JUKI TL Series User manual

SERVICE MANUAL
TL series
1-NEEDLE LOCKSTITCH SEWING MACHINE WITH
AUTOMATIC THREAD TRIMMER FOR PROFESSIONAL
No.00
40175681

CONTENTS
[1] SPECIFICATIONS ........................................................................................... 1
[2] NAMES OF COMPONENTS ........................................................................... 3
[3] DISASSEMBLY AND ASSEMBLY .................................................................. 3
[4] PRINTED CIRCUIT BOARD DIAGRAM (CONNECTOR LAYOUT) ............. 16
[5] ADJUSTMENTS OF COMPONENTS ........................................................... 17
WARNING :
To avoid the risk of re, electric shock, injury to persons or damage to components, especially
keep the following :
• 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).

–1 –
[1] SPECIFICATIONS
(1) Power switch
ON•OFF 2-step changeover switch (common to lamp) located at the belt cover section of the right-hand
side of main unit.
(2) Drive control components
Drive : Built-in motor timing belt method
Control : Foot pedal controller method 50 to 1,500 sti/min
Low speed rotation of 80 sti/min while needle up/down switch is ON
(3) Table, stand and handle components
Main unit : Portable type main unit with soft case (Case is folded in two and packed with main unit.)
One-touch type auxiliary table knee lifter is provided as standard. (Packed together)
Handle : Pull-up/down from machine main unit type
Table/stand: Separately sold fully-sunken type table and stand can be used.
(4) Arm and bed components
Material : Aluminum die casting arm and bed separate body type
Bed form : Flat bed portable type
(5) General mechanism
1. Thread take-up : Slit type link thread take-up for one-touch threading
2. Hook : DB type horizontal full-rotary hook
3. Pressing pressure adjustment : Stepless adjusting screw with pressing pressure indicator method
4. Lighting device : Built in face cover Switch : Slide type Lamp : LED lamp
5. Needle thread post : Two posts for small thread spool and large thread spool
Thread guide of thread post is of draw-out type and capable of
one-touch threading
6. Bobbin thread winder : One-touch action : Starting method by controller Automatic stop when
bobbin thread winding completed
7. Needle thread threading : One-touch threading from thread spool to needle tip
8. Presser foot : Commercially-available presser foot for industrial sewing machine
(SL2) can be used. (Setscrew type)
9. Lift of presser foot : By lever : 7 mm Max. by lever : 12 mm By knee lifter : 12 mm
10. Thread tension : Disk pressure adjusting type with simplied disk pressure scale
11. Drop feed : 2-step changeover by knob method (Feed dog : UP : DOWN)
12. Power switch : ON • OFF 2-step
(6) Feed mechanism
1. Feed amount adjustment : Dial method ...... Stepless 0 to 6 mm
2. Reverse feed stitch : Lever method .... Feed amount conforms to that of normal feed stitch.

–2 –
(7) Special mechanism
1. Automatic thread trimming : Thread trimming switch is used in common for pushbutton type and
for external foot pedal switch type.
Switch fails to work even when pressing it within two seconds after
the rotation of thread trimmer.
2. Needle bar stop position : Electric brake stop method
Stop by controller : Down stop
Stop by automatic thread trimming : UP stop
Stop by bobbin winder : UP stop
3. Automatic needle hole threading : Hook section rotates and automatically returns by lowering threading
lever.
4. Needle up/down switch : Switch is of pushbutton type and up/down stop can be performed by
half rotation of main shaft when operating switch for a short period of
time. When switch is continuously held ON, sewing machine
continuously runs at a speed of 80 sti/min until switch is turned OFF.
5. Prevention of reverse setting of needle : Needle is attachable to normal direction only.
6. Motor protection
Overcurrent : When motor is locked for 0.5 to 1 second due to sudden overload,
motor power is automatically turned OFF and returns to the ON state
immediately.
Overheat : When motor temperature has abnormally risen, motor power is turned
OFF(thermal cut) and returns to the ON state when temperature has
fallen.
(8) Dimensions and weight
Main unit : 452W x 219L x 350H (mm)
Weight : 11.5kg
(9) Power consumption
Whole sewing machine : 120V 1.1A 60Hz
: 230V 98W 50Hz/60Hz

–3 –
[2] NAMES OF COMPONENTS
[3] DISASSEMBLY/ASSEMBLY
Page
Outer Components
1. Arm cover asm. ...................................... 4
2. Belt cover and motor cover .................... 4
3. Face plate asm. ...................................... 4
4. Bed cover mas. asm. .............................. 5
5. MAIN circuit board asm. ......................... 5
Function components
1. Motor asm. and transformer asm. .......... 5
2. Handwheel and clutch ............................ 6
3. Thread tensioner asm. ........................... 6
4. Presser bar ............................................. 7
5. Needle bar .............................................. 7
6. Thread take-up ....................................... 8
7. Reverse feed stitch lever ........................ 8
8. Idler ........................................................ 8
9. Stitch dial ................................................ 9
10. Automatic thread trimming switch case .. 9
Page
11. Wire holder ............................................ 10
12. Knee lifter lever .................................... 10
13. Hook driving shaft pulley ...................... 11
14. Hand lifter lever .................................... 12
15. Drop-feed knob ..................................... 12
Automatic thread trimming components
1. Looper mas. asm. ................................. 13
2. Moving knife arm
installing plate mas. asm. ..................... 13
3. Moving knife base mas. asm. ............... 14
4. Thread trimming solenoid mas. asm. ... 14
Indicating needle of
presser spring regulator
Face cover
Pressure indicating plate
Thread take-up thread guide
Thread take-up spring
Presser bar connection thread guide
LED lamp
Needle bar thread guide
Needle bar thread bracket
Presser spring regulator
Thread guide base
Side cover
Thread guide No.1
Standard presser foot asm.
Arm cover asm.
Throat plate asm.
Bobbin winder shaft
Thread take-up spring adjusting plate
Belt cover
Handwheel
Stitch dial
Speed limit vr knob
Automatic thread trimming switch
Reverse feed stitch lever
Hole for knee lifter lever setting
Bed cover rubber seat
Bed cover
Drop-feed knob
Thread guide rod
Needle threader lever
First tention
Needle up/down switch
Hand lifter lever

–4 –
1. Arm cover asm.
3. Face plate asm.
Preparation
○ Remove arm cover.
2. Belt cover and motor cover
Outer Components
❶ Arm cover setscrew
SM5042005SN
❸ Arm cover
❻ Convex of presser spring
regulator knob ❺ Slit of presser regulating screw
❸ Face plate asm.
❶ Lamp connector
❺ Face cover
❷ Face plate asm. setscrew
SL5040631SE ❻ Hand lifter lever spring
❹ Indicating needle of
presser spring regulator
❷ Motor cover setscrew
SM5041255SN
❶ Belt cover setscrew
SM5041255SN
❹ MAIN circuit
board case cover
Disassembly Assembly Point
○Remove two ❶setscrews.
○Disconnect and remove ❷con-
nector.
○Insert
❷connector.
○Align
❻convex with ❺slit and
tighten the setscrew.
○There should be no torsion or dis-
torsion in presser spring regulator.
○Align precisely slit portion with con-
vex portion.
○Do not press each lead wire.
Disassembly Assembly Point
○Remove four ❶setscrews and
remove belt cover.
○Remove three ❷setscrews and
remove motor cover.
○Attach belt cover and tighten ❶
setscrews.
○Attach motor cover and tighten
❷setscrews.
○There should be no difference
in level between belt cover and
front face of frame.
○Make motor cover come closely
contact with belt cover.
Disassembly Assembly Point
○Disconnect ❶connector and ❻
remove.
○Remove ❷setscrews and re-
move ❸face plate asm.
(together with face cover).
○Attach
❸face plate asm., tighten
it with face plate asm. ❷set-
screws, and attach ❻hand lifter
lever spring.
○Insert
❶connector.
○There should be no difference in
level around the cover when face
cover is closed.
○❺should not come in contact
with ❹indicating needle.
❷ Bobbin
winder
connector

–5 –
5. MAIN circuit board asm.
Preparation
○Remove arm cover asm.
○Remove MAIN circuit board case
cover and lamp connector.
Note)
4. Bed cover mas. asm.
1. Motor asm. and
transformer asm.
Preparation
○ Remove arm cover asm.
○ Remove belt cover and
motor cover respectively.
Make a memorandum of
cord wiring.
❶ Bed cover setscrew
SM5051255SN
❶ Bed cover setscrew
Function Components
❷ Power
transformer
setscrew
SM5040855SN
❸ Motor setscrew nut
❶ Motor asm.
setscrew
SM5050855SN
❺ Cord guide
plate setscrew
SM5030655SN
❷ MAIN circuit board case setscrew A
SL5030831SF
❸ MAIN circuit board setscrew
❹ MAIN circuit board case
setscrew B SM5031401SE
Porality exists.
Never loosen this screw.
❻ clip band (3 places)
Disassembly Assembly Point
○ Remove six ❶setscrews and re-
move bed cover.
○ Attach bed cover and tighten set-
screws.
Disassembly Assembly Point
○Remove 7 connectors of each
lead wire.
○Cut
❻clip bands (3 places).
○Remove
❷setscrews and ❹set-
screw, and remove circuit board.
○Press play of circuit board to at-
tach circuit board to the front side
and tighten two setscrews.
○Insert each lead wire into con-
nectors.
○Read the note and understand it.
○There are color indications on
the circuit board for inserting
connectors.
Disassembly Assembly Point
○ Remove cord guide plate ❺set-
screws and ❺-1 in previous item,
and cut ❻clip band.
○ Loosen ❹cord presser.
○ Remove two ❶setscrews, E-ring,
and MP shield plate. Then remove
motor asm.
○ Remove two ❷setscrews and re-
move transformer asm.
Make sure of wiring route.
○ Attach transformer and tighten ❸
setscrews.
○ Attach motor asm. and MP shield
plate, and fix it with E-ring. Then
tighten it with ❶setscrews.
○ Fix it with ❹cord presser.
○ Attach cord guide plate asm. and
tighten ❺and ❺-1 setscrew.
○ Connect cord guide plate and cord.
○ Loosen ❸nuts to adjust mo-
tor tension.
○ Belt tension : the belt should
sag 3 to 4 mm when center
of belt is applied with 1.96N
load.
❺-1
❹
E-ring
MP shield plate
❸ Setscrew to set the
circuit board and cover to
circuit board case
Do not insert in the reverse
direction. (See page 16.)
Do not loosen this screw.

–6 –
2. Handwheel and clutch
Preparation
○Remove belt cover.
○Remove arm cover.
❾ Motor pulley
❻Groove of
handwheel bushing
❽ Handwheel bushing stopper pin
❹ Angle portion of clutch spring
❼ Convex of handwheel bushing
❸ Groove of clutch spring support
󱢳 Groove of handwheel
3. Thread tensioner asm.
❶ Handwheel
setscrew
❷ Handwheel
❶ Thread take-up spring
adjusting plate setscrew
SL5030801SN
❷ Thread tensioner setscrew
SM8040602TP
❸ Thread take-up spring
❹ Thread tensioner asm.
❺ Thread tension disk presser
❺ Hook portion of clutch spring
❻ Thread take-up
spring adjusting
plate
When removing motor
pulley, remove cord guide
plate setscrews ❺and
❺-1 in previous item.
Disassembly Assembly Point
○ Remove ❶setscrew.
○ Lower presser foot and remove
❷setscrew.
○ Remove ❸spring together with
❹thread tensioner asm. and ad-
justing plate.
○ Attach ❻adjusting plate and ❸
spring to thread tensioner asm.
and attach it to frame. Then x it
with ❷setscrew.
○ Tighten ❶adjusting plate set-
screw.
○ Place upward the scale of ❺
thread tension disk presser.
○ See items 9 and 10 on page 19
for adjustment of pressure and
thread take-up spring of stroke.
Disassembly Assembly Point
○ Remove ❶setscrew.
○ Remove cord guide plate setscrew
and remove cord guide plate asm.
○ Remove ❸spring support.
○ Move ❹in the direction where
clutch spring is released and re-
move clutch spring.
○ Face ❻to motor side and ❽is
hard to drop.
○ Draw out ❽and remove ❾.
○ Attach ❾and enter ❽.
○ Enter ❻groove of bushing to ❽
stopper pin and attach bushing.
○ Enter ❺hook portion of spring
to slit in the center of handwheel
bushing
○ Enter ❺clutch spring to ❸
groove of spring support and at-
tach cord guide plate asm. Then
tighten setscrew.
○ Align ❼convex of bushing
with 󱢳groove of handwheel
and attach handwheel. Then
tighten setscrew.
○ Clearance provided between
convex of ❸clutch spring sup-
port and clutch plate is 2 ± 0.5
mm.
○ See item 12 on page 19 for ad-
justment.

–7 –
4. Presser bar
Preparation
○Remove arm cover asm.
○Remove face plate mas. asm.
○Remove presser foot and setscrew.
❻ Presser bar lifting lever
❽ Hand lifter lever
❸ Presser bar
❷ Presser spring regulator
❼ Indicating needle of
presser spring regulator
❹ Presser spring
❺ Presser bar connection asm.
❶ Presser bar connection setscrew
SM8060502TP
Threader support plate
setscrew (upper)
SL5040631SE
Threader support plate mas. asm.
Threader support plate
setscrew (lower)
SM4040655SN
5. Needle bar
Preparation
○Remove arm cover asm.
○Remove face plate mas. asm.
○Remove presser bar.
○Remove needle bar threading guide
as well.
Needle bar
crank left screw
❶ Needle bar upper bushing felt
❷ Needle bar connection setscrew
SM8060510SP
❻ Needle bar threader guide setscrew
❺ Needle bar
❹ Needle clamp
❸ Needle bar thread bracket setscrew
A1420-001-000
Disassembly Assembly Point
○ Lower ❽lever and loosen ❶set-
screw.
○ Drawing ❸upward, remove ❹
spring.
○ Remove ❺connection and ❻lever.
○ Remove regulator ❷screw.
○ Do not remove ❼indicating needle.
❸is hard to remove since secrew
mark is attached.
○Attach regulator ❷screw.
○Set ❻lever to frame, and
then set ❺connection.
○Attach
❹spring when setting
❸presser bar from upper
side.
○Set
❹spring under ❼indicating
needle.
○Lower ❽lever and temporarily
tighten it at the position where top
end of ❸protrudes approximately
4 mm from frame.
For the adjustment, see item 3 on
page 18.
○Needle should not interfere with
presser foot.
Disassembly Assembly Point
○Remove
❸and ❹.
○Remove ❶felt. (Push up
needle bar upper bushing ❶
felt with ❺and draw it out.)
○Loosen setscrew of ❷and
❻. (Pushing needle bar ❺
upward is acceptable.)
○Draw out ❺upward.
○Remove left ❻screw and re-
move crank rod.
○Attach crank rod and tighten it with
❻.
○Perform positioning of needle bar
and tighten needle bar connection
❷setscrew.
○Set needle bar and attach ❹and ❸.
○Insert
❶into hole.
○Temporarily tighten ❻, and perform
adjustment of vertical height after at-
taching threader support plate asm.
○Position of needle bar is the place
where upper engraved line of
needle bar is aligned with lower
end face of needle bar bushing at
the needle lower dead point.
See item 2 on page 18 for the ad-
justment.
○See item 15 on page 23 for height
adjustment of threader hook of
threader support plate mas. asm.

–8 –
7. Reverse feed stitch lever
Preparation
○Remove belt cover.
8. Idler
Preparation
○ Remove belt cover.
6. Thread take-up
Preparation
○Remove arm cover asm.
○Remove face plate mas. asm.
○Remove presser bar.
○Remove needle bar.
❷ Convex portion of idler installing plate
❶ Idler setscrew
SM5040855SN
❺ Feed regulator
❶Reverse feed
stitch lever spring
❹Reverse feed
stitch lever arm
❷ Needle bar
crank setscrew
❺ Thread take-up
❶ Thread take-up supporting shaft setscrew
SM8050602TP
❸ Thread take-up
supporting shaft
❹ Needle bar crank
❻ Thread take-up
support
❸ Reverse feed stitch
lever mas. asm.
❷ Reverse feed stitch lever setscrew
SM5040855SN
Disassembly Assembly Point
○Loosen
❶setscrew.
○Loosen two ❷setscrews.
○Draw out thread ❸take-up sup-
porting shaft.
○Remove
❺and ❻together with
❹needle bar crank.
○Set needle bar crank to thread
take-up, attach it onto main unit
and tighten setscrews (2 pcs.).
○Set ❻to ❺, enter thread take-
up supporting shaft ❸to ❻, at-
tach it onto frame and tighten ❶
setscrew.
○Tighten setting portion (flat por-
tion) of needle bar crank with
screw No. 1.
○Press
❸shaft to frame side while
viewing the torque and tighten ❶
setscrew.
Disassembly Assembly Point
○Remove
❶spring from arm.
○Remove two ❷setscrews.
○Remove
❹lever arm from the slot
of ❺regulator when removing ❸.
○Attach ❸lever and set with ❷
setscrews.
○Hook lever spring ❶to lever arm
❹.
○Set
❹lever arm to the slot of ❺
regulator.
Disassembly Assembly Point
○Remove
❶setscrew and remove
idler asm.
○Assemble idler and tighten it with
❶setscrew.
○Belt tension : Belt sags 6 to 7
mm when center of the belt is
applied with a 1.96N load.
○Belt tension can be changed only
by removing belt cover. Move ❷
convex portion to the left or right.