JUKI AMS-210EN Series Quick start guide

40087239
No.E388-00
ENGINEER’S MANUAL
Computer-controlled, Cycle Machine
With Input Function
AMS-210EN 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 instructions in detail.
It is advisable to use the Instruction Manual and Parts List together with this Engineer's Manual when carrying out
the maintenance of these machines.
This manual gives the "StandardAdjustment" on the former section under which the most basic adjustment value
is described and on the latter section the "Results of Improper Adjustment" under which stitching errors and
troubles arising from mechanical failures and "How To Adjust" are described.

CONTENTS
1. Specifications ........................................................................................................ 1
2. Configuration........................................................................................................... 2
(1) Names of main unit .................................................................................................................. 2
(2) IP-420 operation panel............................................................................................................. 3
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) Adjustment of the moving knife and counter knife position............................................ 31
(19) Floating amount of the thread tension disk ...................................................................... 31
(20) Second thread tension connection / disconnection......................................................... 33
(21) AT unit connection / disconnection.................................................................................... 35
(22) Wiper adjustment ................................................................................................................. 37
(23) Adjusting the pre-load of the X-Y table .............................................................................. 39
(24) Adjustment of the tension of the X timing belt.................................................................. 41
(25) Adjustment to positions of X-motor and Y-motor (Backlash adjustment to gear)......... 43
(26) Adjusting of the presser lower arm (Motor type only)...................................................... 43
(27) Adjustment when the presser plate sheet is replaced (Motor type only) ....................... 45
(28) Height of the slider and pasting of the presser plate sheet
(Pneumatic type only) .......................................................................................................... 47
(29) Adjusting the speed of the work clamp feet (Pneumatic type only)................................ 49
(30) Making the origin setting gauge ......................................................................................... 51
(31) Adjusting the X origin sensor ............................................................................................. 51
(32) Adjusting the Y origin sensor ............................................................................................. 53
(33) Adjustment of the bobbin winder driving wheel position ................................................ 55
(34) Adjusting the bobbin winder amount................................................................................. 55
(35) Adjustment of the shuttle upper spring and lower thread holder position .................... 57
(36) Shuttle felt............................................................................................................................. 57
(37) Shape of the shuttle race ring.............................................................................................59

(38) Adjustment of thread take-up spring ................................................................................. 59
(39) Needle thread clamp device connection/disconnection .................................................. 61
(40) Adjusting the needle thread clamp notch.......................................................................... 63
(41) Adjusting the needle thread clamp sensor........................................................................ 65
4. Memory switch ...................................................................................................... 67
(1) Start and change .................................................................................................................... 67
(2) Function list............................................................................................................................ 68
5. Supplemental remarks of each function number and
explanation of each function ............................................................................... 85
(1) Feeding frame operational sequence setup ........................................................................ 85
(2) Fixed refuge position setup .................................................................................................. 90
(3) Bank function setup............................................................................................................... 91
(4) Port I/O setup.......................................................................................................................... 94
(5) Simplified program setup....................................................................................................107
(6) Version display..................................................................................................................... 120
(7) Keylock setup....................................................................................................................... 121
(8) Customize function setting of key lock ............................................................................. 123
(9) Communication screens of the maintenance personnel level (Program rewrite) ......... 130
(10) Information screen at the maintenance personnel level ................................................ 134
(11) Test sewing function ......................................................................................................... 136
6. Test mode ........................................................................................................... 139
7. Printed wiring board and dip switch................................................................ 155
(1) Various printed wiring boards ............................................................................................ 155
(2) Dipswitch setup.................................................................................................................... 163
8. Table of exchanging gauge parts according to sewing specifications and
needle size used ................................................................................................ 164
9. Option list........................................................................................................... 165
(1) Method of pedal switch cable set connections................................................................. 172
(2) Method of mechanical valve unit connections.................................................................. 174
10.Maintenance ....................................................................................................... 175
(1) Replacing the fuse ............................................................................................................... 175
(2) Changing the voltage specification.................................................................................... 176
(3) Greasing • lock-tight parts .................................................................................................. 177
(4) Parts to which grease • lock-tight is applied ..................................................................... 178
(5) Replenishing the designated places with grease ............................................................. 186
11. Error code list .................................................................................................... 191
12. Message list....................................................................................................... 199

13.Troubles and corrective measures .................................................................. 203
(1) Mechanical parts .................................................................................................................. 203
(2) Sewing conditions ............................................................................................................... 207
(3) Electrical components......................................................................................................... 216
14.Circuit diagrams ................................................................................................ 226
(1) Block diagram ..................................................................................................................... 226
(2) Power supply circuit diagram A ........................................................................................ 227
(3) Power supply circuit diagram B ........................................................................................ 228
(4) Power supply circuit diagram C ........................................................................................ 229
(5) Servo motor circuit diagram.............................................................................................. 230
(6) Sensor-pedal circuit diagram ............................................................................................ 231
(7) MAIN•PANEL board circuit diagram ................................................................................. 232
(8) Motor•solenoid circuit diagram......................................................................................... 233
(9) Air system circuit diagram................................................................................................. 234
15.Drawing of the table........................................................................................... 235

Contents
1. Specifications.......................................................................................................236
2. Standard adjustments..........................................................................................237
(1) Driver adjustments ......................................................................................................................237
(2) Amount of floating adjustments for thread tension disc ........................................................237
3. Memory switch .....................................................................................................239
(1) List of functions...........................................................................................................................239
4. Maintenance..........................................................................................................240
(1) Grease lock-tight application points .........................................................................................240
Computer-controlled, Cycle Machine with Input Function
(Slide Take-Up Lever Specifications)
AMS-210ENHL1306/7300

– 1 –
No. Application
AMS-210ENHS AMS-210ENSS AMS-210ENHL AMS-210ENSL AMS210ENHS AMS-210ENSS AMS-210ENHL AMS-210ENSL AMS-210ENHL AMS-210ENSL
Sub-class 1306 1510 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) 100mm
2Max. sewing speed 2800sti/min (when sewing pitch is 4mm or less)
3Stitch length 0.1 to 12.7mm (Min. resolution : 0.05mm)
4 Feed motion of feeding frame Intermittent feed (2-shaft drive by stepping motor)
5Needle bar stroke 41.2mm
6Needle S type: 134 No. 90, H type: 135 x 17 No. 110 (S type: DP x 5 # 14, H type: DP x 17 # 18)
7 Method to lift feeding frame Pulse motor Air Pulse motor Air
8Feeding frame shape Right and left united Right and left separated Right and left united
9Lift of feeding frame Standard 25mm, Max. 30mm Max. 30mm 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 No. 2 (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 Memory of pattern data Sewing machine, Media
• Sewing machine : Max. 999 patterns (Max. 50,000 stitches/pattern)/Max. 500,000stitches
• Media : Max. 999 patterns (Max. 50,000 stitches/pattern)/25 million stitches max. (CF card, 128M)/Approx. 50 million stitches max. (CF card, 256M)
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)
23 Sewing speed limitations 200 to 2,800 sti/min (Scale : 100 sti/min steps)
24 Pattern selector facility Pattern No. selection method (Cycle sewing: 20 cycle/30 step)
(Sewing machine : 1 to 999, Media : 1 to 999)
25 No. of sheets counter Up/Down method (0 to 9,999)
26 Sewing counter Up/Down method (0 to 9,999)
27 Bobbin thread counter Up/Down method (0 to 9,999)
28 Memory back-up In case of a power interruption, the pattern being used will automatically be stored in memory.
29 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.
30 Sewing machine motor 550W servo motor
31 External dimensions 1,200mm (W) x710mm (L) x 1,200mm (H) 1,200mm (W) x770mm (L) x 1,200mm (H)
(Excluding thread stand) (Excluding thread stand)
32 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
33 Power consumption 450VA
34 Working temperature/humidity Temperature: 5 to 35°C, Humidity: 35 to 85% (no condensation)
35 Supply voltage/frequency Japan, export: 3-phase 200V/220V (1-phase 100V/120V), China, general export: 1-phase 200V to 240V, Europe: 1-phase 230V, Rating ±10%, 50/60Hz
36 Air pressure used — Standard: 0.35 to 0.4MPa, Max. 0.55MPa — Standard: 0.35 to 0.4MPa, Max. 0.55MPa
37 Air consumption — 1.8dm3/min (ANR) — 1.8dm3/min (ANR)
38 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) 1. 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-420)
Power switch
Control box
Foot pedal
Manual pedal (Excluding pneumatic type)
– 2 –
Air regulator
(for pneumatic type only)

(2) IP-420 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.
Contrast control
Brightness control
CompactFlash (TM) eject button
CompactFlash (TM) slot
Cover detection switch
Connector for external switch
Connector for control-box connection

– 4 –
MEMO

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.-(33) 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 .
22.7 to 22.9mm
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
– 9 –

1. Mount the main shaft according to “3.-(1) Main shaft connection/disconnection”, and mount the crank rod
unit .
2. Adjust the clearance to 22.7 to 22.9 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 ofArrow 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
B
A
4.6mm

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
Standard Adjustment
Standard Adjustment
Align
Align
13.5mm