JUKI HZL-T100 User manual

SERVICE MANUAL
HZL-T100
®
COMPUTER SEWING MACHINE

CONTENTS
[1] SPECIFICATIONS ··············································································· 1
[2] CONFIGURATION ··············································································· 4
[3] ASSEMBLY / DIASSEMBLY ································································· 5
[4] CIRCUIT BOARD CONNECTING DIAGRAM ······································· 12
[5] ADJUSTMENT ······················································································ 13
WARNING :
• When disassembling, assembling or adjusting the sewing machine, remove the power plug.
• When assembling, be careful about the electrical cord being caught with other components,
damage to the covered parts of the cord or miswiring.
• When replacing the part(s), use the genuine part(s).
To avoid the risk of fire, electric shock, injury to persons or damage to
components, especially keep the following:
Frame components
1. Top cover, top board ································ 5
2. Handle, face plate cover ·························· 5
3.Operatinglever··········································5
4.Frontpanel·················································6
5. Bed base, cylinder bed lower cover ········ 6
Functional components
1. Microcomputer circuit board, main shaft
detecting·····································································7
2.Motor,controlbox······················································7
3. Idler, bobbin winder base (asm.) ······························ 8
4.Transformer,powerswitch········································ 8
5. Needle bar connecting rod, needle throwing STM ·· 9
6.Face plate (asm.) ······················································ 9
7. Main shaft, operating lever receiving plate ············ 10
8.Cylinder bed receivingplate (asm.) ························10
9.Needle bar frame stud (asm.) ·································· 11
Sewing components
1.Heightofneedlebar································································································································13
2. Needleentry (lateral) inthe throat plate (needleplate) ······································································· 13
3.Heightofthepresserfoot······················································································································13
4.Heightofthefeeddog····························································································································14
5.Adjustingtheneedletohooktiming ······································································································14
6. Clearance betweentheneedle and the blade point············································································15
7. Position of the detent plate of the inner hook (position of the bobbin case opening lever) ················ 15
8.Adjustingthelongitudinalfeed···············································································································16
9.Buttonholechange-overswitch···············································································································17
10.Verticalposition of automatic threader hook ······················································································· 17
11.Adjustingthetension·························································································································18-21
Automatic thread trimmer components
1. Positionof the thread trimmingswitch and one-stitch switch······························································ 22
2.Timingofthreadtrimming·······················································································································22
3. Position of the moving knife (draw-in position of the moving knife) ···················································· 23
4.Adjustmentoftheknifedrivinglink········································································································23
(Clearance between the driving link roller and the thread trimming cam)
5.Adjustmentofthe knifedisengagingplate ···························································································· 24
(Engagement of the disengaging plate and the thread trimming cam)
6.Looperstroke(verticalstroke)················································································································24
7.Adjustingthepositionofknife·················································································································25
8.Stoppositionofthreadtrimmer··············································································································25

(1) Speed regulating components
Slide control system
Stepless speed change gear
When using this controller, the slide control mechanism is inoperative.
The control speed is same as the speed controlled by the slide control mechanism.
(2) Table stand components
Main unit case
Handle
(3) Bed type
Cylinder bed and flat bed
Quickly change over by a finger control
(4) General mechanism
1. Thread take-up
2. Hook
3. Pressure regulator
4. Lighting mechanism
5. Needle thread stand
6. Bobbin thread winder
7. Needle threader
8. Presser foot
9. Replacement of presser foot
10. Power switch
11. Lubrication
12. Cable
[1] SPECIFICATIONS
For straight stitching : 116 to 750 rpm
For stitching methods other than straight stitching : 116 to 500 rpm
For winding a bobbin : 116 to 700 rpm
: The main unit case covers the components exclude the under cover and
the handle.
: Designed to be tilted from the main unit of the sewing machine.
: Link type thread take-up with slit for one-touch utility thread eyelet
: Full-rotary, vertical-axis hook
: Constant pressure applying system
: Built in face plate cover
The power switch of the sewing machine is commonly used as the lamp
switch.
: Horizontal type thread stand built in the top board
: Bobbin winder shaft sliding method
Thebobbin winder startswinding a bobbinby operating thestart/stop switch.
:One-touch
: Exclusive transparent presser foot
: Snap-on/-off type
: 2-step power switch commonly used as the lamp switch
: No lubrication is required ( under the normal operating conditions).
* Lubricationg the inner hook is prohibited.
: A 1.9 m long power cable is removable.
-1--1-
-1--1-
-1-

-2--2-
-2--2-
-2-
(5) Needle bar rocking mechanism
1. Needle bar rocking method
2. Straight stitching
3. Stitch width
4. Adjustment of stitch width
5. Standard line
6. Needle bar driving system
(6) Feed mechanism
1. Feed amount
2. Reverse feed amount
3. Adjustment of feed amount
4. Reverse feed stitch
5. Feed mechanism
(7) Special-purpose mechanism
1. Automatic thread trimmer
2. Automatic needle threading device
3. Automatic buttonholing
4. Selection of stitch patterns
: By the arc method
: Left, center, right
: Max. 6 mm depending on the stitch pattern
: By sliding the lever (The stitch width adjusting mechanism is effective when
the manual operation indication LED lights up.)
When manually adjusting, notice of change-over of the set value is given by
the buzzer sound.*
As for the part of automatic set value, the notice is given by the flash on/off of
LED.*
: Left standard line
: By a stepping motor
: 0 to 4 mm
: 0 to 2.4 mm
:By sliding the lever(Thefeed amount adjusting mechanismis effective when
the manual operation indication LED lights up.)
When manually adjusting, notice of change-over of the set value is given by
the buzzer sound.*
As for the part of automatic set value, the notice is given by the flash on/off of
LED.*
: The machine performs reverse feed stitching at low speed only when the
switch is ON.
: By a stepping motor
The moving knife trims the thread while the main shaft makes a revolution (
or a shaft revolution form its lower stop position) by setting the operation
lever to the thread trimming position. (116 rpm)
The hook automatically rotates and returns to its home position by lowering
the threading lever.
Auto-return type full automatic buttonholing
Buttonhole size can be specified as desired. When the buttonhole is fin-
ished, the machine automatically stops after performing fastening stitching.
(The machine gives an error message on the LCD to prevent the operator
from starting the machine without setting the machine for the buttonholing.)
Straight stitch Direct selection by the touch switch *
Other stitch patterns by shift selection (99 stitch patterns)*
Shift direction change-over switch is provided. *

-3--3-
-3--3-
-3-
5. Number of stitch patterns
6. Slow start function
7. Constant stop position of the
needle bar
8. Prevention of incorrect needle
insertion
9. Prevention of overheat
10. Bobbin case
11. Presser foot storage box
12. Automatic lock stitch
13. Thread tension unit:
14. Memory:
(8) Dimensions and weight
Dimensions
Weight
(9) Electric rating
Entire unit of the sewing machine
Lamp
Continuous stitch patterns 43*, One point stitch patterns 57* Total 100 stitch
patterns
Buttonhole : Buttonhole(small), Buttonhole(large), Eyelet buttonhole *, Deco-
rative buttonhole
Approx. 1 stitch is sewn at the speed of 116 rpm after the start switch is
turnedON.
Needle bar can be stopped in its highest position or lowest position by using
the synchronizer shielding plate and photo-interrupter.
· Needle bar stops in its lowest position at the time of the end of sewing.
· Needle bar stops in its highest position when the stitch pattern is selected
while it stops in its lowest position.
· Needle bar stops in its highest position at the time of thread trimming,
bobbin winding or lifting the presser foot.
A needle can be attached on the machine only when installing direction of
the needle is correct.
If the sewing machine rotation is locked for two seconds, the power to the
motor is automatically turned OFF. When the temperature of the motor ab-
normally rise, the power to the motor is turned OFF.
(Thermal cut) After the temperature of the motor has sufficiently lowered, the
machine can be started.
Integral witch the inner hook
Presser feet supplied as standard accessories of the machine are stored in
the auxiliary bed of the main unit of the sewing machine.
When the lock stitch is set, 3-stitches of the lock stitch are automatically per-
formed at sewing -start & -end.
In case of the one-point stitch pattern, the lock stitch switch is automatically
turned ON. *
Pre-tension, Disc pressure type thread tension with 2nd tension.
Memory capacity 20 pcs.
Every time the clear key is pressed, the stitch patterns set are cleared from
the last one. *
When keeping pressing the clear key, all the stitch patterns set are cleared.
400 mm (width) x 175 mm (depth) x 280 mm (height)
8.5 kg
220-240 V, 85 W, 50 Hz
(12 V, 5 W)

[2] CONFIGURATION
-4--4-
-4--4-
-4-
Power/Light switch
Hand wheel
Handle
Speed controller receptacle
Power cord receptacle
Speed controller
Electric power cord
Presser foot lifter/thread trimming lever Pattern (Number) selector
buttons
Face cover
Auxiliary bed
(Accessory box)
Stitch balance control
Start/stop button
(When speed controller is not used.)
Automatic backtack button
Top cover
Sewing speed setting lever
(When speed controller is not used.)
Reverse stitch button
Liquid crystal display (LCD)
Pattern No. increase/
decrease selector button
Pattern memory button
Pattern clear button
Straight stitch direct button
Needle set screw
Feed dog
Buttonholinglever
Presser foot release button
Needle threader
Presser foot holder Needle
Presser foot
Hook cover button
Bobbin
Bobbin case
Throat plate
(needle plate)
Bobbin winder
Spool pin
Bobbin winder thread guide
Thread tension dial
Pattern display panel
Thread spool cap
Manual stitch width
button & lever
Manual stitch length
button & lever

-5--5-
-5--5-
-5-
Frame components
1. Top cover, top board
Disassembly Assembly Point to be checked
When removing the top cover, bend
hinge . (The top board can be
removed with the arm cover attached.)
Remove five screws in the top board.
Lifting the top board, draw out the
connector.
* Do not remove the screw in the
bobbin thread winding amount
adjusting plate.
· Set the top cover in place with closed.
· Set the top board on the frame.
· Set the top board with its rear right
section accurately fitted with the face
plate cover.
· The hinge easily bend when closing
the top cover.
· Be careful to connect the connector
without fail.
· Take care not to allow the top board
to become loose.
2. Handle, face plate cover
Preparation required
Remove the top board.
Disassembly Assembly Point to be checked
Remove one retaining ring of the
handle.
Remove handle .
Loosen screw in the face plate
cover, and remove the cover.
· Set the handle on the frame.
· Attach the retaining ring to the handle.
·Set thecover onthe frame,and tighten
the screw.
· Carefully check the installing
direction of the handle.
· Securely attach the two installing
bosses in the face plate.
[3] ASSEMBLY / DISASSEMBLY
3. Operating lever
Preparation required
Remove the top board.
Disassembly Assembly Point to be checked
Loosen screw in the operating
lever, and draw out the operating lever. · Set the lever in place, and tighten the screw. · Take care not to allow the screw to become loose while the sewing
machine is in operation.
j
k
j
k
l
j
Retaining
ring of the
handle
Screw in the face
plate cover
Handle
(asm.)
Face plate
cover
j
k
l
m
Screw in the
operatinglever
j
j
Top cover
Face plate cover
Top board
Rear right
section
Top board screws
Hinge section
j
k

-6--6-
-6--6-
-6-
4. Front panel
Preparation required
Remove the top board.
Remove the front cover.
Remove the operating lever.
Disassembly Assembly Point to be checked
Loosen screw in the face plate of
thepanel.
(You may loosen and tilt the lamp
instead of loosening screw .)
Loosenscrew at the center of panel.
Loosen two screws in the bottom of
panel.
· In order to release the engaging
section to eliminate loose fitting,
remove the panel while lifting it.
Assemble through without fail.
· Tighten the four screws which have
been loosened.
Caution:
Make sure that the indicator
connecting cable has been connected.
Fit needle thread guide pin in the
groove on the front panel in the correct
manner.
Face plate cover
guideshaftA
5. Bed base, cylinder bed lower cover
Disassembly Assembly Point to be checked
Remove three screws in the rubber
seatA.
Remove three screws in the bed
base.
Remove two screws in cylinder bed
lower cover , and remove the cover.
· Attach the bed base on the frame.
· Fix the bed base by tightening the
screw which have been removed.
·Set the three rubber seat A on the bed
base with accuracy.
[Top surface of the frame]
[Side face of frame (face frame)]
[Bottom view of frame]
Center screw of panel
Screw at the bottom of panel
Screw in the side
face of panel Engaging section to
eliminate loose fitting
Needle thread guide pin
Engaging section of the panel
Engaging section at the center of panel
Needlebar
connecting rod
Mainshaft Bobbin winder shaft
ko
n
j
k
l
o
m
n
k
j
k
m
n
j
k
l
Screw in the bed base
Screw in the
cylinder bed
lower cover
Screw in the rubber seat A
j
k
l
l

-7--7-
-7--7-
-7-
Functional components
1. Microcomputer circuit board,
main shaft detecting
Preparation required
Remove the top board.
Remove the face plate cover .
Remove the front panel.
Disassembly Assembly Point to be checked
· Remove connectors (14 connec-
tors).
Cut cable clip , and remove the
lead from the radiating plate.
Remove two screws in the micro-
computer circuit board.
(Do not remove the screw in the radi-
atingplateattachedby anasterisk(*).)
Remove one screw in the main
shaftdetecting platecircuit board,and
remove the circuit board.
· Attach the microcomputer circuit
board on the frame, and fix it by
tightening the two screws.
· Connect the connectors.
(See page 12.)
· Attach the main shaft detecting plate
printed circuit board in place, and fix
it using the screw.
Caution:
Removing/attaching the
microcomputer circuit board.
Be sure to carefully remove the micro-
computer circuit board taking care not to
preventtheprinted circuitboardfrom com-
ingincontactwiththemetalfittingsmarked
with a double circuit and not to allow the
radiatingplate marked witha double circle
to come in contact with the motor belt,
transformer and other components.
· The shielding plate of the main shaft
should not come in contact with the
sensor when installing the printed
circuit board in place.
Cable clip
Screw in main
shaft detecting
circuit board
Screw in the microcomputer
circuit board * Screw in the radiating plate
Metalfittings
Radiating plate
2. Motor, control box
Preparation required
Remove the top board.
Remove the face plate cover.
Remove the front panel.
Disassembly Assembly Point to be checked
Remove two screws in the motor.
Lift stopper in the cover, and remove
the cover.
· Remove the motor belt and the con-
nector, then remove the motor.
Remove screws in the electrical box.
· Attach the electrical box in place, and
fix it with the screws.
· Set the leads in place. (See page 12.)
· Fit the cover to the electrical box.
(Pass leads through the hole in
the cover.)
· Attach the motor in place.
· Fit the leads of the motor in the
indented section of the cover.
· Take care of the belt tension.
j
k
l
j
k
l
j
k
l
m
Screw in the motor
Screw in the electrical box
Stopperof
the cover
Pass the leads
through the hole
in the cover.
jk
l
m

-8--8-
-8--8-
-8-
3. Idler, bobbin winder base (asm.)
Preparation required
Remove the top board and the handle.
Remove the face plate cover.
Remove the front panel.
Remove the microcomputer circuit board.
Disassembly Assembly Point to be checked
Loosen screw in the idler, then pull
the idler (asm.) toward you.
Remove two screws in the bobbin
winder base, and remove the base.
* Set the bobbin winder to its operating
state (by setting the shaft to its right
side).
· Check the timing of thread trimming,
then attach the idler (asm.).
·Attachthebobbinwinderbaseinplace,
and fix it with the screws.
· Refer to No. 2 on page 12 for the
correct timing of thread trimming.
· Belt tension: The belt should slacken
by 4 to 6 mm when applying a 200g
loadto center of the belt.
· When winding a bobbin, the bobbin
winding switch should be turned OFF.
4. Transformer, power switch
Preparation required
Remove the top board and
the front face cover.
Remove the front panel.
Remove the microcomputer circuit board.
Remove the idler and the motor.
(Remove the timing belt.)
Remove the cover of the electrical box.
Disassembly Assembly Point to be checked
Remove two screws in the trans-
former.
(Metal fittings come off simulta-
neously with the screws.)
· Remove the connector from the
printed circuit board.
Remove two screws in the power
switch.
· Remove the connector from the
printed circuit board.
· Attach the transformer to the frame,
and fix it with the screws.
· Attach the power switch to the frame,
and fix it with the screws.
· Refer to page 12 for how to connect
the connector.
· Take care of the polarity of the
connector.
j
k
m
j
k
l
Screw in the transformer Screw in the power switch
Metalfittings
j
k
l
[Top surface]
Screw in the bobbin winder base
Center of the belt
j
k
m
Screw in the idler