Troubleshooting (PLK, XC-G Sereis)

①Isn't the needle thread tension too strong? Adjust the needle thread tension.
Click here for needle thread tension adjustment.
②Is the strength of thread take-up spring adequate? Adjust the needle thread take-up spring.
Click here on adjusting the needle thread take-up spring.
③Are there scratches on the thread contacting part of the needle plate, hook, and presser foot?Replace if any scratches are found.
④Is thermal cut the cause?Slow down the sewing speed.
Click here on how to sew.

①Isn't the bobbin thread tension too strong? Adjust the bobbin thread tension.
Click here for bobbin thread tension.
②Are there scratches on the thread contacting part of the needle plate and bobbin case? Replace with a new part if there are any scratches.

①Isn't the thread tale length after trimming too short? Adjust with the pre-tension.
Click here for adjusting the needle thread remaining length after the thread is cut.
②Isn't the thread take-up spring motion too large? Adjust the thread take-up spring motion.
Click here on adjusting the thread take-up spring.

①Is the gap between the needle and hook too large? Adjust the gap (position) between the needle and hook (middle).
Shuttle hook: Click here for gap adjustment of the needle and hook (middle).
Full rotary hook: Click here for position adjustment of the needle and hook.
②Is the timing right on the needle and hook tip? ​Adjust the timing by position adjustment of the needle and hook.
Shuttle hook: Click here for position adjustment of the needle and hook (middle).
Full rotary hook: Click here for position adjustment of the needle and hook.
③Is the hook driver pushing the needle too much? Adjust the gap between the needle and hook driver.
Click here for gap adjustment of the needle and driver.
④Is the needle attached correctly? Check the needle is attached correctly.
Click here for the needle attachment.

①Is the fixed knife dull?Sharpen or replace the fixed knife.
Shuttle hook: Click here for position adjustment of fixed knife.
Full rotary hook: Click here for the relationship between the knife point of fixed knife and moving knife.
②Check the position of thread cutting cam.
Shuttle hook: Click here for position adjustment of thread cutting cam.
Full rotary hook: Click here for the attaching position adjustment of thread cutting cam.
③Are the position and holding position of the moving knife correct? Adjust the moving knife.
Shuttle hook: Click here for position adjustment of moving knife.
Full rotary hook: Click here for the relationship between the knife point of fixed knife and moving knife.
④Does stitch skipping occur at thread cutting?Refer to “Too many stitch skipping”.
⑤Are the thread cutting solenoid and air cylinder working? Check from the test output mode.
​Click here how to check the output signal.
⑥Is the thread cutting setting turned OFF? Turn the thread cutting setting ON from the program mode.
Click here for the program mode.

①Isn't the needle thread tension too weak? Adjust the needle thread tension.
Click here for adjusting the needle thread tension.
②Isn't the bobbin thread tension too weak? Adjust the bobbin thread tension.
Click here for adjusting the bobbin thread tension.
③Is the strength of thread take-up spring adequate? Adjust the needle thread take-up spring.
Click here on adjusting the thread take-up spring.
④Is the presser foot height adequate? Adjust the center press height.
Click here to adjust the top and bottom amount of presser foot.
Click here to adjust height position of presser foot, and control the presser foot height during sewing.
⑤Is the presser foot timing adequate? Adjust the center press timing.
​Click here to adjust the center press timing.

①Does the wiper interfere with the needle or presser foot? Adjust the wiper height.
②Is the wiper function turned OFF? Set the wiper function ON.
Click here for wiper adjustment.

①Do you hold the sewing material adequately? Adjust the external clamp.
Click here for the solenoid type “adjustment of clamp”.
Click here for the air type “adjustment of clamp”.
②Does the sewing material slide in the clamp? Make sure to perform anti-slippery processing on the clamp.

①Is the ambient temperature out of usage range? Use in the ambient temperature of 5°C to 35°C.
②Is the gap between the sensor and detection plate too large? Adjust the gap between the sensor and detection plate to 1.0 to 1.5 mm.
Click here for the adjustment of XY machine origin point.

Insert the USB memory that contains the system. While pressing the F key on the control panel, turn the power ON to enable the selection of language and model setting, and the system can be restored to default.
Click here for system reinstallation.

①Is the external clamp position filling up the area?Move the external clamp to the center area with your hand.
②Are the X axis and Y axis encoder connector inserted firmly?Check the connector.
Click here for cable connection.

Are the X axis and Y axis encoder connectors inserted the other way around?Check the connector.
Click here for cable connection.

Locate the machine head tilting detection switch on the rear of the head section, and check if it is detected.If it shows detected, turn the limit switch ON.
Click here for attaching the sewing machine tilting detection switch.

①Check if air is supplied adequately to the sewing machine's main body.
Click here for air tube piping.
②Is the sensor ON? Check the sensor.
​Click here for checking the input signal at sewing enabled condition.

Check if the USTP code is entered after the TRIM code through the program settings of operational panel.
Click here for teaching.

Are the setting data and step data installed correctly? Perform importing from the USB memory for initial setting that comes with the product.
Click here for initial setting of the setting table.

①Is the turning switch in the manual mode (MANUAL)? Set the turning switch to the automatic mode (AUTOMATIC).
Click here for automatic (normal mode)/manual (test mode) turning switch.
②Is the sensor holding in the correct position? Check it is holding on the correct position.
Click here for checking the input signal at sewing enabled condition.

①Is the needle attached correctly? Check if the needle is inserted all the way, and the direction of the needle is correct.
Click here for the needle attachment.
②Isn't the presser foot pressure too weak? Adjust the presser foot pressure according to a sewing object.
Click here for adjustment of pressing pressure.
③Are there any scratches on the hook tip? If there are scratches, fix the hook tip with an oil-stone or replace with a new hook.
④Is the needle bent? Replace with a new needle if the needle is bent.

①Isn't the stitch balancing of the needle thread too weak? Turn the stitch balancing knot clockwise little by little to strengthen the stitch balancing.
Click here for needle thread balancing.
②Isn't the thread take-up spring too weak? When the spring is too weak, turn the stitch balancing knot clockwise little by little to strengthen.
③Isn't the thread take-up spring motion too small? When the motion is too small, turn the needle thread adjuster clockwise little by little to make the working amount large.
Click here for adjustment of thread take-up spring (lock stitch top and ordinary feed)
④Isn't the bobbin thread balancing too weak? It is almost not necessary to adjust the bobbin thread balancing; however, a little adjustment may be necessary depending on a sewing material and thread. The most adequate condition is when a thread edge coming out from the bobbin is lifted, the thread is fed every time you lift the thread edge.
Click here for bobbin thread balancing.

①Is the needle attached correctly? Check if the needle is inserted all the way, and the direction of the needle is correct.
Click here for the needle attachment.
②Isn't the thread take-up spring too strong? When the spring is too strong, turn the stitch balancing knot counterclockwise little by little to weaken.
③Isn't the operation of thread take-up spring too fast? When the operation is too fast, turn the needle thread adjuster counterclockwise little by little to make it slow.
Click here for adjustment of thread take-up spring (lock stitch top and compound feed)
④Isn't the needle thread balancing too strong? Turn the stitch balancing knot counterclockwise little by little to weaken the stitch balancing.
Click here for needle thread balancing.
⑤Is the needle bent? Replace with a new needle if the needle is bent.
⑥Are there any scratches on the hook and bobbin case? If there are scratches, fix them with an oil-stone or replace with a new part.
⑦Are there any scratches on the needle hole of needle plate? If there are scratches, refine the needle hole or replace with a new needle plate.

①Isn't the pressure too strong? Adjust the presser foot pressure according to a sewing material.
Click here for adjustment of presser foot pressure.
②Isn't the needle thread balancing too strong? Turn the stitch balancing knot counterclockwise little by little to weaken the stitch balancing.
Click here for needle thread balancing.
③Isn't the bobbin thread balancing too strong? Turn the stitch balancing screw counterclockwise little by little.
Click here for bobbin thread balancing.
④Is the feed dog out too much from the needle plate surface? According to a sewing material, adjust the feed dog height within the range of 0.8 to 1.2 mm.
Click here for adjusting the feed dog.

①Isn't the presser foot pressure too weak? Adjust the presser foot pressure according to a sewing object.
Click here for adjustment of pressing pressure.
②Is the feed dog not out enough from the needle plate surface? According to a sewing material, adjust the feed dog height within the range of 0.8 to 1.2 mm.
Click here for adjustment of feed dog.
③Is the needle bent? Replace with a new needle if the needle is bent.

①Is the needle attached correctly? Check if the needle is inserted all the way, and the direction of the needle is correct.
Click here for the needle attachment.
②Is the feed timing right? When the feed and needle encounter is misaligned significantly, the needle is likely to brake. Perform adjustment.
Click here for the relationship between the needle and feed dog (lock stitch total feed).
③Is the needle bent? Replace with a new needle if the needle is bent.

Reset to restore to the factory setting.
Click here for setting method to restore back to the factory setting.

Please contact the sales representative of sewing machine shop that you purchased your sewing machine. If the shop where the sewing machine was purchased is unknown, please contact your nearest JUKI sales companies..
Click here for contact.
You can also download from the following.
Click here for technical materials of XC-G500.

Each solenoid can be force output from the program mode E (↓+↑+A).
①Presser lifting solenoid: Can be checked by turning ON/OFF the function “OFO”.
②Thread cutting solenoid: Can be checked by turning ON/OFF the function “OAO”.
③Wiper solenoid: Can be checked by turning ON/OFF the function “OBO”.
④Backstitch solenoid: Can be checked by turning ON/OFF the function “OCO”.
⑤Tension opening solenoid: Can be checked by turning ON/OFF the function “ODO”.
Click here for the problem diagnostics of each solenoid.

Check the display pattern of the status display LED.
Click here for the display pattern of the status display LED.

Check the error display list.
Click here for error display.

Check the error/message display.
Click here for the error/message display list.