Juki DLU-5490N, DLU-5490N-7 User Manual
UKI
®
Preface
This Engineer's Manual mainly consists
adjust", and "Results
the maintenance and repair
especially
"Standard adjustment".Please read this manual carefully before using the units
in order to get the most out
of
improper adjustment". All technical personnel who are responsible for
of
the DLU-5490N and DLU-5490N-7 should carefully read
of
them and to enjoy using them for a long time.
CAUTION
1.
K~ep
powN
opuatmg.
your
switch
hands
is
away
tumed
from
the needle
ON or while
the
\'>'hen
machine
the
2.
is
of
three sections; "Standard adjustment",
Do
not
put
your
lingen
into
the
1hnad
take-up
v.hile
the
mil<:hine is
operating
co•er
3.
Be
the m•chine
sure to
"How
tur~
the
had
or
to
powtr
rema•lng
switch
the
OFF
Vbelt
befora tihing
5.
II
your
"'•chine
4.
Ourin9
operation,
other
per!on's
handwhul,
not
pl~ce
dangerous.
BEFORE
•
Don't
be
cardul
head or
V belt,
anything
lunds
bobbin
winder
dose
to them. Doing
.
OPERATION
run
the
machine
not
to_
tO
allow
come close
or
mator.
your
Al1o,
so
mly
before
or
any
to
tha
do
Ia
g\Jard or
machine with any of
filling
is
any
<>Iller
the
oil reservoir.
• After setting up your machine, make sure that
lower
revolution
direction
the
needle
by
momentarily
of
the
by
turning
handwheel:
the
handwheel
switching
the
counterclockwise
power
handwheel's end).
the
Run
one
Confirm
newly installed machine at a
month.
the
ratings of your power source by the machine plate stuck on
motor (power voltage,
Do
not wipe
the
surface of the machine head with lacquer thinner.
phase
etc.)
speed
pro>ided with a belt covor, finger
prot~to,,
do
not
operate
them
removed.
it
runs
in
and
watch
"on"
when
of 4,000 s.p.m.
your
the correct direction;
the
(correct rotational
viewed
or
handwheel's
from
the
lower for the
the
CONTENTS
1.
SPECIFICATIONS
2.
APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . 2
STANDARD
3.
( 1) Height
(2) Timing between the needle
(3) Height
Feed
(4)
(5)
(6) Walking
(7) Relationship between the walking foot graduation plate . . . . • . . . . • . • . . . . . . . . . . . . . . . . . 7
(8) Top feed vertical timing
(9) Top feed horizontal timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0)
( 1
11)
(
( 12) Position
( 13) Position
(14)
DISASSEMBLING
4.
(1) Disassembling
(2} Disassembling and reassembling the
5.
HOW
1)
(
(2)
(3)
(4)
6.
HOW
(1) Trajectory
(2)
REPLACING
7.
8.
INSTALLING
1)
(
(2)
(3)
9.
TROUBLES
10.
HOW
11. PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.
TABLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . .
.timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tilt
of
Longitudinal position
Normal
Position
TO REMOVE
How
to
How to remove play
How
to
How
to remove play
TO ADJUST THE TOP FEED
Position
Description
Installing the stand other than
PF·6 pedal components
TO
USE
................................•.................•......
ADJUSTMENT . . . . . . . . . . . • . • . • • . . . . • . . . • . . . . • . . . . . . . . . . . . . . . . • . • 3
of
the needle bar
of
the feed dog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . 3
the feed dog
foot
pressure
and
reverse
of
the reverse feed solenoid
of
the wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
of
the PF-6 partial shirring stopper
AND
and
PLAY...........
remove play from the walking
remove play
of
walking
of
the roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . 27
THE
MOVING
AND
ADJUSTING
of
the PF·6 partial shirring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
AND
CORRECTIVE MEASURES
GAUGES
........
and
...........................
and
presser
.................................
of
the walking
feed pitches
REASSEMBLING PROCEDURES
reassembling the
from
the walking
from
the
from
the
foot
.....•..
KNIFE
THE
.................•.............
.........................
:
......
the
hook,
foot
pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
foot
......
.....................................
face
top
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
foot
foot
reverse
feed control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
reverse
feed control lever shaft
DRIVE
JUKI
MECHANISM
·
............•............
............
PARTIAL
Z·type stand . . . . . . . . . . . . . . . . • . . . . . . . . . • . • . . . . 29
, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
,
.................
..........
and
top
feed
feed drive mechanism
rock shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
adjusting
,
SHIRRING DEVICE (PF·6)
.•...•.......•..•...............
,
.......................
·.
. . . . . . . . . . . . . . . . 7
, . . . . . . . . . . . . . . . . . . .
,
...............
...........................
components......................
.........
link
..................
........
..........
..........................
,
....................
, . . . . . . . . . . . . . . . 19
, . . . . . . . . . . . . . . . . 25
,
.... , ..... , ... , ..
.....
, . . . . . . . . . . . . . . . . . .
, . . . .
,
.. , ......
,,.
,
•.....
,
...
•.
. . . . . . . . . . 26
, . . . . . . . . . . . • 29
, . . 24
,..
,
....
:.
. . . .
, . . . . .
, . 5
, 13
, 28
11
11
15
15
26
30
31
35
38
·
1.
SPECIFICATIONS
Model
Sewing
I
Stitch length
2
Needle bar stroke
3
Top feed amout
4
speed
5 Needle (standard)
6
7
8
Presser
Lift
Lift
foot
pressure
of
walking foot
of
presser foot
(by knee lifter)
(by hand lifter)
Gauges (Walking foot,
9
feed dog, throat plate)
10 Height
II
12
13
of
feed dog
Feed system
Thread take-up
Thread take-up stroke
DLU-5490N
DLU-5490N-7(-7-0B,
4,000spm
(normal
o-
-7-WO,
speed),
5mm
-7-WB)
4,500spm
(0-
0.197")
(max.
30.7mm (1.209")
0-
8mm (0.315") (depends
on
DBX I #II
4-
5kg (at the standard height
(0.118") for the standard version (BB)
3mm
Standard: I
4.5-
Omm
5 .5mm
(0.394"),
of
Max:
(0.177"-
presser spring regulator)
13mm (0.512"}
0.217")
DLU-491 Replacement gauges may be used. (standard: BB)
DLU-490 Replacement gauges may be used. (Some
0.7-
0.8mm
Commonly
(0.028"-
known
as
"swing"
O.o31")
Link type
Standard:
107mm (4.213"), Max. 112mm
(4.409")-
speed)
gauges used)
of
them may
not
system
Min. 105mm (4.134")
be used.)
14 Lubrication
15
Oil
return system
16
Lubricating oil
17 Wiper
18 Automatic
stitching device
19
Motor
20 Motor
21
22 Solenoid
Power
output
supply
drive
.
reverse
AC
servomotor (applicable only
Provided
Rated output: 400W, Max. output: 55
automatic
3-phase
thread
or
single-phase
trimmer)
(applicable
power DC-3!V (applicable only to a version with automatic thread trimmer)
Fully automatic
By
plunger pump
New
Defrix Oil No. I
Provided
on
on
5490N-7-0B and 5490N-7WB
to
a version with automatic thread trimmer)
only
supply
Max. sewing speed limit
23
200spm- max. sewing speed (applicable only to a version with automatic
thread trimmer)
Needle up/down stop
24
switch
The machine usually stops with its needle down.
machine can be stopped with its needle up.
25 Auto-lifer Available as an option (applicable only
trimmer)
5490N-7-
0W
to a version
to
WB
(applicable only to a version with
with
automatic
By
thread
using this switch, the
a version with automatic thread
trimmer)
-]-
2. APPLICATIONS
* Extensively
uniforms, etc.
Needle Needle system
DBx
I
used
# 9
#II
#14
#16
#18
for
The
light· to medium-weight
standard threads used with the models are
Thread
count
#80
#60
#50
#50-#30
general
Georgette, T/C broadcloth Light-weight mate.rials
Wool, general broad
Drill,
cotton
Overcoating, denim
fabrics
Material
gaberdine
in
men's suits, ladies'
cotton
or synthetic fiber threads
cloth
wear,
working
Medium-weight
General
Heavy-weight materials
wear,
of
#80 to #30.
Application
materials
fabrics
students'
--
-2-
3.
STANDARD ADJUSTMENT
STANDARD
(1) Height
With the needle bar
line on the needle bar according to the type
of
the needle bar
in
its lowest position, align the bottom end
~®
I
(2) Timing between the needle and the
When the bottom end
bar aligns with marker line
that hook point 0 meets the center
a clearance
between the needle and the hook point.
ADJUSTMENT
of
needle used.
~o
€l
hook
of0.04
of
the bushing with the appropriate marker
(For a
DB
needle)
Align the bottom end
bushing
needle bar
(For
Align the bottom end
bushing
needle bar
of
the lower bushing
(@
(0.002") to O.lmm (0.004") should be provided
aDA
or
~
with marker line
f)
needle)
~
with marker line @ on
f)
®)
on the needle bar, adjust
of
needle 0 . At this time,
of
needle bar
.
of
needle bar
.
of
the ascending needle
fi.)
on
so
(3) Height
Feed
(4)
I/777/J
of
the feed dog
timing
Needle
Feed
dog
V/Z//1//,
When the feed dog is
the top edge
(0.028" to 0,031" )
0.7-0.8mm (0.028'"-0.031
of
in
the feed dog is 0.7 to 0.8mm
above
")
=~~
Throat
plate
When the front 1st or 2nd tooth
throat plate surface, the upper end
needle should be flush with the throat plate surface.
Throat
plate
of
the feed dog
of
the eyelet
its highest position,
the throat plate
is
flush with the
of
surface.
the descending
-3-
HOW
TO ADJUST
RESULTS OF IMPROPER
ADJUSTMENT
o Loosen the needle bar clamp screw to perform adjustment.
0
Loosen the three
(A
version without the automatic thread trimmer has two
hook
setscrews to perform adjustment.
setscrews.)
Changing the needle bar height
o
disturbs the feed and hook timings.
So, avoid altering the needle bar
height unless the type
of
needle has
been changed.
If the clearance between the needle
0
and hook blade point is too large, stitch
or
skipping
thread breakage may
frequently occur.
o
If
the clearance between the needle
and hook blade point is too small, the
needle
may
scratch
the
hook
blade point.
If
the
hook
o
timing is advanced,
tighter stitches will be produced,
but
stitch skipping may often
occur.
o A delayed
hook
timing
is
effective
for preventing balloon stitches and
stitch skipping.
o
For
a version without the auto·
rna tic thread trimmer, use the
lowest marker line to make adjust-
rnent.
0
Loosen screw
f)
,
and
move driving forked
adjustment.
(The
distance betwce> the
standard feed dog
So,
this may be used for easier adjustment.
(81613-450-AOO)
o Loosen the two setscrews
top
of
and
crank 0 to
bottom
ends
of a tooth
is
about 0.8mm (0.031").
make
of
th)
the feed eccentric cam. o
o
If
the feed dog is too high, the
needle may sway and possible bend
or break.
the contrary,
On
too
low, insufficient feed power
may
result, often causing stitch
if
the feed dog is
jam.
Increasing the feed dog height adds
but
to feed power,
time, chances
also increase.
If
the feed dog descending timing
is advanced, chances
at the same
of
puckering may
of
thread
splitting, balloon stitches
will be
reducect;ho~ever,
stitches will be loose.
-4-
STANDARD ADJUSTMENT
(5) Tilt
of
The standard tilt
A
of
Front up
_,_fvvvv,__:_=·
[Note] The tilt
(6) Walking
Type
BA,
BB,
D
the
feed dog
of
the feed dog is obtained by aligning the marker
the feed rocker.
Standard
.A•
,--_:_f"""""JL__.
1
foot
of
E
_
__i_---'i~£!.:_j..L
of
the feed dog
pressure and presser
gauge
Height
regulator knob
BC
Front down
Throat
plate
of
the
DLU-5490N
foot
pressure
A B
of
presser spring
43
43
43
Height
cannot
of
adjusting
50
50
50
be
adjusted.
dot
on the feed bar shaft with point
A
J
L
M
N
p
s
(Standard adjustments)
[Note
I]
The suitable pressures
So, properly adjust the pressures for each type
[Note 2] Distance B represents the height
adjusting knob
If
screw.
presser spring regulating nut
distance
slot in the presser bar base may be impaired. So
is
you do not have a scale etc., take the position where the white marker line on the
B.
If
the walking foot adjusting screw is excessively tightened, the durability
43
43
43
43
43
43
ofthewalking
depressed until its top end
is
50
50
50
50
50
50
Adjusting nut
foot and presser foot vary, depending on the type
of
material.
of
the walldng foot adjusting screw when the walldng foot
is
engaged with the pin
aligned with the snap ring (colored in silver)
be
careful.
of
the walking foot adjusting
as
a reference for
I
R
of
material.
oft
he
-5-
Loosen
shaft
to
the
setscrew
perform
HOW TO ADJUST
of
the feed
adjustment.
bar
shaft,
and
tum
the feed bar
feed dog
Setting
IMPROPER
it
RESULTS OF
ADJUSTMENT
0
Setting
up
the
is effective for preventing
puckering.
down
reduces chances
breakage when sewing knit.
with
its
front
with its front
of
fiber
0
A :
Turn
the
pressure,
0
B : Bring the presser
contact with the throat plate surface, push the walking foot
adjusting knob down, and turn the walking foot adjusting
screw clockwise to increase the walking foot pressure,
or
counterclockwise to decrease
presser spring regulator clockwise
or
counterclockwise
foot
down. With the presser foot sole in
to
decrease it.
it.
to
iilcrease the
The
standard adjustments depend
o
on
the
type
of
material.
The pressures
and
presser
to
the shirring capability
of
the walking
foot
are closely related
machine.
When· the walking
kept
constant, the shirring capa-
bility
is
enhanced as the presser
foot
pressure' is-decreased.
When the presser
kept
constant,
foot
pressure
foot
pressure
the shirring capability is enhanced as the walking
foot
pressure is increased.
If
the presser
low, however,
be decreased, leading
If
the walking foot pressure is
high, the walking
foot
pressure
the
feed power
foot
to
may
stitch
the material.
As
the
sewing speed
the feed power reduces.
crease the presser
sewing at high speed.
when
is
foot
increased,
So, in-
pressure
of
the
is
scratch
foot
is
is
too
will
jam.
too
-6-
STANDARD ADJUSTMENT
(7) Relationship between
the
walking foot graduation plate and indicator
With the partial shirring stopper indicator set at
foot graduation plate, when the top feed adjusting knob
clockwise to set the indicator at the'maximum value, the top feed
indicator should align with
plate.
Partial shirring dial
Dial
"8"
on the walking
"8"
on the walking foot graduation
Stopper indicator
Top feed indicator
is
turned
(8) Top feed vertical timing
With.
the dial set at
"3",
at
turn the hand wheel by hand
"3"
and the top feed indicator
direction. The moment the presser foot sole
touches the throat plate surface, the top feed
go
dogs should start to
up.
in
the normal
0
Screw
Driving
roller
-7-
HOW TO ADJUST
0
With the indicator set at the maximum value, loosen the screw,
at the rear
indicator with
of
the machine arm.
"8"
on the plate. Retighten the screw.
Move
the plate to align the
RESULTS OF IMPROPER
ADJUSTMENT
0
If
the relationship between the
walking foot graduation plate
and
the indicator
it
is
difficult
is
not correct,
to
know a proper to
feed amount.
o Remove the side cover from the back
loosen
the
screw.
of
the sewing machine,
Tum the handwheel until the presser foot sole touches the throat
plate surface. Lightly press the driving roller
driving arm (front)
of
the walking foot driving arm.
in
direction
A,
and securely tighten the screw
of
the walking foot
After adjustment, check the walking foot dog for proper motion.
[Precaution]
is
The top feed vertical timing
timing. The timing may
the bottom feed timing has been changed,
(I)
the lift
of
(2)
(3)
a
gauge
the bottom feed dog has been changed, or
has been changed. feed power.
Avoid adjusting the top feed vertical timing
factory-adjusted to the standard
be
somewhat disturbed
as
when
much
as
possible.
and
o
If
the walking foot and feed dog
start to
foot comes in contact with the
throat plate,
decrease.
after the presser foot comes in
go
up
before the presser
shirring
If
they start to
amount will
go
contact with the throat plate
surface, the upper cloth
will
pushed back, resulting in decreased
shirring
In
the
amount.
former
case,
the
presser
may bind with consequent reduced
up
be
bar
-8-
STANDARD ADJUSTMENT
Max. lift A
of
each type
of
walking foot
the following values, recheck the adjustment.
(9)
Top
feed horizontal timing
Cam
screw
No.2
is
as
shown below.
If
the max. lift
BA-
BC
E
D
J
M
p
s
o With the needle bar in its highest
)mziiiif.:=-Aiigned
is
significantly different from
types
types
types
Approx. 3mm
Approx. 1.6mm
(0.118")
(0.063")
types Approx. 2.7mm (0.106")
types
Approx. 2.4mm
position, the
should
cam
be
slightly below the main
screw
(0.094")
No.2
shaft axis.
The cam screw
No.2
reaches
the
main shaft axis when the color
boundary line
of
the descending
needle bar aligns with the bottom
end
of
the needle bar lower
bushing when the handwheel
is
turned in the nonnal direction.
( 1 0) Longitudinal position
With the top feed amount set
at
provided between the front end
Roller
Feed
rocker
bar
0
of
the walking foot
the maximum
of
the slot in the walking foot mount and the roller.
(8
mm (0.315")), a clearance
of
Ll
mm (0.043") should be
Feed rocker
shaft crank
(lower)
-9-
HOW
TO ADJUST
o Loosen the screw
No.2
first, and then the screw No.
l.
the screwdriver applied to the screw, slowly turn the hand wheel
not
with care taken
the screw
adjustment,
No.2
securely tighten the screws.
(Fig, 1) (Fig,
to cause the cam
to adjust the
top
to
move. Loosely tighten
feed horizontal timing. After
2)
With
RESULTS OF IMPROPER
ADJUSTMENT
o
If
the walking
high, the needle
foot
bar
goes
up
may hit the
walking foot when the presser
rides over an overlapping section.
Also, the
will be as shown in Fig.
path
of
the walking
I,
means reduced walking foot feed
power.
If
the walking
high enough, its
shown in Fig. 2.
walking
foot
may damage
foot
path
As
does
not
will be
a result, the
back the material.
(Fig,
1)
o
If
the horizontal feed timing
foot
is
walking
bottom
the
upper
earlier than the
feed, the walking foot pulls
cloth
(Fig.
back before the
feed dog completes its feed
often
causing scratches
material
contrary,
the walking
upper
or
poor
if
the timing
foot
cloth
when the feed dog
feeds the material,
scratches
(Fig.
on
the materiaL
I)
The horizontal feed
of
timing
on
shirring. On the
is
too
fails
to
feed the
often
causing
the
walking
will be delayed.
2)
(Fig.
The horizontal feed
timing
of
the walking
will
be
advanced.
too
foot
foot
which
go
up
as
or
push
2)
of
motion,
the
late,
foot
foot
the
o
Turn
the
top
feed adjusting
the
maximum
("8"
on the
until the horizontal feed bar reaches its front
of
in the direction
feed rocker shaft
Move the feed
the
crank
rocker
clearance between the slot
roller
to
1.1
mm
(0.043").
knob
to
set the
top
feed scale).
arrow), then loosen
(lower)
bar forward
to
release the feed rocker bar.
or
backward
in
the walking
top
Turn
the
foot
end
screw
to
mount
feed
amount
the handwheel
position (shown
of
the'
adjust the
and the
at
After adjustment, tighten the screw.
-
10-
If
the longitudinal position
o
foot
is
walking
feed
components
inaccurate, the
may
interfere
with each other. After adjustment,
top
feed
set the
maximum, and
components
between
for
them.
amount
check
any
at the
the
contact
of
the
top
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