JUKI DLU-5494N-7 User manual

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

CONTENTS
1. PREFACE.................................................................................................... 1
2. SET-UP........................................................................................................ 1
(1) Installing M-91 small sized motor unit ................................................................................................1
(2) Installing to the table ............................................................................................................................2
(3) Adjusting the belt (when M-91 is used)............................................................................................... 2
(4) Adjusting the belt cover (when M-91 is used) .................................................................................... 3
(5) Connecting the cords ...........................................................................................................................4
(6) Attaching the circuit board ..................................................................................................................5
(7) Connecting for IP-110 panel.................................................................................................................7
(8) Installing the operation display panel...............................................................................................10
(9) How to use the operation display panel ...........................................................................................10
(10) Adjusting the bottom feed pitch display......................................................................................... 11
3. INSTALLING THE OPERATION PANEL.................................................. 12
4. CONNECTING THE CORD....................................................................... 13
5. HOW TO USE THE OPERATION PANEL ................................................ 14
(1) Names and functions of each components......................................................................................14
(2) Adjusting the contrast of the operation panel display .................................................................... 16
(3) Production control switch connecting connector ...........................................................................16
6. SCREEN LIST........................................................................................... 17
(1) Fundamental screen list.....................................................................................................................17
(2) Pop-up list ...........................................................................................................................................18
(3) Other screens......................................................................................................................................19
7. OPERATING PROCEDURE OF THE SEWING PATTERN ...................... 20
(1) Selecting procedure of the sewing pattern ......................................................................................20
(2) Editing procedure of the sewing pattern ..........................................................................................20
(3) Teaching mode....................................................................................................................................23
(4) Selecting the sleeve to be sewn ........................................................................................................23
(5) Selection of the alternate sewing ......................................................................................................24
(6) Insertion and deletion of the step .....................................................................................................25
(7) Operating procedure of the number of stitches of the reverse stitching...................................... 26
8. PATTERN OPERATION............................................................................ 27
(1) Sewing pattern register ......................................................................................................................27
(2) Copy of the sewing pattern ...............................................................................................................29
(3) Deletion of the sewing pattern...........................................................................................................30
9. HOW TO USE THE BOBBIN THREAD COUNTER ................................. 31
10. NO. OF PCS. COUNTER........................................................................ 32
11. BOTTOM FEED AMOUNT DISPLAY...................................................... 32
12. RE-SEWING SWITCH............................................................................. 33
13. NEEDLE UP/DOWN COMPENSATION SWITCH .................................. 33
14. ON/OFF SWITCH OF THE MATERIAL EDGE SENSOR .................. 33
15. AUTOMATIC THREAD TRIMMING SWITCH .................................... 33
16. ONE-SHOT AUTOMATIC STITCHING SWITCH ............................... 33
17. THREAD TRIMMING PROHIBITION SWITCH .................................. 33
18. INFORMATION ....................................................................................... 34
(1) Information operator level..................................................................................................................34
(2) Setting for functions...........................................................................................................................37
(3) External interface................................................................................................................................41
19. ERROR DISPLAY ................................................................................... 42
(1) Error code list (Error display in panel) .............................................................................................43

– 1 –
For setup or handling of DLU-5494N-7 (1-needle, bottom and variable top feed lockstitch machine with
automatic thread trimmer), refer to the Instruction Manual for DLU-5494N-7.
In addition, for the details of handling of SC-910 (sewing machine controller) and IP-110, similarly, refer to the
respective Instruction Manuals.
SC-910 control box can be used for DD (direct-drive) system machine head and the belt-drive system
machine head by connecting the separately-available small-sized motor unit (M-91).
When using the small-sized motor unit, it is necessary to install the motor unit to the control box before
installing the control box to the table.
Install the motor unit to the control box following the instructions below.
SC-910 control box M-91 small-sized motor unit
(separately-available article)
2. SET-UP
1. PREFACE
(1) Installing M-91 small sized motor unit
1. When tightening the screw, securely
insert the hexagonal wrench key into
the screw hole section to tighten.
2. Hexagonal wrench key is attached to
M-91.
3. Be careful that the motor shaft does
not hit against anything. (If a strong
shock is given to the motor shaft,
there is the possibility that the motor
is damaged.)
1) Lay down the control box while the rear cover is
placed under the control box.
2) Remove tie-mount A.
3) Adjust the hole section of the installing base of
M-91 to the hole section of the installing plate.
4) Temporarily tighten ve places with counter-sunk
screws 1supplied with the unit as accessories.
5) Securely tighten them with hexagonal wrench
key 2supplied with the unit as accessories.
1
2
A

– 2 –
1
1) Install the control box to the table with the tting
bolt (asm.) supplied with the unit as accessories.
At this time, insert the nut and washer supplied
with the unit as accessories as shown in the
gure so that the control box is securely xed.
2) Set the machine head to the table after installing
the control box (or with small-sized motor) to the
table. (Refer to Instruction Manual for the sewing
machine.)
(2) Installing to the table
1) Adjust the belt tension by turning upper and
lower nuts 1of the adjustment bolt and adjust
the height of the center of the motor so that the
belt sags 15 mm (9.8N) when the center of the
belt is pressed by hand.
(3) Adjusting the belt (when M-91 is used)
Plain
washer
Spring
washer
Hexagonal nat
When the belt tension is excessively low,
medium or low speed rotation becomes
uneven, or stop accuracy is deteriorated.
When the tension is excessively high,
deterioration of the motor is advanced.
So, be careful.
Approx. 15mm / 9.8N

– 3 –
1) Adjusting the clearance of the cover
Loosen cover setscrew 1and adjust so that the
left and right clearances between the belt cover
and the belt are equal to each other.
(4) Adjusting the belt cover (when M-91 is used)
2) Adjusting the roll-in prevention pin
Adjust the roll-in prevention pin with the
hexagonal wrench key supplied with the unit as
accessories so that the clearance between the
belt and roll-in prevention pin 2is approximately
4 mm.
4mm
3mm
4) Installing the belt cover
1. Adjust the notch section of the pulley outer cover
4to the gap of screw 5of the pulley inner
cover and insert the outer cover to the inner
cover.
2. Tighten screw 5to complete the adjustment of
the cover.
3) Adjusting the off-belt prevention pin
Adjust the off-belt prevention pin with the
hexagonal wrench key supplied with the unit
as accessories so that the clearance between
the belt and off-belt prevention pin 3is
approximately 3 mm.
Perform the adjustment of the cover with
the hexagonal wrench key supplied with
the unit as accessories. At this time, be
careful that the screw is not excessively
loosened.
1. Be careful of the direction of rotation
of the motor and determine the
position of the pin. (Position shown
in the gure is the installing position
when the motor rotates in the
direction of the arrow mark.)
2. Perform the adjustment of the cover
with the hexagonal wrench key
supplied with the unit as accessories.
At this time, be careful that the screw
is not excessively loosened.
Perform the adjustment of the cover with
the hexagonal wrench key supplied with
the unit as accessories. At this time, be
careful that the screw is not excessively
loosened.
1
2
3
4
5

– 4 –
(5) Connecting the cords
Following connectors are prepared on the front face of SC-910. Connect the connectors coming from the
machine head to the corresponding places so as to t the devices mounted on the machine head.
1 CN30
Synchronizer : it detects the needle bar
position.
2 CN35
CP-160 panel : Various kinds of programmed
sewing can be executed.
(Refer to the Instruction Manual for each panel
for the details of functions.)
3 CN33
Not used
4 CN31
Machine head connector 4P
5 CN42
External input/output connector : input/
output of up/down detection signal, rotation
prohibition signal, etc. is prepared.
6 CN48
Safety switch (standard) : When tilting the
sewing machine without turning the power
OFF, the operation of the sewing machine is
prohibited so as to protect against danger.
Optional switch : by changing over the internal
functions, 6 kinds of functions can be selected.
7 CN40
Presser foot lifter solenoid. (For automatic
presser foot lifter type only)
8 CN46
Machine head solenid : Thread trimming,
reverse-stitching solenoid, touch-back switch,
etc.
9 CN47
Optional circuit board connection connector :
Required when using JUKI standard bobbin
thread remaining amount detection sensor,
etc.
!0 CN38
, CN39
Motor signal connector
!1 CN32
Standing machine pedal : JUKI standard
PK-70, etc. Sewing machine can be controlled
with the external signal.
!2 CN34
IP-110 panel (LCD panel) : Various kinds of
programmed sewing can be executed.
!3 CN45
Material end detection sensor ED-4, etc.
!4 CN43 FAN
* By adding this unit (optional unit B), the machine
can be used as 1-needle, bottom and variable
top feed lockstitch machine with automatic
thread trimmer.
!5 CN132
Shirring LED, bottom feed amount
!6 CN133
External shirring input
!7 CN134
Top feed amount
!8 CN139
Stepping motor control
!9 CN141
Up/down detection, thread trimming, reverse
feed stitching
@0 CN138
Shirring release input (extreme left)
1
8
2
3
7
4
5
6
!0
!1
9
!3
!4
!2
!0 !5
!6
!7
!8
!9
@0
WARNING :
• To prevent personal injury caused by abrupt start of the sewing machine, carry out the work after
turning OFF the power switch and a lapse of 5 minutes or more.
• To prevent damage of device caused by maloperation and wrong specications, be sure to connect
all the corresponding connectors to the specied places.
• To prevent personal injury caused by maloperation, be sure to lock the connector with lock.
• As for the details of handling respective devices, read carefully the Instruction Manuals supplied
with the devices before handling the devices.
Optional unit B
(KT-01(EPF) p.c.b. A (asm.))

– 5 –
1) Open the front cover according to the instructions
given in the Instruction Manual for the control
box main unit.
2) Insert stud 2supplied with the unit as
accessories to KT-01(EPF) p.c.b. A (asm.) 1.
3) Insert KT-01(EPF) p.c.b. A (asm.) 1to connector
CN47 3of the main unit as illustrated.
4) Securely fix KT-01(EPF) p.c.b. A (asm.) 4to
the control box main unit using three screws 5
supplied with the unit as accessories.
Be careful of the inserting direction.
1. Insert KT-01(EPF) p.c.b. A (asm.) from
the oblique lower section, check the
inserting position and insert it until
“click” sounds since connector CN47
3is hidden by the cover located in
the upper section of the control box
main unit.
2. Do not forcibly press the circuit board.
(6) Attaching the circuit board
Inserting position
Rear side
2
3
5
4
1
2

– 6 –
Be sure to open / close the front cover
with your hands.
5) Pass through table hole Aunder the table
cords 9of thread trimer solenoid, reverse feed
stitching solenoid, etc., synchronizer cord 7, IP
panel cord !0, operation display panel cord 6,
top feed detection cord 8and motor control cord
!1 .
6) Loosen setscrew !2 in front cover !3.
7) Pressing the side of front cover !3 in the direction
of the arrow, open the front cover toward you.
8) Connect 14P cord 9coming from the machine
head to connector !4 (CN46).
9) Connect 7P connector 7coming from the
machine head to connector !5 (CN30).
10) Connect connector !8 coming from the machine
head to connector !6 (CN38, CN39). (Connect
8P connector to CN38 and in case of 9P
connector, connect to CN39.)
11) When the optional AK118 device is attached,
connect 2P connector !7 coming from the AK
device to connector !9 (CN40).
!3
!2
A
7
!0
6
9
8
!1
!8
!6
7
!4
!7
!9
!5
9

– 7 –
12) Connect 6P connector !1coming from the
machine head to connector @1 (CN139).
13) Connect 4P connector 8coming from the
machine head to connector @2 (CN134).
14) Connect 14P connector 6coming from the
operation display panel to connector @3 (CN132).
15) Insert KT-01(EPF) relay connector @ 0 to
connector @4 (CN141) and connector @5 (CN42).
1. When using the AK device, set whether to use the AK device after conrming how to select the
auto-lifter function.
(Refer to "Instruction Manual for SC-910".)
2. Be sure to securely insert the respective connectors after checking the inserting directions
since all connectors have the inserting directions.
(When using a type with lock, insert the connectors until they go to the lock.)
The sewing machine is not actuated unless the connectors are inserted properly.
In addition, not only the problem of error warning or the like occurs, but also the sewing
machine and the control box are damaged.
1) The connector for connecting IP-110 is prepared.
When connecting, insert the connector until it is
locked to 1(CN34).
(7) Connecting for IP-110 panel
2) After inserting the connector, put all cords
together with cable clip band 2located on the
side of the box.
At this time, bundle the connectors which are
arranged above the wire saddle to wire saddle
3and those which are arranged below the wire
saddle to wire saddle 4.
!1
@1
8
6
@5
@3
@0
@2
@4
1
3
2
4
When the connectors are not properly
connected, the p.c.b. does not work
normally.

– 8 –
3) Close front cover 5while paying attention to
pinching of the wire.
Lightly press portion Band insert front cover 5
with “click”.
4) After that, x it with the screw 6.
Push
Pushing the hook portion, push the band to remove it.
1. Fix the cable clip band following the attaching procedure as shown in the gure.
2. When removing the cord, remove the wire saddle rst and the cable clip band next.
3. To remove the cable clip band, as show in the illustration of how to remove the cable clip band,
pressing the hook of cable clip band, push the band to remove the cable clip band.
How to x cable clip band 2
Pull
How to remove cable clip band 2
Push
Pull
Push the hook.
5
B
6

– 9 –
5) Connect motor output cord 7to connector 8
located on the side of the box.
6) Connect connector 4P 9of the power switch to
connector !0.
7) Make sure that the power switch is turned OFF
and insert power supply cord !1 coming from the
power switch into the power plug socket.
Route the motor output cord from the
front face of the box.
1. Check again the supply voltage and
the voltage designated on the control
box before connecting the power
supply cord.
2. Prepare the power switch conformed
to the safety standard.
3. Be sure to connect the ground wire (
green / yellow).
!1
7
8
9
!0

– 10 –
1) Fix operation display panel 1in tapped hole
Ain the rear section of the machine arm using
screw 2and washer 3.
2) Attac h o p e r ation d i s p l a y panel 1t o t h e
aforementioned place so that it is in parallel to
the bed surface and does not come in contact
with the lower section of the machine arm.
• Operation indication panel
1Partial shirring switch
・
This is the switch used to change over the partial shirring process.
3,4Partial shirring pattern indicator lamps (LEDs) under the alternate stitching mode
・ If partial shirring pattern or is selected under the alternate stitching mode, LED 3will light up. If partial
shirring pattern or is selected under the aforementioned mode, LED 4will light up.
・ If the machine is not operated under the alternate stitching mode, both LEDs 3and 4will go out.
(Note)
○……Lights up
●……Goes out
2Indicator lamp (LED) of the partial shirring process step
・ Indicates the current state of partial shirring process step.
(8) Installing the operation display panel
(9) How to use the operation display panel
No contact
2
3
1
A
1
Parallel to
the bed surface
3
14
2
Partial shirring
process step
Indicator lamp (LED)
A B C D
1○ ● ● ●
2○ ○ ● ●
3○ ○ ○ ●
4○ ○ ○ ○
5● ○ ○ ○
6● ● ○ ○
7● ● ● ○
8● ● ● ●

– 11 –
(10) Adjusting the bottom feed pitch display
When the display of the bottom feed pitch does not correspond with the scale of the pitch dial, perform the
setting below.
1. Adjust the scale of the bottom feed pitch dial to
"0".
2. Turn the variable resistor VR1 1located on the
right side of the rear of the operation display
panel, and adjust so that the bottom feed display
is set to the minimum display.
3. Adjust the scale of the bottom feed pitch dial to
"5".
4. Turn the variable resistor VR2 2located on the
right side of the rear of the operation display
panel, and adjust so that the bottom feed display
is set to 5.0.
2 VR2
1 VR1

– 12 –
3. INSTALLING THE OPERATION PANEL
Type B (Type name plate TYPE B0 ＊)Type C (Type name plate TYPE C0 ＊)
Type B Type C
IP-110 / bracket type classied by model correspondence table
WARNING :
To protect against possible personal injury due to abrupt start of the machine, be sure to start the
following work after turning the power off and ascertaining that the motor is at rest.
1) Attach operation panel 1to the machine head using screw 2, plain washer 3, toothed lock washer 4
and spacer 5(for type C) supplied with the operation panel.
2) The positions of the holes in the bracket for installing the operation panel are different from each other
according to the respective models. Refer to the table below.
No. Mounted machine
head Bracket type Installing hole used Part No. of screw Remarks
1 DDL-9000 Type B 2－4SS4121415SP(3/16-28)
2 DLN-9010 Type B 2－4SS4121415SP(3/16-28)
3 LH-31 ＊＊ Type B 1－5SS6111210SP(11/64-40)
4 LZ-228 ＊N Type B 3－4SS4121415SP(3/16-28)
To be xed on the exclusive
bracket for installing standard
panel
5 DDL-5550N Type C 1－3SS7121410SN(3/16-24)
Use 2– 3in case of optional
unit (V0 and the like).
6 DDL-8700 Type C 1－3SS7121410SN(3/16-24)
7 DLN-5410N Type C 1－3SS7121410SN(3/16-24)
8 DLU-5494N Type C 1－3SS7121410SN(3/16-24)
1
3
4
2
5
1
3
4
2
5
3
4
2
1
34
21
3
2
5

– 13 –
4. CONNECTING THE CORD
Bottom surface of table
WARNING :
Turn OFF the power and start the work after 5 minutes or more have passed so as to prevent
accidents caused by abrupt start of the sewing machine.
1) Pass cord 1and FG cord 3(for type C) of the
operation panel through hole Ain the machine
table to route it to the underside of the table.
2) Connect the connector of cord 1to connector
CN34 2in the control box.
3) For type C, x FG cord 3to the power switch with wood screw 4supplied with the panel as accessories.
Wire FG cord 3after bundling it with the power cable and the like with cable clip band 5supplied with
the panel as accessories.
1
2
A1
3
3
45

– 14 –
(1) Names and functions of each components
5. HOW TO USE THE OPERATION PANEL
1Re-sewing switch
2
Needle up/down compensating switch
3Screen changeover switch
4With/without reverse feed stitch
at sewing start switch
5With/without reverse feed stitch
at sewing end switch
6Reset switch
7Teaching switch
8Information switch
9Material edge sensor switch
!0 One-shot stitching switch
!1 With/without automatic thread
trimmer switch
!2
Thread trimming prohibiting switch
!3 Counter value setting switch
!4 Max.speed limitation variable
resistor
!5 Power display lamp
!6 Media cover
!7 Media slot
(Media inserting opening)
!8 CompactFlash (TM)
Optional :
Part No.40000100
（ ）
1Re-sewing switch
2Needle up/down
compensating switch
3Screen changeover
switch
4 With/without reverse
feed stitch at sewing
start switch
5With/without reverse
feed stitch at sewing
end switch
6
Reset switch
This switch is used to continue sewing from the step on the way
after replacing bobbin thread when bobbin thread has run out during
program stitching step.
This is the switch to perform needle up/down compensating stitching.
(Needle up/down compensating stitching and one stitch compensating
stitching can be changed over with function setting No. 22.)
This is the switch to change over the screen.
This is the switch to turn ON/OFF automatic reverse feed stitch at
sewing start.
* This switch cannot be used with the sewing machine which is not
provided with automatic reverse feed stitching device.
This is the switch to turn ON/OFF automatic reverse feed stitch at
sewing end.
* This switch cannot be used with the sewing machine which is not
provided with automatic reverse feed stitching device.
This is the switch to make the value of bobbin thread counter or
sewing counter the set value.
!6
1
!7
34!0 9
25!4
!5 6!3
7
!2 8
!1
!8

– 15 –
7Teaching switch
8
Information switch
9Material edge sensor switch
!0
One-shot stitching switch
!1 With/without automatic
thread trimmer switch
!2
Thread trimming
prohibiting switch
!3
Counter value setting
switch
!4
Max. speed limitation variable resistor
!5 Power display lamp
!6Media slot cover
!7Media slot
(Media inserting opening)
This is the switch to set the setting of the number of stitches with
the value of number of stitches which has been actually sewn.
This is the switch to perform various function settings.
Rendered effective when the material edge sensor is installed on
the machine.
Used for selecting whether or not the material edge sensor is used
during sewing.
When this switch is set to effective at the time of program stitching,
the sewing machine automatically operates up to the specified
number of stitches.
When this switch is set to effective at the time of program stitching,
the sewing machine automatically performs thread trimming when
the specied number of stitches has been completed.
This switch prohibits all thread trimmings.
* This switch cannot be used with the sewing machine which is not
provided with the automatic thread trimming device.
This is the switch to set the value of bobbin thread counter or No.
of pcs. counter.
When moving the resistor in the left direction, max. speed is limited.
This lamp lights up when the power switch is turned ON.
This is the cover for media inserting opening.
To open the cover, place your nger on the notch located on the
side of the cover as shown in the gure and push the cover in the
direction of left slanting rear.
* There are some functions that are not able to be operated
with the cover opened.Do not close the cover unless the
CompactFlash(TM) is completely inserted.
To set CompactFlash(TM), place the label face of the
CompactFlash(TM) to the front and insert the part that has a
small hole (place the notch of the edge to the rear) to the panel.
To remove the CompactFlash(TM), hold it between your ngers
and draw it out.
* When the inserting direction of the CompactFlash(TM) is wrong,
the panel and the CompactFlash(TM) may be damaged.Do not
insert anything other than the CompactFlash(TM).

– 16 –
1
3
2
A
1
3
2
A
1) Press in the direction of arrow mark the click of
section Aof cord outlet cover 2assembled in
the rear of operation panel 1and remove the
cover.
2) Turn LCD screen display brightness adjustment
variable resistor 3to adjust the brightness
(contrast) of LCD screen.
Light Shade
1. To prevent the operation panel from
breakage, do not touch the circuit
board pattern and the connector
terminal.
2. Do not disassemble the operation
panel to prevent it from breakage.
(2) Adjusting the contrast of the operation panel display
1) Press in the direction of arrow mark the click of
section Aof cord outlet cover 2assembled in
the rear of operation panel 1and remove the
cover.
2) Connect the optional relay cable connector
to CN105 3of the production control switch
connecting connector.
(3) Production control switch connecting connector
Optional relay cable A (asm.)
JUKI Part No. 40008168
3 2 1
CN105
+5V
SW
GND
1
2
3
Prepare the switch main unit by the
customers or ask JUKI business office
about it.

– 17 –– 17 –
6. SCREEN LIST
WELCOME screen is displayed immediately after turning ON the power.
The screen immediately after WELCOME screen becomes the pattern edit screen.
Every time switch is pressed, the screen changes.
■Number of stitches of back tuck stitching setting screen
Setting of number of stitches of reverse stitching is performed.
■Pattern edit screen
Step editing of the pattern is performed.
(1) Fundamental screen list
■Pattern operation screen
Register, copy or deletion of the pattern is performed.

– 18 –– 18 –
■Pattern step insertion/deletion pop-up
Insertion/deletion of the step is performed.
■Pattern register pop-up
Selection of the pattern to be registered is performed.
■Pattern copy pop-up
Pattern of copy source or pattern of copy destination is selected.
■Pattern deletion pop-up
Pattern to be deleted is selected.
(2) Pop-up list