JUKI IP-100A Quick start guide

ENGINEER’S MANUAL
40011067
No.E355-01
Computer-controlled, Direct-drive, High-speed, 1-needle,
Lockstitch, Zigzag Stitching Machine
LZ-2290A Series
IP-100A / SC-915
IP-100D / SC-916
R

PREFACE
This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance
of the machines.
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 Manuals and Parts Lists for LZ-2290A and LZ-2290A-SR together
with this Engineer’s Manual.
This manual gives the “Standard Adjustment” on the former page under which the most basic adjustmenr 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
(1) Specifications of the machine head...................................................................................................... 1
(2) Stitch pattern table................................................................................................................................ 2
(3) Function list .......................................................................................................................................... 3
(4) Cautions in operation............................................................................................................................ 4
2. NAME OF EACH COMPONENT .................................................................................... 4
3. STANDARD ADJUSTMENT .......................................................................................... 6
(1) Height and inclination of the feed dog .................................................................................................. 6
(2) Adjusting the feed timing ...................................................................................................................... 6
1) Adjusting the feed timing (Excluding A-SR).................................................................................... 6
2) Adjusting the feed timing (for A-SR only) ....................................................................................... 8
(3) Adjusting the feed amount.................................................................................................................. 10
1) Adjusting the feed amount (Excluding A-SR) ............................................................................... 10
2) Adjusting the feed amount (A-SR only) ........................................................................................12
(4) Position of the feed dog...................................................................................................................... 14
(5) Adjusting the slippage of materials (For A-SU and A-DU).................................................................. 16
(6) Adjusting the origin of the needle rocking motor ................................................................................ 18
(7) Adjusting the needle entry position (In terms of needle rocking direction) ......................................... 20
(8) Adjusting the needle entry position (In terms of longitudinal direction) .............................................. 20
(9) Adjusting the longitudinal play at the needle bar ................................................................................ 20
(10) Position of the needle bar connection guide..................................................................................... 22
(11) Height of the needle bar ................................................................................................................... 22
(12) Adjusting the needle-to-hook timing and the needle guard .............................................................. 24
(13) Position of the bobbin case stopper ................................................................................................. 26
(14) Orientation of the needle bar thread holder...................................................................................... 26
(15) Position of the thread tension ........................................................................................................... 28
(16) Position of the pre-tension................................................................................................................ 28
(17) Position of the thread take-up spring guard...................................................................................... 30
(18) Installing the thread take-up thread guide B..................................................................................... 30
(19) Installing the thread take-up ............................................................................................................. 30
(20) Installation of the presser foot .......................................................................................................... 32
(21) Installing and adjusting the bobbin winder unit................................................................................. 32
(22) Adjusting the amount of oil in the hook (A-SS/-7, A-SU/-7, A-SR) ................................................... 34
(23) Adjusting the thread trimming unit (Thread trimmer type only)......................................................... 36
(24) Initial position of the moving knife (Thread trimmer type only) ......................................................... 36
(25) Timing of the thread trimming cam (Thread trimmer type only)........................................................ 38
(26) Installing/removing the knife unit (Thread trimmer type only)........................................................... 38
(27) Stop position of the needle after thread trimming (Needle UP stop) ................................................ 38
(28) Clearance provided between the main shaft handwheel and the stator........................................... 40
(29) Position of the automatic reverse stitching magnet (Excluding A-SR) ............................................. 40
(30) Adjusting the thread tension releasing solenoid (Thread trimmer type only).................................... 40
(31) Adjusting the stitch length dial (Excluding A-SR) ............................................................................. 42
(32) Adjusting the lubrication mechanism (A-SS and A-SU, A-SR only) ................................................. 44
(33) Adjusting the position of the thread draw-out wire
(For the machine with thread trimmer only) ......................................................................................44
(34) Adjusting the stroke of the thread draw-out wire
(For the machine with thread trimmer only) ......................................................................................46
(35) Installing the wiper base (WB type only) .......................................................................................... 46
(36) Adjusting the wiper solenoid (WB type only) .................................................................................... 48
(37) Position of the wiper ......................................................................................................................... 48
1) WB type ........................................................................................................................................ 48
2) CB type......................................................................................................................................... 50

4. PROCEDURES OF DISASSEMBING/ASSEMBLING AND CAUTIONS .................... 52
(1) Adjusting and assembling of the gear box (large) .............................................................................. 52
(2) Replacing the motor ........................................................................................................................... 54
(3) Replacing the timing belt .................................................................................................................... 56
(4) Removing/installing the gear box cover.............................................................................................. 58
(5) Disassembling/assembling the needle bar support base shaft (asm.) ............................................... 58
(6) Adjusting/assembling the reverse feed control lever (A-SR only) ...................................................... 70
5. MAINTENANCE............................................................................................................ 76
(1) Changing procedure between single phase 100 to 120V and 3-phase 200 to 240V ......................... 76
(2) Replacing procedure of the printed circuit board................................................................................ 77
(3) Maintenance of the hook lubricating pipe oil filter............................................................................... 78
(4) Cleaning the cooling fan ..................................................................................................................... 79
(5) Applying the exclusive grease ............................................................................................................ 80
(6) Hook shaft gear .................................................................................................................................. 84
(7) Adjusting the needle rocking link ........................................................................................................ 85
(8) Lubricating to face plate section (A-SS and A-SU, A-SR only) .......................................................... 86
(9) Protruding amount of the hook shaft .................................................................................................. 88
(10) Adjusting the feed stepping motor unit (A-SR only).......................................................................... 88
(11) Draining of CB type .......................................................................................................................... 89
(12) Cleaning the dust bag of CB type..................................................................................................... 89
6. OPERATION PANEL.................................................................................................... 90
(1) Names of the respective sections....................................................................................................... 90
(2) Information.......................................................................................................................................... 92
(3) Matters that demand special attention regarding the operation panel, IP-100 ................................. 106
7. SPECIFICATIONS OF SC-915/916............................................................................ 107
8. FUNCTION SETTING PROCEDURE OF SC-915/916............................................... 107
(1) How to change over to the function setting mode ............................................................................ 107
9. FUNCTION SETTING LIST ........................................................................................ 111
10. DETAILED EXPLANATION OF SELECTION OF FUNCTIONS.............................. 115
11. EXTERNAL OUTPUT/INPUT CONNECTORS......................................................... 121
(1) Connector connection diagram......................................................................................................... 121
12. ERROR DISPLAY..................................................................................................... 122
(1) ERROR DISPLAY ............................................................................................................................ 122
(2) Error code list (Error display in panel) .............................................................................................. 123
(3) Warning list....................................................................................................................................... 126
13. SCREWS FOR ATTACHMENTS ............................................................................. 127
14. SPARE PARTS......................................................................................................... 127
15. OPTIONAL CORD .................................................................................................... 128
(1) Relay cord A asm. for standing machine (Part No. M9701351AA0) ................................................ 128
(2) Relay cord A asm. for DC24V (Part No. M9703351AA0) ................................................................. 129
16.TROUBLES AND CORRECTIVE MEASURES......................................................... 130
(1) With regard to lubrication.................................................................................................................. 130
(2) With regard to sewing....................................................................................................................... 132
(3) With regard to mechanical components ........................................................................................... 137
17. CONFIRMATION ...................................................................................................... 144
18. BLOCK DIAGRAM ................................................................................................... 145
(1) Block diagram A (for SC-915)........................................................................................................... 145
(2) Block diagram B (for SC-916)........................................................................................................... 146
(3) Operation panel block diagram......................................................................................................... 147
19. DRAWING OF TABLE.............................................................................................. 148
CUSTOM PATTERN NEEDLE ENTRY POSITION DATA SHEET ....................................................... 149

−1−
LZ-2290A-SU / -7
4,500 rpm (*1)
2.5mm/2.5 mm (*3)
(Stepless fine adjustment)
1.4mm
LZ-2290A-SS / -7
5,000 rpm (*1)
5 mm/4 mm (*3)
(Stepless fine adjustment)
1.2 mm
LZ-2290A-DS / -7
5mm/4 mm (*3)
(Stepless fine adjustment)
1.2 mm
Light- to medium-weight materials
10 mm (*2)
8 kinds 14 patterns
(Custom pattern : 500 stitches, 20 kinds can be stored.)
SCHMETZ 438, ORGAN DPX5 : #65 to #90
178 mmX517 mm
4,000 rpm (Excluding a certain territory of export)
33.4 mm
Built-in in the upper face of machine head type (with bobbin thread retaining plate)
Electromagnetic front-wiping system (WB), electromagnetic side-wiping system (CB)
Built-in electromagnetic system
5.5 mm
10 mm
6 to 6.5 mm
Direct drive system (compact AC servo motor)
Timing belt system
Rated output 450W
3-phase 200 to 240V, Single phase 100 to 120V
DC34V
Presser foot micro-lifting screw is provided as standard.
1. AK-121 (Auto-lifter : Part No. : GAKA21000B0)
2. Exclusive grease tube for maintenance 10g (JUKI grease A Part No. : 40006323)
3. Exclusive grease can for maintenance 500g (Part No. : 23640204)
4. Touch-back kit asm. (Part No. ; 40010795) ... Other than WB, CB, OB, A-SR)
5. Optional switch kit (Part No. ; 40003640)
LZ-2290A-DU / -7
2.5mm/2.5 mm (*3)
(Stepless fine adjustment)
1.4mm
1. SPECIFICATIONS
* 1 : The sewing speed is regulated in accordance with zigzag width (A-SR : zigzag width and feed amount).
* 2 :Zigzag width is regulated to 8 mm at the time of delivery. (Max. zigzag width of all machines is 10 mm.)
* 3 : Normal and reverse feed amounts are regulated to 2 mm at the time of delivery.
Model
Application
Max. sewing speed
Max. zigzag width
Max. feed amount
(Normal/reverse)
Stitch pattern
Needle
Dimension of the bed
Number of revolution
of resistor pack
Needle bar stroke
Bobbin winder
Wiper
Automatic reverse
stitching device
Lubrication
Lift of the presser foot
(by hand lifter)
Lift of the presser foot
(by knee lifter)
Lift of the presser foot
(by AK auto-lifter)
Kind of the hook
(Part No.)
Bobbin case (asm.)
Heightofthefeed dog (standard)
Lubricationoftheface
plate section
Drive system
Transmissionfunction
Motor output
Operating power
Solenoid drive power
Additional function
Major optional
devices
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
Lubrication system to oil tank for hook
lubrication
JUKI New Defrix Oil No. 1 is used.
(Equivalent to ISO VG7)
Plunger pump is employed.
22525877
40003598 (with idle-prevention spring)
Minute quantity lubrication by oil wick
Full non-lubrication
23557259 (Non-lubrication hook)
Non-lubrication
4,000 rpm (*1)
LZ-2290A-SR-7
5,000rpm (*1)
5mm/5 mm
(0.1 adjustment by electronic control)
14 kinds 20 patterns
Stepping motor
control
Lubrication system to
oil tank for hook
lubrication
JUKI New Defrix Oil
No. 1 is used.
(Equivalent to ISO
VG7)
Plunger pump is
employed.
22525877
40003598 (with idle-
prevention spring)
1.2 mm
Minute quantity
lubrication by oil wick
(1) Specifications of the machine head
40003609 (with idle-prevention spring)