JUKI DP-2100 Quick start guide

40018531
No.E363-00
R
DP-2100
Computer-controlled Dry-head, Lockstitch,
Sleeve Setting Machine
with Multi-programming Device
ENGINEER’S MANUAL

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 these machines 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 by 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 of these machines.
In addition, for the motor for the sewing machine with thread trimmer, refer to the separate Instruction Manual
or Engineer’s Manual for the motor. And 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 “Results of Improper Adjustment” under which stitching errors and troubles
arising from mechanical failures are described together with the “Adjustment Procedures”.

CONTENTS
1. SPECIFICATIONS...................................................................................1
2. CONFIGURATION ..................................................................................2
(1) Sewing machine main unit ................................................................................. 2
(2) Operation panel ................................................................................................... 3
3. STANDARD ADJUSTMENT ...................................................................4
(1) Adjusting the height of the needle bar .............................................................. 4
(2) Adjusting the needle and the hook .................................................................... 4
(3) Removing the main shaft motor and the coupling ........................................... 6
(4) Adjusting the main shaft belt tension ............................................................... 8
(5) Adjusting the hook shaft belt tension ............................................................... 8
(6) Adjusting the feed belt tension .......................................................................... 10
(7) Adjusting the height of the feed foot bar .......................................................... 12
(8) Adjusting the height of the presser foot bar..................................................... 12
(9) Adjusting the amount of alternate vertical movement .................................... 14
(10) Height of the presser screw ............................................................................. 16
(11) Assembling the guide plate .............................................................................. 16
(12) Adjusting the initial position of the auto-lifter................................................ 18
(13) Adjusting the speed of the auto-lifter .............................................................. 18
(14) Adjusting the stroke of the auto-lifter ............................................................. 20
(15) Adjusting the thread trimmer cam ................................................................... 20
(16) Adjusting the initial position of the moving knife .......................................... 22
(17) Adjusting the initial position of the thread trimmer solenoid ....................... 22
(18) Adjusting the position of the moving knife and the counter knife ............... 24
(19) The fixing position of the auxiliary feed motor pulley ................................... 24
(20) The fixing position of the main feed motor pulley .......................................... 26
(21) The fixing position of the thrust collar of AT solenoid ................................... 26
(22) The fixing position of the thread tension shaft collar .................................... 28
(23) Adjusting the height of the feed foot ............................................................... 28
(24) Adjusting the height of the auxiliary feed foot ............................................... 30
(25) Adjusting the height of the presser foot ......................................................... 30
(26) Adjusting the feed eccentric cam .................................................................... 32
(27) Adjusting the assembly of the counter knife guard plate ............................. 32
(28) Replacing procedure of the top feed belt........................................................ 34
(29) Replacing procedure of the bottom feed belt ................................................. 48
4. PARTS TO BE GREASED ......................................................................50
5. SET-UP MANUAL FOR IP-200 ...............................................................52
(1) Connecting procedure of operation panel with external vehicle .................... 52
(2) Re-setup of operation panel ............................................................................... 56
(3) Re-setup of main program.................................................................................. 59
(4) Re-setup of servo program................................................................................. 65
(5) When using smart media other than that which has been packed
together ................................................................................................................ 71

6. INITIALIZING THE BACKUP DATA ........................................................ 72
7. SEWING DATA LIST ............................................................................... 73
8. MEMORY SWITCH DATA LIST ..............................................................76
9. ERROR CODE LIST ............................................................................... 82
10. TROUBLES AND CORRECTIVE MEASURES ....................................87
(1) Mechanical parts ................................................................................................. 87
(2) Electrical parts..................................................................................................... 93
11. CIRCUIT DIAGRAM ..............................................................................104
(1) Block diagram (1/2) ............................................................................................. 104
(1) Block diagram (2/2) ............................................................................................. 105
(2) Head and table/stand circuit diagram................................................................ 106
(3) Main and panel circuit diagram .......................................................................... 107
(4) Power source A circuit diagram ......................................................................... 108
(5) Power source B circuit diagram ......................................................................... 109
(6) Power source C circuit diagram ......................................................................... 110
(7) Motor circuit diagram .......................................................................................... 111
(8) Servo motor circuit diagram ............................................................................... 112
12. VARIOUS PRINTED WIRING BOARDS ............................................... 113
(1) FLT-T p.c.b. ........................................................................................................... 113
(2) FLT-S p.c.b............................................................................................................ 113
(3) PWR p.c.b............................................................................................................. 114
(4) MAIN p.c.b. ........................................................................................................... 114
(5) PANEL p.c.b. ........................................................................................................ 115
(6) DATA p.c.b. ........................................................................................................... 115
13. DRAWING OF THE TABLE ...................................................................116
(1) Slant table ............................................................................................................ 116
(2) Work top table ...................................................................................................... 117
(3) Edge Stopper A ................................................................................................... 118
(4) Edge Stopper B ................................................................................................... 119

−1 −
1. SPECIFICATIONS
Limitation by the amount of alternate vertical movement of presser foot and feed foot
Limitation by stitch length
Max. sewing speed (rpm) Stitch length (mm)
3,500 1.5 to 4.0
2,500 4.1 to 6.0
*1. The maximum sewing speed is limited in accordance with the amount of alternate vertical movement of
presser foot and feed foot, and stitch length.
2. Limitation by the stitch length is automatically limited.
3. Set the limitation by the amount of alternate vertical movement with the memory switch K02.
Max. sewing speed (rpm)
3,500
2,600
2,000
1,600
No. Specifications
DP-2100
Computer-controlled dry-head, lockstitch, sleeve
setting machine with a multi-program device
3,500 rpm (*1)
Intermittent belt feed by direct drive of stepping motor
Both top and bottom 1.5 to 6 mm
Panel input
0.1mm
30.7mm
DP X 17 #10 to #14
Full-rotary non-lubrication horizontal-axis hook
Bobbin case for full-rotary non-lubrication
horizontal-axis hook
Standard aluminum bobbin
By hand lifter : 5.5 mm, by auto-lifter : 10 mm
3.5 mm (0.2 to 0.3 mm at the time of delivery)
Slot stop position adjustment
Non-lubrication
99 programs
30 steps
Provided
Possible
Smart media
Exclusive grease : 23640204 (500g can)
JUKI grease A : 40006323 (tube of 10g)
106 Kg (head 65 Kg)
MC-650
50Hz / 60Hz
560VA
0 to 40, Less than 90%
Workplace-related noise at sewimg speed
n=3,000 min
-1
: LPA ≦ 84dB(A)
Noise measurement according to DIN 45635-48-A-1
Item
Model
Model name
Max. sewing speed
Feed system
Stitch length
Stitch length adjustment system
Stitch length adjustment minimum resolution
Needle bar stroke
Needle
Hook
Bobbin case
Bobbin
Presser foot lift
Amount of alternate vertical movement of
presser
foot/feed foot Max.
Adjustment of amount of alternate vertical movement
of presser foot/feed foot
Lubrication
Number of programs that can be inputted
Number of steps that can be inputted (per program)
Data mirroring
Right/left alternate sewing
Data record
Grease
Weight of complete set
Control box model
Power voltage
Frequency
Rated current
Power/power consumption
Operating temperature/humidity
Noise
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Amount of vertical movement of feed foot (mm)
Less than 0.3
Not less than 0.3 to 1.5
Not less than 1.5 to 2.5
Not less than 2.5 to 3.5
Amount of vertical movement of presser foot (mm)
(2.7)
(1.5)
(2.5)
(3.5)
3-phase
200V/220V/240V
Single phase
220V/230V/240V
2.6A/2.4A/2.2A 2.8A/2.6A/2.5A

−2 −
2. CONFIGURATION
1 Sewing machine head
2 Operation panel
3 Control box
4 Auxiliary table (WORK TOP TABLE)
5 Power switch
6 Main pedal
7 Auxiliary pedal
8 Thread stand
9Shirring release switch
!0 Knee switch for step changeover
(1) Sewing machine main unit
1
2
3
4
5
6
7
8
9
!0

−3 −
(2) Operation panel
1 Touch panel, LCD display section
2 Smart media slot card (Use with the lid closed.)
3 Slide switch (Unused • OFF)
4 Connector for RS-232C communication
5 Variable resistor for adjusting color LCD screen contrast
6 Connector for external input
7 Cable
1
2
3
4
5
6
7
(Front face) (Right side face)

−4 −
3. STANDARD ADJUSTMENT
(1) Adjusting the height of the needle bar
To align
1
1. Bring the needle bar to its lower dead point, and adjust so that the upper marker line engraved on the
needle bar aligns with the bottom end face of the needle bar lower bushing.
Standard Adjustment
0.04 to 0.1 mm
3
4
(2) Adjusting the needle and the hook
1. Adjust the blade point of hook to the center of needle so that the clearance between the blade point
and the needle is 0.04 to 0.1 mm when the lower marker line engraved on the needle bar aligns with
the bottom end face of the needle bar lower bushing. Then tighten three setscrews in the hook.
* RP hook (dry hook) rolls thread waste or cloth dust, and there is a possibility of breakdown or sewing
trouble. Periodically perform cleaning of the hook.
Standard Adjustment
To align

−5 −
1
2
5
6
Adjustment Procedures Results of improper Adjustment
1. Remove throat plate auxiliary plate 1, hook cover asm. 2and hook
base 3.
2. Turn the handwheel and adjust the lower marker line engraved on the
needle bar to the bottom end face of the needle bar lower bushing.
3. Loosen three setscrews in the hook, adjust the needle to the blade
point, and tighten three setscrews in the hook.
4. Put bottom feed belt 4on hook base 3, and assemble them to the
hook shaft base.
5. Assemble throat plate auxiliary plate 1and hook cover asm. 2.
™ When the clearance is excessively
narrow, the blade point of hook is
damaged, and when it is
excessively wide, stitch skipping
will be caused.
™ Place counter knife guard plate 5
located inside hook base 3to the
inside of counter knife 6since
pull-up trouble will be caused.
1. Turn the handwheel by hand to bring the needle bar to its
lower dead point.
2. Remove the plug of the face plate cover.
3. Loosen needle bar connection setscrew 1to adjust the
height.
4. Tighten needle bar conection setscrew 1, and attach the
plug.
™ Stich skipping or thread breakage
may occur.
Adjustment Procedures Results of improper Adjustment

−6 −
(3)Removing the main shaft motor and the coupling
1. Clearance between main shaft motor 1and coupling 2has to be 0.5 mm.
Standard Adjustment
Flat section
3
2
Screw No. 1 3
0.5mm
Screw No. 1 7
5
6
4
8
1
A
7