JUKI AW-3SD User manual

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INSTRUCTION MANUAL
Ver：1.00
AW-3SD

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CONTENTS
1. GENERAL ..........................................................................................1
1-1. Specications of AW-3SD .............................................................................................. 1
1-2. Conguration .................................................................................................................. 2
2. INSTALLATION .................................................................................. 4
2-1. Installing the AW-3SD ..................................................................................................... 4
2-2. Installation location ........................................................................................................ 4
3. OPERATION PROCEDURE............................................................... 5
3-1. Opening/closing the cover door.................................................................................... 5
3-2. Removing the device cover ........................................................................................... 6
3-3. How to thread the device with the bobbin thread........................................................ 7
3-4. How to set a bobbin........................................................................................................ 9
3-5. Length of remaining thread to be removed................................................................ 11
3-6. Device operation lamp.................................................................................................. 11
3-7. Behavior of the AW-3SD device when the power is turned ON ................................ 12
3-8. Program mode list ........................................................................................................ 12
3-9. Basic operation and setting......................................................................................... 15
3-10. Operating the AW ........................................................................................................ 16
3-11. Setting the AW number-of-stitches input mode, AW operation mode and
remaining-thread allowance length......................................................................... 19
3-12. Example of operation ................................................................................................. 24
3-13. Turning OFF of the power .......................................................................................... 29
3-14. Error display and error handling procedure ............................................................ 29
3-15. Detection of errors related to the AW........................................................................ 31
3-16. List of errors................................................................................................................ 32
3-17. Cautions....................................................................................................................... 33
4. MAINTENANCE ............................................................................... 34
4-1. Attaching / removing the cover ................................................................................... 34
4-2. Cleaning......................................................................................................................... 35
4-3. Replacing the fuse ........................................................................................................ 37
4-4. Replacing the gripper tube .......................................................................................... 37
4-5. Adjusting the air ow for the remaining thread guide .............................................. 38
5. TROUBLESHOOTING ..................................................................... 39

– 1 –
1. GENERAL
1 Applicable bobbin, bobbin case Exclusive double-capacity bobbin and bobbin case.
2 Applicable thread count #5 to #30 (Japan), 135 to 45 (TEX), 020 to 060 (TKT)
3 Applicable type of thread Synthetic thread
4 Remaining-thread removal and
bobbin winding operation
Possible while the sewing machine is in operation.
5Condition setting according
to the thread type
Conditions to be met to unravel the thread at the beginning of wind-
ing a bobbin can be set.
6Line voltage 200,220,240 Vac ±10 %, Single phase 50/60 Hz
7Power consumption 100 VA
8Air pressure used 0.4 to 0.5 MPa
* Adjustment of the air pressure may be required depending on the
thread to be used. (The air pressure for the AW-3SD has been
factory-set to 0.5 MPa at the time of shipment.)
9Air consumption 156 Nℓ / min (max. value)
10 Dimensions 700 mm (W ) × 650 mm (L ) × 430 mm (H ) (Accessories included)
11 Mass of the device 38 kg
12
Operating temperature range
5 ˚C to 35 ˚C
13
Operating humidity range
35 % to 85 % (No dew condensation)
14 Noise - Equivalent continuous emission sound pressure level (LpA) at
the workstation : A-weighted value ≦ 80.0 dB ; (Includes KpA =
2.5 dB) ; according to ISO 10821- C.6.2 -ISO 11204 GR2.
Conventionally, a series of operations including the replacement of a bobbin in the sewing machine hook,
removal of thread remaining on a bobbin, winding of a bobbin, threading of the bobbin case tension spring,
threading of the thread guide claw hole and trimming of thread have been carried out manually. Now, this
device is developed to carry out the series of operations full-automatically. This device is provided with new
functions in addition to the conventional AW-3's functions, thereby not only helps increase e󰀩ciency of sew-
ing work but also improves convenience.
Refer to the technical data on the JUKI industrial computer-controlled sewing machine PLK-J, "Sewing
machine head", "Operation panel" and "Control device" for information about the main body of the sewing
machine.
1-1. Specications of AW-3SD

– 2 –
1-2. Conguration
* The illustration shows the PLK-J6040R.
❸
❹
❺
❻
󱢴
󱢵
❶
❾
󱢶
❽
󱢳
󱢷
❷
❼

– 3 –
Name Function
❶Main body of device It is mounted under the sewing machine bed and is the mechanical
section of the device which carries out replacement of the bobbin,
removal of thread remaining on the bobbin, winding of thread on a
bobbin, threading, thread trimming and thread unraveling automatical-
ly.
❷Angle section It connects the main body of the AW device to the sewing machine
bed.
❸Carrier arm It is the mechanism for carrying a bobbin case to the hook, bobbin
setting section, remaining thread removal section and bobbin winding
section.
❹Bobbin setting section It serves as an intermediary place used in the case of putting/removing
a bobbin on/from the device.
❺Remaining thread removal
section
It is the mechanism for removing the thread remaining on the bobbin
taken out from the hook. It consists of the remaining thread removal
roller, suction vacuum, etc.
❻Thread unraveling section It is the mechanism for unraveling the tip of thread to be wound on a
bobbin at the beginning of bobbin winding. It consists of the bobbin
unraveling roller, etc.
❼Nozzle Thread from the bobbin thread cone comes from the tip of the noz-
zle by way of the thread path. The thread coming out of the nozzle is
wound on a bobbin.
❽Bobbin thread winding
section
It is the mechanism for winding thread on a new bobbin, threading the
bobbin case and trimming the thread. It consists of the clutch plate,
threader, thread trimming knife, etc.
❾Thread feeding unit It is used to feed the thread bit by bit from the tip of the nozzle and
accurately measure the length of thread wound on a bobbin during
bobbin winding.
󱢳Electrical control box of
the device
It is the box which contains the PCB for controlling the operation of
the device. This electrical control box is di󰀨erent from the one for the
sewing machine.
󱢴Device operation lamp It indicates that the device is in operation.
󱢵Dust bag It is the place to store the remaining thread removed from the bobbin.
󱢶Cover It is used to prevent the operator from coming in contact with the mov-
ing part of the device.
󱢷Power source distribution
box
It distributes the power source to the sewing machine side and the AW
device side.

– 4 –
2. INSTALLATION
2-1. Installing the AW-3SD
Refer to the "Engineer's Manual for the AW-3SD" for details.
2-2. Installation location
For the installation location, carefully check the following points.
(1) This device uses an optical sensor. In order to protect the optical sensor from malfunctioning, do not in-
stall the device near a window or in any other location where it is likely to be exposed to direct sunlight.
Alternatively, install the device in a direction where it will not be exposed to direct sunlight.
(2) In order to avoid malfunctioning, do not use the device near any equipment that generates large elec-
trical noise. In addition, it is preferable to keep the power supply line away from the aforementioned
equipment.
* Be aware that the warranty may no apply if the aforementioned conditions are not met.

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3. OPERATION PROCEDURE
3-1. Opening/closing the cover door
It is necessary to open cover door ❶on the top of the table to set up a bobbin in the device. When you want
to open cover door ❶, twist switch ❷on the front face of the sewing machine by hand in the direction of the
arrow in the gure. Then, the end portion of the cover door goes up from the top of the table. Remove cover
door ❶holding its end portion with your hand.
To close cover door ❶, insert protruding portion ❸of cover door ❶until it comes in contact with the table
opening section and release your hand from it. Cover door ❶is closed by twisting switch ❷in the opposite
direction of the arrow in the gure.
Be sure to close cover door ❶ for the sake of safety whenever you carry out sewing.
In addition, if cover door ❶ is not closed securely, the sensor will detect that the door is in
the opened state to disable starting of sewing.
It should be noted, however, origin retrieval and inching operation are allowed to start. So,
be careful.
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of
the sewing machine.
❶
❷
❶
❸

– 6 –
3-2. Removing the device cover
It is necessary to remove device cover ❶when passing the bobbin thread or conducting maintenance.
Loosen hand-turned knob ❷ as shown in the gure. Then, shift device cover ❶to the left to remove the de-
vice cover ❶downward.
Be sure to close device cover ❶ for the sake of safety whenever you carry out sewing.
❶
❷

– 7 –
3-3. How to thread the device with the bobbin thread
In order to accurately measure the length of thread from the bobbin thread cone ❶to be wound on a bobbin,
guide the thread from the bobbin thread cone ❶through the bobbin thread feeding unit and draw the thread
out from the nozzle as illustrated in the gure.
Install the spool holder disk to the lowest possible position. If it is installed at a high position, an excessive
tension will be applied to the thread drawn from the bobbin thread cone ❶, causing a trouble.
❶❶
❾❾
❺❺
❻❻
❼❼
❽❽
❷❷
❸❸
❹❹
1) Insert the power plug to a receptacle and turn ON the power to the device. Press , Wait until initial-
ization operation of the device is completed. (Approx. 10 seconds)
2) Pass the thread drawn from bobbin thread cone ❶through thread tension controller ❷.
3) Wind the thread on thread length measuring roller ❸by one layer.
4) Pass the thread through thread guide ❻by way of tension controllers ❹and ❺.
It should be noted that the tube extending between thread tension controllers ❹and ❺is intended to
prevent thread from tangling on the shaft of the respective thread tension controllers. Pass the thread
through the space inside the curved part of tube ❾.
5) Pass the thread through the hole in the tip of thread feed arm ❼.
6) Press Aon the standard screen 2. When the AW operation panel is displayed, press B.
Be aware that the thread feed arm ❼ may operate when B is pressed.
A
B

– 8 –
󱢴
󱢳
When the thread is put in thread path tube ❽,
it is sucked. Put the thread in the tube, while
pulling the thread from the bobbin thread cone,
until the length of thread coming out of the tip of
nozzle 󱢳becomes approximately 13 cm. If the
thread stops halfway, pull it back slightly several
times.
At this time, the bobbin winder nozzle is at
its advanced position. In this state, adjust the
length of thread while observing the scale on
label 󱢴as a guide.
7) Suction is stopped by pressing B
again.