on the top cover 2 Loosen setscrew 1 in the alternate vertical dial and remove the alternate vertical dial At this time be careful that a pin and a spring are in the hole of section A 3 Loosen installing screws 2 of the detection switch of the amount of alternate vertical movement and adjust the distance from the inner diameter of the bushing to the edge of the switch body to 8 0 1 mm Then tighten the installing screws 4 Adjust the scale 1 to the convex section on the top cover place the pin and the spring in the hole of section A install the alternate vertical dial and tighten setscrew 1 in the alternate vertical dial Caution When the position of the detection switch of the amount
14. Installing the pneumatic device components List B 40 3 Installing the 5 step switch List C 40 4 Parts list 41 5 PORTION TO WHICH LOCKTITE IS APPLIED 42 6 SELECTIVE PARTS AND CONSUMABLE PARTS 43 7 ENGRAVED MARKER DOTS ON THE HANDWHEEL 44 8 LUBRICATION ROUTE DIAGRAM 44 9 PNEUMATIC PIPING 45 10 MACHINE HEAD WIRING WITH THREAD TRIMMER ONLY 46 1 Connector coming from the machine head 46 2 Connector coming from the pneumatic device 47 3 Connector coming from the relay cable Inserting side to the control box 48 11 TABLE OF TROUBLES AND CORRECTIVE MEASURES 49 1 With reagard to sewing 49 2 With regard to lubrication
15. R2 C1 535 R30 R2 C1 Z S W W Y S W W X X V V Z Y Y Y V V 1 1 W W 1 1 X X 1 1 S S Z Z 11 0 8 0 8 5x160 800 120 Thickness 1 5 Thickness 1 5 Thickness 0 5 Thickness 0 8 0 5 7 5 7 5 11 5 7 Style of tpe Helvetica Reg Condensed Condensed voided letters Dimension drawing in detail 1 2 3 4 5 6 7 8 9 1 4 3 4 Depth 10 Drill a hole at the time of set up 2 Installing position of stopper for drawer on the reverse side 3 JUKI logotype 4 16 depth 30 5 Top surface C1 5 6 18 drill 7 3 13 drilled hole 8 2 3 5 depth 10 9 2 3 4 depth 10 Top surface Table Part No 21413703 Please do not hesitate to contact our distributors or agents in your area for further information when necessary The description covered in this engineer s manual is subject to change for improvement of the commodity without notice 02 10 Printed in Japan E R INTERNATIONAL SALES H Q 8 2 1 KOKURYO CHO CHOFU SHI TOKYO 182 8655 JAPAN PHONE 81 3 3430 4001 to 4005 FAX 81 3 3430 4909 4914 4984 TELEX J22967 Copyright C 2001 2002 JUKI CORPORATION All rights reserved throughout the world
16. connector Pin No Relay cable asm 21443957 Relay cable asm 21414958 1 AK Black AK Black 2 AK White AK White 2 pin connector Pin No Relay cable asm 21443957 1 Thread trimmer Red 2 2P LED Black 3 Needle UP switch Yellow 4 2P switch White 5 BT switch Brown 6 BT Blue 7 Tension release Yellow 8 Thread trimmer Orange 9 10 Earth Green Yellow 11 12 GND Red 13 BT Green 14 Tension release Blue 3 Connector coming from the relay cable Inserting side to the control box 14 pin connector 49 11 TABLE OF TROUBLES AND CORRECTIVE MEASURES 1 With reagard to sewing Thread breakage Thread is worn out Needle thread trails 2 to 3 cm from the wrong side of the fabric Stitch skipping Thread path needle point hook blade point or inner hook resting groove on the throat plate has sharp edges or burrs Needle thread tension is too high Needle comes in contact with the blade point of hook Needle thread tension is too low Thread take up spring works excessively or the stroke of the spring is too small Feed timing is not proper Timing between the needle and the hook is excessively advanced or retarded Thread melts due to needle heat Clearance between the needle and the blade point of hook is too large Needle to hook timing is e
17. feed rod 2 Move the position of boss 2 on the cam rod up or down to adjust the position 3 After the adjustment tighten the nut If the boss is fixed in the upper section of the long hole Amount of movement becomes large If the boss is fixed in the lower section of the long hole Amount of movement becomes small Standard The lower engraved marker line on top feed rear arm 3 aligns with the center of hinge screw 4 Caution 1 The max sewing speed is specified in accordance with the sewing conditions 2 Set the max sewing speed appropriately in accordance with the respective conditions given taking care not to exceed the corresponding specified value In case of the machine with the thread trimmer 1 Remove the top cover 2 Loosen setscrew 4 in the vertical adjusting arm 3 Adjust the position of vertical adjusting arm 1 to 83 to 84 mm from edge 2 of the machine arm and assemble it so that it aligns with the edge of vertical change base 3 in the lateral direction 4 Securely tighten setscrew 4 in the vertical adjusting arm 5 Set the alternate vertical dial to the minimum and attach the top cover 6 Turn the alternate vertical dial and check to be sure that the scale of dial and the amount of alternate vertical movement are correct Increase the vertical stroke of the walking foot in accordance with the sewing products Sewing sponge material or the like Sewing material with overlapped
18. of alternate vertical movement is changed check whether the relation between the alternate vertical dial and the sewing speed is normal Sewing speed may not change even when turning the alternate vertical dial 30 3 Adapting SC 380 to DNU 1541 7 When using SC 380 for DNU 1541 7 it is necessary to set the parameters below However the manufacturing No Mfg No of SC 380 is In case of A in case there is LU51 of the model LU 1510 is in the table of simplified setting value for JUKI sewing machine of SC 380 and in case of in case there is no LU51 of the model LU 1510 in the table of simplified setting value for JUKI sewing machine of SC 380 the contents to be set are different So be careful 1 In case the manufacturing No Mfg No is A 1 Select LU 1510 LU51 from the table of simplified setting value for JUKI sewing machine Select program mode 1 A B 2 Change the parameters below For the selection of each program mode from the normal mode and the details of functions refer to the Engineer s Manual for the SC 380 1 P mode selection setting of number of rotations of the machine head used stopping angle etc 2 C mode selection C setting of input Caution 1 In case of the machine head with DL device set as I2 IO1 Caution 2 In case of the machine head with 2 pitch device set as IF IO4
19. paint thinner or the like and reassemble it using LOCKTITE after removing any moisture from the mating faces If it is hard to remove a part which has been fixed using LOCKTITE heat it using a torch lamp or the like to help remove the part Feed adjusting rod Fedd adjusting base LOCKTITE applied Feed adjusting rod hinge screw Cylinder connecting screw LOCKTITE applied Cylinder connecting screw hinge screw Knife driving shaft front arm Rotary knife base Rotary knife base connecting link LOCKTITE applied Rotary knife base connecting link hinge screw Cam roller shaft Cam roller Cam follower LOCKTITE applied Vertical change base arm pin LOCKTITE applied Vertical adjusting arm Setscrew LOCKTITE applied Vertical change base support shaft Knife driving shaft connecting link Knife driving shaft connecting link hinge screw LOCKTITE applied Knife driving shaft rear arm Cam driving base Thread release bar LOCKTITE applied Thread release bar coupling Thread release bar coupling nut Alternate dial shaft bushing LOCKTITE applied Top cover B Guide roller LOCKTITE applied Guide roller shaft Solenoid arm LOCKTITE applied Cam follower shaft nut Cam driving base Cam follower Cam follower spring Cam follower shaft 43 6 SELECTIVE PARTS AND CONSUMABLE PARTS Common to all models Name of selective part Part No Marking Remarks H
20. pneumatic device B asm 1 1 2 3 4 a b c 38 Part No 21332309 SS4110815SP No Note Name of part Side cover Side cover setscrew Q ty 1 1 Automatic presser foot lifter components For all models List A 3 Parts list Removing parts list Part No PA400150100 SM6082502TP 21356506 NM6080001SE SD0720331SP 21356605 21356803 SM6051002TP 21356704 PJ304065102 21356308 21356407 SS6151040SP CM3002000B1 CM300200001 No 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 Note Name of part Automatic presser foot lifter cylinder Cylinder installing screw Cylinder connecting screw Nut Hinge screw Automatic presser foot lifter lever A Automatic presser foot lifter lever B Hexagon bolt Automatic presser foot lifter lever shaft Elbow Presser foot lifter cylinder stay front Presser foot lifter cylinder stay rear Cylinder stay installing screw Caution seal for being caught Caution seal for injury to finger Q ty 1 4 1 1 1 1 1 2 1 2 1 1 4 1 1 Installing parts list Set part No of automatic presser foot lifter Caution These parts Nos are the set parts Nos of the parts from lists A to D NO Set Part No Set name of part Q ty Contents of set List No Applicable model A B C D 1 GAKA20010A0 Kit AK120A
21. the spring Refer to 9 Feed cam timing Troubles Causes Checking Corrective measures 50 2 With regard to lubrication Loose stitches Balloon stitches or isolated idling loop Loose stitches Needle thread rises Irregular stitches Bobbin thread is not passed to the fork end of bobbin case tension spring Thread paths have been poorly finished Bobbin fails to move smoothly Bobbin case is improperly engaged Thread is not well tightened in the reverse feed Height of the feed dog is too high Feed timing is excessively advanced Hard to slip thread is used Needle thread has not been fully pulled up Stroke of the thread take up spring is improper Thread paths have been poorly finished Bobbin thread tension is too low Bobbin has been wound too tight Pressure of the idle prevention spring is too high Check the bobbin thread route Check the finish of the respective thread paths Check the change of bobbin thread tension Compare the height with the standard value Check the stroke of the thread take up spring Check the finish of the respective thread paths Check the state of bobbin winding Check the idling amount of the bobbin Correctly pass thread to the bobbin case Finish using a fine emery paper or buff Replace the bobbin or the hook Replace the bobbin case or the hook Use the optional walking foot and presse
22. trimming is short Decrease the number of threading of the needle thread Replace the rotary knife or the fixed knife with a new one Refer to 3 1 4 Rotary knife and fixed knife Troubles Causes Checking Corrective measures To the next page 52 4 Others Thread remains uncut after thread trimming Rotary knife stops during operation Needle thread is not caught Bobbin thread is not caught Both needle and bobbin threads cannot be trimmed The blades of rotary knife and fixed knife have worn out or broken C h e c k w h e t h e r a synthetic thread is used Pressure of the fixed knife is insufficient Thread is too thick Thread trimming timing is excessively retarded Pressure of the knife is too high C h e c k t h e t h r e a d trimmer cam timing Top end of the rotary knife has broken or been scratched Check the routing of bobbin thread Top end of the rotary knife has broken or been scratched Pressure of the knife is too low Rotary knife fails to work Replsace the rotary knife or fixed knife with a new one Refer to 3 1 3 Thread trimmer cam timing Refer to 3 1 4 Rotary knife and fixed knife Use a thread within the specified value Refer to 3 1 3 Thread trimmer cam timing Refer to 3 1 4 Rotary knife and fixed knife Refer to 3 1 3 Thread trimmer cam timing Replace th
23. 0 3 mm At this time the adjustment can be easily performed when inserting a thing of 9 mm thick between the top surface of the throat plate and the bottom face of the presser foot 4 Tighten clamping screw 3 in the presser bar bracket Move the presser foot to the left or the right and tighten the screw in the state that the presser foot does not interfere with the walking foot 5 Remove the thing inserted between the top surface of the throat plate and the bottom face of the presser foot and attach side cover 2 1 Remove the knee press plate and tilt the machine arm 2 Loosen stopper screw nut 1 and adjust the lifting amount by the screwing amount of stopper screw 2 Adjust the height from the top surface of the throat plate to the bottom face of the presser foot to 16 0 5 mm 3 Taking care not to move stopper screw 2 tighten stopper screw nut 1 Tighten stopper screw 2 Lifting amount is decreased Loosen stopper screw 2 Lifting amount is increased When the lifting amount is higher than the specified value The top end of the needle bar interferes with the walking foot and the walking foot may be damaged when the presser foot is raised When the lifting amount is lower than the specified value The presser foot is not sufficiently raised and the working property may be deteriorated When the lifting amount is higher than the specified value The presser foot is held raised from the top sur
24. 2 to reverse feed link installing base 1 with reverse feed link hinge screw 3 2 Install straight joint 5 to the inlet port of reverse feed cylinder 4 and install muffler 6 to the exhaust port 3 Install reverse feed link hinge screw 8 and cylinder connecting screw nut 9 to cylinder connecting screw 7 4 Install cylinder connecting screw 7 to reverse feed cylinder 4 5 Temporarily tighten the reverse feed link installing base 1 to window plate D 0 with setscrew 1 6 Enter reverse feed cylinder 4 to window plate D 0 and tighten with washer 2 and setscrew 3 Adjust so that straight joint 5 and muffler 6 face downward and enter reverse feed link hinge screw 8 in the groove of reverse feed link 2 7 Move the piston rod of reverse feed cylinder 4 by hand and tighten setscrew 3 so that reverse feed cylinder 4 smoothly moves 8 Tighten the window plate packing B and window plate D 0 in order with the setscrew At this time place the groove of reverse feed link 2 in the reverse feed link hinge screw on the side of the feed regulator connecting rod 9 Insert the air hose into straight joint 5 Reverse feed control lever 34 6 Installing the touch back switch List D 1 Install touch back switch 1 with switch installing plate setscrew 2 and switch installing plate washer 3 7 Installing the pneumatic components List E 1 Install pneumatic components asm 1 onto the table with setscrews 2 2 Connect the air ho
25. 3 Loosen setscrew 4 in the feed rocker link pin and remove feed rocker link pin 5 4 Remove feed rocker link 6 from feed driving rocker 7 5 Loosen the setscrew in the feed driving rocker support and move feed driving rocker support 8 to the right or left 6 Draw out feed driving rocker 7 7 Install reverse feed link hinge screw nut 0 and reverse feed link hinge screw 1 to feed regulator connecting rod 9 8 Install the above parts by reversing the above order 33 1 2 3 4 5 6 7 8 9 0 1 2 3 3 4 5 6 7 8 9 1 2 4 Installing the reverse feed control lever1 Reverse feed control lever List B 1 Install reverse feed control lever spring bracket 1 with setscrew 2 2 Install reverse feed control lever stopper 3 to the machine arm with setscrew 4 3 Install lever return spring bracket 5 to the machine arm 4 Insert the reverse feed control lever into the reverse feed control lever shaft and install reverse feed shaft link 6 with push screw 7 Install so that the projection of the reverse feed shaft link enters under the reverse feed control lever 5 Hook lever return spring 8 to the lever spring bracket and the tension spring bracket 6 Adjust the position of the reverse feed control lever For the adjusting procedure refer to 14 Position of the reverse feed control lever 5 Installing the automatic reverse feed device List C 1 Install reverse feed link
26. 616SD No 1 2 3 4 5 6 7 8 9 Note Name of part Lever spring bracket Lever spring bracket setscrew Reverse feed control lever stopper Reverse feed control lever stopper setscrew Lever return spring bracket Reverse feed shaft link Reverse feed shaft link push screw Lever return spring Reverse feed control lever stopper screw washer Q ty 1 1 1 1 1 1 1 1 1 Part No 21348503 21348701 SD0800352SP PA320150200 PJ301065104 PX015101000 21348602 SD0800352SP NM6060003SC 21348909 SS7151210SP WP0641601SD SM6061602TP No 1 2 3 4 5 6 7 8 9 0 1 2 3 Note Name of part Reverse feed link installing base Reverse feed link Reverse feed link hinge screw Reverse feed cylinder Straight joint Muffler Cylinder connecting screw Reverse feed link hinge screw Cylinder connecting screw nut Window plate D Reverse feed link installing base setscrew Washer Setscrew Q ty 1 1 1 1 1 1 1 1 1 1 2 2 2 Part No 21348859 SS7110840SP WP0501016SD No 1 2 3 Note Name of part Touch back switch Switch installing plate setscrew Switch installing plate washer Q ty 1 2 2 Part No 23105554 SK3482500SC No 1 2 Note Name of part Pneumatic components asm Setscrew Q ty 1 4
27. R ENGINEER S MANUAL 29353505 No E349 01 1 Needle Unison Feed Lockstitch Machine DNU 1541 1 Needle Unison Feed Lockstitch Machine with Safety Mechanism DNU 1541S 1 Needle Unison Feed Lockstitch Machine with Automatic Thread Trimmer DNU 1541 7 PREFACE This Engineer s Manual is written for the technical personnel who are responsible for the service and maintenance of the machine The Instruction Manual for this machine intended for the maintenance personnel and operators at an apparel factory contains operating instructions in detail And this manual describes Standard Adjustment Adjustment Procedures Results of Improper Adjustment and other important information which are not covered in the Instruction Manual It is advisable to use the relevant Instruction Manual and Parts List together with this Engineer s Manual when carrying out the maintenance service of this machine Regarding the motor for the sewing machine with automatic thread trimmer separately refer to the Instruction Manual for the motor and Engineer s Manual In addition for the control panel refer to the Instruction Manual for the control panel This manual gives the Standard Adjustment on the former page under which the most basic adjustment value is described and on the latter page the Adjustment Procedures and Results of Improper Adjustment under which the steps of adjusting procedure and stitching errors and troubl
28. WN stop angle Presser lifter output duty Thread trimming mode Remarks Reverse revolution after thread trimming Symbol H N V M SLN R8 D8 FUD TR Initial value 3500 1200 1200 2000 0 60 32 MF PRG Modified value 3000 600 600 1800 1 48 24 FL J1 Unit rpm rpm rpm rpm stitch deg deg 31 3 C mode selection C setting of input Caution 1 In case of the machine head with DL device set as I2 IO1 Caution 2 In case of the machine head with 2 pitch device set as IF IO4 IFA ON and OB OT4 4 D mode selection D setting of improving the quality of tacking alignment 5 Q mode selection A C setting of the speed inflection point by means of the alternate vertical dial 6 H mode selection D setting of the speed that does not exceed maximum speed of machine head 3 Thread trimming sequence DNU 1541 7 Function name Change over of input signal function Remarks Presser lifting signal Caution 1 Refer to Caution 2 Symbol I2 IF OB Initial value I01 F W Modified value F no no Function name Stop immediately before end tacking Tacking alignment No of stitch compensation for tacking Remarks Stop before tacking Tacking compensation Start tacking ON compensation Start tacking OFF compensation End tacking OFF compensation Symbol CSJ BM
29. at of the presser foot in accordance with the sewing products Sewing sponge material or the like Sewing material with overlapped sections When the alternative vertical strokes of the walking foot and presser foot are considerably different The stitch pitch is different from the value set by the dial Decrease the number of revolution of the motor a little since the feed efficiency is decreased 14 Standard Adjustment 2 Top feed cam timing In case of DNU 1541 and DNU 1541S In case of DNU 1541 7 1 2 3 4 5 1 5 Main shaft Top feed cam rod To align Conditions Feed amount 6 mm When needle and walking foot are lowered Main shaft Top feed cam rod Screw No 2 Top feed cam rod 2 3 4 To align 15 Adjustment Procedures Results of Improper Adjustment 2 Top feed cam timing In case of DNU 1541 and DNU 1541S 1 Set the scale of stitch dial to 6 2 Adjust the amount of alternate vertical movement to the standard value Refer to the item 8 Feed motion 3 Loosen two setscrews 1 in the top feed cam 4 Turn top feed cam 5 to the position where three points of top end 2 of the needle eyelet top surface 3 of the throat plate and walking foot 4 pressing face are aligned with one another on condition that the amount of alternate vertical movement of both the walking foot and the presser foot is equal 5 Securely t
30. atic lubrication Others Concentration tank type oil wick lubrication excluding some parts JUKI New Defrix Oil No 2 equivalent to ISO VG32 476 6 mm x 178 mm 255 mm x 99 mm V belt effective diameter 93 3 mm Outer diameter 160 mm 2P 400W DNU 1541 7 1 needle unison feed lockstitch machine with automatic thread trimmer Max 3 000 rpm 30 to 5 Air cylinder type with touch back switch 1 mm to 6 5 mm Alternate foot stroke adjusted by dial Cam driven scissors type SC 380 2 Standard Adjustment Standard Adjustment 2 Longitudinal position of the feed dog 2 STANDARD ADJUSTMENT 1 Needle entry position 1 2 3 1 2 3 8 0 2 mm 60 mm a a A Top surface of throat plate Conditions Needle bar at lowest dead point Feed amount 0 mm Conditions Needle bar at lowest dead point Feed amount 0 mm A Clearance between the feed dog and the throat plate when the feed dog travels fully to the front 3 Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1 Set the stitch dial to 0 2 Turn the handwheel to bring the needle bar to the lowest dead point of its stroke 3 Loosen clamping screw 1 in the needle bar rocking rear arm 4 Provide a clearance of 8 0 2 mm between presser bar 2 and walking bar 3 and securely tighten the clamping screw In the state that th
31. d trimming mechanism may not function 26 Standard Adjustment 3 Thread trimmer cam timing 1 2 3 Conditions Engraved marker dot on the handwheel is aligned with engraved marker dot on the machine arm Engraved marker dot on machine arm Red engraved marker dot Handwheel 4 Rotary knife and fixed knife 1 2 3 4 5 6 A Bed counter sinking To align Rotary knife base groove Engraved marker line of front end position White engraved marker dot Colorless engraved marker dot upper Colorless engraved marker dot lower Engraved marker dot on machine arm Engraved marker line of alignment of blade sections 27 Adjustment Procedures Results of Improper Adjustment 1 Tilt cam driving bracket 2 in the direction of the arrow mark and make it come in contact with the periphery of thread trimmer cam 1 2 Turn the handwheel in the reverse direction of rotation loosen setscrews 3 in the thread trimmer cam and adjust so that the engraved marker dot on the machine arm is aligned with the red engraved marker dot on the hand wheel when thread trimmer cam 1 comes in contact with cam driving bracket 2 3 Tighten setscrews 3 in the thread trimmer cam Caution Tighten setscrews 3 in the thread trimmer cam so that there is no thrust play at the hook shaft Rotary knife 1 Raise the cam follower in the direction of the arrow mark Refer to the item 1 Cam follow
32. djustment Procedures Results of Improper Adjustment 1 Set the stitch dial to 0 2 Turn the handwheel to bring the needle bar to the lowest dead point of its stroke 3 Loosen the clamping screw in the feed rocker described in the previous item 2 4 Move the feed base and adjust so that needle 1 enters in the center of feed dog 2 Then securely tighten the clamping screw a a In addition adjust the lateral clearances A B of the feed dog in terms of the window of throat plate to almost equal values When the height of the feed dog is higher than the specified value Stitch pitch becomes larger than the scale of the feed dial Balloon stitches will result Return of sewing product will occur When the height of the feed dog is lower than the specified value Stitch pitch becomes smaller than the scale of the feed dial Feed force will be deteriorated Stitch skipping or thread breakage will result Poorly tensed stitches will result Needle breakage will result 1 Set the stitch dial to 0 2 Turn the handwheel to bring the height of the feed dog to the maximum Bring the needle bar to the lowest dead point of its stroke 3 Loosen setscrew 1 in the vertical feed bar shaft turn vertical feed bar shaft 2 and adjust feed dog 3 from top surface 4 of the throat plate center section to the dimension A Then securely tighten the setscrew 6 Standard Adju
33. e 2 Set the screw No 1 of balancer 1 so that it faces directly above and securely tighten the setscrews At this time the edge of top feed cam 2 comes in close contact with that of balancer 1 20 Standard Adjustment 13 Position of the reverse feed control lever 1 2 3 1 0 5 mm 1 52 5 1 mm In case of DNU 1541 7 In case of DNU 1541 and DNU 1541S Stitch dial Stitch dial To be almost flush Reverse feed control lever Feed regulator Reverse feed lever shaft 21 Adjustment Procedures Results of Improper Adjustment In case of DNU 1541 7 1 Set the stitch dial to the maximum 2 At this time loosen hexagon headed bolt 3 in the feed regulator to adjust so that a clearance of 1 0 5 mm is provided between reverse feed control lever 1 and reverse feed control lever stopper 2 In case of DNU 1541 and DNU 1541S 1 Set the stitch dial to 0 2 At this time loosen hexagon headed bolt 3 in the feed regulator to adjust so that a distance of 52 5 1 mm is provided between the top surface of the machine bed and reverse feed control lever 1 Standard Bottom surface of reverse feed control lever 1 is almost flush with the top surface of the machine bed Caution Check that reverse feed control lever 1 does not interfere with the machine bed or machine arm when the stitch dial is set to the maximum When the position of the reverse feed control lever is low
34. e fixed knife with a new one Correctly thread the bobbin thread Replace the rotary knife Refer to 3 1 4 Rotary knife and fixed knife Adjust the synchronizer timing Replace the thread trimmer solenoid Troubles Causes Checking Corrective measures From the next page Use separately available 21144308 Needle thread lubricator B1114012000 Thread guide bar B91351230B0 Silicone oiler Adjustment of the thread take up spring Decrease the tension of the thread take up spring and decrease the stroke of the spring to improve irregular stitches 53 12 DRAWING OF THE TABLE 810 86 1200 330 15 228 30 57 159 75 16 80 80 80 72 2 339 7 0 5 68 1 0 5 30 25 5 14 9 52 52 5 90 40 125 75 195 200 480 520 20 50 21 0 5 40 100 80 26 8 5 8 5 30 20 40 20 0 5 0 21 0 5 0 30 65 380 for Z type stand 358 for T type stand 21 5 140 183 0 0 1 103 55 31 43 86 5 200 210 141 193 27 5 40 21 5 184 29 55 120 33 25 66 5 29 22 5 139 22 5 39 1 390 15 138 8 1 40 16 5 0 5 17 5 0 5 16 5 0 5 20 17 5 0 5 16 5 0 5 R10 R242 5 R242 5 4 R8 2 R8 2 R27 5 R10 R10 R10 2 R22 5 4 R8 R10 R10 4 R21 5 4 R22 5 R30 R30 R10 R10 R2 R2 R30 R30
35. e presser foot is raised adjust the clearance to 8 0 2 mm at the position where the distance from the top surface of the throat plate to the presser foot is 60 mm Caution Tighten the screw so that the needle bar rocking shaft has no thrust play The throat plate comes in contact with the feed dog and contacting noise occurs and the throat plate or the feed dog may be damaged Irregular stitches may result Stitch skipping or needle breakage will result Poorly tensed stitches will result 1 Set the stitch dial to 0 2 Turn the handwheel to bring the needle bar to the lowest dead point of its stroke 3 Loosen clamping screw 3 in the feed rocker 4 Move the feed base and adjust so that needle 1 enters in the center of the needle hole in feed dog 2 Then securely tighten the clamping screw in the feed rocker a a Standard When the feed amount is maximum A approximately 1 5 mm 4 Standard Adjustment Standard Adjustment 4 Height of the feed dog 3 Lateral position of the feed dog 1 2 1 2 3 4 a a A B A Conditions Needle bar at lowest dead point Feed amount 0 mm Adjust the position to almost A B Conditions Feed amount 0 mm Height of feed dog is maximum Model Dimension A DNU 1541 0 8 to 0 9 mm DNU 1541S DNU 1541 7 0 4 to 0 5 mm 5 Adjustment Procedures Results of Improper Adjustment A
36. en hinge screw nut 1 in the horizontal feed rear arm 2 Move horizontal feed connecting rod 2 so that the distance from the center of the horizontal feed shaft to that of the hinge screw is 20 0 5 mm and tighten the nut 3 Turn the handwheel to check the needle sway Standard The engraved marker line on horizontal feed rear arm 3 aligns with the center of the hinge screw Adjustment Procedures Results of Improper Adjustment 1 Set the stitch dial to 6 2 Loosen two setscrews 1 in the feed adjusting eccentric pin 3 Turn feed adjusting eccentric pin 2 to adjust the stitch length Direction A reverse feed pitch is increased Direction B normal feed pitch is increased 4 After the adjustment securely tighten the setscrews Standard When the direction of the notch of eccentric pin is set to the right sideway as shown in the illustration the feed amount of normal and reverse feeds are nearly the same Respective stitch lengths of normal and reverse feeds do not match 18 Standard Adjustment 12 Balancer DNU 1541 DNU 1541S 1 2 1 2 Top feed driving rod To come in close contact with each other Main shaft intermediate bushing Screw No 1 Condition Needle bar is at the lowest dead point 19 Adjustment Procedures Results of Improper Adjustment Vibration is increased 1 Turn the handwheel to bring the needle bar to the lowest point of its strok
37. ener shaft and adjust the clearance A to A 0 8 0 15 mm Then tighten the setscrews Caution Tighten the screws so that the opener shaft 4 has no thrust play Stitch skipping or thread breakage will result Poorly tensed stitches will result Poorly tensed stitches will result Standard of the lowest dead point of the needle bar 1 Set the scale of stitch dial to 0 2 Turn the handwheel to bring needle bar 1 to the lowest dead point of its stroke 3 Loosen the setscrew in the face plate to remove the face plate 4 Loosen clamping screw 2 in the needle bar bracket At this time if the screw is fully loosened needle bar 1 falls Loosen the screw to such an extent that needle bar 1 is moved up or down by hand 5 Adjust the distance from the bottom end of the needle bar frame to the bottom end of the needle bar to the dimension A and tighten the clamping screw For DNU 1541 7 there is a marker line engraved on needle bar 1 Timing between the needle and the blade point of the hook 1 Set the scale of stitch dial to 0 2 Loosen clamping screw 2 in the needle bar bracket turn the handwheel and adjust so that the distance from the top end of needle eye in needle 3 to blade point 4 of the hook to 2 0 0 2 mm C when needle bar 1 is raised by 2 15 0 15 mm B from its lowest dead point Then retighten the screw For DNU 1541 7 there is a marker line engraved on needle bar 1 3 Turn the handwheel t
38. er 2 Turn the handwheel in the normal direction of rotation in the state that the cam follower is raised 3 Loosen clamping screw 6 in the knife driving shaft rear arm turn knife driving shaft 5 and adjust so that the engraved marker dot on the machine arm aligns with the colorless marker dot upper engraved on the handwheel when the blade section of rotary knife 1 aligns with the top end of the blade section of fixed knife 2 there is an engraved marker line on rotary knife 1 4 Tighten the clamping screw Standard The rotary knife base groove is almost aligned with the bed counter sinking at the initial position of rotary knife 1 Checking Make sure that the distance between the top end of the blade section of fixed knife 2 and the engraved marker line of the front end position of rotary knife 1 is 0 0 5 mm when rotary knife 1 travels to the front end Knife pressure 1 Loosen knife adjustment screw nut 4 2 Adjust the pressure by screwing amount of knife pressure adjusting screw 3 so that the maximum deflection amount is 0 25 to 0 3 mm at point A in the section where the rotary knife travels to the front end from the initial position Tighten knife pressure adjusting screw 3 Pressure is increased Loosen knife pressure adjusing screw 3 Pressure is decreased 3 Tighten the nut 4 When the timing is retarded Thread trimming action does not complete even at the needle up stop position and thread is
39. erse revolution to lift needle Adjustment of thread trimmer cam red Needle down stop position yellow Thread trimming position 45 9 PNEUMATIC PIPING Name of cylinder Display No Remarks Automatic reverse feed stitching 1 Presser lifter 2 Cylinder drawing side AK type only Presser lifter 3 Cylinder pushing side AK type only DL 4 DL type only 3 2 1 2 1 4 3 Regulator 2 3 1 4 4 46 10 MACHINE HEAD WIRING WITH THREAD TRIMMER ONLY 1 Connector coming from the machine head 12 pin connector 6 pin connector 14 pin connector 15 pin connector DL type only 9 pin connector DL type only Name of part Pin No Remarks DL control switch 1 G N D Green and Black DL control switch 2 SW1 White DL control switch 5 SW2 Red Name of part Pin No Remarks Synchronizer 1 SGND Black Synchronizer 4 UDET White Synchronizer 5 DDET Green Synchronizer 6 5V Red Name of part Pin No Remarks 5 string switch 1 BTSW Brown 5 string switch 2 GND Red 5 string switch 3 Needle UP Orange 5 string switch 4 BT cancel Yellow 5 string switch 5 DL Pink 5 string switch 6 DL Gray 5 string switch 10 DL LED 24V White 5 string switch 13 No function 5 string switch 14 No function Pin No 1 Thread trimmer Black 2 3 4 5 BT switch Black 6 BT
40. es arising from mechanical failures are described CONTENTS 1 SPECIFICATIONS 1 2 STANDARD ADJUSTMENT 2 1 Needle entry position 2 2 Longitudinal position of the feed dog 2 3 Lateral position of the feed dog 4 4 Height of the feed dog 4 5 Adjusting the opener DNU 1541S 6 6 Needle to hook timing 6 7 Lift of the presser foot 8 1 Hand lifter 8 2 Knee lifter 8 8 Feed motion
41. face of the throat plate even when the hand lifter is returned to its home position When the lifting amount is lower than the specified value The presser foot is not sufficiently raised and the working property may be deteriorated 10 Standard Adjustment 8 Feed motion 1 Amount of alternate vertical movement In case of the machine without the thread trimmer 1 2 3 4 1 2 3 4 83 to 84 mm 1 Lower engraved marker line Hinge screw Standard of amount of alternate vertical movement Upper engraved marker line Approx 5 mm Medium engraved marker line Approx 4 mm Lower engraved marker line Approx 3 mm Standard Table of sewing speed In case of DNU 1541 and DNU 1541S Amount of alternate vertical movement of the walking foot and presser foot Less than 3 mm 3 mm to less than 4 mm 4 mm to less than 6 5 mm Stitch length 6 mm or less 2500 rpm 2000 rpm 1600 rpm Stitch length More than 6 mm and 9 mm or less 2000 rpm 2000 rpm 1600 rpm In case of DNU 1541 7 refer to 3 2 Alternate vertical dial In case of the machine with the thread trimmer Operator s side Edge of machine arm To align with edge 11 Adjustment Procedures Results of Improper Adjustment 1 Amount of alternate vertical movement In case of the machine without the thread trimmer 1 Loosen hinge screw nut 1 in the top
42. h setscrew Q ty 1 2 Pneumatic device components List B Part No GAKA2302D00 BT0600401EB HX00295000C D6043555B00 No 1 2 3 4 Note Name of part Solenoid valve D Air hose Wire mark 4 Pin terminal male Q ty 1 1 1 3M 1 1 42 No Portion to which LOCKTITE is applied Part No LOCKTITE No 1 Feed adjusting rod hinge screw SD0800402TP LOCKTITE 638 2 Vertical change base arm pin 10715308 LOCKTITE 638 3 Alternate dial shaft bushing 10715100 LOCKTITE 638 4 Cylinder connecting screw hinge screw SD0720331SP LOCKTITE 243 5 Alternate vertical change base support shaft setscrew SS8150710SP LOCKTITE 243 6 Guide roller shaft D2423245E00 LOCKTITE 638 7 Rotary knife base connecting link hinge screw SD0500301SP LOCKTITE 243 8 Knife driving shaft connecting link hinge screw SD0600403TP LOCKTITE 243 9 Cam follower shaft D2434141E00A LOCKTITE 243 10 Cam roller shaft D2444141E00 LOCKTITE 638 11 Thread release bar 21441209 LOCKTITE 243 No 1 No 2 No 3 No 4 No 5 No 6 No 7 No 8 No 9 No 10 No 11 5 PORTION TO WHICH LOCKTITE IS APPLIED LOCKTITE has been applied to the following parts at the time of assembly at the factory Avoid disassembling these parts to the most When an assembly which includes the aforementioned parts has been forced to be disassembled be sure to wash the LOCKTITE applied part using a
43. ighten the setscrews Standard The screw No 2 in top feed cam 5 faces almost right above at the lowest dead point of the thread take up In case of DNU 1541 7 1 Set the scale of stitch dial to 6 2 Set the scale of alternate vertical dial to 3 3 Remove the setscrews in the window place C and remove the window plate C and the window plate packing C 4 Loosen two setscrews 1 in the top feed cam 5 Turn top feed cam 5 to the position where three points of top end 2 of the needle eyelet top surface 3 of the throat plate and walking foot 4 pressing face are aligned with one another on condition that the amount of alternate vertical movement of both the walking foot and the presser foot is equal 6 Securely tighten the setscrews Standard The screw No 2 in top feed cam 5 faces almost the front at the highest dead point of the needle bar as observed from the window plate side Pitch error at high or low speed is apt to occur 16 Standard Adjustment 10 Needle sway Optional selection only of DNU 1541 7 1 2 3 20 0 5 mm Horizontal feed shaft Engraved marker line Standard Adjustment 11 Stitch length of normal reverse feed 1 2 A B Feed adjusting base Notch Feed adjusting rod Conditions Feed amount 6 mm Notch portion 17 Adjustment Procedures Results of Improper Adjustment Needle breakage or stitch skipping will result 1 Loos
44. is moved 6 Securely tighten the setscrews Standard The setscrew No 1 in the horizontal feed eccentric cam faces almost right above when the blade point of hook aligns with the center of needle Caution 1 If the cam slips in the axial direction at the time of adjustment torque becomes heavy So be careful 2 Adjust the horizontal feed rod so that it comes almost in the center between the edge of horizontal feed cam lid 3 and that of horizontal feed eccentric cam 3 After adjusting the horizontal feed timing re adjust the vertical feed timing Adjustment Procedures Results of Improper Adjustment 2 Alternate momentum 1 Set the stitch dial to 0 2 Turn the handwheel to make sure that the amount of alternate vertical movement of walking foot 1 and presser foot 2 is almost equal 3 When the amount is not equal loosen setscrew 3 in the top feed rear arm and adjust so that the amount should be equal Adjust the amount almost to A B When the amount of alternate vertical movement of the walking foot is larger than that of the presser foot 1 Loosen setscrew 3 in the top feed rear arm in the state that walking foot 1 is raised a little press walking foot 1 to the feed dog 2 Re tighten the setscrew and turn the handwheel to make sure of the amount of the amount of alternate vertical movement of the walking foot and the presser foot Adjust the vertical stroke of the walking foot so that it is larger than th
45. l change base 6 and attach top feed stopper plate B 9 5 Tighten alternate vertical link spacer 0 to top feed stopper plate B 9 with setscrew 1 and tighten alternate vertical link 2 with hinge screw 3 6 Remove the top feed stopper plate attached to the machine arm and tighten top feed stopper plate 4 with setscrew 5 7 Tighten alternate vertical link support 7 to the machine arm with setscrews 8 8 When installing window plate F 7 enter alternate vertical link hinge screw 5 to the hole of alternate vertical link 2 and attach it to the machine arm 9 Install the pneumatic device components asm 10 Install the 5 step switch asm and connect the relay cord with it 11 Insert the air hose and check the operation When actuating DL the amount of the alternate vertical movement becomes maximum and the walking foot goes up 3 Installing the 5 step switch List C 1 Install 5 step switch 1 with 5 step switch setscrews 2 1 2 2 Installing the pneumatic device components List B 1 Replace manifold a attached to the solenoid valve B being used now with solenoid valve D 1 2 Caulk the pin terminal male and female to the top end of the cord 3 Insert the pin terminal male and female into the plug CN1 Insert it after making sure of the inserting position 4 Connect the air hose with solenoid valve B 1 2 3 4 5 6 7 8 9 0 1 2 3 6 4 5 CN1 1 4 7
46. ng torque adjusting screw 2 located at the periphery of hook driving shaft sprocket wheel to adjust the working torque Direction A Working torque is large Direction B Working torque is small When the amount of oil is short Loose stitches will result Irregular stitches will result Hook is heated resulting in seizure When the amount of oil is too much Thread is stained with oil In addition the cloth may be stained 1 Remove the plug of lubricating hole of oil tank 2 Fill JUKI New Defrix Oil No 2 up to line 2 of H high level from lubricating hole 1 of oil tank Check the oil amount once a day and refill oil if it is below line 3 of L low level 3 Adjustment of the amount of oil in the hook is performed with oil amount adjustment screw 4 after loosening nut 5 Turning the screw clockwise will increase the amount of oil in the hook or counterclockwise will decrease it 4 The appropriate amount of oil when a sheet of paper is placed near the periphery of the hook is to such an extent that splashes of oil from the hook appear in approximately five seconds as shown in the figure on the left 24 Standard Adjustment 3 STANDARD ADJUSTMENT OF THREAD TRIMMER COMPONENTS DNU 1541 7 1 Thread trimmer device 1 Cam follower 2 Solenoid arm 1 1 2 3 4 11 to 12 mm Conditions Thread trimmer solenoid is at rest 2 3 4 5 6 7 8 0 5 mm 25
47. not trimmed Length of needle thread remaining on the needle after thread trimming will be longer When the timing is advanced Defective thread trimming will result Length of needle thread remaining on the needle after thread trimming will be shorter and needle thread may slip off at the start of sewing or after thread trimming Stitch skipping at the start of sewing will result When the amount of engagement is large Length of needle thread remaining on the needle after thread trimming will be shorter Double trimming will result When the amount of engagement is small Single thread remaining will result Length of needle thread remaining on the needle after thread trimming will be longer When the knife pressure is high Blade section of the fixed knife or rotary knife may be broken Torque at the time of thread trimming becomes heavy and motor stop will result Defective thread trimming will result When the knife pressure is low Failure of thread trimming will result 28 Standard Adjustment 2 Alternate vertical dial 1 2 8 0 1 mm Installing position of the detection switch of the amount of alternate vertical movement Alternate vertical dial Detection switch of amount of alternate vertical movement Bushing Convex section Top cover Spring Pin Hole of section A Red Green White Black Amount of alternate vertical
48. o raise the needle bar by 2 15 0 15 mm B from its lowest dead point Loosen hook setscrewss 5 and adjust so that blade point 4 of the hook almost aligns with the center of the needle 3 Then retighten the screws For DNU 1541S loosen setscrews 6 in the lower shaft gear to perform the adjustment Then retighten the screws 4 Loosen hook setscrews 5 move the hook to the left or the right and adjust so that a clearance of 0 02 to 0 05 mm is provide between blade point 4 of the hook and needle 3 at the position where blade point 4 of the hook almost aligns with the center of needle 3 Then securely tighten the screws 0 0 15 8 Standard Adjustment 7 Lift of the presser foot 1 Hand lifter 2 Knee lifter 1 2 3 1 2 9 0 3 mm 16 0 5 mm Hand lifter Top surface of throat plate Condition State that the hand lifter is raised Top surface of throat plate Condition Lifting amount when the stopper screw of knee lifter spring hook comes in contact with the machine bed In case of the machine provided with the auto lifter refer to the item 4 2 Auto lifter 9 Adjustment Procedures Results of Improper Adjustment 1 Loosen setscrew 1 in the side cover located on the antioperator s side of the machine arm and remove side cover 2 2 Loosen clamping screw 3 in the presser bar bracket to set the hand lifter to the raised state 3 Adjust the lifting amount to 9
49. ook shaft gear A 21404009 A Tolerance 36 to 24 m Hook shaft gear B 21404108 B Tolerance 24 to 12 m Hook shaft gear C 21404207 C Tolerance 12 to 0 m standard Hook shaft gear D 21404306 D Tolerance 0 to 12 m Name of selective part Part No Remarks Roller bearing SB32000060A Tolerance 0 to 2 m standard Roller bearing SB32000060B Tolerance 2 to 4 m Roller bearing SB32000060C Tolerance 4 to 6 m Name of selective part Part No Remarks Tension release bar 23006406 L 57 4 mm standard Tension release bar 21348206 L 57 9 mm Tension release bar 10321107 L 58 5 mm For DNU 1541 Nameof consumable part Part No Remarks Needle MC372001600 SCHMETZ 135 X 17 Nm 160 Hook asm B1830241HC0 With bobbin case Bobbin B9117201000 For DNU 1541S Name of consumable part Part No Remarks Needle MC372001600 SCHMETZ 135 X 17 Nm 160 Hook asm B1830241SB0 With bobbin case Bobbin B9117201000 For DNU 1541 7 Name of consumable part Part No Remarks Needle MC372001600 SCHMETZ 135 X 17 Nm 160 Hook asm D1830241EA0 Bobbin case D1837141EA0 Bobbin D9117141E00 Aluminum bobbin Rotary knife D2423241E00 Fixed knife D2424241E00 Clamp spring D2429241E00 44 7 ENGRAVED MARKER DOTS ON THE HANDWHEEL 8 LUBRICATION ROUTE DIAGRAM Range of needle up stop position white Needle up stop position at the time of rev
50. r foot Refer to 4 Height of the feed dog Lower the height by 0 2 mm than the standard value Retard the feed timing Use silicone oil Refer to 4 Others Increase the needle thread tension Use the optional walking foot Top devided type Adjust the thread take up spring to move to approximately 1 mm from the initial position when hook draws thread maximumly Finish with a fine emery paper or buff Increase the tension of the bobbin thread Decrease the tension applied to the bobbin winder Decrease the pressure of the idle prevention spring Troubles Causes Checking Corrective measures Troubles Causes Checking Corrective measures Oil does not enter the hook Oil amount in the oil tank is too small Oil amount adjusting screw is improperly adjusted Lead groove in the hook shaft is clogged with dust Check the oil level Refer to 15 Lubrication Draw out the hook shaft and wash the lead groove 51 3 With regard to thread trimming One or several stitches skip at the start of sewing Thread slips off the needle eyelet Defective thread trimming Needle thread remaining at the needle top after thread trimming is short Bobbin thread remaining after thread trimming is short Needle is too thick Needle hole in the feed dog is too large Presure of the presser foot is too low Needle thread slips off the needle eyelet at the
51. re that the distance from the bottom face of the presser foot to the top surface of the throat plate is 16 0 5 mm When adjustment is required remove automatic presser foot lifter lever shaft 9 and automatic ptresser foot foot lifter lever A 6 loosen nut 4 and turn cylinder connecting screw 3 Turning in the direction of A will decrease the distance or in the direction of B will increase it After the completion of adjustment tighten the nut 10 Make sure that a clearance of 0 5 to 1 5 mm is provided between automatic presser foot lifter lever A 6 and the thread release supporting plate when the presser foot is lowered 11 For the kit A tighten knee lifter knee switch B asm 1 with wood screws 2 List D A B 1 2 3 4 5 6 7 8 9 0 1 2 3 0 2 37 2 Installing the pneumatic device components When installing the automatic presser foot lifter to DNU 1541 and DNU 1541S after set up of the machine List B Refer to 4 1 7 Installing the pneumatic components When installing the automatic presser foot lifter to DNU 1541 7 after set up of the machine List C 1 Assemble the additional parts List C to filter regulator a air joint b and quick joint A elbow c which are included in the pneumatic components asm being used now 2 Install on the table filter regulator a with wood screws 3 and pneumatic device B asm 1 with wood screws 4 3 Connect the air hose with
52. se with pneumatic components asm 1 8 Parts list List of the parts to be removed Caution 1 The parts with asterisk mark are those to be used after replacing 2 The part with mark is the exclusive part for the machine without the automatic reverse feed device List of the installing parts Part No of the automatic reverse feed device set Caution This part No is the set part No of the parts from list A to E 1 23 1 2 Table Part No SS4110815SP 21331806 21332002 SS6120930SP 22610505 No 1 2 3 4 5 Note Name of part Window plate B setscrew Window plate B Window plate packing B Reverse feed control lever setscrew Reverse feed control lever Q ty 5 1 1 2 1 Part No 21348552 No Note Name of part Automatic reverse feed device set Q ty 1 2 35 Reverse feed link hinge screw components List A Reverse fedd control lever components List B Automatic reverse feed device components List C Touch back switch components List D Pneumatic components List E Part No NS6150430SP SD0800402TP No 0 1 Note Name of part Reverse feed link hinge screw nut Reverse feed link hinge screw Q ty 1 1 Part No 22656003 SS4150615SP 11100500 SS7112420SP 10120004 22656102 SS7120760SP 13515606 WP0502
53. sections If the the amount of alternate vertical movement is increased the stitch pitch may be different from the value set by the dial Decrease the number of revolution of the motor a little since the feed efficiency is decreased 12 Standard Adjustment 2 Alternate momentum 1 2 3 B Top surface of feed dog Top surface of throat plate Top surface of throiat plate Conditions Feed amount 0 mm Amount of alternate vertical movement In case of the machine without thread trimmer In case of the machine with thread trimmer Standard Adjustment 9 Feed cam timing 1 Horizontal feed cam timing 1 2 3 Screw No 1 Main shaft Conditions Blade point of the hook aligns with the center of needle when feed amount is 0 Feed amount maximum A 3 13 Adjustment Procedures Results of Improper Adjustment Pitch error at high or low speed is apt to occur Needle thread tension will vary Stitch tightness at normal and reverse feed will vary 1 Horizontal feed cam timing 1 Set the scale of stitch dial to 0 2 Loosen two setscrews 1 in the horizontal feed eccentric cam 3 Turn the handwheel to make the blade point of the hook align with the center of needle 4 Set the scale of stitch dial to the maximum 5 Turn feed eccentric cam 2 and adjust the timing so that the feed dog no longer moves even when the reverse feed control lever
54. start of sewing Needle thread slips off t h e n e e d l e e y e l e t immediately after thread trimming Thread cannot be trimmed Check the routing of needle thread Thread tension given by the tension controller No 1 is too high Check the rising amount of the thread tension disk No 2 at the time of thread trimming Thread trimming timing is excessively advanced There are scratches on the hook Tension of the bobbin thread is too high Check whether the needle thread remaining at the needle top at the start of sewing is short Check whether the needle thread remaining at the needle top after thread trimming is short A hard to slip thread is used The blades of rotary knife or fixed knife have worn out or broken Pressure of the knife is insufficient Thread the needle thread correctly Adjust so that abnormal thread tension is not applied to the needle thread Decrease the tension given by the tension controller No 1 Adjust so that the disk is raised by means of the thread release solenoid Refer to 3 1 3 Thread trimmer cam timing Polish with buff or replace the part Decrease the tension of the bobbin thread Replace the needle with a thinner one Replace the feed dog with an optional one with small needle hole Increase the pressure of the presser foot Refer to the Cause of the previous item Needle thread remaining at the needle top after thread
55. stment Standard Adjustment 6 Needle to hook timing 5 Adjusting the opener DNU 1541S 1 2 3 4 5 6 7 8 1 2 3 4 5 A C 3 4 6 C B 0 02 to 0 05 mm A Condition Swing angle of opener is maximum A Clearance betwen top end of opener 1 and inner hook 7 Axial direction B Clearance between inner hook 7 and nail 8 of inner hoop presser when opener 1 moves to front end Diameter direction C Clearance between opener and nail 2 of inner hook 2 when opener 1 moves to front end Diameter direction Conditions Feed amount 0 mm Needle bar goes up from the lowest dead point Model Dimension A DNU 1541 56 55 mm DNU 1541S DNU 1541 7 58 55 mm 8 B 7 Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment Timing of the opener 1 Turn the handwheel to move the opener 1 to the front end in the direction of the arrow mark 2 Loosen clamping screw 5 in the opener arm and turn opener shaft 4 to adjust the clearance B to B 0 4 mm in the state that opener 1 comes in contact with nail 2 of inner hook Then tighten the clamping screw Reference C 0 8 mm Standard Screw No 2 of the opener cam faces almost directly below at the lowest dead point of the thread take up Adjusting the position of the opener 1 Loosen setscrews 3 and 6 in the thrust collars of opener shaft 2 Move the op
56. xcessively advanced or retarded Height of the needle bar is improper Presser foot is rising Blade point of the hook is blunt Improper typr of needle is used Thread take up spring excessively works or the stroke of the spring is too small Feed timing is not proper Check the sharp edge or burr on the respective parts Check the clearance Check the specified dimension Check the clearance Check the specified dimension Check the lowest point of the needle bar Check the pressure of the presser foot Check the blade point of the hook Remove the sharp edges or burrs on the blade point of hook using a fine emery paper Buff up the groove section on the throat plate Adjust the needle thread tension Refer to 6 Needle to hook timing Adjust the needle thread tension This trouble occurs a lot when using synthetic threads Decrease the tension of of the thread take up spring and increase the stroke of the spring Refer to 9 Feed cam timing Refer to 6 Needle to hook timing Decrease the sewing speed Use silicone oil Refer to 4 Others Refer to 6 Needle to hook timing Tighten the presser spring regulator Correct the blade point of the hook or replace the hook Replace the needle with one which is thicker than the current needle by one count Decrease the tension of the thread take up spring and increase the stroke of
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