JUKI ACF-164-1903 Quick start guide

R
ENGINEER’S MANUAL
29347606
No.00
Button Attaching Indexer
ACF-164-1903

PREFACE
This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance
of the sewing machine. This manual describes “Adjustment Procedure”, “Results of Improper Adjustment”, and
other functions which are not covered by the Instruction Manual intended for the maintenance personnel and
sewing operators at a sewing factory.
All personnel engaged in repair of ACF-164-1903 are required to carefully read Section 2 “Standard Adjustment”
which contains important information on the maintenance of ACF-164-1903.
The “Standard Adjustment” consists of two parts ; the former part presents illustration and simplified explanation
for the convenience of reconfirmation of the required adjustment values in carrying out actual adjustment after
reading this manual once; and the latter part provides “Results of Improper Adjustment” in which sewing and/or
mechanical failures, and the correcting procedures are explained for those persons who perform such adjustment
for the first time.
It is advisable to use “ACF-164-1903 Parts Book” together with this Engineer’s Manual.

CONTENTS
1. SPECIFICATIONS .......................................................................................................... 1
(1) Main unit................................................................................................................................................ 1
(2) Button sewing machine ......................................................................................................................... 1
(3) Button feeder......................................................................................................................................... 2
2. CONFIGURATION OF THE MAIN PARTS .................................................................... 3
3. NAME OF EACH PART AND PREPARATION FOR TRIAL RUN................................. 4
(1) Operating switches................................................................................................................................ 4
(2) Adjusting the seam allowance............................................................................................................... 6
(3) Adjusting the position of the work clamp............................................................................................... 8
(4) Adjusting the stacker............................................................................................................................. 9
(5) Adjusting the knee switch...................................................................................................................... 9
4. OPERATION OF LK ..................................................................................................... 10
(1) NAMES ON THE operation BOX OF LK............................................................................................. 10
(2) HOW TO OPERATE THE operation BOX OF LK ............................................................................... 10
1) Setting the item data.................................................................................................................... 10
2) Changing to the other sewing pattern........................................................................................... 13
3) Performing sewing using the function keys (
P1
,
P2
and
P3
keys) ........................................ 13
4) Adjusting the position of the button clamps ..................................................................................14
5) Checking the contour of a sewing pattern .................................................................................... 15
(3) Winding the bobbin thread .................................................................................................................. 16
1) To wind a bobbin while the sewing machine is performing sewing .............................................. 16
2) To wind a bobbin independently................................................................................................... 16
5. ADJUSTMENT OF COMPONENTS OF LK ................................................................. 17
(1) Adjusting the feed plate....................................................................................................................... 17
(2) Adjusting the button clamp jaw lever................................................................................................... 17
(3) Adjusting the lifting amount of the button clamp ................................................................................. 18
(4) Adjustment of the pressure of the button clamp unit........................................................................... 18
(5) Adjustment of the wiper....................................................................................................................... 19
(6) Adjustment of the wiper spring............................................................................................................ 19
(7) Adjusting the rising amount of the thread tension disk........................................................................ 20
(8) The moving knife and counter knife .................................................................................................... 20
(9) Cleaning the filter ................................................................................................................................ 21
(10) Adjusting the height of the needle bar............................................................................................... 21
(11) Adjusting thre needle-to-hook relation .............................................................................................. 21
(12) How to use the memory switch ......................................................................................................... 22
1) Starting the memory switch .......................................................................................................... 22
2) Example of the memory switch setting .........................................................................................23
3) Setting the counter operation ....................................................................................................... 24
4) Table of functions of the memory switch ......................................................................................25
6. OPERATION OF ACF .................................................................................................. 26
(1) Explanation of the operation panel of ACF ......................................................................................... 26
(2) Preparation before operation .............................................................................................................. 27
(3) Inputting and confirming data.............................................................................................................. 27
1) Memory number selection ............................................................................................................ 27
2) Input of the sewing data ............................................................................................................... 28
3) Checking the sewing data ............................................................................................................ 31
4) Counter settings ........................................................................................................................... 33
(4) Operation ............................................................................................................................................ 34
1) Automatic operation...................................................................................................................... 34
2) Manual operation.......................................................................................................................... 35
3) Independent operation.................................................................................................................. 35
4) Emergency stop............................................................................................................................ 36
5) Error message and the reset procedure....................................................................................... 36

7. SWITCHES INSIDE THE PANEL BOX AND THE CONTROL BOX ........................... 42
(1) Inside the panel box ............................................................................................................................ 42
(2) Inside the control box .......................................................................................................................... 42
8. ADJUSTMENT OF UNIT .............................................................................................. 46
(1) Carriage unit........................................................................................................................................ 46
(2) Button feeder components .................................................................................................................. 56
(3) Detecting mechanism and its adjustment ........................................................................................... 63
(4) Replacing the components and positioning them ...............................................................................66
9. MAINTENANCE INSPECTION..................................................................................... 69
(1) Maintenance and inspection of the sewing machine components ...................................................... 69
(2) Maintenance and inspection of electrical components........................................................................ 69
(3) Diagnostic feature ............................................................................................................................... 69
10. PERFORMANCE FLOW CHART............................................................................... 75
11. SEQUEMCE CHART .................................................................................................. 83
12. AIR PIPING................................................................................................................. 85
13. WIRING COMPONENTS ............................................................................................ 87
14. CONFIGURATION (ELECTRICAL UNIT) .................................................................. 89
(1) Components of control box and its function ........................................................................................ 89
(2) Connector and its functions of the control box .................................................................................... 90
(3) Power voltage ..................................................................................................................................... 91
(4) Measuring the DC power voltage........................................................................................................ 92
(5) Changing the thermal values inside the switch box ............................................................................ 93
(6) Replacing fuses................................................................................................................................... 93
(7) Replacing the P-ROMs for data .......................................................................................................... 94
(8) CPU circuit board ................................................................................................................................ 95
(9) I/O circuit board................................................................................................................................... 96
(10) Power circuit board ........................................................................................................................... 97
(11) Panel circuit board ............................................................................................................................ 98
(12) Functions of the stepping motor driver.............................................................................................. 98
(13) I/F circuit board whole asm. .............................................................................................................. 99
15. BLOCK DIAGRAM ................................................................................................... 100
16. BLOCK DIAGRAM ................................................................................................... 101
17. WIRING DIAGRAM................................................................................................... 102
18. CIRCUIT DIAGRAM ................................................................................................. 105
(1) Transformer (ass’y) ........................................................................................................................... 105
(2) Power circuit board (ass’y) circuit diagram ....................................................................................... 106
(3) Circuit diagram of the stepping motor driver (ass’y).......................................................................... 107
(4) Circuit diagram of the stepping motor (ass’y).................................................................................... 107
(5) Circuit diagram of the indexer switch ................................................................................................ 108
(6) Output circuit board diaram............................................................................................................... 109
19. TROUBLES AND CORRECTIVE MEASURES........................................................ 111
20. TROUBLES AND CORRECTIVE MEASUTRES ..................................................... 112

−1 −
1
2
6
4
5
6
Outer diameter of buttons to be sewn (mm)
Sewing size (mm)
Button clamp jaw lever
Needle hole guide
Feed plate
Length
Width
Thickness
(mm)
Standard
For small buttons
ø10 to ø15
0 to 3.5
0 to 3.5
2.2 Engraved
mark
MAZ165070B0 H
MAZ167140A0
MAZ15601000
MAZ15502000
Optional
For medium-size buttons
ø12 to ø18
0 to 4.5
0 to 4.5
2.7
MAZ166070B0 J
MAZ168140A0
MAZ15601000
MAZ15602000
Part
No.
Right
Left
Engraved
mark
1. SPECIFICATIONS
(1) Main unit
1Feed interval : 25 to 650 mm (1 to 25.6”)
2Overall feed amount : 650 mm (25.6”)
(When the machine is set to the long-sized material sewing
mode : 1,200 mm)
3Number of buttons
which can be sewn : 1 to 20 pcs. (the machine is
set to the independent sewing
mode when sewing only one
button on the material.)
4Distance from the top end of the
garment body to the 1st button : 40 to 140 mm (1.6 to 5.5")
(20 mm or more : when the
special order part is used.)
5Distance from the side end of the
garment body to the button : 12 to 25 mm (0.5 to 1")
6Applicable garment sizes
that can be sewn (standard) : Width 220 to 420 mm (8.7 to 16.5")
Length 400 to 880 mm (15.7 to 34.6")
7Number of patterns
that can be stored in memory : 20
8Power supply : 200V (3-phase) (Rated voltage ±10%)
9Power source frequency : 50/60 Hz
!0 Power consumption : 600 VA (Rated voltage ±10%)
!1 Operating air pressure : 0.5 MPa
!2 Air consumption : 20 Nl/min. or less
!3 Machine dimensions : Width 1,860 mm
Depth 970 mm
Height 1,250 mm
!4 Weight : 220 kg
(2) Button sewing machine
1Machine head : LK-1903 (exclusive machine head)
2Sewing speed : Normal 2,300 rpm
Max. 2,700 rpm [only when using the Z165 (for small button)
and cotton thread]
3Needle : DP x 17 #14
4Buttons : Kind : Flat buttons (2-holed, 4-holed)
5Lifting amount of
button clamp jaw lever : 11 mm
6Number of standard patterns : 33

−2 −
(3) Button feeder
1Discrimination of buttons to be fed : By vibration system using the piezoelectric feeder
2Button setting method : Buttons are loaded from the rear section of device
3Individual button feed : By index method
4Detection of a failure : Provided with three detectors ™The first detector detects a
button at the section where
the button is correctly
positioned.
™The second detector checks
whether the button is correctly
inserted in the carrier pin.
™The third detector detects a
button at the button clamp jaw
lever.
5Driving source for the feeder : DC motor (24 Vdc)
6Function of sewing buttons
without cross-over stitch : Provided
7Automatic button
discharging function : Provided
8Independent operation of the
sewing machine : Possible
9Time required to feed a button : 0.5 sec./pc.
Noise: Workplace-related noise at sewing speed
n = 2,300 min–1 : LPA ≦84 dB(A)
Noise measurement according to DIN 45635-48-B-1.

−3 −
2. CONFIGURATION OF THE MAIN PARTS
1Sewing machine head
2Button feeder
3Work clamp (carriage unit)
4Stacker
5Operation panel of ACF
6Power switch
7Knee switch
8Emergency stop switch
9Hand switch
!0 Thread stand
!1 Conveyor
!2 Cloth plate
!3 Operation panel of the feeder
!4 Air gun
!5 Operation box of LK
!6 Hand pulley
1. Before you put the machine into operation for the first time after the set-up, clean it
thoroughly. Remove all dust gathering during transportation and oil it well.
2. Confirm that the voltage has been correctly set.
Confirm that the power plug has been properly connected to the power supply.
3. Never use the machine in the state where the voltage type is different from the designated one.
4. The sewing machine has been completely adjusted at the time of delivery. For caution’s sake,
however, turn ON the power switch after releasing the stop-motion and turning the handwheel
by hand when operating the machine for the first time.
5. Operate the machine with the air pressure set to 0.5 MPa (5 kgf/cm2).
CAUTION :
To avoid malfunction and damage of the machine, confirm the following :
12
3
4
5
6
7
8
9
!0!1
!2
!3
!4
!5
!6

−4 −
A
3. NAME OF EACH PART AND PREPARATION FOR TRIAL RUN
(1) Operating switches
1Power switch
Use this switch to turn ON/OFF the power to the unit.
(If installing the optionally available MC-6,use independent power for the MC-16 that is located on
section A on the right-hand side of the main unit.)
2Emergency stop switch
Use this switch to stop the machine from running.
3Knee switch
This switch is used as the start switch.
4Hand switch
This switch is used as the work clamp release switch.
5Feeder switch
6Button feeder switch
Used to supply buttons to the button clamp jaw lever.
7Set-up switch
This switch is used for operating the spinner oscillating arm under the step-operation mode. The spinner
oscillating arm performs step operation as long as the switch is held pressed.
8Button discharging switch
This switch is used to discharge buttons in the index unit.
d
1
2
3
4
5
6
7
8
9
!0
!1
!2

−5 −
9Feeder breaker
This is the breaker for the spinner oscillating arm motor and index unit motor. This breaker can be reset
by pressing.
!0 Men’s / Ladies mode selective switch
Used to change modes when sewing men’s or ladies’ wear.
!1 Body of the garment / finished garment mode selective switch
Used to change modes when sewing garments using the finished workpiece table (Optional :
G55101640A0).
!2 Stacker release switch
This switch is used when sewing garments using the second presser (Optional : G55141640A0).
This switch is used for taking out the materials from
the stacker after the predetermined number of pieces
of finished material has been stacked. Lift lever in the
direction of arrow A, and the second presser will move
away from the stacking board to allow the operator to
take out the materials from the stacker.
(Caution) Do not take out the workpieces while the
stacker is in operation. Doing so is very
dangerous.
Stacker release switch
A

−6 −
(2) Adjusting the seam allowance
1In the case of sewing garment bodies of men’s wear (set Men's/Ladies' mode selective switch !0
mounted on the right-hand side of the operation panel to its lower side.) (See p.4.)
1) Adjust the seam allowance from the side end of
the garment to the button (distance A in the figure),
and from the top end of the garment to the 1st button
(distance B in the figure.)
(Caution) Be sure to make adjustment of the seam
allowance after you have turned OFF the
power switch.
2) The number of buttons and the intervals between
the buttons can be adjusted using the panel
switches. (Refer to “Inputting the sewing data” on
page 28.)
™Adjusting distance A
Loosen screws 1in setting plates,right 2and left 3. Shift the respective setting plates to the desired
values and tighten the screws.
™Adjusting distance B
Loosen thumbscrew 1, and shift gauge 2to the right or left until desired scale value 3is reached.
Then tighten the thumbscrew.
As viewed from above the unit
A
B
As viewed from above the unit
1
23
1
2
3
111