JUKI DLU-5494N-7, SC-910, M-91, IP-100C, KT-01 Instruction Manual

ENGLISH

INSTRUCTION MANUAL

CONTENTS

1. PREFACE.................................................................................................... 1

2. SET-UP........................................................................................................ 1

(1) Installing M-91 small sized motor unit................................................................................................1

(2) Installing to the table............................................................................................................................2

(3) Adjusting the belt (when M-91 is used) ..............................................................................................2

(4) Adjusting the belt cover (when M-91 is used)....................................................................................3

(5) Connecting the cords...........................................................................................................................4

(6) Attaching the circuit board..................................................................................................................5

(7) Connecting for IP-100 panel ................................................................................................................7

(8) Installing the operation display panel ..............................................................................................10

(9) How to use the operation display panel...........................................................................................10

(10) Adjusting the bottom feed pitch display ........................................................................................11

3. INSTALLING THE OPERATION PANEL .................................................. 12

4. CONNECTING THE CORD....................................................................... 13

5. HOW TO USE THE OPERATION PANEL ................................................. 14

(1) Names and functions of each components .....................................................................................14

(2) Adjusting the contrast of the operation panel display....................................................................16

(3) Production control switch connecting connector...........................................................................16

6. SCREEN LIST........................................................................................... 17

(1) Fundamental screen list ....................................................................................................................17

(2) Pop-up list ...........................................................................................................................................18

(3) Other screens .....................................................................................................................................19

7. OPERATING PROCEDURE OF THE SEWING PATTERN....................... 20

(1) Selecting procedure of the sewing pattern......................................................................................20

(2) Editing procedure of the sewing pattern..........................................................................................20

(3) Teaching mode ....................................................................................................................................23

(4) Selecting the sleeve to be sewn........................................................................................................23

(5) Selection of the alternate sewing......................................................................................................24

(6) Insertion and deletion of the step .....................................................................................................25

(7) Operating procedure of the number of stitches of the reverse stitching......................................26

8. PATTERN OPERATION ............................................................................ 27

(1) Sewing pattern register......................................................................................................................27

(2) Copy of the sewing pattern................................................................................................................29

(3) Deletion of the sewing pattern ..........................................................................................................30

9. HOW TO USE THE BOBBIN THREAD COUNTER .................................. 31

10. NO. OF PCS. COUNTER ........................................................................ 32

11. BOTTOM FEED AMOUNT DISPLAY ..................................................... 32

12. RE-SEWING SWITCH ............................................................................ 33

13. NEEDLE UP/DOWN COMPENSATION SWITCH .................................. 33

14. ON/OFF SWITCH

15. AUTOMATIC THREAD TRIMMING SWITCH

16. ONE-SHOT AUTOMATIC STITCHING SWITCH

17. THREAD TRIMMING PROHIBITION SWITCH .................................. 33

18. INFORMATION ....................................................................................... 34

(1) Information operator level .................................................................................................................34

(2) Setting for functions...........................................................................................................................37

(3) External interface ...............................................................................................................................41

19. ERROR DISPLAY ................................................................................... 42

(1) Error code list (Error display in panel) .............................................................................................43

OF THE MATERIAL EDGE SENSOR .................. 33

..................................... 33

............................... 33

1. PREFACE

For setup or handling of DLU-5494N-7 (1-needle, bottom and variable top feed lockstitch machine with automatic
thread trimmer), refer to the Instruction Manual for DLU-5494N-7.
In addition, for the details of handling of SC-910 (sewing machine controller) and IP-100, similarly, refer to the
respective Instruction Manuals.

2. SET-UP

SC-910 control box can be used for DD (direct-drive) system machine head and the belt-drive system machine
head by connecting the separately-available small-sized motor unit (M-91).
When using the small-sized motor unit, it is necessary to install the motor unit to the control box before installing
the control box to the table.
Install the motor unit to the control box following the instructions below.

SC-910 control box

(1) Installing M-91 small sized motor unit

2

1

M-91 small-sized motor unit
(separately-available article)

1) Lay down the control box while the rear cover is
placed under the control box.

2) Remove tie-mount A.

3) Adjust the hole section of the installing base of M­91 to the hole section of the installing plate.

4) Temporarily tighten five places with counter-sunk
screws 1 supplied with the unit as accessories.

5) Securely tighten them with hexagonal wrench key

2 supplied with the unit as accessories.

A

– 1 –

Cau tion

1. When tightening the screw, securely
insert the hexagonal wrench key into the
screw hole section to tighten.

2. Hexagonal wrench key is attached to M-

91.

3. Be careful that the motor shaft does not
hit against anything. (If a strong shock
is given to the motor shaft, there is the
possibility that the motor is damaged.)

(2) Installing to the table

Plain
washer

Spring
washer

Hexagonal
nat

1) Install the control box to the table with the fitting
bolt (asm.) supplied with the unit as accessories.
At this time, insert the nut and washer supplied
with the unit as accessories as shown in the figure
so that the control box is securely fixed.

2) Set the machine head to the table after installing
the control box (or with small-sized motor) to the
table. (Refer to Instruction Manual for the sewing
machine.)

(3) Adjusting the belt (when M-91 is used)

Approx. 15mm / 9.8N

1

1) Adjust the belt tension by turning upper and lower
nuts 1 of the adjustment bolt and adjust the height
of the center of the motor so that the belt sags 15
mm (9.8N) when the center of the belt is pressed
by hand.

When the belt tension is excessively low,
medium or low speed rotation becomes

Cau tion

uneven, or stop accuracy is deteriorated.
When the tension is excessively high,
deterioration of the motor is advanced. So,
be careful.

– 2 –

(4) Adjusting the belt cover (when M-91 is used)

1) Adjusting the clearance of the cover

Loosen cover setscrew 1 and adjust so that the
left and right clearances between the belt cover
and the belt are equal to each other.

Cau tion

1

2) Adjusting the roll-in prevention pin

Adjust the roll-in prevention pin with the hexagonal

4mm

2

wrench key supplied with the unit as accessories
so that the clearance between the belt and roll-in
prevention pin 2 is approximately 4 mm.

Cau tion

Perform the adjustment of the cover with
the hexagonal wrench key supplied with
the unit as accessories. At this time, be
careful that the screw is not excessively
loosened.

1. Be careful of the direction of rotation
of the motor and determine the position
of the pin. (Position shown in the figure
is the installing position when the motor
rotates in the direction of the arrow
mark.)

2. Perform the adjustment of the cover
with the hexagonal wrench key supplied
with the unit as accessories. At this
time, be careful that the screw is not
excessively loosened.

5

3

3mm

4

3) Adjusting the off-belt prevention pin

Adjust the off-belt prevention pin with the
hexagonal wrench key supplied with the unit as
accessories so that the clearance between the belt
and off-belt prevention pin 3 is approximately 3
mm.

Perform the adjustment of the cover with

Cau tion

the hexagonal wrench key supplied with the
unit as accessories. At this time, be careful
that the screw is not excessively loosened.

4) Installing the belt cover

1. Adjust the notch section of the pulley outer cover
4 to the gap of screw 5 of the pulley inner cover
and insert the outer cover to the inner cover.

2. Tighten screw 5 to complete the adjustment of
the cover.

– 3 –

(5) Connecting the cords

WARNING :

• To prevent personal injury caused by abrupt start of the sewing machine, carry out the work after
turning OFF the power switch and a lapse of 5 minutes or more.

• To prevent damage of device caused by maloperation and wrong specifications, be sure to connect
all the corresponding connectors to the specified places.

• To prevent personal injury caused by maloperation, be sure to lock the connector with lock.

• As for the details of handling respective devices, read carefully the Instruction Manuals supplied
with the devices before handling the devices.

Optional unit B

(EPF p.c.b. A (asm.))

8

@0

!7

!9

!6

9

7

1

!0

!2

2

!8

!5

!0

6

!4

3

!3

!1

5

4

Following connectors are prepared on the front face of SC-910. Connect the connectors coming from the
machine head to the corresponding places so as to fit the devices mounted on the machine head.

1 CN30
2 CN35

3 CN33
4 CN31
5 CN42

6 CN48

7 CN40
8 CN46

9 CN47

Synchronizer : it detects the needle bar
position.
CP-160 panel : Various kinds of programmed
sewing can be executed.
(Refer to the Instruction Manual for each panel
for the details of functions.)
Not used
Machine head connector 4P
External input/output connector : input/output
of up/down detection signal, rotation
prohibition signal, etc. is prepared.
Safety switch (standard) : When tilting the
sewing machine without turning the power
OFF, the operation of the sewing machine is
prohibited so as to protect against danger.
Optional switch : by changing over the internal
functions, 6 kinds of functions can be selected.
Presser foot lifter solenoid. (For automatic
presser foot lifter type only)
Machine head solenid : Thread trimming,
reverse-stitching solenoid, touch-back switch,
etc.
Optional circuit board connection connector :
Required when using JUKI standard bobbin
thread remaining amount detection sensor,
etc.

!0 CN38, CN39

Motor signal connector

!1 CN32

!2 CN34
!3 CN45

!4 CN43 FAN

* By adding this unit (optional unit B), the machine can be

used as 1-needle, bottom and variable top feed lockstitch
machine with automatic thread trimmer.

!5 CN132
!6 CN133
!7 CN134
!8 CN139
!9 CN141

@0 CN138

Standing machine pedal : JUKI standard PK­70, etc. Sewing machine can be controlled
with the external signal.
IP-100 panel (LCD panel) : Various kinds of
programmed sewing can be executed.
Material end detection sensor ED-4, etc.

Shirring LED, bottom feed amount
External shirring input
Top feed amount
Stepping motor control
Up/down detection, thread trimming, reverse
feed stitching
Shirring release input (extreme left)

– 4 –

(6) Attaching the circuit board

1) Open the front cover according to the instructions
given in the Instruction Manual for the control box
main unit.

3

Inserting position

2

1

Rear side

2) Insert stud 2 supplied with the unit as accessories
to EPF p.c.b. A (asm.) 1.

Cau tion

Be careful of the inserting direction.

3) Insert EPF p.c.b. A (asm.) 1 to connector CN47
3 of the main unit as illustrated.

1. Insert EPF p.c.b. A (asm.) from the
oblique lower section, check the
inserting position and insert it until

Cau tion

“click” sounds since connector CN47 3
is hidden by the cover located in the
upper section of the control box main
unit.

2. Do not forcibly press the circuit board.

5

4) Securely fix EPF p.c.b. A (asm.) 4 to the control
box main unit using three screws 5 supplied with
the unit as accessories.

4

– 5 –

5) Pass through table hole A under the table cords
9 of thread trimer solenoid, reverse feed stitching
solenoid, etc., synchronizer cord 7, IP panel cord
!0, operation display panel cord 6, top feed
detection cord 8 and motor control cord !1 .

A

6

!1

!2

8

!3

9

!0

7

6) Loosen setscrew !2 in front cover !3.

7) Pressing the side of front cover !3 in the direction
of the arrow, open the front cover toward you.

Cau tion

Be sure to open / close the front cover with
your hands.

!4

!9
!5

!6

!7

9

7

!8

8) Connect 14P cord 9 coming from the machine
head to connector !4 (CN46).

9) Connect 7P connector 7 coming from the machine
head to connector !5 (CN30).

10)

Connect connector !8 coming from the machine
head to connector !6 (CN38, CN39). (Connect 8P
connector to CN38 and in case of 9Pconnector,
connect to CN39.)

11)

When the optional AK118 device is attached,
connect 2P connector !7 coming from the AK
device to connector !9 (CN40).

– 6 –

@4

@2

Cau tion

12)

@1

!1

Connect 6P connector !1coming from the machine
head to connector @1 (CN139).

13)

Connect 4P connector 8 coming from the machine
head to connector @2 (CN134).

8

14)

Connect 14P connector 6 coming from the
operation display panel to connector @3 (CN132).

@0

@3

6

15)

Insert EPF relay connector @0 to connector @4
(CN141) and connector @5 (CN42).

@5

1. When using the AK device, set whether to use the AK device after confirming how to select the
auto-lifter function.
(Refer to "Instruction Manual for SC-910".)

2. Be sure to securely insert the respective connectors after checking the inserting directions since
all connectors have the inserting directions.
(When using a type with lock, insert the connectors until they go to the lock.)
The sewing machine is not actuated unless the connectors are inserted properly.
In addition, not only the problem of error warning or the like occurs, but also the sewing machine
and the control box are damaged.

(7) Connecting for IP-100 panel

1

3

2

1) The connector for connecting IP-100 is prepared.
When connecting, insert the connector until it is
locked to 1(CN34).

2) After inserting the connector, put all cords together
with cable clip band 2 located on the side of the
box.
At this time, bundle the connectors which are
arranged above the wire saddle to wire saddle 3
and those which are arranged below the wire
saddle to wire saddle 4.

4

– 7 –

How to fix cable clip band 2

How to remove cable clip band 2

Cau tion

Pull

1. Fix the cable clip band following the attaching procedure as shown in the figure.

2. When removing the cord, remove the wire saddle first and the cable clip band next.

3. To remove the cable clip band, as show in the illustration of how to remove the cable clip band,
pressing the hook of cable clip band, push the band to remove the cable clip band.

Pull

Push

Pushing the hook portion, push the band to remove it.

Push

Push the hook.

3) Close front cover 5 while paying attention to
pinching of the wire.
Lightly press portion B and insert front cover 5
with “click”.

4) After that, fix it with the screw 6.

5

6

B

– 8 –

7

5) Connect motor output cord 7 to connector 8
located on the side of the box.

6) Connect connector 4P 9 of the power switch to
connector !0.

8

!0

9

!1

Cau tion

Route the motor output cord from the front
face of the box.

7) Make sure that the power switch is turned OFF
and insert power supply cord !1 coming from the
power switch into the power plug socket.
(Illustration is for the japanese specification 100V
type.)

1. Check again the supply voltage and the
voltage designated on the control box
before connecting the power supply

Cau tion

cord.

2. Prepare the power switch conformed to
the safety standard.

3. Be sure to connect the ground wire (
green / yellow).

– 9 –

(8) Installing the operation display panel

1) Fix operation display panel 1 in tapped hole A in
the rear section of the machine arm using screw

2 and washer 3.

3

2

A

1

1

Parallel to
the bed surface

No contact

(9) How to use the operation display panel

・Operation indication panel

ABCD

2) Attach operation display panel 1 to the
aforementioned place so that it is in parallel to the
bed surface and does not come in contact with the
lower section of the machine arm.

1

2

3

4

1 Partial shirring switch

・

This is the switch used to change over the partial shirring process.

2 Indicator lamp (LED) of the partial shirring process step

・ Indicates the current state of partial shirring process step.

Partial shirring process step

1
2
3
4
5
6
7
8

Indicator lamp (LED)

A

○
○
○
○

●

●

●

●

B

●
○
○
○
○

●

●

●

●

●
○
○
○
○

●

●

C

D

●

●

●
○
○
○
○

●

(Note)

○……Lights up

●……Goes out

3,4 Partial shirring pattern indicator lamps (LEDs) under the alternate stitching mode
・ If partial shirring pattern or is selected under the alternate stitching mode, LED 3 will light up. If partial shirring

pattern

or is selected under the aforementioned mode, LED 4 will light up.

・ If the machine is not operated under the alternate stitching mode, both LEDs 3 and 4 will go out.

– 10 –

(10) Adjusting the bottom feed pitch display

When the display of the bottom feed pitch does not correspond with the scale of the pitch dial, perform the
setting below.

1. Adjust the scale of the bottom feed pitch dial to
"0".

2. Turn the variable resistor VR1 1 located on the
right side of the rear of the operation display panel,

1VR1

2VR2

and adjust so that the bottom feed display is set to
the minimum display.

3. Adjust the scale of the bottom feed pitch dial to
"5".

4. Turn the variable resistor VR2 2 located on the
right side of the rear of the operation display panel,
and adjust so that the bottom feed display is set to

5.0.

– 11 –

3. INSTALLING THE OPERATION PANEL

WARNING :

To protect against possible personal injury due to abrupt start of the machine, be sure to start the
following work after turning the power off and ascertaining that the motor is at rest.

Type B (Type name plate TYPE B0＊)

1

Type C (Type name plate TYPE C0＊)

2

3

4

2

3

4

1

2

4

3

5

5

1) Attach operation panel 1 to the machine head using screw 2, plain washer 3, toothed lock washer 4 and
spacer 5 (for type C) supplied with the operation panel.

2) The positions of the holes in the bracket for installing the operation panel are different from each other
according to the respective models. Refer to the table below.

IP-100 / bracket type classified by model correspondence table

Type B

No.

1
2
3

4

1

2

Mounted
machine head

DDL-9000
DLN-9010
LH-31＊＊

LZ-228＊ N

3

4

Bracket type

Type B
Type B
Type B

Type B

5

Installing
hole used

2 −4
2 −4
1 −5

3 −4

Type C

2

1

Part No. of screw

SS4121415SP(3/16-28)
SS4121415SP(3/16-28)

SS6111210SP(11/64-40)

SS4121415SP(3/16-28)

3

Remarks

To be fixed on the exclusive
bracket for installing standard
panel

5

DDL-5550N

6

DDL-8700

7

DLN-5410N

8

DLU-5494N

Type C
Type C
Type C
Type C

1 −3
1 −3
1 −3
1 −3

SS7121410SN(3/16-24)
SS7121410SN(3/16-24)
SS7121410SN(3/16-24)
SS7121410SN(3/16-24)

– 12 –

Use 2 – 3 in case of optional
unit (V0 and the like).