JUKI IP-100 Engineer's Manual

Lockstitch, Zigzag Stitching Machine LZ-2290A Series IP-100 / SC-915 R

of the sewing machine. This manual describes “Adjustment Procedure”, “Results of Improper Adjustment”, and other functions which are not covered by the Instruction Book intended for the maintenance personnel and sewing operators at a sewing factory. All personnel engaged in repair of LZ-2290A Series • IP-100 / SC-915 are required to carefully read Section 2 “Standard Adjustment” which contains important information on the maintenance of LZ-2290A Series • IP-100 / SC-915. The “Standard Adjustment” consists of two parts ; the former part presents illustration and simplified explanation for the convenience of reconfirmation of the required adjustment values in carrying out actual adjustment after reading this manual once; and the latter part provides “Results of Improper Adjustment” in which sewing and/or mechanical failures, and the correcting procedures are explained for those persons who perform such adjustment for the first time. It is advisable to use “LZ-2290A Series • IP-100 / SC-915 Parts Book” together with this Engineer’s Manual.

(1) Specifications of the machine head ...................................................................................................... 1 (2) Stitch pattern table................................................................................................................................ 2 (3) Function list .......................................................................................................................................... 3 (4) Cautions in operation............................................................................................................................ 3 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 (3) Adjusting the feed amount .................................................................................................................... 8 (4) Position of the feed dog ........................................................................................................................ 8 (5) Adjusting the slippage of materials (For ASU and ADU) .................................................................... 10 (6) Adjusting the origin of the needle rocking motor ................................................................................ 12 (7) Adjusting the needle entry position (In terms of needle rocking direction) ......................................... 14 (8) Adjusting the needle entry position (In terms of longitudinal direction) .............................................. 14 (9) Adjusting the longitudinal play at the needle bar ................................................................................ 14 (10) Position of the needle bar connection guide..................................................................................... 16 (11) Height of the needle bar ................................................................................................................... 16 (12) Adjusting the needle-to-hook timing and the needle guard .............................................................. 18 (13) Position of the bobbin case stopper ................................................................................................. 20 (14) Orientation of the needle bar thread holder ...................................................................................... 20 (15) Position of the thread tension ........................................................................................................... 22 (16) Position of the pre-tension ................................................................................................................ 22 (17) Position of the thread take-up spring guard...................................................................................... 24 (18) Installing the thread take-up thread guide B ..................................................................................... 24 (19) Installing the thread take-up ............................................................................................................. 24 (20) Installation of the presser foot .......................................................................................................... 26 (21) Installing and adjusting the bobbin winder unit ................................................................................. 26 (22) Adjusting the amount of oil in the hook (ASS/-7, ASU/-7) ................................................................ 28 (23) Adjusting the thread trimming unit .................................................................................................... 28 (24) Initial position of the moving knife..................................................................................................... 30 (25) Timing of the thread trimming cam ................................................................................................... 30 (26) Installing/removing the knife unit ...................................................................................................... 32 (27) Stop position of the needle after thread trimming (Needle UP stop) ................................................ 32 (28) Clearance provided between the main shaft handwheel and the stator ........................................... 32 (29) Position of the automatic reverse stitching magnet .......................................................................... 34 (30) Adjusting the thread tension releasing solenoid ............................................................................... 34 (31) Adjusting the stitch length dial .......................................................................................................... 36 (32) Adjusting the lubrication mechanism (ASS and ASU only) .............................................................. 38 (33) Adjusting the position of the thread draw-out wire (For the machine with thread trimmer only) ...................................................................................... 38 (34) Adjusting the stroke of the thread draw-out wire (For the machine with thread trimmer only) ...................................................................................... 40 (35) Installing the wiper base (WB only) .................................................................................................. 40 (36) Adjusting the wiper solenoid (WB only) ............................................................................................ 42 (37) Position of the wiper ......................................................................................................................... 42 1) WB type ........................................................................................................................................ 42 2) CB type ......................................................................................................................................... 44

(1) Adjusting and assembling of the gear box (large) .............................................................................. 46 (2) Replacing the motor ........................................................................................................................... 48 (3) Replacing the timing belt .................................................................................................................... 50 (4) Removing/installing the gear box cover.............................................................................................. 50 (5) Disassembling/assembling the needle bar support base shaft (asm.) ............................................... 52 5. MAINTENANCE............................................................................................................ 64 (1) Replacing procedure of the printed circuit board ................................................................................ 64 (2) Maintenance of the hook lubricating pipe oil filter ............................................................................... 65 (3) Cleaning the cooling fan ..................................................................................................................... 66 (4) Applying the exclusive grease ............................................................................................................ 67 (5) Hook shaft gear .................................................................................................................................. 71 (6) Adjusting the needle rocking link ........................................................................................................ 72 (7) Lubricating to face plate section (ASS and ASU only) ....................................................................... 73 (8) Protruding amount of the hook shaft .................................................................................................. 75 (9) Draining of CB type ............................................................................................................................ 75 (10) Cleaning the dust bag of CB type ..................................................................................................... 75 6. OPERATION PANEL.................................................................................................... 76 (1) Names of the respective sections....................................................................................................... 76 (2) Information .......................................................................................................................................... 78 (3) Matters that demand special attention regarding the operation panel, IP-100 ................................... 92 7. SPECIFICATIONS OF SC-915 ..................................................................................... 93 8. FUNCTION SETTING PROCEDURE OF SC-915 ........................................................ 93 (1) How to change over to the function setting mode .............................................................................. 93 9. FUNCTION SETTING LIST .......................................................................................... 97 10. DETAILED EXPLANATION OF SELECTION OF FUNCTIONS .............................. 101 11. EXTERNAL OUTPUT/INPUT CONNECTORS......................................................... 107 (1) Connector connection diagram......................................................................................................... 107 12. ERROR DISPLAY..................................................................................................... 108 (1) ERROR DISPLAY ............................................................................................................................ 108 (2) Error code list (Error display in panel) .............................................................................................. 109 (3) Warning list ....................................................................................................................................... 112 13. SCREWS FOR ATTACHMENTS ............................................................................. 113 14. SPARE PARTS......................................................................................................... 113 15. OPTIONAL CORD .................................................................................................... 114 (1) Relay cord A asm. for standing machine (Part No. M9701351AA0) ................................................ 114 (2) Relay cord A asm. for DC24V (Part No. M9703351AA0) ................................................................. 115 16.TROUBLES AND CORRECTIVE MEASURES......................................................... 116 (1) With regard to lubrication.................................................................................................................. 116 (2) With regard to sewing ....................................................................................................................... 118 (3) With regard to mechanical components ........................................................................................... 123 17. CONFIRMATION ...................................................................................................... 128 18. BLOCK DIAGRAM ................................................................................................... 129 (1) Block diagram A ............................................................................................................................... 129 (2) Operation panel block diagram......................................................................................................... 130 19. DRAWING OF TABLE.............................................................................................. 131 CUSTOM PATTERN NEEDLE ENTRY POSITION DATA SHEET ....................................................... 132

1. SPECIFICATIONS (1) Specifications of the machine head * 1 : The sewing speed is regulated in accordance with the destination at the time of delivery. (Zigzag width is also regulated.) * 2 : Zigzag width is regulated to 8 mm at the time of delivery. (Max. 10 mm is applied to all zigzag machines.) * 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 (WB only) Automatic reverse stitching 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.) Height of the feed dog Lubrication of the face plate section Drive system Transmission function Motor output Operating power Solenoid drive power Additional function Device and optional 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 LZ-2290ASS / –7 5,000 rpm (*1) 5 mm/4 mm (*3) (Stepless fine adjustment) 1.2 mm LZ-2290ASU / –7 4,500 rpm (*1) 2.5 mm/2.5 mm (*3) (Stepless fine adjustment) 1.4mm LZ-2290ADS / –7 5mm/4 mm (*3) (Stepless fine adjustment) 1.2 mm LZ-2290ADU / –7 2.5mm/2.5 mm (*3) (Stepless fine adjustment) 1.4mm 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) 40003609 (with idle-prevention spring) Non-lubrication 4,000 rpm (*1) 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 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 200V, Single phase 100V DC34V Presser foot micro-lifting screw is provided as standard. AK-121 (auto-lifter device) Grease tube part No. (40006323) 500 g tin of exclusive grease for maintenance (Part No. : 23640204) Touch-back kit (asm.) (Part No. : 23546658) (For types other than WB, CB and 0B)

(2) Stitch pattern table Straight stitch Standard zigzag stitch 2-step zigzag stitch 3-step zigzag stitch Scallop (right) Scallop (left) Blind stitch (right) Blind stitch (left) Custom pattern Number of stitches for pattern Max. zigzag width – 10 10 10 10 10 10 10 Remarks Standard scallop Crescent scallop Equal-width scallop Equal-width scallop Standard scallop Crescent scallop Equal-width scallop Equal-width scallop 1 2 4 6 24 12 24 12 2+a – Name of pattern Stitch pattern Up to 500 a a （ ） （ ） （ ） （ ） （ ） （ ） （ ） （ ）

(4) Cautions in operation 1) Be sure to drain oil in the oil tank and attach the air vent cap (red rubber cap) supplied with the machine to the air vent (golden bushing) located on the side face of the machine bed when transporting the sewing machine. 2) In the case where placing ASS or ASU type machine on a stand or the like before setting the machine to the machine table, to protect the oil tank from damage, take car if there is any protruding object under the stand or the like. 3) Be sure to securely set the connector of the safety switch to the control box to prevent accidents at the time of maintenance. 4) Oil is kept in the gear box for lubrication. It is not necessary to replace the oil. Do not remove the gear box cover except when it is necessary. * When the box cover has been removed, it is necessary to replace the packing. 5) Be sure to operate the sewing machine with the bobbin case removed when making the sewing machine run idle. If the bobbin thread is in the bobbin case, the thread protrudes from the bobbin case and is entangled in the hook race or the hook shaft. As a result, the trouble will be caused. (3) Function list Sewing Straight stitch Standard 2-step 3-step Blind stitch Scallop Custom Free Overlapped Program Pattern Continuous Cycle Max. number of steps Max. number of stitches in each step Max. number of registers that can be performed Max. number of stitches Free stitching Overlapped stitching Program stitching Conden- sation Conden- sation custom Custom pattern (Internal memory) Custom pattern (Smart media) Zigzag width and stitch base line setting Pattern register Continuous stitching register Cycle stitching register 9 19 20 500 10,000 64 Start 20 End 20 500 20 10,000 500 999 499,500 99 20 500 10 10,000 20 500 10 10,000

2. NAME OF EACH COMPONENT 1 Needle thread draw-out device 7 Pedal !4 Bobbin winder (LZ-2290A (U)-7) 8 Knee lifter lever !5 Tension controller No. 1 2 Wiper switch (WB/CB type) 9 Power switch !6 Thread stand 3 Thread take-up cover !0 TB switch !7 Oiling inlet 4 Finger guard !1 Stitch length dial !8 Reverse feed stitching lever 5 Thread tension controller !2 Condensation dial !9 Mirror switch 6 Control box !3 Operation panel @0 Handwheel 1 2 3 4 5 6 7 8 9 !0 !1 !2 !3 !5 !6 !7 !8 @0 !9 !4

1 Needle thread draw-out device (LZ-2290A (U)-7) This device draws out needle thread at the time of thread trimming. 2 Wiper switch (WB/CB type) This switch is used to wipe needle thread after thread trimming from the cloth by means of the wiper signal which is output from the PSC box. 3 Thread take-up cover This is a cover to protect the human body from the contact with the thread take-up. 4 Finger guard This is a guard to protect the human body (mainly fingers) from the contact with needle. 5 Thread tension controller 6 Control box This box contains circuit to control sewing machine and motor, output circuits to activate respective outputs (thread trimming solenoid, reverse feed stitching solenoid, etc.), pedal sensor to detect pedal action, and power circuit to activate respective functions. 7 Pedal This pedal performs sewing machine speed control, thread trimming action, presser lifting action (for AK118 only), etc. by operation of depressing the front part of pedal or the back part of pedal. 8 Knee lifter lever 9 Power switch This is the power switch for motor, PSC, operation panel, etc. !0 TB switch This is an operation switch to perform reverse feed stitching by means of the TB switch. !1 Stitch length dial !2 Condensation dial !3 Operation panel This panel is used for setting automatic reverse feed stitching, pattern stitching, zigzag width, etc. !4 Bobbin winder This is a bobbin winder which is built in the machine head. !5 Tension controller No. 1 !6 Thread stand !7 Oiling inlet This is the oiling inlet for hook lubrication. (For ASS and ASU only) !8 Reverse feed stitching lever !9 Mirror switch This is an operation switch to inverse scallop pattern or custom pattern by means of the mirror switch. @0 Handwheel

3. STANDARD ADJUSTMENT (1) Height and inclination of the feed dog Standard Adjustment (2) Adjusting the feed timing Standard Adjustment A B Standard height : 1.2 mm : LZ-2290ASS, LZ-229ADS : 1.4 mm : LZ-2290ASU, LZ-2290ADU Inclination : The feed dog should be almost leveled when the top surface of the ascending feed dog is flush with the top surface of the throat plate. (ASS, ADS) Reference for the height and inclination of the feed dog ™When the respective marker dots are leveled, the height is 1.2 mm and the inclination is leveled. (ASS, ADS) Timing mark F engraved on face plate Feed rocker cam Feed rocker rod Alignment of timing marks Timing mark I engraved on face plate Marker line engraved on thread take- up 1.2 mm Throat plate Feed dog Hole for screwdriver Top suface of throat plate Comes down. 1.2 mm Leveled Leveled Operator’s side Position of marker dot (Inclination) Position of marker dot (Height) 1 2 3

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Set the feed amount to 0 mm. Feed amount is regulated to (max. 2 mm at the time of delivery.) 2) Adjusting the height of the feed dog Loosen screw 1 and adjust the height of the feed dog by turning feed driving link shaft 2. 3) Adjusting the inclination of the feed dog Loosen screw 3. Put a screwdriver through the hole for the screwdriver and adjust the inclination of the feed dog by turning the feed rocker shaft with the screwdriver. (Caution) 1. If the feed rocker shaft is not pressed in the direction A (a) during the adjustment procedure, there will be a play at the feed bar or washer will come off. So, be sure to adjust the feed dog with the feed rocker shaft pressed in the direction A (a). 2. Check to be sure that the feed dog is leveled with the feed amount currently used when the top surface of the ascending feed dog is flush with the top surface of the throat plate. 3. For the adjustment of slippage of materials for ASU and ADU, refer to (5) Adjusting the slippage of materials and adjusting the feed timing. ™Perform the adjustment of the inclination of the feed dog according to the sewing process. (Example) ™When the feed force is required in such a process of tape attaching or the like : Adjust so that this side of the feed dog is raised. ™When using the slippery material in such a process of attaching a facing of girdle : Adjust so that the feed dog should be leveled. A. Adjusting procedure by removing the gear box cover (ASS,ADS) 1) Remove the gear box cover. (Refer to the item 4-(1).) 2) Adjust the marker line engraved on the thread take-up to the timing mark I engraved on the face plate. 3) Set the feed amount to 2.5 mm. However, the feed amount has to be set to “0” mm only for LZ-2290SU and LZ-2290DU. 4) In the aforementioned state, loosen the setscrew in the hook driving shaft sprocket and adjust the timing mark engraved on the feed rocker cam to the timing mark engraved on the feed rocker rod. (Caution) In this case, the hook timing (thread trimming timing for the machine equipped with a thread trimmer) changes. Be sure to perform re-adjustment.) B. Adjusting procedure with the gear box cover attached (For fine adjustment) (ASS,ADS) 1) Set the feed amount to "0" mm. 2) Adjust the marker line engraved on the thread take-up to marker line J engraved on the face plate. 3) In the aforementioned state, loosen the setscrew in the hook driving shaft sprocket. Now, turn the hook driving shaft to adjust so that the feed dog comes down. Adjust so that the top surface of the feed dog is aligned with the top surface of the throat plate when the feed dog comes down. * There is a slight inclination at the feed dog. Adjust the feed dog so that “0” to 6 teeth come out from the top surface of the throat plate. (Caution) After the aforementioned adjustment, “hook timing” and further “thread trimming cam timing” for the machine equipped with a thread trimmer will change. Be sure to re-adjust them properly. ™For the adjustment of ADU and ASU, refer to (5) Adjusting the slippage of materials and adjusting the feed timing.

(3) Adjusting the feed amount Standard Adjustment (4) Position of the feed dog Standard Adjustment LZ-2290ASS, DS Condition : Feed amount : maximum Feed bar A B Feed crank stud Timing mark Normal feed amount regulation metal fitting Feed spring hook Feed converting arm A (asm.) Feed adjusting link Reverse feed amount regulation metal fitting LZ-2290ASU, DU 1 2 3 1 2 1 A=B

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment [Feed “0” adjustment] 1) Set the stitch length dial at “0”. 2) Loosen screw 1, and align the timing mark on the feed crank stud with that on the feed crank stud support. (The position of the timing mark differs with models.)Insert a sheet of paper between the throat plate and the presser foot, turn the handwheel by hand and check that the needle entry points are the same. If the points are not the same, perform again fine adjustment. (Fine adjustment is necessary since the marks are standard.) 3) When loosening screw 1, confirm that there is no axial play at the feed converting arm A (asm.) and tighten screw 1. [Normal feed adjustment] 4) Set the stitch length dial at the maximum value of the gauge to be used. * Normal feed is regulated to 2 mm at the time of delivery. 5) Loosen screw 2, make the feed adjusting link come in contact with the screw and tighten screw 2. [Reverse feed adjustment] 6) Loosen screw 3, pushing the feed lever down to make the sewing machine enter the reverse feed stitching mode, press reverse feed amount regulation metal fitting against the projecting section of the reverse feed adjusting link B. Now, tighten screw 3. (Set the condensation stitch length adjusting dial to the maximum value on the scale.) * Reverse feed is regulated to 2 mm at the time of delivery. 7) To decrease the reverse feed stitching length for fastening stitching, use the condensation stitching function. (Refer to “Adjusting the condensation stitching mechanism” in the Instruction Manual for the LZ-2290A Series.) 8) When the ratio of sewing length (as many as 10 stitches) of normal and reverse feed is approximately 90% in case of straight stitch feed amount of 2 mm, the adjustment is OK. ™If the timing marks are not aligned with each other, the actual feed amount will be different from the feed amount specified on the stitch length dial. ™If the timing marks greatly separate from each other, the normal or reverse feed amount will be increased causing the feed dog to come in contact with thread trimming counter knife. (In case of thread trimming) ™The feed dog will come in contact with the throat plate. 1) Adjust the stitch length dial to the maximum feed amount the feed dog to be used. * Feed amount of both normal feed and reverse feed is regulated to 2 mm at the time of delivery from the factory. The maximum feed amount of the feed dog at the time of delivery is 2 mm. (Feed dog part No. : 22581508) 2) Turn the handwheel, and fix the feed dog so that the clearances in front and rear are the same at the position where the feed dog does not come in contact with the throat plate. (A = B) 3) In the case where the gear box (large) cover is not opened, loosen setscrews 1 in the feed bar crank to adjust the position. 4) In the case where the gear box (large) cover is opened, loosen setscrew 2 in the feed rocker shaft crank to adjust the position. Max. normal feed amount of the mechanism LZ-2290ASS, ADS=5 mm LZ-2290ASU, ADU=2.5 mm Max. reverse feed amount of the mechanism LZ-2290ASS, ADS=4 mm LZ-2290ASU, ADU=2.5 mm Normal feed → large Reverse feed → small Nomal feed → small Reverse feed → large

(5) Adjusting the slippage of materials (For ASU and ADU) Standard Adjustment 1.4mm θ 1.4 mm θ θ Standard state of engraved marker dot of vertical feed link shaft Standard height of feed dog Operator’s side Sewing direction Upper material Lower material Minus slippage of material Upper material Lower material Upper material Lower material “0” slippage of material Plus slippage of material Standard position 1 2 3 2 3 3 3 3 Engraved marker line on thread take-up Timing mark on face plate G Horizontal feed cam Horizontal feed rod Alignment of timing marks I

Adjustment Procedures Results of Improper Adjustment 1) To adjust the height and inclination of the feed dog, loosen setscrews 1 in the vertical feed link shaft and turn vertical feed link shafts 2 and 3 with a screwdriver. 2) The standard inclination is the position where the engraved marker dots of vertical feed link shafts 2 and 3 face in the direction of 9 o’clock (left side). 3) The standard height of the feed dog is 1.4 mm from the top surface of the throat plate. ◎ This machine can adjust “Amount of slippage of materials” by adjusting the height and inclination of the feed dog. 4) Mainly adjust vertical feed link shaft 3. The amount of slippage of materials can be adjusted by the position of the engraved marker dot which means the size of each theta θ of the inclination of the feed dog. * Points of adjustment. 1. Quality of finished products is improved when the slippage of materials is slightly adjusted to the minus state. (Operator’s hand pressure should be considered in actual sewing.) 2. When performing the adjustment, simultaneously adjusting vertival feed link shafts 2 and 3 makes it difficult to see the characteristic of the slippage of the material. So, set 2 to the standard state (reference) and mainly adjust 3. 3. In the case where the slippage of material (0 to minus) cannot be obtained by adjusting vertical feed link shaft 3 only, adjust vertical feed link shaft 2 so that theta θ , inclination of the feed dog is increased. 1) Adjust the engraved marker line on the thread take-up to timing mark G on the face plate. 2) Set the feed amount to 2.5 mm. However, for LZ-2290SU and LZ- 2290DU, set it to "0" mm. 3) In this state, loosen the setscrew in the hook driving shaft sprocket, and adjust timing mark on the horizontal feed cam to that of the horizontal feed rod. (Caution) In this case, the hook timing (thread trimming timing in case of the machine with thread trimmer) changes. Be sure to perform re-adjustment. ™The height 1.4 mm of the feed dog has been factory-set at the time of delivery. Change the height in accordance process the process. (Characteristic of slippage of materials changes. So, be careful. ™When the adjustment of the height of the feed dog has been performed, the sewing pitch is different from the scale on the stitch length dial. Re- adjust the scale with the actual sewing pitch. ™Characteristic of slippage of materials changes in accordance with materials. (The relation between the direction of the engraved dot and slippage of materials described in the Engineer’s Manusl is the standard of adjustment.) ™Adjust on the left-hand side the adjusting positions of the engraved marker dots of vertical feed link shafts 2 and 3. If the position of the engraved marker dot is on the right-hand side, the effect of prevention of slippage of material is difficult to be obtained. Range of use of engraved marker dot Left Right

(6) Adjusting the origin of the needle rocking motor Standard Adjustment ™Adjustment of the origin is performed in case the needle rocking amount in terms of the center is not equal when (7) Adjusting the needle entry position is performed, or the motor or the sensor is required to be replaced. Assemble link 9 and motor shaft so as to be flush with each other. When the link is at 90˚, move the light-up sensor from the rightend to the left. The position of the origin “0” is when the sensor gose out. 1) 2), 5) 3 ) 4), 6), 8) 6) Needle rocking motor cover Needle rocking unit base Motor Origin sensor (asm.) Sensor installing base 90˚ Positioning jig 90˚ 1 2 3 6 6 5 7 8 9 1 4 Needle bar support base 9)

Adjustment Procedures Results of Improper Adjustment 1) Remove four setscrews 1 in the needle rocking motor cover. 2) Remove three setscrews 2 and counter sunk screw 3. (At this time, loosen setscrew 4 in the needle bar support base shaft connecting stud as well. Refer to the item “(7) Adjusting the needle entry position”.) * When assembling, after temporarily tightening screws 3 and 2, tighten in the order of 3 and 2. 3) Move the needle bar in the direction of the face plate, draw out the needle bar support base shaft from the needle bar support base shaft connecting stud, and remove the shaft together with the needle rocking unit base from the machine arm. In case of replacing or adjusting the needle rocking motor * For the replacement of the sensor, refer to the item of the sensor. 4) Loosen setscrew 5 in the motor link bracket and remove link 9. 5) Loosen four setscrews 6 in the needle rocking unit base and remove the motor to replace. 6) Tighten setscrew 5 in the motor link bracket. (Check also setscrew 7 in the motor link.) In case of replacing or adjusting the sensor 7) Confirm that the sensor lamp lights up in the hook adjusting mode.(Refer to (12) Adjusting the needle-to-hook timing and the needle guard.) 8) Loosen setscrews 8 in the sensor installing plate, move the sensor installing plate to the right-hand end once, and gradually move it to the left-hand side. Tighten setscrews 8 when the sensor lamp goes out. This state is “0” of the origin. (However, it is when the link 9 is at 90˚.) 9) To determine the position of the sensor, it is convenient to make a positioning jig as shown in the figure on the left.

(7) Adjusting the needle entry position (In terms of needle rocking direction) Standard Adjustment Needle bar support base shaft connecting stud 1 2 3 (9) Adjusting the longitudinal play at the needle bar Standard Adjustment As observed from the face plate side Engraved marker dot For an excessive play For an excessive play It is not necessary to remove the face plate. Needle bar support base guide shaft Needle bar 1 2 3 (8) Adjusting the needle entry position (In terms of longitudinal direction) Standard Adjustment Hole for adjusting needle entry position Needle enters the center of needle slot.

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment D C A = B 1) Loosen setscrews 2 and remove bobbin winder unit 1. 2) Set both zigzag width and stitch base line to the position of "0" in the hook adjusting mode. Set the position of the needle to the center and temporarily tighten it. Refer to (12) Adjusting the needle-to-hook timing and the needle guard. 3) Set the zigzag width to 8 mm which is factory-adjusted at the time of delivery, move the needle bar by hand to adjust so that the clearances of zigzag widths C and D are equal and securely tighten screw 3 in the needle bar support base shaft connecting stud. Conditions : Needle enters the center of zigzag width. : Max. zigzag width (8 mm) (Caution) Do not flap or strongly press the needle bar at the time of adjustment. 1) Loosen screw 1 in the face plate. 2) Remove rubber cap 2. Then tighten screw 1 while pressing pin 3 in the needle bar support base guide located inside the face plate with a screwdriver. 3) At this time, move the needle bar to the right and left by hand to confirm that there is neither extra load nor a longitudinal play. 4) If the load applied to the needle bar and the longitudinal play existing at the needle bar at the rightmost needle throw position differ from those at the leftmost needle throw position, perform the adjustment by turning pin 3 in the needle bar support base guide to change the orientation of the engraved marker dot (toward the direction where the load and play are larger). (Caution) 1. Be sure to check the longitudinal play at the needle bar support base. In the case where there is any longitudinal play or extra load, the needle throwing action will be affected. 2. Refer to (5) Disassembling/assembling the needle bar support base shaft (asm.) of 4. PROCEDURES OF DISASSEMBLING/ ASSEMBLING. ™Thread will not be uniformly tensed when the needle throws to the right and left, or thread breakage or needle breakage will result. C = D A B Adjustment Procedures Results of Improper Adjustment 1) Loosen the screw, which can be observed through the hole for adjustment, in the needle bar support base guide shaft with the face plate attached. 2) Move the needle bar back or forth to adjust so that the needle enters the center of the needle slot in the throat plate. 3) Fix the needle bar support base guide shaft. 4) Be sure to check the needle throw torque applied to the needle bar support base. (Caution) 1. The needle entry position in terms of the longitudinal direction should be finely adjusted. If the needle bar has to be moved by a large margin for the adjustment of the needle entry position in case of replacement of gauges, carry out the adjustment referring to “(10) Position of the needle bar connection guide”. 2. Be sure to check the left/right plays at the needle bar support base. In the case where there is any extra load applied to the base, needle throwing action will be affected. ™When there is a longitudinal play at the needle bar, a clearance between the needle and the blade point of the hook occurs. As a result, sewing trouble or worn-out of the blade point of the hook will result.

(10) Position of the needle bar connection guide Standard Adjustment (11) Height of the needle bar Standard Adjustment Conditions : Zigzag width : “0” Position of needle position changing lever : Center ™Part No. of engraved indication E : 22536502 A Dimension : 12.2 mm B Dimension : 3.4 mm 2 Engraved indication Timing gauge Needle bar support base Needle bar connection guide Needle bar crank rod guide 1 2 3 4 5 1 A B A E

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen the screw in the needle bar support base shaft connecting stud referring to "(7) Adjusting the needle entry position (in terms of needle rocking direction)". 2) Remove the thread take-up cover, thread take-up and face plate. Then loosen screws 2 and 3 in the needle bar connection guide together with screws 4 and 5 in the needle bar crank rod guide. 3) Loosen screw 1 in the needle bar support base guide shaft and adjust the needle entry point in terms of longitudinal direction. Then tighten the screw. (Refer to “(9) Adjusting the needle entry position (in terms of longitudinal direction”.) 4) Bring the needle bar to the lower dead position. Move the needle bar support base in the needle rocking direction until a position at which the base smoothly slide without a play is found. Now, temporarily tighten screw 3 in the needle bar connection guide. 5) Bring the needle bar to the upper dead position. Move the needle bar support base in the needle rocking direction until a position at which the base smoothly slide without a play is found. Now, temporarily tighten screw 2 in the needle bar connection guide. 6) Sliding the needle bar support base, tighten screws 2 and 3 in the needle bar connection guide. 7) Tighten screws 4 and 5 in the needle bar crank rod guide the same as the steps 4), 5) and 6). * Set the needle throw slide at the needle bar support base, pressing or drawing the portion near section A, to 5N (500g) or less. 8) Loosen the screw in the needle bar support base shaft connecting stud referring to "(7) Adjusting the needle entry position (in terms of needle rocking direction)". 9) Attach the thread take-up cover, thread take-up and face plate in position. (Caution) 1. Be sure to check the longitudinal play at the needle bar support base. In the case where there is any longitudinal play or extra load, the needle throing action will be affected. 2.Refer to (5) Disassembling/assembling the needle bar support base shaft (asm.) of 4. PROCEDURES OF DISASSEMBLING/ASSEMBLING. 1) Set the mode to the hook adjusting mode. (Refer to (12) Adjusting the needle-to- hook timing and the needle guard.) 2) Remove the presser foot, throat plate, woodruff plate 2 and feed dog. 3) Place woodruff plate 2 on the surface of the machine bed onto which the throat plate is to be attached. Now, loosen setscrew 1 and adjust so that the distance from the top face of woodruff plate 2 to the bottom end of the needle bar is equal to the height of the "1" side of the timing gauge as shown in the figure. (Caution) 1. Thickness of the throat plate may be different from that of woodruff plate 2. So, be sure to use woodruff plate 2 for the adjustment. (Thickness of woodruff plate 2 : 2 mm) 2.Perform the adjustment with zigzag width set to "0" and with the needle positioned at the center of the zigzag stroke. ™Engraved indication "1" side is the height of the needle bar and "2" side the needle-to-hook timing. (Caution) 1. Even when the timing gauge is used, the indented part of the needle may come in contact with the blade point of the hook in accordance with the kind or size of the needle.In this case, slightly up or down the needle bar to adjust the height to the indented part of the needle. 2.The state of delivery of LZ-2290A Series is with timing gauge E (Engraved indication E).

(12) Adjusting the needle-to-hook timing and the needle guard Standard Adjustment ™Lifting amount of the needle (bar) : 3.4 mm (Adjust with engraved marker dot 2 of timing gauge E.) ™When the zigzag width is maximized, a distance of 0.2 to 0.5 mm should be provided between the top end of the needle eyelet and the blade point of the hook when the needle reaches the leftmost end of the zigzag stroke. ™The needle guard : • has to guard the needle both on the right- and left-hand sides. • A clearance of 0 to 0.05 mm should be provided between the needle and the blade point of the hook (when the needle reaches the rightmost end of the zigzag stroke). Remarks Marker lines engraved on the face plate ™The needle-to-hook timing is adjusted using timing gauge E as described above. However, you can use the marker lines engraved on the face plate for reference when adjusting it. ™Be sure to remember that the marker lines are used only for reference. So, it is recommended to use the timing gauge for adjusting the needle-to-hook relation so as to make the most of many functions of the LZ-2290A Series models of sewing machine. 0.2 to 0.5 mm Woodruff plate Fig. 1 Fit the blade point of the hook onto the indented part of the needle. (Approximately 0.05 mm) Fig. 2 Fig. 3 1. Hook adjusting mode Information screen Hook adjusting mode setting screen Hook adjusting mode 1 2 3 4 5 6 7 3 4 5 6 7 E 0 to 0.05 mm Blade point of the hook Needle Needle guard

Adjustment Procedures Results of Improper Adjustment ™If the timing relation between the needle and the blade point of the hook is excessively advanced, smaller thread loops will be made particularly when the needle throws to the right or stitch skipping and thread breakage will result. ™If the timing relation between the needle and the blade point of the hook is excessively retarded, larger thread loops will be made particularly when the needle throws to the left resulting in tilted thread loops and stitch skipping. ™If the needle guard does not come in contact with the needle, the needle vibrates when the sewing machine runs at high speed resulting in thread breakage and stitch skipping. ™If the needle comes in contact with the blade point of the hook, the blade point will be damaged resulting in an extraordinary shortened service life of the hook. (Caution) 1. Part No. of the hook for LZ-2290ASS Series is 2252877. Part No. for LZ-2290ADS Series is 23557259. Designate the hook with the part No. when replacing it. 2. When changing the kind or size of the needle, be sure to check the clearance between the needle and the blade point of the hook. 3. The maximum zigzag width is regulated to 8 mm since the standard gauge is 8 mm at the time of delivery. 1. Hook adjusting mode 1) When performing the hook adjusting, turn ON the power. When the needle bar is not in UP position, turn the handwheel to bring the needle bar to its UP position. 2) Press switch 1 for approximately three seconds to display the information screen. 3) Press 2 to enter the hook adjusting mode. 4) Zigzag patterns of straight stitch and standard zigzag stitch can be selected in the hook adjusting mode. Straight stitch 3 : Changeover of straight stitch and standard zigzag stitch can be performed. 4 : Position of stitch base line is set with "+" and "-". Standard zigzag stitch 5 : Changeover of straight stitch and standard zigzag stitch can be performed. 6 : Zigzag width is set with "+" and "-". (Initial value is set to 8 mm.) 7 : Position of stitch base line is set with "+" and "-". 5) Turn ON/OFF the power to return from the hook adjusting mode to the normal sewing mode. * Sewing machine does not work even when the front part of the pedal is depressed during the hook adjusting mode. * Needle throwing works by turning the handwheel by hand. * Needle bar moves when the set value is changed at needle UP position. (Caution) 1. It is possible for zigzag width and position of the stitch base line to set up to the width of 10 mm regardless of the max. zigzag width limitation at the time of the hook adjusting mode. 2. When using the hook adjusting mode for the machine to which presser foot, gauge, etc. are attached, be very careful in performing the adjustment. 2. Adjusting the hook position ™Adjust the height of the needle bar with engraved marker dot 1 of timing gauge E. At this time, the needle bar is in its lowest position. 1) After adjusting the height of the needle bar, set the needle to the position of zigzag width "0" and adjust the hook so that the blade point of the hook is brought to the center of the needle at the height of engraved marker dot 2 of timing gauge E. 2) At this time, adjust so that the blade point of the hook slightly comes in contact with the needle when the needle guard does not come is contact with the needle. Then tighten the screw in the hook. 3. Confirmation 1) Confirm that the distance from the top end of needle eyelet to the blade point of the hook is 0.2 to 0.5 mm in case of the leftmost needle throwing position at the time of max. zigzag width. 2) When zigzag width 10 mm is used or the indented part of the needle is different in shape, re-adjust the height of the needle bar. 4. Adjusting the needle guard 1) Maximize the zigzag width (see the table below). Adjust by bending the needle guard so that the needle does not come in contact with the blade point of the hook at both the rightmost and left most needle throwing positions. At this time, adjust so that a clearance of 0 to 0.05 mm is provided between the needle and the blade point of the hook. 2) The needle guard is used so that the blade point of the hook does not come in contact with the needle to prevent the blade point from damage. When you desire to replace the hook, be sure to adjust the position of the needle guard. Name of pattern Stitch pattern Max. zigzag width Standard zigzag 10 mm 2-step zigzag 10 mm 3-step zigzag 10 mm Name of pattern Stitch pattern Max. zigzag width Scallop 10 mm Blind stitch 10 mm Custom pattern – 10 mm

(13) Position of the bobbin case stopper Standard Adjustment (14) Orientation of the needle bar thread holder Standard Adjustment ™The bobbin case stopper 2 should be located within the range from the position at which top end A of the bobbin case stopper is aligned with line B to the position that is 0.5 mm away from line B in direction C. ™The needle bar thread holder varies in accordance with the needle bar. ™The orientation of the needle bar is set so that the flat portion of the bottom end of the needle bar faces front of the operator. Install the holder so that the thread hole faces to this side. Front (Good) (No good) ™There are two kinds of the needle bar thread holders. (1).... In case of with auxiliary thread take-up and with flat portion at the bottom of needle bar (2).... In case of without auxiliary thread take-up and with flat portion at the bottom of needle bar (1) (2) A B C 1 1 2 1 2 f 2 Flat portion

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen screw 1 and adjust the position of bobbin case stopper 2 by turning the entire unit of the bobbin case stopper. (Caution) After the position of bobbin case stopper 2 has been adjusted, turn the bobbin case by fingers in the reverse direction of rotation to confirm that the bobbin case will never slip out of the small claw of bobbin case stopper 2. 1) Loosen needle bar thread holder screw 1, and adjust the position of needle bar thread holder 2 with respect to the needle bar. 2) Loosen the screw in the needle bar connection, and adjust the entire unit of the needle bar and needle bar thread holder. ™If the orientation of the needle bar thread holder is not properly adjusted, the thread is likely to untwist resulting in thread breakage.

(15) Position of the thread tension Standard Adjustment (16) Position of the pre-tension Standard Adjustment Striking face on the machine arm Thread tension controller Setscrew nut 1 Almost in parallel to the machine arm Thread should enter the rotary disk straight. Fig. 2 Orientation Fig. 1 Longitudinal position Thread tension controller 1 * Felt of the thread tension controller is a consumable part. Replace it when it is consumed. Part No. of felt : 22528509

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen screw 1, and adjust the position of the thread tension in the state that the thread tension controller is pushed to the striking face on the machine arm. 1) Loosen setscrew nut 1, and adjust the longitudinal position of the pre-tension so that the thread is parallel to machine arm as shown in the figure. 2) Adjust the orientation of the pre-tension so that the thread enters the rotary disk straight. 3) Adjust the pressure of the pre-tension so that the rotary disk rotates smoothly. ™If the orientation of the pre- tension is improper, the thread is bent, and unstable tension and slip of the rotary disk will occur resulting thread breakage or stitch skipping. 1) Pressure of the pre-tension is excessively low : Rotary disk does not rotate smoothly, and defective stitching or thread breakage will occur. 2) In case of the sewing machine with thread trimmer, if the pressure of the pre-tension is excessively high : Thread slip at the needle top after thread trimming or thread slip at the needle top at the start of sewing will occur.

(17) Position of the thread take-up spring guard Standard Adjustment (18) Installing the thread take-up thread guide B Standard Adjustment (19) Installing the thread take-up Standard Adjustment D F C G A B E Tension disk Stopper rubber Thread take-up spring guard Direction of rotation ™Fix the thread take-up with pressed in the direction of rotation. 1 1 NG 1

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen screw 1, and adjust the position of the thread take-up spring guard so that the stopper rubber 2 does not come in contact with the outer periphery of the thread tension disk 3. ™If the thread take-up guide B is installed with faced upward, the thread will come in contact with the edge of the machine arm. This will adversely affect the quality of the finished seam. ™If the thread take-up is not fixed taking the correct method, timing of the thread take-up with respect to the needle bar and the feed mechanism will change. This will change the feeling of finished seam or cause thread breakage. 1) Loosen the screw 1, and adjust the position of the thread take-up thread guide B so that is installed with leveled. 1) Slightly tighten three setscrews 1. Then tighten three setscrews 1 with the thread take-up pressed in the direction of rotation.

(20) Installation of the presser foot Standard Adjustment (21) Installing and adjusting the bobbin winder unit Standard Adjustment ™The top surface of the throat plate should be closely fitted on the reverse side of the presser foot 4. ™A clearance of 1 mm should be provided between the end of needle rocking motor installing boss and the bobbin winder driving wheel (asm.) 2. At this time, tilt the bobbin winder lever 4 in the direction A and adjust so that the bobbin winder shaft 5 does not rotate when turning the bobbin winder shaft 5 by hand. Screw 1 Throat plate Needle rocking motor installing boss 3 1mm Main shaft 2 1 A 4 5 3 4 5 2

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment ™If the presser foot is not closely fitted on the throat plate, the material will not be fed straight and the material will flop causing thread breakage and stitch skipping. ™When tightening screw 2 so as to lift upward, the lifting amount is decreased even when the presser foot is lifted with the presser lifting lever or the like. ™Be sure to set the orientation of the presser foot to the front. When the orientation is tilted, the needle hole does not align with the throat plate and the needle and the presser foot may interfere with each other. 1) Loosen screws 1. 2) In the state that bobbin winder lever 4 is tilted in the direction A, slightly press bobbin winder driving wheel 2 to rubber ring 3 of the bobbin winder unit. 3) Temporarily tighten screws 1 and in the state that bobbin winder lever 4 is tilted in the direction A, turn bobbin winder shaft 5 by hand, and check that the bobbin winder shaft does not rotate. If bobbin winder driving wheel 2 and rubber ring 3 shift with each other, adjust again. 4) Securely tighten screws 1. 1) Put the pressser foot 4 in the presser bar 3, and insert screw 1, At this time, do not tighten screw 1. 2) Turn the handwheel until the feed dog 5 descends under the top surface of the throat plate. 3) Applying a pressure onto the presser foot, tighten screw 1 with the sole of the presser foot closely fitted on the top surface of the throat plate. 3) Apply a pressing pressure onto the presser foot with the presser lifting lever lowered and tighten screw 1 with the sole of presser foot 4 closely fitted on the top surface of the throat plate. 4) When using presser foot other than presser foot 4 which is delivered as standard, there is a case where a clearance is provided between presser foot 4 and the throat plate according to presser foot 4 to be used. At this time, fix presser foot 4to be used with screw 1. Then loosen screw 2 and lower presser foot 4. 5) When tightening screw 2, tighten it so as to lower it in the downward direction. 6) Adjustment of the orientation of presser foot 4 can be performed by loosening screw 2 and turning presser bar 3. ™When turning the bobbin winder shaft by hand in the state that the bobbin winder lever is tilted in the direction A, if the bobbin winder shaft rotates, the bobbin thread is not completely wound up. ™If the bobbin winder driving wheel and the rubber ring are strongly pressed with each other, the service life of the rubber ring is shortened.

(22) Adjusting the amount of oil in the hook (ASS/-7, ASU/-7) Standard Adjustment (23) Adjusting the thread trimming unit Standard Adjustment Race surface Approx. 1.5 mm Appropriate amount of oil (large) Race surface Approx. 0.5 mm Appropriate amount of oil (small) Oil splash on a sheet of paper while the machine is operating for 5 seconds (4,000 rpm) 3 1 2 (39mm) (Frontmost) 5 4 6 (34 ± 0.5mm) 1 Decrease Increase L-shaped spanner 4 4 3 2

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1 2 4 3 The amount of oil in the hook can be adjusted with oil amount adjusting screw 1. 1) Adjusting procedure Turning (clockwise) oil amount adjusting screw 1 increases the oil amount in the hook and turning (counterclockwise) it decreases the oil amount in the hook. (Caution) 1.When adjusting the amount of oil in the hook, perform the adjustment in a way of reducing the oil amount after somewhat increasing it. 2.The amount of oil in the hook has been adjusted at the max. number of revolution at the time of delivery. When you always use the sewing machine at low speed, there is a possibility that trouble occurs due to the lack of amount of oil in the hook. When the sewing machine is used always at low speed, perform the adjustment of the amount of oil in the hook. 1) Move moving knife 2 forward until it will go no further (by approximately 39 mm) and confirm that the end of slide plate 3 is spaced 34 ± 0.5 mm from the top of the moving knife 2. 2) Adjust the opersting pressure of counter knife 1 and moving knife 2 by tightening screw 5 in clamp plate 4 . 3) At this time, the force to move moving knife pin 6 in the direction of the arrow is more or less than 600 gf. 4) If screw 5 is excessively loose, defective thread trimming may occur. ™When the moving knife is properly positioned : ™ When the moving knife is positioned in the front : 1) In the case where the needle thread is trimmed twice : ™When the moving knife is positioned in the rear : 2) In the case where the needle thread is not trimmed : How to solve the aforementioned troubles 1) In the case where the needle thread is trimmed twice : Slightly loosen screws 1 to 4, and slant the knife base in the direction A. Then tighten screws 1 to 4. 2) In the case where the thread is not trimmed : Slightly loosen screws 1 to 4, and slant the knife base in the direction B. Then tighten screws 1 to 4. Needle eyelet Needle eyelet A B Knife base Needle thread on the material side Bobbin thread Needle eyelet Needle thread on the needle side <> 1) Hook shaft oil wick 2 is a consumable part. To stabilize the oil amount in the hook, it is recommended to periodically replace it. Hook shaft oil wick 2 is mounted on the top end of hook shaft 4. Remove the needle and the parts around the needle (presser foot, needle, throat plate, feed dog, hook and woodruff plate), put a spanner, top end of which is L-shaped to screw 3 section of hook shaft oil wick, turn the handwheel in the normal direction of rotation by hand, and draw out the screw. It is possible to replace hook shaft oil wick 2 while hook shaft 4 is not removed. If hook shaft 4 is drawn out, refer to 5- (9) Protruding amount of the hook shaft. 2) Hook shaft oil wick screw 3 (B1808552000) in which hook shaft oil wick 2 (11015906) is entered is assembled in hook shaft 4. Draw out the old hook shaft oil wick 2 in hook shaft oil wick screw 3 and push a new hook shaft oil wick 2. At this time, be sure to check that hook shaft oil wick 2 has entered up to the end of hook shaft oil wick screw 3. ™ When re-assembling, check that the hole at the top end of hook shaft oil wick screw 3 is not broken. 3) Assemble hook shaft oil wick screw 3 to the top end of hook shaft 4. ™ When oil wick is stained, decrease of oil amount in the hook or unstableness of oil amount will result. ™When hook shaft oil wick 2 is not entered up to the end of hook shaft oil wick screw 3, hook shaft oil wick screw 3 comes off during operation and the oil amount in the hook cannot be adjusted. Besides, hook shaft oiling inlet is closed and oil amount in the hook is hard to be obtained. ™When the hole is broken, replace the screw with a new one. Oil amount in the hook becomes unstable. 1 2 3 4 Name of part Part No. 2 Hook shaft oil wick 11015906 3 Hook shaft oil wick screw B1808552000

(24) Initial position of the moving knife Standard Adjustment (25) Timing of the thread trimming cam Standard Adjustment ™ Moving knife pin 1 should be aligned with marker dot 2. ™ Acceptable range of the position of moving knife is as wide as the marker dot. (See the figure shown above.) ™Press roller arm 6 until roller 4 fits in the groove in thread trimming cam 8. Now, lightly turn the main shaft handwheel carefully in the reverse direction until it stops. At this time, the marker dot engraved on the machine arm should be aligned with the red marker dot engraved on the handwheel. Adjust the thread trimming cam longitudinally within the width of a dot. (Rearmost) Latch (Frontmost) 1 2 Marker dot 3 6 7 8 4 5 Machine arm Internal mechanism of thread trimming unit Width of adjustment Red engraved marker dot on handwheel Engraved marker dot on machine arm Handwheel

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen nut 3 in the knife driving arm 7 , and adjust the initial position of the moving knife. Loosen/tighten nut 3 after roller 4 has fitted in the groove on the thread trimming cam 8 by pressing roller arm 6 with fingers. This will prevent knife driving arm 7 from moving out of position thereby allowing you to perform the adjustment in safety. 2) After adjusting the initial position of the moving knife, turn the handwheel in the state that roller 4 has fitted in the groove on the thread trimming cam 8, and check that the latch has securely entered when the moving knife moves forward or backward until it will go no further. (You can hear “click” when the latch has entered.) (Caution) When a feed dog other than that which is delivered as standard is used, there is a case where the feed dog interferes with counter knife according to its shape. In case of interference, move the feed dog to the left side from the engraved dot and check that there is no interference with each other. ™If the initial position of the moving knife is not properly adjusted, the moving knife will fail to cut the thread or cut the thread at a wrong position reducing the length of remaining thread after thread trimming. ™If the timing of the thread trimming cam is excessively advanced, the knife will fail to cut the thread or the length of the thread remaining after thread trimming will be decreased resulting in slip-off of the thread. ™If the timing of the thread trimming cam is excessively retarded, the knife will fail to cut the thread or the moving knife will fail to fully return to the home position making the moving knife projects at the start of sewing. If the timing of the thread trimming cam is not correct, adjust it in the following steps of procedure. 1) Loosen two screws 5 in the cam. 2) Turn the main shaft handwheel until the red marker dot engraved on the handwheel is aligned with the marker dot engraved on the machine arm. 3) Push roller arm 6 until roller 4 fits in the groove in thread trimming cam 8. Lightly push thread trimming cam 8 on the handwheel side and turn it in the reverse direction until it will go no further. Now, tighten two screws 5 in the cam.

(26) Installing/removing the knife unit Standard Adjustment (27) Stop position of the needle after thread trimming (Needle UP stop) Standard Adjustment (28) Clearance provided between the main shaft handwheel and the stator Standard Adjustment 1 ™The standard stop position of the needle (position at which the marker dot engraved on the machine arm is aligned with the white marker dot engraved on the handwheel) is when the marker line engraved on the thread take-up is aligned with the marker line engraved on the face plate (60˚). ™Adjusting range is within one engraued marker dot in front and rear. Handwheel Machine arm (Advances) (Retards) Adjusting range Handwheel 1 mm 1 A B 1 2 3 2 6 5 4 Knife unit Knife unit A: Needle UP stop B: Needle DOWN stop D H F C G A B E J I Pulley cover

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen screw 1 and remove fixing plate 2. 2) Remove screw 3, and the knife unit will come off. Installation is carried out analogously in reverse order. (Caution) When installing the knife unit, take care to allow pin 5 of moving knife (asm.) 4 to securely rest on knife yoke (asm.) 6. 1) Provide a clearance of 1 mm between handwheel 1 and the pulley cover. If the clearance is excessively narrow, the position detecting magnet comes in contact with the synchronizer, and if it is excessively wide, defective detection may occur. 2) Be sure to adjust screw No. 1 in the handwheel 1 to the flat portion of the motor shaft and tighten the screws in the order of No. 1 and No. 2. 1) Stop the needle in its upper stop position. Loosen screw A in the figure and adjust the stop position of the needle by moving the screw within the slot. ™ To advance the stop position a in the direction 1 ™ To retard the stop position a in the direction 2 2) For the lower stop position of the needle, stop the needle in its lower stop position, loosen screw B and adjust the stop position within the slot. (Caution) 1. Do not rotate the sewing machine with screws A and B loosened during performing adjustment. 2. Be sure only to loosen screws A and B and not to remove them. 3. Do not adjust needle DOWN stop screw B. ™When the stop position retards, there is a possibility that wiper interferes with needle in case of with wiper.

(29) Position of the automatic reverse stitching magnet Standard Adjustment (30) Adjusting the thread tension releasing solenoid Standard Adjustment ™Max. feed amount LZ-2290ASS, ADS = 5 mm LZ-2290ASU, ADU = 2.5 mm Standard delivery : 2 mm ™Max. reverse feed amount LZ-2290ASS, ADS = 4 mm LZ-2290ASU, ADU = 2.5 mm Standard delivery : 2 mm ™Presser plate of the thread tension releaser 1 should be engaged with roll pin 2 and auxiliary pin of the thread tension releaser 3. ™When the solenoid is pushed by fingers in the direction A, it should move smoothly. Also, when the solenoid is released, it should smoothly return to its home position. ™When the solenoid is pushed in the direction A, the tension disk should rise. Return spring (Inside the machine arm) 1 A 2 4 3 1 6 4 5 4 2 3 Apply grease e

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen two setscrews 1. Adjust the position by moving automatic reverse stitching magnet 2 itself. 2) When the reverse feed lever is pressed down and plunger 3 moves in the direction a at the maximum feed amount, cushion rubber4 should be able to slightly rotate. ™If the thread tension releasing solenoid fails to be engaged with the auxiliary pin of the thread tension releaser, the tension disk will not rise at the time of thread trimming resulting in slip-off of the thread. ™If the thread tension releasing solenoid fails to be engaged with the roll pin, the return spring lacks, or the solenoid fails to smoothly return to its home position, the tension disk will be held raised after thread trimming. 1) If the thread tension releasing solenoid fails to smoothly move when it is pressed in the direction A, loosen four setscrews 4 and adjust the center of thread tension releasing solenoid 5. 2) If the tension disk fails to rise when the thread tension releasing solenoid is pressed in the direction A, check first the position of the thread tension controller, then remove thread tension releasing solenoid 5. Then loosen nut 6 and adjust the position of presser plate of the thread tension releaser 1. (Caution) Use grease tube (40006323) supplied as accessories and periodically apply grease.

(31) Adjusting the stitch length dial Standard Adjustment (a) Assembling the stitch length dial (b) Assembling the condensation dial * The name of part or the like in the parentheses ( ) in the description is the explanation in case of (b) Assembling the condensation dial. 1) Apply the exclusive grease to feed adjusting screw 1 and feed adjusting shaft 2 (condensation adjusting shaft !4). 2) Screw feed adjusting screw 1 in feed adjusting shaft 2 (condensation adjusting shaft !4) and temporarily connect them. 3) Insert feed adjusting screw 1 which has been temporarily connected in step 2) into the stitch length dial section (condensation dial section) until it will go no further. 4) Attach feed adjusting base 3 onto the machine srm with two setscrews 4. 5) Turn clockwise feed adjusting screw 1 until it will move no further using a slit screwdriver. 6) Tighten setscrew 5 in the feed controller. (Caution) Note that the end face of feed adjusting shaft 2 should be flush with that of feed controller !3. ™At this time, feed controller !3 and the components of the stitch length dial are in the alignment and the components are in the state of being fixed. (Caution) If the components should move, perform the work again from step 5). 7) Place stitch length dial spring 6 and then flat washer 7 (2 pcs. at the stitch length dial section). Adjust the scale "0" on stitch length dial 8 (scale "1" on condensation dial 9) to the marker dot engraved on the machine arm, insert the dial into the machine arm, and fix stitch length dial 8 (condensation dial 9) with setscrew !0. 8) (Turn condensation dial 9 and adjust the scale “0” to the marker dot engraved on the machine arm.) 9) (Press condensation stopper (asm.) !1 to condensation adjusting shaft !4 from the back of the machine arm and tighten setscrew !2 to fix the stopper. Fix it without any play in the thrust direction.) (b) Assembling the condensation dial (a) Assembling the stitch length dial Apply grease. (Exclusive grease) 1 2 3 4 5 6 7 8 9 !0 !1 !2 1 !4 3 4 6 7 !0 7 !3 Apply grease. (Exclusive grease) Use grease tube (40006323) supplied as accessories for the exclusive grease.

Adjustment Procedures Results of Improper Adjustment Model LZ-2290ASS, ADS LZ-2290ASU, ADU Shape Part No. 23534407 23545007 Max. scale –4 mm –2.5 mm ™When the work of step 7) (work of step 9) has been completed, turn stitch length dial 8 (condensation dial 9) and check that the dial moves as specified in the scale. ™When the marker dot engraved on the machine arm cannot be adjusted, check and re-adjust from the work of step 5). Max. scale of the stitch length dial With regard to condensation dial Model Max. scale Part No. of stitch length dial LZ-2290ASS, ADS 5 mm 11071909 LZ-2290ASU, ADU 2.5 mm 26302000

(32) Adjusting the lubrication mechanism (ASS and ASU only) Standard Adjustment (33) Adjusting the position of the thread draw-out wire (For the machine with thread trimmer only) Standard Adjustment ™Forced lubrication is performed to the hook by means of the plunger pump placed in the hook shaft front bushing in the machine head (ASS, ASU) A B 0.5 to 1 mm 8 to 12 mm 3 1 1 2 3 4 5 2 3 Upper marker line Lower marker line 2 (A B) Oiler

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1. Standard position of the thread draw-out wire 1) Loosen setscrew 1. 2) Turn the thread draw-out wire together with thread draw-out wire installin base 2, adjust the installing position of the thread draw-out wire so that a distance of 8 to 12 mm is provided between the top end of thread draw-out wire 3 and the guide portion of thread take-up thread guide A 4, and tighten screw 1. (Caution) At this time, leave a space of 0.5 to 1 mm between the thread draw-out wire 3 and the top surface of the thread take-up thread guide A 4. 3) Finely adjust with setscrews 5 so that the top end of thread draw-out wire 3 is placed approximately in the center (A B) of thread take-up thread guide A 4. 2. When turning OFF the thread draw-out unit 1) It is possible to turn OFF with the function setting No. 89 described in the function setting list. 3. When you desire to increase the needle thread draw-out amount 1) Loosen setscrew 1 and adjust so that A > B is obtained. 1) When the top end of oil amount indicating rod 3 comes down to the lower marker line of oil amount indicating window 2, remove oil inlet cap 1 and fill oil up to the upper marker line of oil amount indicating window 2. ™The amount of oil to be filled is approximately 150 cc. (Defrix Oil No. 1) ™Part No. of oil : MDFRX1600C0 (Caution) Oiling is performed with oiler (B19210120A0) supplied as accessories. Be careful that dust such as thread waste and the like is not oiled to the top end section of the oiler when oiling. ™If the stroke of the thread draw- out wire is insufficient, the length of the needle thread remaining after thread trimming will be reduced resulting in stitch skipping and slip-off of the thread at the start of sewing. ™If the stroke of the thread draw- out wire is excessive, thread breakage will occur at the start of sewing.

(34) Adjusting the stroke of the thread draw-out wire (For the machine with thread trimmer only) Standard Adjustment (35) Installing the wiper base (WB only) Standard Adjustment 1 ™ As observed from the operator, wiper 2 should be leveled. Leveled 2 1 Not to come in contact with each other Not to come in contact with each other 6 4 3 5 6 2 3 4

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen setscrew 1 with hexagon wrench key 3 supplied with the machine as accessory. 2) Turn the thread draw-out wire together with thread draw-out wire installing base 2 and adjust up or down the top end of thread draw-out wire 4. (Caution) 1. When making the remaining amount of needle thread longer, adjust the position of thread draw-out wire 4 to the position where wire 4 does not come in contact with needle thread 5. 2. When making the remaining amount of needle thread shorter, take care so that thread draw-out wire 4 and thread guide 6 do not come in contact with each other. 3. When turning OFF the thread draw-out unit, it can be turned OFF with the function setting No. 89 of the control box. 1) Loosen two setscrews 1 and adjust the installing position of the wiper base. Setscrews 1 are used commonly to fix wiper base 3 and auxiliary thread take-up lever installing base 4. So, it is necessary to adjust the installed state of the wiper base while checking the respective bases for inclination and torsion. 2) When the auxiliary thread take-up lever is not used, enter spacer, MAO91003000 as thick as auxiliary thread take-up lever installing base 4. * For CB type, refer to 2) CB type of (37) Position of the wiper.

(36) Adjusting the wiper solenoid (WB only) Standard Adjustment (37) Position of the wiper 1) WB type Standard Adjustment C ™When the wiper solenoid 3 is OFF (in the normal state), the pin A should be lightly fitted onto the leftmost end of the slot while providing no clearance between them. (State A) Confirm that the pin comes in contact with the rightmost end of the slot at position C when the wiper solenoid is actuated (when it is pressed in direction B). Wiper base Light contact A Comes in contact during operation 3 ™When the wiper is in operation, it should not come in contact with the auxiliary thread take-up lever. ™When needle stops in its upper stop position, a clearance of approximately 2 mm should be provided between the needle tip and the wiper. ™When the wiper is operated after the presser foot has been raised by operating the presser bar lifting lever, it should not come in contact with the presser foot. ™When the presser foot is raised as high as 10 mm by operating the knee-lifter, the wiper should not come in contact with the presser foot. (If the wiper comes in light contact with the presser foot, no problem will result.) 10 mm (knee-lifter) 2 mm 5.5 mm (presser bar lifting lever) Marker dot on machine arm Needle White marker dot Upper stop position 1 2 B 1

Adjustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1) Loosen setscrews 1 and 2 when wiper solenoid 3 is not actuated (OFF). Adjust pin A to state A by moving the entire unit of wiper solenoid 3. * For CB type, refer to 2) CB type of (37) Position of the wiper. 1. Loosen setscrew 1 (one each for both sides) and adjust the position of the wiper. (Caution) Carefully tighten setscrews 1 while preventing the wiper from twisting.

2) CB type Standard Adjustment 5 6 9 !0 2 1 0.5 to 1 mm 2 mm 3 8 4 To be almost parallel To be convex by 1 to 3 mm 8 3 4 Needle (extreme left of 8 mm zigzag width) Needle (extreme left of 8 mm zigzag width) Going Return Going Return 4 7 0 to 1 mm To be flush Wiper link A Ratchet mechanism 3 !3 !4 !5 !6 !3 3 4 !1 !2 3

Adjustment Procedures Results of Improper Adjustment 1. Adjusting the moving path of the wiper 1) Set the needle to UP stop position. Adjust the white marker dot of handwheel 1 to the marker dot of pulley cover 2. When wiper link A is moved by hand, wiper 3 slides to and fro by means of ratchet mechanism. At this time, adjust the wiper so that it passes the center of needle when going and moves in front of the center of needle when returning by means of the ratchet mechanism. Loosen wiper setscrew 8 and move wiper 3 up and down to adjust so that the vertical clearance between the needle and wiper 3 is approximately 2 mm when returning. In addition, adjust the clearance between the sides to approximately 0.5 mm to 1 mm. * When wiper setscre w 8 is loosened, both the directions of vertical and rotation become free. 2. Adjusting the wiper stroke 1) To adjust the wiper stroke, loosen setscrews 5 and 6, and move the wiper up and down to adjust so that it is positioned at approximately 1 to 2 mm from the left end of presser foot (Part No. : 40003542) which is delivered as standard. 3. Adjusting the position of the clamp head 1) Adjust so that the top end plane of wiper is almost parallel to the edge of clamp head 4. Loosen setscrews 9 to adjust the lateral direction, and loosen setscrews !0 to adjust the vertical direction.Adjust the clearance between clamp head 4 and wiper 3 with nuts !1 and !2. 2) Protruding section of clamp head 4 comes above wiper 3. 4. Adjusting the waiting position of the wiper 1) Lateral position : Adjust the lateral position so that the clearance between the suction port of clamp head 4 (clamp ball section) and the concave of wiper 3 is approximately 0 to 1 mm. 2) Vertical position : Adjust the vertical position so that bottom face of wiper 3 is almost flush with the suction port of clamp head 4 (clamp ball section). * For the adjustment of wiper 3, perform the adjustment work to repeatedly perform items 1. through 4. 5. Replacing the presser knife The needle thread cutting knife is mounted on the presser delivered as standard for the bird's nest prevention (CB) type. The needle thread cutting knife is an article of consumption. When the knife becomes dull, replace it with a new one. 1) Remove two setscrews !4 in the knife fixing plate using a precision screwdriver and remove knife fixing plate !3. 2) Remove two setscrews !5 in the knife using a precision screwdriver and remove knife !6(ceramic) from fixing plate !3. Then replace the knife. (Caution) 1. When replacing knife !6 (ceramic), be careful of the injury to the fingers. 2. When replacing knife !6 (ceramic), be careful of its direction and position. (It should be almost parallel to knife fixing plate !3.) 3) When using the bird’s nest prevention type as the needle thread clamp type When using as the needle thread clamp type, perform the setting below. [Example of use] • When using as the interlacing failure prevention at the time of sewing from the cloth end. • When using the normal presser. (presser without knife) 1. Set the value of function setting No.19 to 1. (Standard “0”) 2. Input the setting of number of stitches of releasing needle thread with function setting No. 28. (“0” to 30 stitches) (Caution)Needle thread clamp ratio when needle does not enter the cloth excessively drops in comparison with that when needle enters the cloth. Be sure to operate the wiper on the cloth. 4) When using the bird’s nest prevention type as the wiper type 1. Set the value of function setting No. 18 to “0”. (Standard 1) ™ Wiper 3 comes close most to the needle when the needle throws to the right. There is a case where the wiper interferes with the needle according to the position of the wiper. In this case, re-adjust the position. ™Adjust so that they slightly come in contact with each other. ™When the protruding section faces the direction other than the upward one, needle thread clamp failure occurs. ™Rate of needle clamp is affected by the adjustment of the wiper waiting position. ™Knife !6 (ceramic) Part No : 11434206

4. PROCEDURES OF DISASSEMBING/ASSEMBLING AND CAUTIONS (1) Adjusting and assembling of the gear box (large) Procedures of disassembling/assembling ™Loosen setscrews 1 and remove the gear box large cover 6. ™Centering the horizontal feed cam 1) Remove feed spring 7. 2) Loosen setscrew 3 in horizontal feed cam rod 4. 3) Loosen setscrews 2 in the feed adjuster cover and adjust so that horizontal feed rod 4 can smoothly move up or down. Then tighten setscrews 2. 4) Turn the handwheel and tighten setscrew 3 in horizontal feed cam rod 4 while performing the centering of the horizontal feed cam. (Check that torque is even in the all ranges.) Hook driving gear(small) Feed adjuster cover Feed adjuster Horizontal feed cam Horizontal feed shaft 3 1 1 1 1 1 1 1 1 1 1 1 1 2 4 (Caution) Clearance provided between hook driving shaft rear metal 5 and hook driving gear (large) is 0.05 ± 0.01 mm. Hook driving gear (large) 5 6 7

Caution in disassembling Caution in assembling ™For removing/installing the gear box cover 6, be sure to refer to the item “(4) Removing/installing the gear box cover” and carefully perform the work. ™The horizontal feed cam and hook driving gear are mounted in the gear box (large). In the case where centering and adjustment of play of the aforementioned components are not securely performed when assembling and adjusting, seizure due to the torque of the sewing machine, abnormal heat, or defective return of the lever will be caused. ™Oil used in gear box Part No. : MDFRX2700C0 ™ Hook drive gear (small) is a selective part. Part No. Name of part Dimention (diameter) 23538903 Hook drive gear (small) S Small 23536303 Hook drive gear (small) A 23536402 Hook drive gear (small) B 23536501 Hook drive gear (small) C 23536600 Hook drive gear (small) D 23536709 Hook drive gear (small) E 23536808 Hook drive gear (small) F Large

(2) Replacing the motor 1) Loosen the setscrews in the handwheel in the order of screw No. 2 2 and screw No. 1. 1. 2) Remove four setscrews 4 in pulley cover 3 with the hexagon wrench key of 4 mm. 3) Remove the pulley cover 3 while paying attention to LED 5 of the synchronizer. 4) Remove the window plate, and loosen coupling setscrews 8 fixed on the motor shaft in the order of screw No. 2 and screw No. 1. 5) Remove four motor setscrews 7 with the hexagon wrench key of 4 mm. 6) Quietly pull out the motor, loosen setscrews 6 in the coupling, and remove the coupling from the motor. 7) Fit the coupling the hole diameter of which is smaller to the new motor, adjust screw No. 1 of setscrews 6 to the flat portion of the motor and tighten it. At this time, set the clearance between the motor and the coupling to 0.5 mm. 8) Insert the motor into the machine arm, adjust screw No. 1 of coupling setscrews 8 to the flap portion of main shaft and tighten it. 9) After installing pulley cover 3, tighten the setscrews in the order of screw No. 1 1 and screw No. 2 2 at the position where a clearance of approximately 1 mm is provided between the handwheel and pulley cover 3. A B Procedures of disassembling/assembling 1 2 3 4 5 6 7 (Short) 8 7 7 7

(Caution) 1. There is the release secton A at the shaft section of the encoder case B in the rear of the motor. 2. When the handwheel is held removed, dust or the like enters from the part and the sensor section is damaged. As a result, malfunction of the motor may be caused. Caution in disassembling Caution in assembling (Caution) 1. Take care of the dust when replacing the motor and install the handwheel quickly. 2. When storing the motor itself for a long period, install the encoder cover (installed at the time of delivery of the motor). 3. Motor setscrew 7 (1 pc.) only located in the lower section on the right-hand is shorter in length. Be careful when assembling.

(3) Replacing the timing belt (4) Removing/installing the gear box cover 9 !1 1 * The timing belt !1 (22505705) of the highest quality is used, and it is not necessary to replace it unless a special trouble occurs. 1) Perform removing/installing of the motor in accordance with the steps of 4. - (2) Replacing the motor. 2) Tilt the sewing machine, remove back- magnet setscrews 9 and remove back- magnet !0. 3) Pressing timing belt !1 in the right-hand direction, turn the timing belt to the front by fingers, then the timing belt can be removed.3) Pressing timing belt !1 in the right-hand direction, turn timing belt !1 to the front by fingers, then timing belt !1 can be removed. 4) Replace timing belt !1 with a new one and install again by reversing the above order. Procedures of disassembling/assembling Procedures of disassembling/assembling Do not open the gear box cover unless a trouble occurs. When it is compelled to open it, take care of the following matters. * Prepare a new gear box large cover packing (23526601). 1) Tilt the sewing machine and prepare an oil receiver under the gear box. 2) Loosen the setscrew of the pipe presser and remove it from the cover. 3) Remove the gear box setscrews and drain oil inside the gear box. 4) When the maintenance of the inside has been completed, close the gear box cover. At this time, replace the packing with a new one. In addition, cleanly wipe oil on the connected face of the cover and the machine bed. Turn the setscrew once more to securely tighten after all setscrews have been tightened once. !0 Rubber cushion Plunger 5) When peeling off safety label 1 in the front of machine bed, there is a rubber plug inside. Remove the rubber plug and fill the gear box with 190 cc of (JUKI genuine) Defrix Oil No. 2.

6 8 ™When removing/installing the motor, unless the motor is defective, loosen coupling setscrew 8 without loosening coupling setscrews 6 and remove the motor with the coupling installed. ™When the motor is separated from the coupling, set the clearance between the end face of the motor and that of the coupling to 0.5 mm when re- assembling. 0.5 mm Caution in disassembling Caution in assembling Caution in disassembling Caution in assembling (Caution) Do not open the gear box unless a trouble occurs. * JUKI genuine oil Defrix Oil No. 2 : MDFRX270000 ™ Replace the packing with a new one.

(5) Disassembling/assembling the needle bar support base shaft (asm.) Procedures of disassembling/assembling 3 3 4 Structure of components Needle bar support base shaft rear metal A Thrust bush Lock nut Needle bar support base shaft 2 1 Lock washer Slide resistance screw Needle bar support base shaft (asm.) 1

* Slide resistance spring 2 which greatly affects the needle rocking performance is mounted in needle support base shaft rear metal B 1. Do not perform the adjustment or the like unless it is necessary. < From disassembling to assembling the needle bar support base shaft (asm.> 1) Removing the outer components 1. Removing the bobbin winder unit Loosen three fitting screws 3 in the bobbin winder unit and remove bobbin winder unit 4. Caution in disassembling Caution in assembling

Caution in disassembling Caution in assembling 2. Removing the thread take-up cover base Loosen two fitting screws 2 in thread take-up cover base 1 and remove thread take-up cover base 1. 3. Removing the thread take-up Loosen three setscrews 3 in the thread take-up and remove thread take-up 4 and thread take-up counter weight 5. 4. Removing the face plate Loosen 7 setscrews 6 in the face plate and setscrew 7 in the face plate thread guide, and remove face plate 8. 5. Removing the needle rocking motor cover Loosen four setscrews 9 in the needle rocking motor cover and remove needle rocking motor cover !0. ™Be careful of the thread take-up knife.

Procedures of disassembling/assembling 1 2 3 4 5 6 7 8 9 !0 !1 !1 Needle bar upper metal section Needle bar upper metal section !2

Caution in disassembling Caution in assembling 2) Removing the presser bar components Remove the presser foot setscrew and remove the presser foot. Loosen presser bar guide bracket screw 1 and remove presser spring regulator 2, presser guide bar 3, presser spring 4 and presser bar 5. 3) Removing the needle bar components Remove the needle clamp screw, and remove the needle and the needle bar thread guide. Loosen needle bar guide bracket screw 6 and remove needle bar 7. 4) Releasing the joint of the needle bar support base shaft Insert a screwdriver from the bobbin winder unit section and loosen setscrew 8 in the needle bar support base shaft bracket. 5) Releasing the slide resistance screw Make sure of the dimension from the processed plane of machine arm 9 to the head of screw !0 using the vernier calipers. Loosen nut !2 and release the resistance of the slide release spring. 6) Remove the needle bar support base from the machine arm Hold the needle bar upper metal section of needle bar support base !1 and draw out needle bar support base !1 from the machine arm in such a way as pulling the metal section to the front and turn it clockwise. * When needle bar support base !1 components are not replaced, perform assembling by reversing the order of removing without proceeding to further steps. * When needle bar support base !1 components are replaced, proceed to the work of steps after 7). Dimension of height of screw !0 9 !2

Caution in disassembling Caution in assembling 7) Removing the needle rocking motor unit. Remove screws 1 and 2, draw out needle bar support base shaft 7 from the needle bar support base shaft bracket, and remove the needle rocking motor unit from the machine arm. 8) Applying grease in the needle support base shaft front and rear bushings Fill the whole of the support base shaft of needle bar support base shaft (asm.) 7 and the grease groove in needle bar support base shaft front and rear bushings 8 in the machine frame with exclusive grease (Part No. : 40006323) supplied as accessories. ™Refer to (5) Applying the e x c l u s i v e g r e a s e o f 5 . MAINTENANCE as well.

Procedures of disassembling/assembling Needle bar crank rod guide Engraved marker dot 1 2 3 4 5 6 7 8 9 !0 Needle bar bracket guide A B 9 Longitudinal play Needle feed unit base !1 !2 !3 !4

Caution in disassembling Caution in assembling 9) Adjusting the longitudinal position of the needle bar 1. Attach the throat plate, attach a needle to the needle bar, lightly press support base shaft guide pin B 1 so as to remove the play of the needle bar, and temporarily tighten setscrew 2 in the support base shaft guide pin B. Further, temporarily adjust the height of the needle bar at the position of the engraved marker line 1 of timing gauge E. (Tighten setscrew 9 in the needle bar bracket.) Tighten setscrew 3 in the support base shaft guide shaft so that the center of needle hole in the throat plate aligns with the needle entry (center of needle hole). 10) Adjusting the lateral position of the needle bar 1. Move needle bar support base shaft (asm.) 4 to the right or left, rotate needle bar support base shaft guide pin B 1 so that the center of right and left motion is obtained and there is no longitudinal play, and tighten setscrew 2 in the support base shaft guide pin B. 2. Move needle bar support base shaft (asm.) 4 to the right or left, and tighten setscrews 5 and 6 in the needle bar bracket guide when the center is obtained while turning the handwheel. 3. Tighten setscrews 7 and 8 in the needle bar crank rod guide when the center is obtained while turning the handwheel. Apply exclusive grease supplied as accessories to the slide parts. (For the details of applying section, refer to the item of (5) Applying the exclusive grease of 5. MAINTENANCE.) 11) Checking the lateral slide torque of the needle bar support base 1. Check that the torque of pushing and pulling is less than 5N within the range of 10 mm of needle bar rocking. Measure at A and B sections using the spring balancer as shown in the figure. 12) Assembling the needle rocking motor unit 1. Removing the needle rocking motor unit Refer to "1) through 3) of 3. - (6) Adjusting the origin of the needle rocking motor. 2. Adjusting the installation of the needle rocking motor unit (In case of a new needle rocking unit or re-selection of needle rocking components) 1) Move needle bar support base shaft !1 to the right side. 2) Temporarily tighten needle rocking motor unit setscrew A !3 after installing the needle rocking motor unit to the arm installing screw section, and temporarily tighten three motor unit setscrews B !2. Then securely tighten in the order of setscrew A !3 and setscrews B !2. 3) Insert needle bar support base shaft !1 into installing hole in the needle rocking link bracket !4. Center of needle hole in throat plate Needle hole in throat plate Needle ™It is easy to obtain the center while temporarily tightening setscrews 5 and 6 in the needle bar bracket guide and gradually increasing the tightening pressure. ™It is easy to obtain the center while temporarily tightening setscrews 7 and 8 in the needle bar crank rod guide and gradually increasing the tightening pressure. ™When the torque is more than 5N within the range of 10 mm of the needle bar rocking, re-adjust from the step 10). ™When the machine is operated with abnormal torque, worn-out or step- out of motor will result.

Procedures of disassembling/assembling 6 7 4 5 9 !1 A B 8 !5 By loosening setscrews 4 in the needle bar support base shaft bracket collar, the connecting shaft slides. 4 4 !0 9 8

Caution in disassembling Caution in assembling 4) Loosen setscrews 4 in the needle bar support base shaft bracket collar. By loosening setscrews 4 in the needle bar support base shaft bracket collar, connecting shaft 5 slides to the right or left. 5) Perform centering while sliding the needle bar support base shaft to the right or left, and set the shaft while temporarily tightening setscrews 4 in the needle bar support base shaft bracket. 1. In order to improve the needle rocking quality, connecting shaft 5 is classified as the selective part. Select connecting shaft 5 which smoothly moves without any play. 2. For coupling connecting shaft 5, insert needle rocking link !1 between connecting shaft 5 and connecting shaft collar 6, and tighten setscrew !5 in the connecting shaft collar so that there is no play. 13) Adjusting needle rocking "0" position 1. Set the mode to the hook adjusting mode (refer to (12) Adjusting the needle-to-hook timing and the needle guard) of 3. STANDARD ADJUSTMENT.), determine needle entry "0", and tighten setscrew 8 in the needle bar support base bracket. 14) Checking the lateral torque of the needle bar support base Check that the torque of pulling and pushing is less than 10N within the range of 10 mm of the needle bar rocking. Measure at A and B sections using the spring balancer as shown in the figure. 15) Tightening the slide resistance screw 1. Adjust the height of the slide resistance screw so that it becomes the height of the spring measured in advance (factory-adjusted value) at 5) Releasing the slide resistance screw or the aimed value of pulling and pushing is 14N to 15N (11N to 18N in the whole region) within the range of 10 mm of the needle bar rocking at A and B sections using the spring balancer as shown in the figure. In addition, the height of the screw can be adjusted to 5.5 ± 1 mm 16) Assembling the outer components 1. Assemble the outer cover removed. 17) Adjusting the hook and the height of the needle bar 1. Perform adjusting of the height of the needle bar, and needle-to-blade point of the hook in the hook adjusting mode (refer to (12) Adjusting the needle-to-hook timing and the needle guard of 3. STANDARD ADJUSTMENT) using timing gauge E. ™When centering is not obtained, needle bar support base bracket 7 moves, and the lateral needle rocking torque becomes heavy when tightening screw 8 in the needle bar support base bracket in the next process, resulting in step- out. ™When tightening setscrews 4 in the needle bar support base shaft bracket collar, be careful so as not to damage sensor slit 9 or origin sensor !0. ™When the torque becomes more than 10N within the range of 10 mm of needle bar rocking, perform re- adjustment from step 12). ™When the machine is operated with the abnormal torque, worn-out or step-out will be caused. ™When the adjustment is performed with the value other than the specified value, problems such as step-out, deterioration of sewing performance, worn-out, etc. can be considered. Be sure to use the machine with the specified value. No. Part No. Name of part Shaft diameter 40008119 Connecting shaft A Large 40008120 Connecting shaft B Medium 40008118 Connecting shaft C Small Dimension of height of screw 5.5 ± 1 mm Apply exclusive grease to the grooves of the holes in connecting shaft 5 and needle rocking link !1. 5 !1 5

5. MAINTENANCE (1) Replacing procedure of the printed circuit board 1. FLT printed circuit board 1) Draw out connector cords of CN1, CN2 and CN3 on FLT circuit board. 2) Remove green/yellow cord attached to FLT circuit board from the screw of earth mecca at the bottom of the box. 3) Remove 6 screws on the side of the pedal sensor side from the outside. 4) Assemble by reversing the above removing order. 2. PWR printed circuit board 1) Remove FLT printed circuit board by the aforementioned removing procedure of FLT printed circuit board. 2) Remove two green/yellow cords attached to PWR printed circuit board from the screw of earth mecca at the bottom of the box. 3) Draw out connector cords of CN11, CN25, CN23, CN13, CN22, CN21 and CN38 on PWR printed circuit board. 4) Draw out connector cord of CN44 on CTL printed circuit board. 5) Remove 9 screws on PWR printed circuit board from the inside of the box. (Caution) It is not necessary to remove FLT printed circuit board in case of the simple substance of the box. Remove connectors and FG wire, and replace PWR printed circuit board after removing the front cover. 6) Assemble by reversing the above removing order. 3. CTL printed circuit board 1) Draw out all inserted connector cords on CTL printed circuit board. 2) Take the draw hook and remove the board together with the rear cover from the main unit of the box. 3) Remove 7 screws on CTL printed circuit board. 4) Assemble by reversing the above removing order.

(2) Maintenance of the hook lubricating pipe oil filter It is recommended to periodically clean the inside of the filter of the hook lubricating pipe oil filter. Remove pipe stop ring (large) 1 and remove thread waste or the like collected to wire netting section 2. * Be careful of the damage of the lubricating pipe or the like at the time of maintenance of the filter. Hook lubricating oil filter 2 1 1

(3) Cleaning the cooling fan 1. Cloth waste or the like gathers around the cooling fan filter section installed on the lower part of the under cover, and there is a case where cooling effect is decreased. 2. When cloth waste or the like gathers, remove fan cover 1 and remove cloth waste or the like gathered around filter section 2. 3. Besides, when cloth waste or the like gathers around filter section 3 as well, remove filter setscrew 4 and remove cloth waste or the like gathered around filter section 3. 3 1 2 4

(4) Applying the exclusive grease * Exclusive grease (40006323) is applied to the portions other than the lubricating portions to which lubrication is necessary 1. It is not necessary to add grease to the portions when the machine is generally used. However, when the machine is used under the severe conditions, it is effective to periodically fill up the exclusive grease (approximately once or twice a year). 2. For applying (filling) grease, it is convenient to apply it using the exclusive lubricator (GDS01007000). [Note when applying grease] 1) Needle bar metal section of the dry-head type machine heads (ADS and ADU) There are grease grooves in needle bar upper and lower metals 2 of the metal section of needle bar support base D (asm.) 1. Draw out the needle bar and fill the grease grooves with the exclusive grease supplied as accessories. * When filling grease, be careful that the inner surfaces of needle bar upper and lower metals 2 are not damaged and dust or the like is not mixed. When newly filling up the grease, make the sewing machine run idle at low speed at 10-second intervals to discharge excess grease which occurs on the needle bar at this time and wipe the grease. Perform this operation several times and use the sewing machine when the excess grease does not occur. About grease groove in metal 1 2

2) Mechanism section of the face plate section Apply the exclusive grease supplied as accessories to all components of the rocking mechanism in the face plate section. However, do not apply grease to the needle bar of lubricating type (ASS and ASU). | When applying grease, the needle bar is stained in black and the sewing product is in danger of being stained. Apply the exclusive grease supplied as accessories to the whole moving components of the mechanism. No. Name of part 1 Needle bar crank rod oil wick 2 Needle bar support base shaft upper metal felt 3 Needle bar bracket guide 4 Needle bar crank rod guide 5 Needle bar bracket 6 Needle bar support base guide pin A 7 Needle bar support base guide pin B 8 Needle bar 9 Needle bar support base shaft upper/ lower metals Lubricating oil Apply JUKI genuine No. 1 oil. Apply JUKI genuine No. 1 oil. Exclusive grease Exclusive grease Exclusive grease Exclusive grease Exclusive grease Exclusive grease Exclusive grease Part No. MDFRX1600C0 MDFRX1600C0 40006323 40006323 40006323 40006323 40006323 40006323 40006323 Remarks Excluding dry-head type Excluding dry-head type Apply grease so that the hole for screwdriver of needle bar crank rod guide is filled up as the standard. Dry-head type only Dry-head type only 1 2 3 4 5 6 9 7 8

3) Feed mechanism section Feed mechanism of ASU and ADU Feed mechanism of ASS and ADS Apply exclusive grease supplied as accessories. 1. Fill whole of feed base shafts A and B, and oil holes 2. Inside of grease groove of bearing of vertical feed link Oiling holes (fill exclusive grease supplied as accessories.) Apply exclusive grease supplied as accessories to whole of feed base shaft. Vertical feed link Grease grooves Apply exclusive grease supplied as accessories. 1. Fill whole of feed base shaft and oil holes. 2. Inside of grease groove of bearing of vertical feed link Apply exclusive grease to whole of feed base shafts A and B. Oiling holes (fill the holes with exclusive grease.) Vertical feed link Grease grooves Apply exclusive grease to link coupling section of vertical feed arm.

Needle bar support base shaft rear metal B Needle bar support base shaft Needle bar support base shaft rear metal B Needle bar support base shaft Lubricator(GDS01007000) Grease Exclusive grease (grease tube : 40006323) supplied as accessories or exclusive grease (23640204) Injection of grease 25 mm (Oiling pipe : 23630007) 4) Needle rocking slide resistance section 1. Spring 4 for the slide resistance is placed in the rear of setscrew 1 and the slide resistance is determined by positioning screw 1 at the time of production. Accordingly, measure the dimension from lock nut 2 to the top end of screw 1 before loosening setscrew 1. 2. Loosen lock nut 2 and turn setscrew 1 to remove setscrew 1, lock nut 2 and lock washer 3. 3. Fill the inside of the metal from the screw hole with the exclusive grease supplied as accessories using the lubricator. 4. Stop lock nut 2 and setscrew 1 at the dimension measured in the aforementioned step 1. 1 23 4 5 1 2

(5) Hook shaft gear 1. Exclusive grease is filled in the bevel gear section. However, when filling grease in case of maintenance or the like, remove the filled grease once and fill grease (EXSON MOBIL LISTAN 2) of 15 cc. (Caution) 1. Heating, noise or seizure will be caused depending on the amount of grease. Keep filling of 15 cc (approximately 13.8 g). 2. Do not use the packing which has been removed once and replace it with a new one. Packing Part No. : 23526809 2. In case of removing the play at hook shaft due to the play at bevel gear When backlash of the hook shaft is large while fixing the hook driving shaft, it is considered that backlash of the bevel gear is increased. When closing backlash, loosen the screws in the order of screw No. 2 2 in the bevel gear (large), screw No. 1 1 in the bevel gear (large) and move the gear to the right or left to close the play. When tightening them, tighten in the order of screw No. 1 1 in the bevel gear (large) and screw No. 2 2 in the bevel gear (large). (Caution) When the backlash is excessively closed, heating or noise will be caused. When the backlash is excessively large, sewing trouble will be caused. Tighten screws at the backlash of approximately 0.1 mm. Screw No. 1 Bevel gear (large) Bevel gear (small) Screw No. 2 1 2 Direction of rotation of hook shaft

(6) Adjusting the needle rocking link The needle rocking link is handled as the selective parts in order to improve the quality performance of needle rocking. When replacing the parts, take care of the selecting procedure of the selective parts. 1. For needle rocking connecting shaft 1, there are four kinds from A through D which are different in outer diameter tolerance respectively. Select the shaft, the play of which is smaller in terms of the hole in needle rocking link 2. 2. For needle bar support base shaft bracket pin 3, there are three kinds from A through C which are different in outer diameter tolerance respectively. Select the pin, the play of which is smaller in terms of the connecting shaft collar hole. 3. Reduce the play as small as possible in the shaft direction of motor link 4 and needle rocking link 2, and assemble them so that needle rocking link 2 rotates by light weight when holding motor link 4 by hand. 4. There are a grease groove at the bush hole section of needle rocking link 2, a grease hole in needle rocking connecting shaft 1, and a grease hole in needle bar support base shaft bracket pin 3. Fill grease (exclusive grease : Part No. 23640204) when replacing them. Apply grease to the outer diameter section as well as the inner diameter section of the rotating parts as well. 5. When installing motor link 4 to motor shaft 5, make the end plane of motor shaft 5 flush with motor link 4 and fix the link. Name of part Part No. Tolerance Needle rocking connecting shaft A 23544109 Maximum Needle rocking connecting shaft B 23544208 Large Needle rocking connecting shaft C 23544307 Medium Needle rocking connecting shaft D 23544802 Small Name of part Part No. Tolerance Needle bar support base shaft bracket pin A 40008119 Large Needle bar support base shaft bracket pin B 40008120 Medium Needle bar support base shaft bracket pin C 40008121 Small 1 2 3 4 5

LISTAN 2 Hook lubrication Lubrication to face plate section Oil filter (asm.) 23630452 Lubricating opening of arm Oil gauge Remainder oil from hook Caution 1 !3 9 1 Gear box (large) Return oil from face plate section (7) Lubricating to face plate section (ASS and ASU only) Amount of lubricating to the face plate section has been factory-adjusted and the adjustment is not necessary. When performing adjustment after disassembling and assembling, perform checking and adjustment below. * minute-quantity lubricating system by means of oil wick is utilized for the lubrication in the face plate section. Oil is supplied to face plate section lubricating tank 1 which is installed in the rear of the back of machine arm by means of pump 8 and the minute-quantity lubrication is performed by means of face plate section oil wick 6 in face plate section lubricating tank 1. With adjustment screw 9, the amount of lubrication by pump can be adjusted. (Already adjusted at the time of delivery from factory) [Adjustment of lubrication to face plate section of LZ-2290A] Caution 2 Lubrication route to face plate (Thin line section) 6 (Caution) 1. Amount of oil pumped up to face plate section lubricating tank 1 is limited by means of adjustment screw 9, 2. Oil lubricated the oil wick falls the pipe by natural fall and returns to the float case. Oil amount adjustment screw in the face plate section lubricating tank is hidden with stop plug at the time of delivery since it is not necessary to be adjusted. When the adjustment is performed by mistake ( m i s t a k e n a s t h e adjustment of oil amount in the hook), re-adjust as shown below. When lightly tightening the screw, return the screw by approximately 0.6 turn from the stop position. <> 1) Adjusting the amount of lubrication to the face plate section Remove stop plug !3 and return adjustment screw 9 by approximately 0.6 turn from the stop position when lightly tightening the screw. Tightening adjustment screw 9 e Amount of lubrication to face plate section lubricating tank 1 is decreased. Loosening adjustment screw 9 e amount of lubrication to face plate section lubricating tank 1 is increased.

Face plate section return pipe 1 2 4 5 6 7 A 2 5 6 1 7 2) Checking lubrication and draining of oil Check that lubrication and draining of oil are performed in face plate section lubricating tank 1 which is installed in the rear of the back of machine arm. Remove the side plate on the back face, and check that oil flows in face plate section lubricating tank 1 through oil pipe 3 and drain pipe 2 when the sewing machine is operated. * When oil enters section A and flows in the direction of face plate section, slightly tighten adjustment screw 9. ™When lubrication and draining of oil are not performed, lubrication in the face plate section becomes insufficient and wore-out or seizure will be caused. ™Be careful of being caught in the sewing machine when operating the sewing machine. Draining of oil 3 Lubrication * Remove face plate section lubricating tank screw 4 and drop face plate section oil wick 6 in face plate section lubricating tank 1 in the hole of lubricating joint 7. (Do not cover the hole of lubricating joint 7.) ™ If the hole of lubricating joint 7 is covered, oil flows backward and oil leakage will be caused. 3) Needle bar crank rod oil wick Oil in face plate section oil wick 6 lubricated in face plate section lubricating tank 1 is transmitted to needle bar crank rod oil wick !1 and the wick performs lubrication in the face plate section when the it comes in contact with crank rod end !0 Be sure to adjust so that crank rod end !0 comes in contact with needle bar crank rod oil wick !1 by 1 to 2 mm. Adjust the contact amount by moving face plate section lubrication presser !2. * In addition, refer to (5) - 2) Mechanism section of the face plate section of 5. MAINTENANCE. ™ If they do not come in contact with each other, worn-out or seizure will be caused. !2 !1 !0

(8) Protruding amount of the hook shaft 1. Protruding amount of hook shaft 1 from the end plane of hook shaft front metal 2 is 9 mm. (Caution) When the protruding amount is excessively large or small, lubrication failure will occur. So, be careful. 1 2 (9) Draining of CB type When the regulator becomes filled with water, turn knob 1 for drain counterclockwise. (10) Cleaning the dust bag of CB type Periodically clean dust bag 1. (When the dust bag becomes excessively filled with waste thread, there may be cases where clamp failure occurs.) 1 9mm 1

1 Re-sewing switch 2 Needle up/down compensating switch 3 Screen changeover switch 4 With/without reverse feed stitch at sewing start switch 5 With/without reverse feed stitch at sewing end switch 6 Reset switch This switch is used to continue sewing from the step on the way after replacing bobbin thread when bobbin thread has run out during program stitching step. This is the switch to perform needle up/down compensating stitching. (Needle up/down compensating stitching and one stitch compensating stitching can be changed over with function setting No. 22.) This is the switch to change over the screen. This is the switch to turn ON/OFF automatic reverse feed stitch at sewing start. * This switch cannot be used with the sewing machine which is not provided with automatic reverse feed stitching device. This is the switch to turn ON/OFF automatic reverse feed stitch at sewing end. * This switch cannot be used with the sewing machine which is not provided with automatic reverse feed stitching device. This is the switch to make the value of bobbin thread counter or sewing counter the set value. 1 Re-sewing switch 2 Needle up/down compensating switch 3 Screen changeover switch 4 With/without reverse feed stitch at sewing start switch 5 With/without reverse feed stitch at sewing end switch 6 Reset switch 7 Teaching switch !5 Power display lamp !6 Smart media cover !7 Smart media slot (Smart media inserting opening) !8 Smart media (Optional : Part No. HX005750000) 8 Information switch 9 Edge sensor switch !0 One-shot stitching switch !1 With/without automatic thread trimmer switch !2 Thread trimming prohibiting switch !3 Counter value setting switch !4 Max.speed limitation variable resistor 6. OPERATION PANEL (1) Names of the respective sections 1 4 !7 3 6 9 !0 !3 !5 !6 2 5 !4 !1 !2 8 7 !8

7 Teaching switch 8 Information switch 9 Edge sensor switch !0 One-shot stitching switch !1 With/without automatic thread trimmer switch !2 Thread trimming prohibiting switch !3 Counter value setting switch !4 Max. speed limitation variable resistor !5 Power display lamp !6 Smart media cover !7 Smart media slot (Smart media inserting opening) This is the switch to set the setting of the number of stitches with the value of number of stitches which has been actually sewn. This is the switch to perform various function settings. This switch cannot be used with LZ-2290A. When this switch is set to effective at the time of program stitching, the sewing machine automatically operates up to the specified number of stitches. When this switch is set to effective at the time of program stitching, the sewing machine automatically performs thread trimming when the specified number of stitches has been completed. This switch prohibits all thread trimmings. * This switch cannot be used with the sewing machine which is not provided with the automatic thread trimming device. This is the switch to set the value of bobbin thread counter or No. of pcs. counter. When moving the resistor in the left direction, max. speed is limited. This lamp lights up when the power switch is turned ON. This is the cover for smart media inserting opening. To open the cover, place your finger on the notch located on the side of the cover as shown in the figure and push the cover in the direction of left slanting rear. Do not close the cover unless smart media is completely inserted. To set smart media, insert smart media into smart media slot and push it until it is almost hidden. To remove smart media, push it further again and it protrudes to the position where it can be held between your fingers. Now, draw it out. * Be very careful of the inserting direction of smart media.

(2) Information Setting and checking of various data can be performed with the information. For the information, there are the operator level and the maintenance personnel level. [Operator level] 1. Turn ON the power. When the needle bar is not in the UP position, turn the handwheel to bring the needle bar to its UP position. 2. Press switch 1 to display the information screen. 3. Press switches 3, 5 corresponding to the various functions. [Maintenance personnel level] 1. Turn ON the power. When the needle bar is not in the UP position, turn the handwheel to bring the needle bar to its UP position. 2. Press switch 1 to display the information screen. 3. Press switches 2 through 8 corresponding to the various functions. Information screen (Maintenance personnel level) 3 : Sewing common data 5 : Sewing management information 2 : Ver display 3 : Sewing common data 4 : Function setting 5 : Sewing management information 6 : Communication mode 7 : Hook adjusting mode 8 : Smart media format Information screen (Operator level) 1 1 3 5 2 3 4 5 6 7 8

1) Ver display Software version of each CPU is displayed. Press switch 2 in the information screen (maintenance personnel level). Ver display screen Explanation of display R V L 01- 01 01 00 Others Level Version Revision Kind of CPU Panel software Main software Servo motor software

2) Sewing common data 1. Press switch 3 in the information screen. 3. Set the items below in the second screen. The second screen of sewing common data setting 2. Set the items below in the first screen. 2 : Limiting procedure of max. zigzag width limitation For the limiting procedure of max. zigzag width limitation, there are two settings below. 3 : Max.zigzag width limitation value * Display varies according to the procedure selected in 2. 1) When the center is set in 2 : Max.zigzag width limitation value (center) 2) When the left/right is set in 2 : Max.zigzag width limitation value (right) Max.zigzag width limitation value (left) 4 : Reference of stitch base line For the reference of stitch base line, there are three settings below. 1) Center 2) Right 3) Left 2: Mirror function setting Mirror inversion means the function that the reverse pattern stitching is performed after pressing the mirror inversion switch during temporary stop of sewing. The sewing patterns that the mirror inversion is possible are scallop, custom, continuous stitching and cycle stitching. For the mirror inversion, there are two settings below. 1) Center 2) Left/right The first screen of sewing common data setting 2 3 4 2 3 4 5 6 !6

1) 1 pattern : Mirror inversion is “1” pattern only. After completion of inversion pattern, the pattern returns to the original one. 2) Continuous : The machine continuously operates the inversion pattern after the inversion until thread trimming is performed or, the mirror switch is pressed again. * For the details, refer to “Mirror switch”, p.15. For the key lock, there are three kinds of settings below. Level “0” : All items can be changed. Level “1” : is displayed on the right end of the screen. Kind of sewing Pattern : Change of pattern and registration Custom : New creation and edit Condensation custom : Edit Continuous stitching : New creation, copy, deletion and edit Cycle : New creation, copy, deletion and edit cannot be changed. Level “2” : is displayed on the right end of the screen. Items other than reverse feed stitching ON/OFF, thread trimming prohibition switch, specifying zigzag stop position and bobbin thread counter cannot be changed. 6 : Selection of max. zigzag width limitation display when the power is turned ON Whether the max. zigzag width limitation value is displayed or not when the power is turned ON can be selected. Every time the setting switch is pressed, display/non-display is changed over alternately. 1) Display 2) Non-display (Caution) Level of the standard delivery is “1”. When changing the locked contents of level “1”, it is necessary to set the level to Level “0” once. 3 : Position of the stitch base line of condensation custom The mode is the operation mode in terms of the stitch base line of condensation custom when the reference of the stitch base line is set to that of center stitch base line. For the condensation custom, there are two settings below. 1) Travelling together : This is the mode that travels the positions of stitch base line of condensation custom and zigzag pattern together. 2) Fixed : This is the mode that fixes condensation custom to the input data position. 4 : Counter function ON / OFF of the function of thread trimming counter or bobbin thread counter is set. When OFF is set, even the counter display is not performed. 5 : Key lock It is possible to lock the setting switch so that the zigzag width that has been set once or the contents of custom pattern is not changed by mistake. However, it is possible to change ON/OFF of the reverse feed stitch, thread trimming prohibiting switch, specified zigzag stop position and bobbin thread counter. Sewing direction LED lights up. LED lights up. Mirror switch ON Pattern mode Continuous mode

4. Press switch !6 for approximately three seconds in the second screen of sewing common data setting. The third screen of sewing common data setting 2 : Change of zigzag timing Zigzag timing can be changed. Needle sway can be prevented by delaying timing when sewing heavy-weight materials or the like. 1. Fast : Standard setting 2. Slow : Timing is delayed by approximately 30fl in terms of the standard. However, to delay timing, conditions below are necessary. 1. When the number of rotation is set to less than 4,000 rpm with the function setting No. 96, Max. number of rotation setting. 2. When the travelling distance of 1 stitch is less than 4 mm. In case of more than 4 mm, needle may travel while it is stuck on the cloth. In case the distance is more than 4 mm and zigzag motion is performed, do not set this function. 7 : Alternate changeover of stitch base line unit between 0.1 mm and 0.2 mm The unit of change of stitch base line position can be changed over to 0.1 mm unit or 0.2 mm unit. 1. 0.1 mm unit : Standard setting 2. 0.2 mm unit : Panel setting is 0.1 mm unit, but actually the position travels every 0.2 mm. 2 7 The second screen of sewing common data setting 2 3 4 5 6 !6

3) Sewing management information For the sewing management information, there are the operator level and the maintenance personnel level. [Operator level] Press switch 5 in the information screen. [Maintenance personnel level] Press switch 5 for approximately three seconds in the information screen. Pictograph on the left end of the sewing management information is shown in reverse video. Sewing management information screen (Maintenance personnel level) 1. Error record display Press error record display switch 6 in the sewing management information screen (maintenance personnel level). Error record screen When switch 7 or !4 is pressed, the error record scrolls up or down. Explanation of display Error record of approximately 100 cases (depending on the memory capacity) can be stored in memory in the order of the latest. Error record display 6 Maintenance management function 4 7 !4 Record No. Error No. Time occurred (Unit : time)

4) Communication mode Uploading and downloading of various data with the sewing machine server utility (hereinafter called SU-1) or the smart media can be performed in the communication mode. For the communication mode, there are the operator level and the maintenance personnel level. The kind of data which can be handled with the operator level is different from that with the maintenance personnel level. Communication function table Kind of data Custom pattern (Vector form) Condensation custom pattern (Parameter form) All sewing machine data Panel Main Servo motor Each program data Operation level Operator Operator Operator Operator Download Upload NG Extension of file VDT EPD MSP PRG Remarks File is vector form. File is parameter form. For downloading, only overwriting is possible. : Panel : Smart media : SU-1

Operating procedure [Operator level] Press communication mode switch 6 in the information screen. [Maintenance personnel level] Press communication mode switch 6 for approximately three seconds in the information screen. ictograph on the left end of the communication screen is shown in reverse video. Communication screen (Maintenance personnel level) Kind of selected data Data selection !4 Data communication source 3 Data communication destination 5 Start of communication 8 Communication method selection 7 1. Communication setting 1 Data selection Press data selection switch !4 in the communication screen. !4 3 5 7 8 Data selection screen Select the data to perform communication, and press set key switch 8 . 2 Communication method selection Press communication method selection switch 7 in the communication screen. Communication method selection screen

Select the method to perform communication and press set key switch 8 . Reference : Communication method cannot be selected by downloading of program. 3 Data communication source 3 4 Data communication destination 5 Set data communication source 3 and data communication destination 5 in the ten key screen, or "+" or "-" key. (Ten key input, or "+" or "-" key input is changed according to the kind of data.) 2. Start of communication After all settings have been completed, press communication start key switch 8 to start communication. When the screen returns to the communication setting screen after display of the during communication screen, communication is completed. However, It is necessary to turn OFF the power after ending the communication of all sewing machine data or program data. (Caution) Never turn OFF the power during communication. In case of OFF, operation cannot be guaranteed.

5) Vector form data (Custom pattern data) 1. The custom pattern created with the panel can be stored as the vector form data. 2. The same custom pattern can be used with other sewing machines by downloading the vector form data which has been stored. 3. The vector form data created with PM-1 can be can be downloaded as the custom pattern. 4. The vector form data which has been stored can be edited with PM-1. Communication screen (Download of vector form) Folder structure of vector form (* .VDT) file in the smart media Upload : Uploading to the smart media is written in the folder of "VDATA". In case there is no folder, the folder of "VDATA" is automatically created. Download : Downloading from the smart media is read from the folder of "VDATA". When creating the pattern with PM-1, store it in the folder of "VDATA". 1 Create folder "VDATA" in the smart media. (It is not necessary to create the folder when it already exists.) 2 Copy the file (extension VDT). Smart media PROG SC915 VDATA VD00001.VDT VD00099.VDT

Upload : Uploading to the smart media is written in the folder of "SC915". In case there is no folder, the folder of "SC915" is automatically created. Download : Downloading from the smart media is read from the folder of "SC915". Store the copy from other media or the like in the folder of "SC915". 1 Create folder "SC915" in the smart media. (It is not necessary to create the folder when it already exists.) 2 Copy the file (extension EPD). 6) Parameter form data (Condensation custom pattern) 1. The condensation custom pattern created with the panel can be stored as the parameter form data. 2. The same condensation custom pattern can be used with other sewing machines by downloading the parameter form data which has been stored. Communication screen (Download of parameter form) Folder structure of parameter form (* .EPD) file in the smart media Smart media PROG SC915 VDATA SC00001.EPD SC00001.MSP

7) All sewing machine data 1. Data such as sewing setting data, adjustment data, etc. which are memorized in the sewing machine can be stored in one package. 2. It is possible to download the all sewing machine data to the other sewing machines to make the same setting. Communication screen (Download of all sewing machine data) Folder structure of all sewing machine data (* .MSP) file in the smart media Reference : When downloading the all sewing machine data, it is necessary that the file and the Ver of the sewing machine have to agree with each other. An error occurs when the file of different Ver is downloaded. (Caution) It is not possible to store and copy the function setting of the servo motor. Smart media PROG SC915 VDATA SC00001.EPD SC00001.MSP Upload : Uploading to the smart media is written in the folder of "SC915". In case there is no folder, the folder of "SC915" is automatically created. Download : Downloading from the smart media is read from the folder of "SC915". Store the copy from other media or the like in the folder of "SC915". 1 Create folder "SC915" in the smart media. (It is not necessary to create the folder when it already exists.) 2 Copy the file (extension MSP).

Upload : Downloading from the smart media is read from the folder of "PROG\SC915". Download : Store the copy from other media or the like in the folder of "PROG\SC915". 1 Create folder "PROG" in the smart media. 2 Create folder "SC915" in the PROG folder. (It is not necessary to create the folder when it already exists.) 3 Copy the program file (extension PRG). 8) Program data 1. When the change of software occurs in the future due to Ver-up or the like, rewriting of the program can be performed. Rewriting of the program is performed with each CPU. Communication screen (Download of IP-100 program data) Folder structure of program (* .PRG) file in the smart media Smart media PROG SC915 VDATA IP010101.PRG MA010101.PRG MT010101.PRG SC915

8 : Formating is performed. Confirm again whether formating can be performed before pressing the switch. !5 : The screen returns to the information screen. (Caution) When formating is performed, all data stored in the smart media are deleted. Take the back- up of necessary data beforehand. 9) Smart media format Perform formating of the smart media. The media formated with the personal computer or the like may not be used. When using the media with IP-100, be sure to perform formating with IP-100. Press smart media format switch 8 in the information screen (maintenance personnel level) Smart media format confirmation screen !5 8

(3) Matters that demand special attention regarding the operation panel, IP-100 1) Kind of IP-100 For the operation panel, IP-100, there are several kinds of types in accordance with the specifications. The type which can be used for LZ-2290A is TYPE-A only. The product of TYPE A0A or TYPE A0B which is indicated on the type name plate seal in the rear of the panel case can be used. Both are compatible in the state of the complete set of the panel. However, when replacing the printed circuit board only, use the printed circuit board after function Rev03 and pattern Rev F/R2 since there are the change of the structure components. In addition, it is necessary to change and set jumper wire W1 (located on the side of RVR1 variable resistor) of the printed circuit board according to the type. Set W1 by changing the jumper post. (Caution) When setting is wrong, LCD screen display is not properly performed. 2) Matters that demand special attention when disassembling the operation panel Operation panel, IP-100 is constructed with precision components. Leave the action such as disassembling the panel case or the like to our service department since injury by electric shock or failure of panel will be caused. If the force more than expected is applied when disassembling the panel case, it may be damaged since it is made of the plastic molding. Especially when performing disassembling (opening/closing) the front panel and the rear panel in the state that the smart media cover attached to the rear case is closed, the small-sized switch mounted on the inside of the printed circuit board interferes with the smart media cover and may be damaged. So, be careful. It is necessary to assemble all screws used in the operation panel with tightening torque of 0.56Ncm. (Excluding screws to fix it on the machine head and to fix the earth wire.) 3) Prohibition of the change of DIP switch setting Do not perform the changeover of DIP switches since the guarantee of control program and stored data cannot be performed. It is not necessary to operate these switches since they are all changeover switches for the production by the manufacturers. (Caution) The 4-string DIP switches are not exposed unless the operation panel case is disassembled. Type name plate seal Setting of W1 TYPE A0A 1-2 pin setting (upper side) TYPE A0B 2-3 pin setting (lower side) TYPE A0A TYPE A0B 1 2 3 1 2 3 W1 W1

7. SPECIFICATIONS OF SC-915 Temperature : 0 to 40˚C Humidity : 90% or less Supply voltage Single phase 100V 3-phase 200V Frequency 50 Hz / 60 Hz Rated currency 8A 3A Operating environment Temperature : 0 to 40˚C Humidity : 90% or less Destination For general export Item Supply voltage Single phase 3-phase 200V/ 200V/220V/240V 220V/240V Frequency 50 Hz / 60 Hz Rated currency 4.6A/4.3A/4.0A 3.0A/2.7A/2.3A Operating environment Temperature : 0 to 40˚C Humidity : 90% or less Destination For CE Item Supply voltage Single phase 220V/230V/240V Frequency 50 Hz / 60 Hz Rated currency 4.3A/4.2A/4.0A Operating environment Temperature : 0 to 40˚C Humidity : 90% or less Destination For JUS Item Supply voltage Single phase 3-phase 200V/ 100V/110V/120V 220V/240V Frequency 50 Hz / 60 Hz Rated currency 8.0A/7.5A/7.0A 3.0A/2.7A/2.3A Operating environment 8. FUNCTION SETTING PROCEDURE OF SC-915 (1) How to change over to the function setting mode WARNING : To avoid possible personal injuries caused by movement other than that you desired, do not operate the switches in the procedure other than those required, as described below, to specify the functions. (Caution) 1. Do not perform switch operations other than those described in the following explanations. 2. Be sure to re-turn the power switch ON after one second or more has passed. 3. If the power is turned ON immediately after turning it OFF, the sewing machine may not work normally. In this case, turn ON the power again. There are two kinds of function settings, Level 1 and Level 2. Level 1 : Change of setting can be performed without turning OFF the power switch. Level 2 : It is necessary to turn OFF the power switch after change of setting. For the details, refer to "9. FUNCTION SETTING LIST". [Setting procedure of Level 2] 1) Turn ON the power. When the needle bar is not in its UP position, turn the handwheel to bring the needle bar to its UP position. 2) Press switch 1 for approximately three seconds. 1 (For use in Japan)

4 3 Setting No. Set value 6 !5 ™Change set value with “+/–” Key of switch 6. The set value has been changed from “0” to “3”. ™When this changed value is acceptable, press switch 8. When you desire to return the value to the previous one, press switch !5. 6 3) Press switch 4 for approximately three seconds. 4) This screen is the function setting screen. Change the setting No. with “+/–” Key of switch 3. For the details of setting No., refer to 9. FUNCTION SETTING LIST. Example) Changing the flicker reducing function (Setting No. 5) Change the setting No. to “5” with “+” Key of switch 3 in the figure above. ™Press switch 6. 8

™Turn OFF the power switch and turn ON the power switch after approximately one second. ™Change of the set value is determined by turning OFF the power switch. [Setting procedure of Level 1] 1) Press switch 1 for approximately three seconds. 2) Press switch 4. 3 3) This screen is the function setting screen. Change the setting No. with “+/–” Key of switch 3. For the details of setting No., refer to 9. FUNCTION SETTING LIST. Example) Changing the number of rotation of reverse feed stitching (Setting No. 8) Change the setting No. to “8” with “+” Key of switch 3 in the figure above. ™ Press switch 6. Setting No. Set value 1 4 6 3

™Change the set value with “+/ –” Key of switch 6. ™Set value has been changed from 1350 to 1250. ™When this changed value is acceptable, press switch 8. Press switch !5 when you desire to return the value to the former one. ™Press switch 1 in case of sewing. 6 !5 8 1