JUKI AMS-210E Series Quick start guide

40034836
No.E369-02
ENGINEER’S MANUAL
Computer-controlled, Cycle Machine
With Input Function
AMS-210E Series
®

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 instruction in derail. And this manual describes “Standard Adjustment”, “Adjustment
Procedures”, “Results of Improper Adjustment”, and other important information which are not covered in the
Instruction Manual.
It is advisable to use the Input Instruction Manual, 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
This manual gives the “StandardAdjustment” on the former page under which the most basic adjustment value is
described, and on the latter page “Results if Improper Adjustment” under which stitching errors and troubles
arising from mechanical failures and “Hoe to adjust” are described.

CONTENTS
1. Specifications ........................................................................................................ 1
2. Configuration........................................................................................................... 2
(1) Names of main unit .................................................................................................................. 2
(2) IP-400 operation panel............................................................................................................. 3
(3) CP-20 operation panel ............................................................................................................. 4
3. Standard adjustment .............................................................................................. 5
(1) Main shaft connection/disconnection .................................................................................. 5
(2) Removal of main shaft motor and coupling......................................................................... 7
(3) Crank rod connection/disconnection ................................................................................... 9
(4) Crank balancer positioning ................................................................................................. 11
(5) Adjustment of intermediate presser cam ........................................................................... 13
(6) Adjustment of intermediate presser bar............................................................................. 13
(7) Intermediate presser variable connection /disconnection ............................................... 15
(8) Intermediate presser variable adjustments........................................................................ 17
(9) Intermediate presser drivie arm .......................................................................................... 19
(10)Lower shaft backlash adjustment and connection/disconnection .................................. 21
(11) Oscillator gear positioning .................................................................................................. 21
(12)Adjustment of hook oil amount........................................................................................... 23
(13)Shuttle connection / disconnection and oil wick piping................................................... 23
(14)Adjusting the height of the needle bar ............................................................................... 25
(15)Hook adjustment................................................................................................................... 27
(16) Thread trimmer presser lifter cam connection/disconnection ........................................ 29
(17) Thread trimmer and presser origin sensor adjustment ................................................... 29
(18) Adjusting the thread trimmer sensor ................................................................................. 31
(19) Adjustment of the moving knife and counter knife position............................................ 33
(20) Floating amount of the thread tension disk ...................................................................... 33
(21) Second thread tension connection / disconnection......................................................... 35
(22) AT unit connection / disconnection.................................................................................... 37
(23) Wiper adjustment ................................................................................................................. 39
(24) Adjusting the pre-load of the X-Y table .............................................................................. 41
(25) Adjustment of the tension of the X timing belt.................................................................. 43
(26) Adjustment to positions of X-motor and Y-motor (Backlash adjustment to gear)......... 43
(27) Adjusting of the presser lower arm (Motor type only) ...................................................... 45
(28) Adjustment when the presser plate sheet is replaced (Motor type only) ....................... 45
(29) Height of the slider and pasting of the presser plate sheet
(Pneumatic type only) .......................................................................................................... 47
(30) Adjusting the speed of the work clamp feet (Pneumatic type only)................................ 49
(31) Making the origin setting gauge ......................................................................................... 51
(32) Adjusting the X origin sensor ............................................................................................. 51
(33) Adjusting the Y origin sensor ............................................................................................. 53
(34) Adjustment of the bobbin winder driving wheel position ................................................ 55
(35) Adjusting the bobbin winder amount ................................................................................. 55
(36) Adjustment of the shuttle upper spring and lower thread holder position .................... 57
(37) Shuttle felt............................................................................................................................. 57
(38) Shape of the shuttle race ring.............................................................................................59
(39) Adjustment of thread take-up spring ................................................................................. 59
(40) Needle thread clamp device connection/disconnection .................................................. 61
(41) Adjusting the needle thread clamp sensor........................................................................ 63
(42) Adjusting the needle thread clamp notch.......................................................................... 65
4. Memory switch ...................................................................................................... 67
(1) Start and change .................................................................................................................... 67
(2) Function list............................................................................................................................ 69

5. Supplemental remarks of each function number and
explanation of each function ............................................................................... 92
(1) Feeding frame operational sequence setup ........................................................................ 92
(2) Fixed refuge position setup .................................................................................................. 96
(3) Bank function setup............................................................................................................... 97
(4) Port I/O setup........................................................................................................................ 101
(5) Simplified program setup....................................................................................................112
(6) Version display..................................................................................................................... 126
(7) Keylock setup....................................................................................................................... 127
(8) Communication screens of the maintenance personnel level (Program rewrite) ......... 128
(9) Information screen at the maintenance personnel level .................................................. 134
(10) Test sewing function ......................................................................................................... 136
6. Test mode ........................................................................................................... 139
(1) Start (CP-20) ......................................................................................................................... 139
(2) Display output test (CP-20) .................................................................................................141
(3) Method of confirmation according to each test program No. (CP-20) ............................ 142
(4) For IP-400.............................................................................................................................. 149
7. Printed wiring board and dip switch................................................................ 165
(1) Various printed wiring boards ............................................................................................ 165
(2) Dipswitch setup.................................................................................................................... 173
8. Table of exchanging gauge parts according to sewing specifications and
needle size used ................................................................................................ 174
9. Option list........................................................................................................... 175
(1) Method of pedal switch cable set connections................................................................. 182
(2) Method of mechanical valve unit connections.................................................................. 184
10.Maintenance ....................................................................................................... 185
(1) Replacing the fuse ............................................................................................................... 185
(2) Changing the voltage specification.................................................................................... 186
(3) Greasing • lock-tight parts .................................................................................................. 187
(4) Parts to which grease • lock-tight is applied ..................................................................... 188
(5) Replenishing the designated places with grease ............................................................. 196
11. Error code list .................................................................................................... 198
12. Message list....................................................................................................... 205
13.Troubles and corrective measures .................................................................. 208
(1) Mechanical parts .................................................................................................................. 208
(2) Sewing conditions ............................................................................................................... 212
(3) Electrical components......................................................................................................... 220
14.Circuit diagrams ................................................................................................ 228
(1) Block diagram A ................................................................................................................. 228
(2) Power supply circuit diagram A ........................................................................................ 229
(3) Power supply circuit diagram B ........................................................................................ 230
(4) Power supply circuit diagram C ........................................................................................ 231
(5) Servo motor circuit diagram.............................................................................................. 232
(6) Sensor-pedal circuit diagram ............................................................................................ 233
(7) MAIN•PANEL board circuit diagram ................................................................................. 234
(8) Motor•solenoid circuit diagram......................................................................................... 235
(9) Air system circuit diagram................................................................................................. 236
15.Drawing of the table........................................................................................... 237

– 1 –
No. Application
AMS-210EHS AMS-210ESS AMS-210EHL AMS-210ESL AMS-210EHL AMS-210ESL AMS-210EHL AMS-210ESL AMS-210EHL AMS-210ESL
Sub-class 1306 1510 2206 2210
1 Sewing area X-Direction (right, left) 130mm; Y-Direction (forward, backward) 60mm X-Direction (right, left) 150mm; Y-Direction (forward, backward) 100mm X-Direction (right, left) 220mm; Y-Direction (forward, backward) 60mm X-Direction (right, left) 220mm; Y-Direction (forward, backward) 100mm
2 Max. sewing speed 2700rpm (when sewing pitch is 3mm or less)
3 Stitch length 0.1 to 12.7mm (Min. resolution : 0.05mm)
4 Feed motion of feeding frame intermittent feed (2-shaft drive by stepping motor)
5 Needle bar stroke 41.2mm
6 Needle S type: DP x 5 # 14, H type: DP x 17 # 18
7 Method to lift feeding frame Pulse motor Air
8 Feeding frame shape Right and left united Right and left separated Right and left united
9 Lift of feeding frame Standard 25mm, Max. 30mm Max. 30mm
10 Intermediate presser stroke Standard 4mm (0 to 10mm)
11 Lift of intermediate presser 20mm
12 Intermediate presser Standard 0 to 3.5mm (Max. 0 to 7.0mm)
DOWN position variable
13 Needle thread clamp device H type S type H type S type H type S type H type S type H type S type
14 Needle thread tension Active tension (electronic thread tension control mechanism)
15 Hook 2-fold semi-rotary hook
16 Lubrication Plane part: grease, hook part: minute volume lubrication (tank type)
17 Lubricating oil JUKI NEW Defrix oil (equivalent to ISO VG32) (Lubrication system)
18 Grease 1. Penetration No. 2 lithium grease, 2. Templex N2, 3. Juki Grease A, 4. Juki Grease B (Caution)1.
19 EEP-ROM, Smart media
Memory of pattern data • EEP-ROM : Max. 200 patterns (Max. 20,000 stitches/pattern)
•Smart media : Max. 999 patterns (Max. 50,000 stitches/pattern)
20 Temporary stop facility Used to stop machine operation during a stitching cycle.
21 Enlarging/Reducing Allows a pattern to be enlarged or reduced on the X axis Y axis independently when sewing a pattern.
function Scale : 1% to 400% times (0.1% steps)
22 Enlarging/Reducing Pattern enlargement / reduction can be done by increasing / decreasing either stitch length or the number of stitches.
method (Only increase/decrease of stitch length when pattern button is selected and CP-20 is used)
23 Sewing speed limitations 200 to 2,700 rpm (Scale : 100 rpm steps)
Pattern No. selection method
24 Pattern selector facility (EEP-ROM : 1 to 200, Smart media : 1 to 999)
(CP-20 is the scroll type.)
25 No. of sheets counter Up/Down method (0 to 9,999) (IP-400 only)
26 Sewing counter Up/Down method (0 to 9,999)
(Bobbin thread counter)
27 Memory back-up In case of a power interruption, the pattern being used will automatically be stored in memory.
28 2nd origin setting facility Using jog keys, a 2nd origin (needle position after asewing cycle) can be set in the desired position within the sewing area.
The set 2nd origin is also stored in memory. (IP-400 only)
29 Sewing machine motor Servomotor 550W
30 External dimensions 1,200mm (W) x710mm (L) x 1,200mm (H) 1,200mm (W) x770mm (L) x 1,200mm (H) 1,200mm (W) x710mm (L) x 1,200mm (H) 1,200mm (W) x770mm (L) x 1,200mm (H)
(Excluding thread stand) (Excluding thread stand) (Excluding thread stand) (Excluding thread stand)
31 Weight (gross weight) Machine head : 69kg, Control box : 16.5kg Machine head : 73kg, Control box : 16.5kg Machine head : 75kg, Control box : 16.5kg Machine head : 77kg, Control box : 16.5kg
32 Power consumption 500VA
33 Working temperature/humidity Temperature: 5-35°C, Humidity: 35-85% (no condensation)
34 Supply voltage/frequency Rated voltage ±10% 50 / 60Hz
35 Air pressure used — Standard: 0.35 to 0.4MPa, Max. 0.55MPa
36 Air consumption — 1.8dm3/min (ANR)
37 Needle highest position After the completion if sewing, the needle can be brought up to its highest position.
stop facility
1. Specifications
Model name
Item
(Caution) Grease type, refer to (3) Greasing • lock-tite parts of [10] Maintenance

MEMO

2. Configuration
(1) Names of main unit
Machine head
Wiper switch
Temporary stop switch
Feeding frame
Intermediate presser
Thread stand
Operation panel (IP-400 or CP-20)
Power switch
Control box
Foot pedal
Manual pedal (Excluding pneumatic type)
– 2 –
Air regulator
(for pneumatic type only)

(2) IP-400 operation panel
(Front view) (Right side view)
– 3 –
Touch panel • LCD display section
READY key →Changeover of the data input screen and the sewing screen can be
performed.
INFORMATION key →Changeover of the data input screen and the information screen can
be performed.
COMMUNICATION key →Changeover of the data input screen and the communication screen
can be performed.
MODE key →Changeover of the data input screen and the mode changeover screen
which performs various detail settings can be performed.
Smart media card slot (Close the cover for use.)
Connector for RS-232C communication
Variable resistor for color LCD →Screen contrast can be adjusted. Adjust it as you desire.
Connector for external input

Item selection LED
LEDs of the selected items light up.
Needle thread clamp ON/OFF key
This key selects effective/ineffective of needle thread
clamp. When it is effective, needle thread clamp
disply LED lights up.
Needle thread clamp display LED
When this LED lights up, needle threas clamp
operaters.
Pattern registration key
This key registers the pattern. When this key is
pressed, the pattern registered here can sew imme-
diately.
X/Y scale, sewing position. etc. can be changed and
registered.
(3) CP-20 operation panel
Pattern No. X scale Y scale
Max. speed Sewing Bobbin
limitation counter winder
Intermediate Thread tension
presser height
– 4 –
“Ready” key
Thiskey changes over the setting state fromthepanel
to the sewing state where the sewing machine actu-
ally operates.
Sewing LED
This LED goes off at the time of setting state and
lights up at the time of sewing state. Changeover
can be performed with “Ready” key.
“Reset” key
This key is used for canceling error or returning the
set value to the initial value.
“Mode” key
This key makes the setting mode of the memory
switch.
“+ / Feed forward” key and “- / Feed backward”
key
This key is used for changing pattern No. and X/Y
scale, and feed forward/feed backward.
“Selection” key
This key selects the item to be set. Item selection
LED of the selected item and the set value are dis-
played.
Data indication LED
This LED indicates the set values of the selected
items such as pattern No., X/Y scale, etc.
CP-20

3. Standard adjustment
(1) Main shaft connection/disconnection
1. Loosen the set screw securing the main shaft counterbalance , and remove the taper screw .
2. Loosen 2 set screws (through the screwdriver hole A), 2 set screws , and 2 set screws .
On this occasion, loosen No. 2 set screw first, and completely remove No. 1 set screw from the flat part of the
main shaft .
3. Remove the main shaft motor .
Refer to “3.-(2) Removal of the main shaft motor and coupling”.
4. Loosen 2 set screws .
On this occasion, be aware that the balancer may rotate due to loosened set screws .
5. Loosen 2 set screws .
6. Loosen 2 set screws .
On this occasion, completely remove No. 1 set screw of the set screws from the flat part of the main shaft
.
7. Loosen 2 set screws and 2 set screws .
8. Pull out the main shaft in the direction of Arrow C.
– 5 –
Screwdriver hole A
No. 1 set screw
No. 2 set screw
No. 2 set screw
No. 2 set
screw
No. 1 set screw
No. 1 set screw
D
F
E
C
Procedures of disassembling
Main shaft taper hole

1. Insert the main shaft into the crank rod , balancer , hand pulley gear A , bobbin winding drive
wheel , and main shaft counterbalance in this order, and mount this assembly on the frame.
2. Tighten the taper screw into the taper hole of the main shaft , and tighten the set screw to secure
the main shaft counterbalance .
3. Lightly press the main shaft counterbalance in the direction of Arrow D and the middle metal in the
direction of Arrow E, and tighten 2 set screws .
(Tighten No. 1 set screw so that it touches the flat part of the main shaft . Then, tighten No. 2 set screw.
Same procedure hereafter)
4. Tighten 2 set screws and 2 set screws . (Make sure that No. 1 set screw touches the flat part of the
main shaft .)
5. Press the hand pulley in the direction ofArrow F to engage the hand pulley gearA with the hand pulley
gear B , and secure them with 2 set screws .
6. Mount the main shaft motor and coupling .
Refer to “3.-(2) Removal of main shaft motor and coupling”.
7. Secure the eccentric cam of the intermediate presser with 2 set screws . Refer to “3.-(5) Adjustment
of intermediate presser cam”.
8. Secure the crank rod with 2 set screws . Refer to “3.-(3) Crank rod connection/disconnection”.
9. Secure the balancer with 2 set screws . Refer to “3.-(4) Crank balancer positioning”.
10. Secure the bobbin winding drive wheel with 2 set screws . Refer to “3.-(34) Adjustment of the bobbin
winder driveing wheel poition”.
* Make sure that no torque is applied by rotating the main shaft .
– 6 –
Procedures of assembling

(2) Removal of main shaft motor and coupling
1. For removal of the main shaft with the coupling,
Loosen 2 set screws on the main shaft side of the coupling , and remove 4 set screws securing the
motor.
2. For removal of the coupling from the main shaft motor , loosen 2 set screws on the main shaft motor
side.
(Caution) The screw (hole) that can be seen first is No. 1 set screw when the main shaft is turned
in the forward direction AA
AA
A. For loosening, loosen No. 2 set screw first, and for tightening,
tighten No. 1 set screw first.
No. 1 set screw
No. 1 set screw
0.7mm
A
– 7 –
No. 2 set screw
Procedures of disassembling

1. For mounting the main shaft motor with the coupling,
(1) Tighten 4 set screws that securing the motor, and tighten 2 set screws on the main shaft side of the
coupling .
(2) The cords of the main shaft motor should be positioned in the lateral direction.
2. For connecting the coupling to the main shaft motor,
(1) Provide a clearance of 0.7 mm between the coupling and main shaft motor .
(2) Apply No. 1 set screw of the coupling to the flat section of the main shaft motor , the main
shaft and secure it.
3. For engaging the coupling,
(1) Position the set screw (No. 1 set screw) on the main shaft motor side between 2 set screws on the
main shaft side, and engage the coupling.
– 8 –
Procedures of assembling

(3) Crank rod connection/disconnection
1. Loosen 3 set screws and 2 set screws . On this occasion, loosen No. 2 set screws first, and completely
disengage No. 1 set screws from the flat section of the oscillator shaft .
2. Pull out the oscillator shaft in the direction of Arrow A.
3. Remove the main shaft according to “3.-(1) Main shaft connection/disconnection”, and remove the crank
rod unit .
– 9 –
22.1 to 22.6mm
Face B No. 2 set screw
No. 1 set screw
C
A
E
D
Procedures of disassembling
No. 1 set screw
No. 2 set screw

1. Mount the main shaft according to “3.-(1) Main shaft connection/disconnection”, and mount the crank rod
unit .
2. Adjust the clearance to 22.1 to 22.6 mm between the under cam of the crank rod unit and Face B
(middle metal bearing mounting face) of the frame, and secure the cam with the set screw .
(Apply No. 1 set screw to the flat section of the main shaft and tighten it first, then tighten No. 2 set screw.
Same procedure hereafter)
3. Pass the oscillator through the oscillator shaft , and mount them on the frame.
4. Pass the thrust collar through the oscillator shaft . Lightly press the oscillator shaft in the direction of
arrow C and the thrust collar in the direction of Arrow D, and tighten 2 set screws . Make sure that No.
1 set screw touches the flat section of the oscillator shaft .)
5. Secure the oscillator according to “3.-(11) Oscillator gear positioning”.
(Caution) 1. Make sure that no torque is applied by rotating the main shaft .
2. When the crank rod unit is connected, disconnected, or positioned, or the oscillator
is positioned, be sure to grease two specified positions and the gear section (E) of the
oscillator .
3. After positioning the crank rod unit (under cam ), be sure to perform “3.-(11) Oscilla-
tor gear positioning”. Wrong positioning of the under cam or oscillator may cause
frictional wear or lock-up.
– 10 –
Procedures of assembling

(4) Crank balancer positioning
[Rotating direction]
When the needle bar lowers and the clearance between the needle bar connecting and needle bar lower
bushing is 4.6 mm, 2 set screws of the crank balancer becomes horizontal position.
[Axial direction]
Bring the main shaft eccentric cam into contact with the crank balancer .
– 11 –
Standard Adjustment
4.6mm
B
A

If the main shaft eccentric cam is not secured, the main shaft eccentric
cam should be positioned first.
1. Loosen 2 set screws securing the crank balancer .
2. Remove 4 set screws , then remove the crank rod cover .
3. Turn the main shaft in the forward direction Aso that the needle bar
lowers and the clearance between the needle bar connecting
and needle bar lower bushing is 4.6 mm.
4. Secure the crank balancer with 2 set screws under the condi-
tions that 2 set screws securing the balancer are horizontally
positioned and the balancer is moved in the direction of Arrow B
to make it into contact with the main shaft eccentric cam . For
tightening 2 set screws , tighten them alternately.
– 12 –
Adjustment Procedures Results of Improper Adjustment
oIf the mounting angle of the crank
balancer is wrong, vibration
during sewing will be intensified.
oIf the sewing machine is used for
a long time under the condition of
wrong securing position, the life
of main shaft bearing may be
shortened.
oIf the crank balancer is not
moved in the direction of Arrow
B, it may interfere with the sew-
ing machine frame.

(5) Adjustment of intermediate presser cam
– 13 –
(6) Adjustment of intermediate presser bar
13.5mm
Standard Adjustment
Standard Adjustment
Align
Align

1. Align the edge of the intermediate presser cam with the center of
the engraved point on the main shaft , align the engraved line on
the intermediate presser cam with the engraved point on the main
shaft , and tighten the set screw .
oStitch skipping and poor tense
stitch may occur.
– 14 –
1. Adjust the thrusting distance of the intermediate presser bar to
13.5 mm, and tighten the set screw after ensuring that the needle
passes through the center of the intermediate pressure.
(Caution) Be aware that the tightening pressure of the set screw
should be from 2.16 to 2.75 N•m (22 to 28 kgf•cm).
oAn excessive thrusting distance of
the intermediate presser bar
may damage the intermediate
presser spring or cause poor
presser lifting.
oExcessive tightening pressure
may deform the intermediate
pressure bar or intermediate
presser bar connecting
resulting in malfunction.
Adjustment Procedures Results of Improper Adjustment
Adjustment Procedures Results of Improper Adjustment

A
27.0mm
Right above
45°
B
E
0.5mm
C
H
D
4.4mm F
Fig J
(7) Intermediate presser variable connection/disconnection
– 15 –
Procedures of disassembling
No. 1 set screw
No. 1 set
screw
No. 1 set
screw
1. Remove the presser adjusting screw . Then, remove the intermediate presser spring and the guide shaft.
2. Remove the intermediate presser auxiliary spring .
3. Remove the step screws , , and .
4. Remove the step screw .
5. Remove the step screw , and then the intermediate presser variable plate and the variable plate
spacer .
6. Remove the step screw , and then the intermediate presser variable link .
(At that time, insert a hexagonal wrench through the arm screw hole A and apply it to the setscrew as a
means of turn stop for the intermediate presser variable arm .)
7. Loosen two each of the setscrews , , and .
At that time, the second screw should be loosened first. The first screw of the setscrew should be removed,
completely separate from the flat part of the intermediate presser variable shaft .
8. After the intermediate presser variable arm and the intermediate presser variable shaft have been
pulled out in the direction of the Arrow B, loosen the setscrew and pull out the intermediate presser
variable shaft from the intermediate presser variable arm .
At that time, both of the setscrews should be separated completely from the flat parts (2 positions) of the
intermediate presser variable shaft .
9. Loosen the two setscrews and remove the intermediate presser coupling , the intermediate presser
motor mounting plate , and the intermediate presser motor .
10. Loosen two each of the setscrews , , and .
At that time, the second screws of the setscrews and should be loosened first. The first screw of the
setscrew should be removed, completely separate from the flat part of the intermediate presser lifting shaft
.
11. Remove the E ring and pull out the intermediate presser lifting shaft in the direction of the Arrow C.
193.8mm
G