JUKI AMB-289 Quick start guide

R
ENGINEER’S MANUAL
AMB-289
Computer-controlled, High-speed, Single thread,
Chainstitch, Button-neck-wrapping Machine
40020579
No.E365-00

PREFACE
This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance
of the machine.
The Instruction Manual for these machines intended for the maintenance personnel and operators at an apparel
factory contains operating instructions in detail. And this manual describes “Standard Adjustment”, “Adjustment
Procedures”, “Results of Improper Adjustment”, and other important information which are not covered by the
Instruction Manual.
It is advisable to use the relevant Instruction Manual and Parts List together with this Engineer’s Manual when
carrying out the maintenance of these machines.
In addition, for the motor for the sewing machine with thread trimmer, refer to the separate Instruction Manual
or Engineer’s Manual for the motor. And for the control panel, refer to the Instruction Manual for the control
panel.
This manual gives the “Standard Adjustment” on the former page under which the most basic adjustment value
is described, and on the latter page “Results of Improper Adjustment” under which stitching errors and troubles
arising from mechanical failures are described together with the “Adjustment Procedures”.

CONTENTS
1. SPECIFICATIONS ........................................................................................................... 1
(1) Specifications ....................................................................................................................................... 1
(2) Shapes of buttons ................................................................................................................................ 2
2. CONFIGURATION ........................................................................................................... 4
(1) Sewing machine....................................................................................................................................4
(2) Operation panel .................................................................................................................................... 5
3. STANDARD ADJUSTMENT ............................................................................................ 6
(1) Adjusting the height of the needle bar ...............................................................................................6
(2) Adjusting the clearance between the needle and the looper ...........................................................6
(3) Adjusting the needle and the needle guide .......................................................................................8
(4) Adjusting the position of the york slide .............................................................................................8
(5) Wiper adjustment ................................................................................................................................ 10
(6) Adjusting the face plate thread tension ........................................................................................... 12
(7) Adjusting the cloth presser cylinder for sewing flat button directly to cloth ............................... 14
(8) Adjusting the position of Y top feed motor ......................................................................................16
(9) Adjusting the position of Y bottom feed motor................................................................................ 18
(10) Adjusting the tongue up/down cylinder .........................................................................................20
(11) Adjusting the chuck up/down motor .............................................................................................. 22
(12) Adjusting the differential feed motor .............................................................................................. 24
(13) Adjusting the tongue stopper .........................................................................................................26
(14) Adjusting the chuck inversion cylinder .......................................................................................... 28
(15) Adjusting the chuck open/close cylinder .......................................................................................30
(16) Adjusting the respective sensors ...................................................................................................32
4. DISASSEMBLING, ASSEMBLING AND ADJUSTMENT ............................................. 36
(1) Disassembling and assembling of the main shaft .......................................................................... 36
(2) Disassembling and assembling of the face plate ............................................................................ 40
(3) Disassembling and assembling of the needle bar rocking base and the needle bar crank rod .... 42
(4) Disassembling and assembling of the needle throwing motor and the needle bar rocking arm ... 44
(5) Replacing the main motor .................................................................................................................48
(6) Replacing the looper rocking base ...................................................................................................50
(7) Disassembling and assembling the looper rocking link and the looper rocking shaft ...............52
(8) Replacing the thread trimmer cylinder .............................................................................................54
(9) Replacing and adjusting the active tension (VCM) ......................................................................... 56
(10) Replacing and adjusting the thread drawing cylinder ..................................................................58
(11) Replacing the thread drawing motor .............................................................................................. 60
(12) Replacing the loader motor .............................................................................................................62
(13) Replacing and adjusting the cloth presser cylinder for sewing
and wrapping flat button with blindstitch ......................................................................................64
(14) Replacing and adjusting the tongue release cylinder ..................................................................66
(15) Adjusting the moving knife and the fixed knife .............................................................................68
5. OPERATION PANEL ..................................................................................................... 72
(1) Sewing method and sewing shape list .............................................................................................72
(2) Data list ................................................................................................................................................ 73
(3) Sensor list ........................................................................................................................................... 75
(4) Comunication function.......................................................................................................................76
(5) Information function ........................................................................................................................... 78

6. SETUP OF IP-200 .......................................................................................................... 79
(1) Connecting procedure of operation panel with external vehicle ...................................................79
(2) Setup of operation panel ...................................................................................................................83
(3) Setup of main program ...................................................................................................................... 86
(4) Setup of servo program .....................................................................................................................92
(5) When using smart media other than that which has been packed together .................................98
(6) Formating ............................................................................................................................................ 99
7. SEWING DATA............................................................................................................. 100
(1) Sewing data list.................................................................................................................................100
(2) Initial sewing data ............................................................................................................................. 104
8. MEMORY SWITCH ...................................................................................................... 105
(1) Memory switch data list ...................................................................................................................105
9. OPTION........................................................................................................................ 110
(1) Optional parts list .............................................................................................................................110
(2) Movable eye-guard ...........................................................................................................................111
10. MAINTENANCE ......................................................................................................... 112
(1) Replacing the attachments ..............................................................................................................112
(2) Replacing the fuse ............................................................................................................................ 113
(3) Greasing parts .................................................................................................................................. 114
(4) Changing the voltage of 100 / 200V ................................................................................................120
11. ERROR CODE LIST ..................................................................................................121
12. TROUBLES AND CORRECTIVE MEASURES ......................................................... 127
(1) Sewing ...............................................................................................................................................127
(2) Electrical parts ..................................................................................................................................129
13. TIMING CHART.......................................................................................................... 150
14. CIRCUIT DIAGRAM ................................................................................................... 152
(1) Block diagram A ...............................................................................................................................152
(2) Block diagram B ...............................................................................................................................153
(3) Block diagram C ...............................................................................................................................154
(4) Block diagram D ...............................................................................................................................155
(5) Power circuit diagram (3-phase 200 to 240V type) ........................................................................156
(6) Power circuit diagram (Single phase 100V type) ........................................................................... 157
(7) Power circuit diagram (Single phase 220 to 240V type)................................................................ 158
(8) Control box and machine head circuit diagram 1 ..........................................................................159
(9) Control box and machine head circuit diagram 2 ..........................................................................160
(10) Head sensor circuit diagram .........................................................................................................161
(11) Motor circuit diagram .....................................................................................................................162
(12) Servo motor circuit diagram ..........................................................................................................163
15. AIR CIRCUIT DIAGRAM............................................................................................ 164
16. DRAWING OF THE TABLE ........................................................................................ 165
(1) Table ................................................................................................................................................... 165
(2) Auxiliary table ...................................................................................................................................166

−1 −
(1) Specifications
1. SPECIFICATIONS
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
28
29
30
31
No. Item
Specifications
Model
Name of model
Application
Feature
Sewing speed
Button size
Button chuck
Needle
Thread used
Lubrication
Grease
Thread take-up lever
Needle throwing method
Feed method
Presser lifting method
Cloth presser method
Thread trimmer method
Thread tension adjustment
Dimensions
Weight of head /
Control box weight
Number of data that can
be stored in memory
Number of times of
cycle sewing
Basic shape setting
range
Pattern selection
Memory backup
Sewing count
Power requirements
Control/operation panels
Button loader
Optiona
Air pressure
AMB-289
Computer-controlled, high-speed, single-thread, chainstitch, button-neck-wrapping
machine
Various buttons sewing (Buttons which can be sewn with the sewing machine)
The machine comes standard with plural sewing patterns by computer-controlled feed,
needle throwing, thread tension and thread trimmer. It can perform efficiently high-
quality button sewing and a multipurpose button sewing machine that can be used as
the general machine.
Max. 1,800 rpm (buttons with neck wraps), 1,200 rpm (button sewing)
Normal speed 1,500 rpm (buttons with neck wraps), 1,000 rpm (button sewing)
Sewing buttons without button neck : 8 mm to 38 mm
Sewing buttons with neck wraps : Max. 32 mm
Counter button : 8 mm to 25 mm
Counter button neck wrapping : Total of material and front button is up to 32 mm.
small : ø 8 to 16 mm (Accessory), medium : ø 14 to 25 mm (Installed on machine head), large : ø 25 to 38 mm (Accessory)
(Part No.40020932) (Part No.40020931) (Part No.40020930)
SM332EXTLG-NY (Standard) #12 to #18
Polyester spun thread #30 to #60, Cotton thread #30 to #60
Non-lubrication
1. Grease tube : 13525506 (containing 10g, green) for gear section of rack or the like and cam section
2. JUKI grease B tube : 40013640 (containing 10g, white) for worm section
3. JUKI grease A tube : 40006323 (containing 10g, white) for other rocking mechanism section to which lubrication is necessary
Needle bar thread take-up lever : Stroke 60 mm
Stepping motor drive
Stepping motor drive
Stepping motor drive
Air drive
Air drive
Active tension (VCM) method
Width : 600 x Height : 400 x Length : 600 (mm)
Head : 65 kg / Control box : 13 kg
Max. 99 patterns
Number of registered patterns : 20 patterns (1 cycle 30 patterns)
Interval between buttonholes : 1.5 to 6.0 mm (in increments of 0.1 mm)
Height of neck wraps : 0, 1.5 to 10.0 mm (in increments of 0.1 mm)
Number of crossover threads : 2 to 64 threads (in increments of 2 threads)
Pattern No. designation method (scroll 1 to 99 patterns)
Pattern data, sewing data, cycle sewing data
Number of times of sewing count method (0 to 9999) up/down
Sewing counter is possible.
Single phase 200V, 220V, 230V and 240V, Three phase 200V, 220V and 240V 400VA
MC-640/IP200D
Provided as standard
Movable eye-guard
0.5 MPa

−2 −
(2) Shapes of buttons
B
A
C
B
DD
H
F
G
E1
H
F
G
E2
G
E3
H
F
G
E3
1) Specifications for 4-holed and 2-holed buttons
A:Buttonhole diameter Needle used : ø 1.5 mm or more when using #12 to #16
Needle used : ø 2 mm or more when using #16 to #18
B:Distance between buttonholes 1.5 to 6.0 mm (in increments of 0.1 mm)
C:Location of buttonholes All holes must be located equidistant from the center of each button.
D:Outside diameter Min. outside diameter : ø 8 mm
Max. outside diameter : ø 32 mm
Line height : within ±0.25 mm
E1:Button with a round edge R (roundness) of button edge must be a 3 mm radius or less.
E2:Button with a V-shaped edge Within 120˚ angle
E3: Button with an angular edge The thickness must be 5 mm or less.
F:Bulge 5 mm or less
G: Area around buttonholes Must be smooth
H:Thickness of button 8 mm or less
2) Specifications for shank button and marble button
A: Buttonhole diameter ø 1.5 mm or more
B: Thickness of button 6.8 mm or less
C: Distance from the Shank button :
bottom of the button 1 mm to 6 mm
head to the center Marble button :
of the buttonhole 1.5 mm or more
D: Length of shank 8 mm or less
E: Height of the 3.5 mm or less
straight section on the000
side face of button
F: Outside diameter Min. outside diameter :
ø 8 mm
Max. outside diameter :
ø 32 mm
G: Distance from the center 2 mm or less
of the hole to the button
edge
A
C
F
E
A
F
E
B
B
D
C
G
(Caution) When the button loader is used, there are cases where the buttons cannot be used due to
the shape. So, be careful.

−3 −
4) Counter button specifications
B
A
C
B
DD
H
F
G
E1
H
F
GG
E2
H
F
G
E2
Commendable dimension
3) Specifications for stay button
Right
side
1 mm or less
Buttonhole
diameter
Outside
diameter
Outside
Buttonhole Buttonhole Thickness
diameter diameter pitch of button
Type A 8.5mm 2.5mm 3.1mm 2.0mm
Type B 10.2mm 3.2mm 4.0mm 2.0mm
Commendable dimension
(Caution)1. For the stay buttons, use those, the
amount of convex on the right side
of which is 1 mm or less.
Thickness of button
Buttonhole pitch
A:Buttonhole diameter Needle used : ø 1.5 mm or more when using #12 to #16
Needle used : ø 2 mm or more when using #16 to #18
B:Distance between buttonholes 1.5 to 6.0 mm
C:Location of buttonholes All holes must be located equidistant from the center of each button.
D:Outside diameter Min. outside diameter : ø 8 mm
Max. outside diameter : ø 25 mm
E1:Button with a round edge R (roundness) of button edge must be a 2 mm radius or less.
E2: Button with an angular edge The thickness must be 5 mm or less.
F:Height of button edge 2 mm or less
G: Area around buttonholes Must be smooth
H:Thickness of button 5 mm or less
(Caution)1.

−4 −
(1) Sewing machine
2. CONFIGURATION
AMB-289 consists of the following components.
1Power ON/OFF switch
2Machine head(AMB-289)
3Operation panel(IP-200D)
4Control box(MC-640)
5Foot pedal
6Start switch
7Thread stand device
1
2
5
4
3
6
7

−5 −
(2) Operation panel
1) Body
1Touch panel・LCD display section
2READY key → Changeover of the data input screen and the sewing screen can be performed.
3INFORMATION key → Changeover of the data input screen and the information screen can be performed.
4COMMUNICATION key → Changeover of the data input screen and the communication screen can be performed.
5MODE key → Changeover of the data input screen and the mode changeover screen which
performs various detail settings can be performed.
6Smart media card slot (Close the cover for use.)
7Slide switch (Not used・OFF)
8Connector for RS-232C communication
9Variable resistor for color LCD →Screen contrast can be adjusted. Adjust it as you desire.
!0 Connector for external input
!1 Cable
2) Buttons to be used in common
The buttons which perform common operations in each screen of IP-200 are as follows :
CANCEL button →This button closes the pop-up screen. In case of the data change
screen, the data being changed can be cancelled.
ENTER button →This button determines the changed data.
UP SCROLL button →This button scrolls the button or the display in the upward direction.
DOWN SCROLL button →This button scrolls the button or the display in the downward
direction.
RESET button →This button performs the release of error.
NUMERAL INPUT button → This button displays ten keys and input of numerals can be performed.
SEWING DATA DISPLAY button →This button displays the sewing data list corresponding to the
pattern No. being selected.
→ Refer to "20. CHANGING SEWING DATA" of the Instruction Manual.
CHARACTER INPUT button →This button displays the character input screen.
→ Refer to "5. NAMING THE PATTERN"of the Instruction Manual.
1
!0
!1
9
8
7
6
2
345

−6 −
3. STANDARD ADJUSTMENT
(1) Adjusting the height of the needle bar
Standard Adjustment
Standard Adjustment
D
C
0.05 to 0.1mm
1
2
To align
32.6mm
37.6mm
(2) Adjusting the clearance between the needle and the looper
3
2
4
29.6mm
34.6mm
B
A
1
To align
Marker
line

−7 −
Adjustment Procedures Results of improper Adjustment
1. Use the timing gauge supplied as accessories.
Loosen screw 1and adjust in case of SM332EXTLG-NY
(standard needle) so that when plane Ais SM332SUPLG-
NY, turn the timing gauge up side down, and plane Baligns
with the height of throat plate when the needle bar comes
down to the lowest position.
(Caution) Adjust the needle at the position of center (aligns
with the engraved marker line on the machine bed).
JUKI Part No. Needle Part No.
MSM3AAN1100 NEEDLE SM332EXTLG-NY #11
MSM3AAN1200 NEEDLE SM332EXTLG-NY #12
MSM3AAN1400 NEEDLE SM332EXTLG-NY #14
MSM3AAN1600 NEEDLE SM332EXTLG-NY #16
MSM3AAN1800 NEEDLE SM332EXTLG-NY #18
MSM3ABN1100 NEEDLE SM332SUPLG-NY #11
MSM3ABN1200 NEEDLE SM332SUPLG-NY #12
MSM3ABN1400 NEEDLE SM332SUPLG-NY #14
MSM3ABN1600 NEEDLE SM332SUPLG-NY #16
MSM3ABN1800 NEEDLE SM332SUPLG-NY #18
[Needle list]
Standard
needle
Remarks
Adjustment Procedures Results of improper Adjustment
1. Use the timing gauge supplied as accessories.
2. Loosen two screws 1, move looper 2and adjust by loosening
screw 4so that the clearance between the needle and the
blade tip of looper is 0.05 to 0.1 mm when plane Cin case of
SM332EXTLG-NY (standard needle) or plane Din case of
SM332SUPLG-NY aligns with the height of the needle bar.
In addition, adjust so that the left position of needle 3aligns
with the top end of looper 2as observed from the front.
(Caution) Adjust the needle at the position of center (aligns
with the engraved marker line on the machine bed).
Long
needle

−8 −
(3) Adjusting the needle and the needle guide
Standard Adjustment
Center
3
4
0 to 0.1mm
1
[The position of the needle and the throat plate]
[The clearance between the needle and the needle guide]
(4) Adjusting the position of the york slide
Standard Adjustment
Locus of york slide
On the same line
Blade tip
of looper
4
5
7
6
2
B
A
Approx.
6mm
0 to 0.2mm
0.2 to 0.4mm
1
8
A
To align
1
3
2

−9 −
Adjustment Procedures Results of improper Adjustment
Adjusting the position of the needle and the throat plate
1. Loosen screws 1and adjust the throat plate 2so that the
needle enters the center of the needle hole.
Adjusting the clearance between the needle and the needle guide
1. Loosen screw 3and adjust so that the clearance between
needle guide 4and the needle is 0 to 0.1 mm at the lowest
position of the needle bar.
(Caution) When the needle size is changed, perform re-
adjustment.
Adjustment Procedures Results of improper Adjustment
1. Adjust the lateral position of needle 8 and the looper shaft so that the left side of
needle 8 aligns with section A of yoke slide 1 .
2. The position of york slide 1 has been factory-assembled so that the clearance between
york slide 1 and the needle 8 is longitudinally 0.2 to 0.4 mm and laterally 0 to 0.2 mm
when the needle bar comes to the lowest position.
3. Adjust the lateral position of yoke slide 1 by loosening setscrew 2 and moving yoke
slide support A 3 to the right and left.
4. Adjust the longitudinal position of york slide 1 by loosening setscrew 4 and moving
york slide cam 5 longitudinally. The motion timing of york slide cam 5 at this time is
adjusted by making the engraved marker line on york slide cam 5 directly below and
tightening the cam with setscrew 4 when the needle bar is at the lowest position.
5. Timing of the yoke slide motion is performed in the order that yoke slide 1 starts moving
from point A to point B immediately after the blade tip of looper has passed the triangle
of the thread.
(Position where the needle bar goes up approximately 6 mm from the lowest position)
6. Loosen setscrews 7 in york slide triangle cam 6 and turn the cam in the direction of
rotation to perform this adjustment.
(Reference) Marks made by the electron pen have been put on york slide cam
5 and york slide triangle cam 6 at the time of delivery from
factory. Make them as the standard of timing adjustment.
7. Adjust the locus of york slide motion by loosening setscrew 4 in york slide cam 5 and
turning the cam in the direction of rotation so that the locus becomes as shown in the
figure.
(Caution) When the needle size is changed, perform re-adjustment.
™ Stitch skipping or thread
breakage will be caused.
™ Stitch skipping or thread
breakage will be caused.

−10 −
(5) Wiper adjustment
Standard Adjustment
[Wiper components]
5
1
!2
6
3
9
!1
2
4
8
!0
3 to 5mm
6 to 8mm
4
7
!3

−11 −
Adjustment Procedures Results of improper Adjustment
Assembling adjustment
1. Temporarily tighten the wiper at the position where cap nut 2
is tightened to wiper cylinder rod !2.
2. Fix wiper guide 3so that wiper guide 3and wiper 4equally
come in contact with each other within the range of the stroke
of cylinder 1.
3. Securely tighten wiper 4.
4. Fix spring A 5so that wiper 4and spring A 5equally come
in contact with each other on the plane within the range of the
stroke of cylinder 1.
5. Adjust the holding force of thread with spring B 6.
6. To adjust the holding force, loosen screw !3 and adjust so
that thread slips off with the force of approximately 20 to 25g
when polyester spun thread #50 is held.
Installing adjustment
1. Turn OFF the air supply, and fully draw out wiper 4.
2. Adjust wiper cylinder installing bases A 8and B 9with the
respective setscrews !0 and !1 so that the vertical clearance
between needle tip 7and the top surface of wiper 4is 3 to 5
mm and the lateral dimension between needle tip 7and the
thread holding section of wiper 4is 6 to 8 mm at the sewing
machine stop position (needle bar upper dead point).

−12 −
(6) Adjusting the face plate thread tension
Standard Adjustment
1
A12mm
1
2
5
6
4
3

−13 −
Adjustment Procedures Results of improper Adjustment
1. Adjust face plate thread tension cylinder 1so that a clearance
is opened between the face plate thread tension cylinder and
tension release plate 2in the state that the air is drawn out.
(For the standard, the distance from frame processed plane
Ato the top end of cylinder shaft is 12 mm at the time of
suction.)
2. When installing tension release plate 2to face plate 3, make
sure that needle thread pressing plate 4is not pressed up,
there is a clearance between the plate and stopper pin 5,
and the top end of tension release plate 2is in the center of
thread pressing base 6.
™ Face plate thread tension fails to
work unless there is a clearance.

−14 −
(7) Adjusting the cloth presser cylinder for sewing flat button directly to cloth
Standard Adjustment
5
1
4
6
7mm
2
3
18.5 ±0.5mm

−15 −
Adjustment Procedures Results of improper Adjustment
1. Loosen cylinder nut 1, turn cylinder knuckle 4and adjust so
that the top surface of the top end of cloth presser 2for sewing
flat button directly to cloth is 18.5 ±0. 5mm from the top surface
of counter button lower plate 3with the cylinder sucked. Then
tighten cylinder nut 1. (For the reference value : 7 mm from
end of cylinder boss 5to end of knuckle 6)
™ When the height of cloth presser
2for sewing flat button directly
to cloth is higher than specified
one, the presser interferes with
chuck click and step-out of top
feed will be caused, or damage
of chuck click will be caused.

−16 −
(8) Adjusting the position of Y top feed motor
Standard Adjustment
1
2
3
5
4
6