JUKI AB-1351 User manual

AB-1351
INSTRUCTION MANUAL
* "CompactFlash(TM)" is the registered trademark of SanDisk Corporation, U.S.A.
ENGLISH

i
CONTENTS
!. Machine (about the sewing machine) ...............................1
Precautions for use.................................................................................................. 1
1. Conguration........................................................................................................ 2
2. Specications ....................................................................................................... 3
2-1. Mechanical specications.............................................................................................. 3
2-2. Electrical specications ................................................................................................. 4
2-3. Sewing shape of belt-loops ........................................................................................... 4
2-4. Garment body presser/work clamp foot specications .............................................. 6
(1) Garment body presser ..................................................................................................................6
(2) Work clamp foot of the sewing machine ....................................................................................... 7
3. Installation ............................................................................................................ 8
3-1. Removing the packing materials................................................................................... 8
3-2. Fixing the machine ......................................................................................................... 9
3-3. Connecting the air coupler ............................................................................................ 9
3-4. Connecting the power plug.......................................................................................... 10
3-5. Assembling the thread stand and installing on the machine ................................... 12
3-6. Installing the machine head support bar.................................................................... 12
3-7. Installing the operation panel IP-420 .......................................................................... 12
3-8. Installing the auxiliary table......................................................................................... 13
3-9. Installing the manual pedal (optional) ........................................................................ 13
3-10. Installing the belt loop feeding unit (optional) ......................................................... 14
3-11. Installing the additional marking light (optional) ..................................................... 15
4. Preparation of the sewing machine.................................................................. 16
4-1. Lubrication .................................................................................................................... 16
4-2. Attaching the needle..................................................................................................... 16
4-3. Threading the machine head ....................................................................................... 17
4-4. Installing and removing the bobbin case ................................................................... 17
4-5. Installing the bobbin..................................................................................................... 18
4-6. Adjusting the thread tension ....................................................................................... 18
4-7. Adjusting the thread take-up spring ........................................................................... 19
4-8. Example of the thread tension..................................................................................... 19
5. Operating the sewing machine ......................................................................... 20
5-1. Emergency stop switch................................................................................................ 20
(1) Method for operating the emergency stop switch ....................................................................... 20
(2) Precautions with the emergency stop switch..............................................................................20
5-2. Winding a bobbin.......................................................................................................... 21
(1) To wind a bobbin while the sewing machine is performing sewing............................................. 21
(2) To wind a bobbin independently .................................................................................................21
5-3. Thread clamp device .................................................................................................... 22
5-4. Placing a belt loop ........................................................................................................ 23
5-5. Adjusting the belt loop tension ................................................................................... 24
5-6. Setting the belt loop thickness.................................................................................... 24

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5-7. Method for changing the belt loop width.................................................................... 25
5-8. Method for adjusting the workpiece stopper ............................................................. 26
5-9. Start switch.................................................................................................................... 26
@. OPERATION (OPERATION PANEL) .................................27
1. Introduction ........................................................................................................ 27
2. Method for using the operation panel .............................................................. 31
2-1. Name of each section of IP-420 ................................................................................... 31
2-2. Buttons to be used in common ................................................................................... 32
2-3. Basic operation of IP-420 ............................................................................................. 33
2-4. Liquid crystal display section when the belt loop individual sewing is selected... 34
(1) Belt loop individual sewing data entry screen.............................................................................34
(2) Belt loop individual sewing screen..............................................................................................36
2-5. How to change over the sewing shape....................................................................... 38
2-6. How to change the belt loop length ............................................................................ 39
(1) How to change the belt loop dimensions .................................................................................... 39
(2) Changing the belt loop length (entire length) and precautions to be taken ................................41
(3) Changing the belt loop length by the selection of the frame of the work clamp foot .................. 41
2-7. How to lower the garment body presser and the work clamp foot .......................... 42
2-8. Using counter................................................................................................................ 43
(1) Setting procedure of the counter ................................................................................................43
(2) Count-up releasing procedure ....................................................................................................46
(3) How to change the counter value during sewing ........................................................................ 46
2-9. How to register a new belt loop pattern number ....................................................... 47
2-10. How to name a belt loop pattern number ................................................................. 49
2-11. How to select a belt loop pattern number................................................................. 50
(1) Selection on the data entry screen .............................................................................................50
(2) Selection by the direct button .....................................................................................................51
2-12. How to copy a belt loop pattern number .................................................................. 52
2-13. Belt loop teaching function........................................................................................ 53
2-14. How to carry out the step operation ......................................................................... 55
(1) Setback step operation ............................................................................................................... 56
(2) Sewing position step operation...................................................................................................56
2-15. Function of canceling grasping of a belt loop for the next sewing ....................... 58
2-16. How to carry out the bartacking setting ................................................................... 59
2-17. Liquid crystal display at the time of setting the bartacking ................................... 60
(1) LK unit data entry screen............................................................................................................60
(2) LK unit sewing screen.................................................................................................................62
2-18. How to select the sewing shape (bartacking setting) ............................................. 64
2-19. List of sewing shapes................................................................................................. 65
2-20. How to change the item data (bartacking setting)................................................... 66
2-21. How to check the sewing shape................................................................................ 67
2-22. How to change the thread tension command from needle entry point to needle entry point .... 68
(1) How to add/change the thread tension command from needle entry point to needle entry point ... 68
(2) How to delete the thread tension command from needle entry point to needle entry point........69
2-23. How to register a new user-pattern........................................................................... 71
2-24. How to change the sewing mode .............................................................................. 72

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2-25. LCD section when the cycle sewing is selected...................................................... 73
(1) Cycle sewing data entry screen..................................................................................................73
(2) Sewing screen of the cycle sewing.............................................................................................75
2-26. How to carry out cycle sewing .................................................................................. 77
(1) Selection of the cycle-sewing data .............................................................................................77
(2) Method to create the cycle-sewing data .....................................................................................78
(3) Method to insert the cycle-sewing data ......................................................................................79
(4) Method for deleting the cycle sewing data.................................................................................. 80
(5) Method for deleting a step of the cycle sewing data...................................................................80
2-27. How to edit the sewing data....................................................................................... 81
(1) Method for changing the sewing data.........................................................................................81
(2) Sewing data list...........................................................................................................................82
2-28. How to change the memory switch data .................................................................. 93
(1) Method for changing the memory switch data ............................................................................ 93
(2) Memory switch data list ..............................................................................................................94
2-29. How to set the device ................................................................................................. 98
(1) Device setting changing procedure ............................................................................................98
(2) Listing of the device settings....................................................................................................... 99
2-30. How to adjust the origin of work clamp foot .......................................................... 101
2-31. Using communication function ............................................................................... 102
(1) Handling possible data .............................................................................................................102
(2) Performing communication by using the media........................................................................102
(3) Performing communication by using USB ................................................................................ 102
(4) Take-in of the data ....................................................................................................................103
(5) Taking in plural data together....................................................................................................104
2-32. Performing formatting of the media........................................................................ 106
2-33. Trial stitching function ............................................................................................. 107
2-34. How to use information ............................................................................................ 109
(1) How to visually check maintenance/inspection information......................................................109
(2) How to reset the warning ...........................................................................................................111
(3) How to set the time ....................................................................................................................111
2-35. How to re-start sewing from the position where the machine has stopped by the
detection of thread breakage ....................................................................................... 112
3. ERROR CODE LIST .......................................................................................... 113
4. Massage list ...................................................................................................... 126
#. Maintenance ....................................................................130
1. Maintenance...................................................................................................... 130
1-1. Discharging drainage water....................................................................................... 130
1-2. Adjusting the height of the needle bar...................................................................... 130
1-3. Adjusting the needle-to-shuttle relation ................................................................... 131
1-4. Adjusting the lift of the work clamp foot .................................................................. 132
1-5. The moving knife and counter knife ......................................................................... 132
1-6. Needle thread clamp device....................................................................................... 133
1-7. Adjustment of the wiper ............................................................................................. 133
1-8. Thread breakage detector plate ................................................................................ 134
1-9. Draining waste oil ....................................................................................................... 134

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1-10. Amount of oil supplied to the hook......................................................................... 134
1-11. Replacing the work clamp foot of the sewing machine ........................................ 135
1-12. Replacing the feed plate of the sewing machine ................................................... 135
1-13. Replacing the fork..................................................................................................... 136
1-14. Replacing the fuse .................................................................................................... 136
1-15. Changing the voltage of 100/200V........................................................................... 137
1-16. Replenishing the designated places with grease .................................................. 138
(1) Addition of grease to the machine head ...................................................................................138
(2) Addition of grease to devices.................................................................................................... 140
1-17. Troubles and corrective measures (sewing conditions)....................................... 142
2. Option................................................................................................................ 144
2-1. Optional parts.............................................................................................................. 144
2-2. Gauges......................................................................................................................... 144
2-3. Miscellaneous ............................................................................................................. 144
2-4. Silicon oil pipes........................................................................................................... 144

– 1 –
!. Machine (about the sewing machine)
Following items have to be checked every working day before the operation of the machine and before the start
of work hours.
1. Ascertain that the oil pan is lled with the predetermined amount of oil.
2. Never operate the machine unless the oil pan has been lled up with oil.
3. Ascertain that the pressure gauge indicates the designated air pressure of 0.5 MPa.
* (This is necessary particularly when the compressor is stopped for a lunch break or the
like.)
If the compressed air pressure is equal to or less than the designated value, troubles such
as interference between the parts can occur. It is therefore necessary to carefully check the
compressed air pressure.
4. Check whether the needle thread/bobbin thread need to be replenished.
5. To perform sewing immediately after turning ON the power switch, perform trial stitching
rst, then proceed with sewing of actual products after the test sewing.
6. In the case drainage water accumulates in the regulator section, expel it from there before
starting work.
Precautions for use

– 2 –
1. Conguration
This machine consists of the following nine sections:
A Mechanical section of the main body structure (table stand, table, covers, start switch, etc.)
B Belt loop feeder unit (belt loop draw-out device, belt loop drawing device, etc)
C Belt loop tension releasing unit
D Pneumatic control equipment section (pneumatic equipment, pneumatic piping, etc.)
E Sewing machine section
F Control device
G Operation panel
H Emergency stop switch
I Belt-loop feeding unit (optional)
J Power switch
The machine is able to automatically sew desired belt-loops only by operating the start switch after
having placed a material (garment body) at the predetermined position on the machine.
When you press emergency stop switch H, the power to the devices are turned OFF to stop them.
G
H
E
D
A
F
I
B
C
J

– 3 –
2. Specications
1
Sewing machine in use LK-1961/AB H (exclusive intermediate machine head AB-1351 based on LK-1900A SS)
2 Sewing speed Max. number of revolutions 2,500 sti/min (adjustable range: 400 to 2,500 sti/min)
The stitching pitch has to be set at 3.2 mm or less. (Stitching pitch is input in increments
of 100 sti/min.)
3 Belt-loop shape
4 Belt-loop width 8 to 20 mm
5 Standard sewing
pattern
* Linear bartacking (exclusive pattern for AB-1351)
Pattern No. selection method (from among 12-stitch, 15-stitch, 21-stitch, 28-stitch,
36-stitch and 41-stitch) is adopted. The widthwise pattern size is input on the operation
panel. The lengthwise pattern size is restricted to the 0 mm, and the widthwise one is
restricted to the range from 6 mm to 23 mm. (The lengthwise pattern size is input in
increments of 0.1 mm.)
* Zigzag bartacking (exclusive pattern for AB-1351)
Pattern No. selection method (from among 28-stitch, 36-stitch, 42-stitch, 56-stitch and
64-stitch) is adopted. The widthwise and lengthwise pattern sizes are input on the
operation panel. The lengthwise pattern size is restricted to the range from 1 mm to 3.2
mm, and the widthwise one is restricted to the range from 6 to 23 mm. (The lengthwise/
widthwise pattern size is input in increments of 0.1 mm.)
6 Lift of the work clamp
foot of sewing machine
The distance from the top surface of the throat plate to the undersurface of the work
clamp foot is 20 mm.
7 Needle bar stroke 45.7 mm (for 1903A)
8 Needle ORGAN needle DP x 17 #14 (Standard)
9 Hook in use Semi-rotary standard hook (x1.0)
10 Thread Spun #50 (recommended) Filament #50
11 Safety feature The machine automatically stops in the case a belt-loop clamping fault or thread
breakage is detected.
12 Lubrication oil JUKI New Defrix Oil No.2
13 Air pressure used 0.5 MPa
14 Air consumption 10 dm³ (ANR)/min or less
15 Dimensions W: 1,200 mm L: 850 mm H: 1,210 mm
16 Weight 205.5 Kg
17 Noise Declaration
- Equivalent continuous emission sound pressure level (LpA) at the workstation :
A-weighted value of 82.0 dB; (Includes KpA = 2.5 dB); according to ISO 10821- C.6.3
-ISO 11204 GR2 at 2,500 sti/min for the sewing cycle, 5.5s ON. (Pattern: No.4, 21
Stitches, Max Speed)
- Sound power level (LWA) ;
A-weighted value of 85.0 dB; (Includes KWA = 2.5 dB); according to ISO 10821- C.6.3
-ISO 3744 GR2 at 2,500 sti/min for the sewing cycle, 5.5s ON. (Pattern: No.4, 21
Stitches, Max Speed)
18 Laser marking Class 2 laser product
Maximum output: 1.0mW
Wave length: 650nm
Safety standard
JIS C 6802:2005
IEC60825-1+A2:2007
2-1. Mechanical specications

– 4 –
2-3. Sewing shape of belt-loops
Work clamp foot for linear
bartacking
Work clamp foot for zigzag
bartacking
No.1 AB
A = 4 mm * (-10 to 19)
B = 59 to 99 mm
A = 6 mm * (-9 to 21)
B = 59 to 99 mm
No.2
B
C
A
A = 4 mm * (-10 to 19)
B = 15 to 30 mm
C = 45 to 99 mm
A = 6 mm * (-9 to 21)
B = 15 to 30 mm
C = 45 to 99 mm
No.3 A
C
B
DA = 4 mm * (-10 to 19)
B = 45 to 109 mm
C = 5 to 11 mm
D = (2) mm
A = 6 mm * (-9 to 21)
B = 45 to 109 mm
C = 5 to 11 mm
D = (2) mm
No.4
CA
B
D
E
A = 4 mm * (-10 to 19)
B = 30 to 50 mm
C = 5 to 11 mm
D = 5 to 30 mm
E = 6 mm * (-14 to 16)
A = 6 mm * (-9 to 21)
B = 30 to 50 mm
C = 5 to 11 mm
D = 5 to 30 mm
E = 12 mm * (-12 to 22)
No.5 CA
B
D
F
E
A = 4 mm * (-10 to 19)
B = 30 to 61 mm
C = 5 to 11 mm
D = 2 to 8 mm
E = 2.5 mm * (-2.5 to 7.5)
F = 10 mm * (0 to 20)
A = 6 mm * (-9 to 21)
B = 30 to 61 mm
C = 5 to 11 mm
D = 2 to 8 mm
E = 4 mm * (-1 to 9)
F = 10 mm * (0 to 20)
No.6
AC
B
D
A = 4 mm * (-16 to 19)
B = 45 to 99 mm
C = 15 to 30 mm
D = 2.5 mm * (-2.5 to 7.5)
A = 6 mm * (-9 to 21)
B = 45 to 99 mm
C = 15 to 30 mm
D = 4 mm * (-1 to 9)
2-2. Electrical specications
1 Number of patterns that
can be stored in memory
99 patterns can be set.
2 Number of cycles that can
be stored in memory
Number of programs: 20
For each program, as many as 30 belt-loops can be set.
3 Input power source Single-phase 200 – 240 VAC, 50/60Hz
3-phase, 200 - 240 VAC, 50/60 Hz (switchable to single-phase 100 - 120 V)
Supply voltage uctuation: Rated voltage ± 10 % or less
* Adaptable to 380/400/415 VAC with the addition of an optional transformer.
4 Power consumption 3-phase, 200 V type: 250 VA (instantaneous maximum power consumption: 450 VA)
Single-phase, 220 V type: 280 VA (instantaneous maximum power consumption: 670 VA)
* Average power when the machine sews 4000 belt-loops in eight hours under No. 4
sewing mode.

– 5 –
1. The range of belt-loop feeding length (the entire length of a belt-loop shown on the
operation panel) is from 58 mm to 130 mm. If the belt-loop feeding length exceeding the
aforementioned range is set, an error will occur.
2. In the case "distance B + distance D" exceeds 66 mm for pattern No. 4 or No. 5, "dis-
tance B + loosening amount/2" exceeds 66 mm for pattern Nos. 7 and 12, or "distance B
+ loosening amount" exceeds 66 mm for pattern Nos. 9 and 11, an error will occur.
3. The dimensions of the belt loop sewing shape displayed on the operation panel are
only for reference. The dimensions vary according to the belt-loop material. Be sure to
adjust the settings of belt loop dimensions so that your desired nished dimensions
are achieved.
* Numerical values shown in parentheses are set values. They are not the nished dimen-
sions.
Work clamp foot for linear
bartacking
Work clamp foot for zigzag
bartacking
No.7 A
B
F
D
E
A = 10 mm * (0 to 15)
B = 30 to 63 mm
D = 4 mm * (0 to 10)
E = 4 mm * (0 to 10)
F = 10 mm * (0 to 20)
Loosening amount = 0 to 20 mm
A = 10 mm * (0 to 15)
B = 30 to 63 mm
D = 3 mm * (0 to 10)
E = 3 mm * (0 to 10)
F = 10 mm * (0 to 20)
Loosening amount = 0 to 20 mm
No.8 B
D
A
A = 10 mm * (0 to 15)
B = 49 to 109 mm
D = 4 mm * (0 to 10)
A = 10 mm * (0 to 15)
B = 45 to 109 mm
D = 3 mm * (0 to 10)
No.9 A
B
D
E
A = 10 mm * (0 to 15)
B = 30 to 60 mm
D = 4 mm * (0 to 10)
E = 6 mm * (-14 to 16)
Loosening amount = 5 to 30 mm
A = 10 mm * (0 to 15)
B = 30 to 60 mm
D = 3 mm * (0 to 10)
E = 12 mm * (-12 to 22)
Loosening amount = 5 to 30 mm
No.10 A
B
D
C
A = 4 mm * (-10 to 19)
B = 45 to 109 mm
C = 5 to 11 mm
D = 4 mm * (0 to 4)
A = 6 mm * (-9 to 21)
B = 45 to 109 mm
C = 5 to 11 mm
D = 3 mm * (0 to 4)
No.11 A
B
D
E
C
A = 4 mm * (-10 to 19)
B = 30 to 50 mm
C = 5 to 11 mm
D = 4 mm * (0 to 4)
E = 6 mm * (-14 to 16)
Loosening amount = 5 to 30 mm
A = 6 mm * (-9 to 21)
B = 30 to 50 mm
C = 5 to 11 mm
D = 3 mm * (0 to 4)
E = 12 mm * (-12 to 22)
Loosening amount = 5 to 30 mm
No.12
A
B
F
D
E
C
A = 4 mm * (-10 to 19)
B = 30 to 56 mm
C = 5 to 11 mm
D = 4 mm * (0 to 4)
E = 2.5 mm * (-2.5 to 7.5)
F = 10 mm * (0 to 20)
Loosening amount = 4 to 16 mm
A = 6 mm * (-9 to 21)
B = 30 to 56 mm
C = 5 to 11 mm
D = 3 mm * (0 to 4)
E = 4 mm * (-1 to 9)
F = 10 mm * (0 to 20)
Loosening amount = 4 to 16 mm