JUKI AE-200A User manual

ENGLISH
AE-200A
INSTRUCTION MANUAL

ii
CONTENTS
!. CAUTIONS BEFORE OPERATION ...............................................................................1
Precautions for use................................................................................................................................... 1
@. CONFIGURATION OF THE MACHINE..........................................................................2
#. OVERVIEW.....................................................................................................................3
1. Features ................................................................................................................................................. 3
2. Specications ........................................................................................................................................ 3
$. INSTALLATION ..............................................................................................................4
1. Table height............................................................................................................................................ 4
2. Auxiliary table ........................................................................................................................................ 5
3. Assembling the sewing machine table and auxiliary table ............................................................... 5
4. Installing the operation panel mounting plate.................................................................................... 5
5. Connecting the operation panel........................................................................................................... 6
6. Lubrication............................................................................................................................................. 7
7. Installing the thread stand.................................................................................................................... 7
8. Removing the covers ............................................................................................................................ 8
9. Threading the machine head................................................................................................................ 9
10. Adjusting the stitch length ............................................................................................................... 10
11. Fitting a needle .................................................................................................................................. 10
12. Loading the bobbin ........................................................................................................................... 11
13. Connecting and adjusting the air source........................................................................................ 11
%. INSTALLING THE OPTIONAL DEVICES ....................................................................12
1. Installing the 2-pedal unit ................................................................................................................... 12
2. Installing the stacker........................................................................................................................... 13
3. Installing and adjusting the bobbin winder ...................................................................................... 21
4. Assembling the thread breakage detecting device and setting of the operation panel ............... 23
5. Installing the bobbin thread remaining amount detecting device.................................................. 26
^. HOW TO USE THE OPERATION PANEL....................................................................33
1. Explanation about switches on the operation panel........................................................................ 33
2. Basic operation of the sewing machine............................................................................................ 35
3. Selecting a pattern .............................................................................................................................. 37
4. Winding a bobbin ................................................................................................................................ 38
5. Using the counter................................................................................................................................ 40
6. Changing the sewing data.................................................................................................................. 41
7. Using the initial value pattern ............................................................................................................ 42
8. Sewing data list ................................................................................................................................... 43
9. Copying a sewing pattern................................................................................................................... 50
10. Using the PATTERN REGISTRATION key........................................................................................ 51
11. Using the PARAMETER REGISTRATION key.................................................................................. 52
12. Performing the cycle sewing............................................................................................................ 53
13. Changing the memory switch data.................................................................................................. 55
14. List of memory switch data .............................................................................................................. 56
15. Setting the upper shirring................................................................................................................. 60
16. Setting the manipulator pressure .................................................................................................... 61
17. Using the teaching ............................................................................................................................ 62
18. Correcting the bottom feed amount readout potentiometer ......................................................... 64

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&. HANDLING AND ADJUSTING THE PARTS ...............................................................65
1. Adjusting the material slippage and manipulator pressure ............................................................ 65
2. Material auxiliary feed air blow .......................................................................................................... 69
3. Hand switch ......................................................................................................................................... 69
4. Material end sensor............................................................................................................................. 70
5. Adjusting the seam allowance ........................................................................................................... 70
6. Adjusting height of the upper manipulator roller............................................................................. 71
7. Pin tuck device S200 for AE-200A...................................................................................................... 72
*. ADJUSTING THE SEWING MACHINE........................................................................79
1. Adjusting the presser foot lifting lever.............................................................................................. 79
2. Thread tension..................................................................................................................................... 79
3. Thread take-up spring......................................................................................................................... 80
4. Presser foot lifting lever ..................................................................................................................... 80
5. Adjusting the presser foot pressure.................................................................................................. 80
6. Adjusting the walking foot pressure ................................................................................................. 81
7. Adjusting the thread take-up amount by thread take-up lever ....................................................... 81
8. How to adjust the amount of oil (oil splashes) in the hook............................................................. 82
9. Needle-to-hook relation ...................................................................................................................... 84
10. Counter knife ..................................................................................................................................... 85
11. Adjusting the feed timing.................................................................................................................. 85
12. Inclination of the feed dog................................................................................................................ 86
13. Height of the feed dog....................................................................................................................... 86
14. Lateral position of the feed dog....................................................................................................... 86
15. Precautions to be taken when correcting the longitudinal position of the walking foot............ 87
(. MAINTENANCE AND INSPECTION............................................................................88
1. Draining the lter regulator ................................................................................................................ 88
2. Cleaning the sensor ............................................................................................................................ 88
3. Lubricating the manipulator roller section ....................................................................................... 88
4. Replacing the fuse .............................................................................................................................. 89
5. List of optional parts for AE-200A...................................................................................................... 89
6. Error code list ...................................................................................................................................... 90
7. Setting data recording paper for AE-200A ........................................................................................ 93

−  −
!. CAUTIONS BEFORE OPERATION
Following items have to be checked every working day before the operation of the machine
and before the start of work hours.
1. Ascertain that the oil pan is lled with the predetermined amount of oil.
2. Never operate the machine unless the oil pan has been lled up with oil.
3. Ascertain that the pressure gauge indicates the designated air pressure of 0.5 MPa.
* (This is necessary particularly when the compressor is stopped for a lunch break or the like.)
If the compressed air pressure is equal to or less than the designated value, troubles such
as interference between the parts can occur. It is therefore necessary to carefully check the
compressed air pressure.
4. Check whether the needle thread/bobbin thread need to be replenished.
5. To perform sewing immediately after turning ON the power switch, perform trial stitching rst,
then proceed with sewing of actual products after the test sewing.
6. In order to prevent the sensor from showing a detecting failure, be sure to clean thread waste
around the sensor using an air gun once or more times a day.
1. For a wider material, fold the material toward you and sew it while putting your hand on it. If you
don't guide the fabric by hand during sewing, the material may warp at the end of sewing.
2. When sewing some patterns, it is also necessary to put your hand on the material at the end of
sewing.
3. Setscrew for the presser bar base
) Never loosen setscrew 1 in the presser bar
base. If it is loosened, the walking foot move-
ment timing will change from the correct one.
2) When it is really necessary to loosen setscrew
1, it should be loosened when the walking foot
comes down to contact the throat plate surface.
1
Precautions for use

− 2 −
@. CONFIGURATION OF THE MACHINE
A Machine head (DLU-5498N-7)
B Start switch
C Operation panel
D Thread stand
E Upper manipulator
F Auxiliary table
G Sewing machine table
H Power switch
I Control box
J T stand
K Bobbin winder
L Air blow SC (Speed controller)
M T stand
N SS52 Stacker device (optional)
O Safety bar (optional)
P Air valve switch
Q Material end sensor
R 2-pedal unit (optional)
S Bobbin winder (optional)
T Air gun
H
A
D
B
C
I
N
O
F
G
J
M
E
P
Q
K
L
R
S
T

−  −
#. OVERVIEW
 Speed of stitch 200 to ,500 sti/min
2Stitch length 0 to 4 mm
 Top feed amount 8 mm (Max.)
4 Presser foot lift (max.) 0 mm (Air-driven)
5 Seam allowance  to 0 mm
6Needle to be used DBx #9 to #8 (Standard: #), 4 #75 (JE type)
7 Sewing condition
A) Curve sewing
B) Material size
C) Number of plies of materials
00 mm R or more
,500 (length) x 500 (width) or less
2 or 
8 Power consumption 220VA
9 Power source -phase 200 to 240 V
Single-phase 200 to 240 V
0 Table height Adjustable between 820 to ,020 mm (Standard: 97 mm)
 Sewing machine dimensions 2,75 (length) x ,200 (width) x ,50 (height) (mm)
Auxiliary table Standard: ,200 (length) x 550 (width) mm
2 Stacker SS52 Workpiece constant-retaining type
 2-pedal unit Provided with the presser foot up/down switch and 2-step start switch; high/low
speed changeover
4 Weight 5 kg (when all options are installed)
5 Noise Declaration
- Equivalent continuous emission sound pressure level (LPA) at the workstation :
A-weighted value of 80 dB; (Includes KPA = 2.5 dB); according to ISO 082- C.6.
-ISO 204 GR2, at sewing cycle: 4 s ON and 7 s OFF.
This automatic machine consists of a bottom & variable top-feed, lockstitch machine with an automatic
thread trimmer, auto-lifter, upper and lower manipulators which control the material end with accuracy,
control box which controls the whole system, operation panel and auxiliary table.
(The sewing machine head is DLU-5498N-7 specically developed for AE-200A.)
Stacker device (SS52), 2-pedal unit, bobbin winder and bobbin thread remaining amount detecting device
are provided as options.
) Easy operation requiring no skill (Even an inexperienced operator is able to carry out work equivalent
to that by a skilled operator.)
2) Increased efciency is promised. (Re-arrangement of two pieces of fabric is required during manual
work. This machine eliminates such a re-arrangement, thereby shortening the time required for
sewing.)
) High-quality is ensured to improve reliability. (The sewing machine sews the materials with a consistent
seam allowance, thereby producing uniform products.)
4) The sewing machine permits the operator to operate it from its side face automatically or manually by
means of the pedal either standing or sitting.
5) The 2-pedal unit ensures accurate placement of the material on the sewing machine.
6) Seam allowance can be set in the range of  and 0 mm.
7) Uneven material feed can be adjusted with ease.
2. Specications
1. Features

− 4 −
$. INSTALLATION
1. Table height
The table height can be adjusted in the range of 820
and ,020 mm. The standard height is 97 mm.
) Install the table stand on a at place.
2) Casters 1 are secured by lowering levers 2.
) Loosen six bolts 3 mounted on the right and left
legs of the table stand to adjust the table height.
917 mm (Standard)
1
2
3
[Table height of the auxiliary table]
) Install the table stand on a at place.
2) Casters 1 are secured by lowering the ON side
of levers 2.
) Loosen six bolts 3 mounted on the right and left
legs of the table stand to adjust the table height.
3
3
2
1
CAUTION :
Be sure not to lift the table by one worker but to lift it with four or more workers for
supporting each of the four corners of the table when adjusting the table height.

− 5 −
2. Auxiliary table
Adjust the auxiliary table height to the sewing
machine table height.
4. Installing the operation panel mounting plate
Install panel mounting plate 1 on auxiliary table 2
with four wood screws 3 and four washers 4.
3. Assembling the sewing machine table and auxiliary table
Fix spacer 1 and auxiliary table joint bracket 4 with
three wood screws 2 on auxiliary table 3. Then,
mount the joint bracket onto table 7 with thumb
screw 5 and washer 6.
1
2
3
4
5
6
7
CAUTION :
When installing the auxiliary table, the related parts may drop off or the table may fall causing
personal injury. To prevent this, be sure to carry out the installation of the auxiliary table with two
workers. One of them has to support the table. When installing the auxiliary table to the sewing
machine table, take care not to allow your hands, ngers, etc. to be caught between them.
CAUTION :
When using tools, take care to prevent parts from dropping resulting in personal injury.
Take also care not to get injured with the tool.
CAUTION :
When using tools, take care to prevent parts from dropping resulting in personal injury.
Take also care not to get injured with the tool.
1
3
2
3
4
4

− 6 −
5. Connecting the operation panel
Pass operation panel cord plug 1 through the hole
in operation panel mounting plate 2.
1
2
3
2
Place operation panel 3 on operation panel
mounting plate 2.
Pass operation panel cord plug 1 through the cord
through-hole in control box 4.
1
4
Open the cover of the control box. Insert operation
panel cord plug 1 into the main PCB connector
CN4.
1

−  −
1. When operating a newly installed sew-
ing machine or a machine which has
not been used a long period, be sure
to run the sewing machine for approxi-
mately 10 minutes for the purpose of
break-in using the bobbin winding key
mounted on the operation panel.
2. Be sure to use JUKI's genuine oil. If
any other oil is used, a trouble may be
caused.
6. Lubrication
Before operating the sewing machine
1) Put magnet 1 supplied with the unit in the
waste oil screw section.
2) Fill oil pan 2 with JUKI New Defrix Oil No. 1 un-
til HIGH mark A is reached.
3) When the oil level lowers below LOW mark B,
re-ll the oil pan with the specied oil.
4) When you operate the sewing machine after lu-
brication, you will see splashing of oil through oil
sight window 3 if the lubrication is normal.
5) Note that the amount of the splashing oil does
not represent the amount of oil in the oil pan.
7. Installing the thread stand
1) Assemble the thread stand unit. Then, insert the
assembled thread stand into the hole in the ta-
ble.
2) Tighten locknut 1 to such an extent that the
thread stand does not uctuate.
1
CAUTION :
When tilting or re-raising the sewing machine, take care not to allow your ngers or any
other part of your body to be caught.
1
A
B
3
2