JUKI AMS-210E Series Engineer's Manual
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JUKI AMS-210E Series Engineer's Manual

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

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Summary of Contents for JUKI AMS-210E Series

  • Page 1 ® Computer-controlled, Cycle Machine With Input Function AMS-210E Series ENGINEER’S MANUAL 40034836 No.E369-02...
  • Page 2 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.
  • Page 3 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 ...................

  • Page 4: Table Of Contents

    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 ....................

  • Page 5: Specifications

    Lubricating oil JUKI NEW Defrix oil (equivalent to ISO VG32) (Lubrication system) Grease 1. Penetration No. 2 lithium grease, 2. Templex N2, 3. Juki Grease A, 4. Juki Grease B (Caution)1. EEP-ROM, Smart media Memory of pattern data • EEP-ROM : Max. 200 patterns (Max. 20,000 stitches/pattern) •...
  • Page 6 MEMO...

  • Page 7: Configuration

    2. Configuration (1) Names of main unit Air regulator Machine head (for pneumatic type only) 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) –...

  • Page 8: Ip-400 Operation Panel

    (2) IP-400 operation panel (Front view) (Right side view) 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.

  • Page 9: Cp-20 Operation Panel

    (3) CP-20 operation panel CP-20 “Ready” key Item selection LED This key changes over the setting state from the panel LEDs of the selected items light up. to the sewing state where the sewing machine actu- ally operates. Sewing LED This LED goes off at the time of setting state and Pattern No.

  • Page 10: Standard Adjustment

    3. Standard adjustment (1) Main shaft connection/disconnection Procedures of disassembling 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.
  • Page 11 Procedures of assembling 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...

  • Page 12: Removal Of Main Shaft Motor And Coupling

    (2) Removal of main shaft motor and coupling Procedures of disassembling 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.
  • Page 13 Procedures of assembling 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.

  • Page 14: Crank Rod Connection/Disconnection

    (3) Crank rod connection/disconnection Procedures of disassembling 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.
  • Page 15 Procedures of assembling 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.

  • Page 16: Crank Balancer Positioning

    (4) Crank balancer positioning Standard Adjustment [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 4.6mm...
  • Page 17 Adjustment Procedures Results of Improper Adjustment o If the mounting angle of the crank If the main shaft eccentric cam is not secured, the main shaft eccentric balancer is wrong, vibration should be positioned first. during sewing will be intensified. 1.

  • Page 18: Adjustment Of Intermediate Presser Cam

    (5) Adjustment of intermediate presser cam Standard Adjustment Align Align (6) Adjustment of intermediate presser bar Standard Adjustment – 13 –...
  • Page 19 Adjustment Procedures Results of Improper Adjustment 1. Align the edge of the intermediate presser cam with the center of o Stitch skipping and poor tense the engraved point on the main shaft , align the engraved line on stitch may occur. the intermediate presser cam with the engraved point on the main shaft...

  • Page 20: Intermediate Presser Variable Connection /Disconnection

    (7) Intermediate presser variable connection/disconnection Procedures of disassembling 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.
  • Page 21 Procedures of assembling 1. Fix the intermediate presser variable shaft to the intermediate presser variable arm by means of the two setscrews so that the length of the shaft section becomes 193.8mm. (Both setscrews should be adjusted level to the intermediate presser variable shaft 2.

  • Page 22: Intermediate Presser Variable Adjustments

    (8) Intermediate presser variable adjustments Standard Adjustment Start the Test Mode I10 (IP-400) or CP-8 (CP-20) and press twice after the completion of origin retrieval. At that time, there shall be coincidence between the center of the arm’s left-side hole C and the second screw of the intermediate presser variable arm –...
  • Page 23 Adjustment Procedures Results of Improper Adjustment o There will be a displacement 1. Start the Test Mode I10 (IP-400) or CP-8 (CP-20). between the variable value of the 2. Tread on the start pedal for origin retrieval, and make adjustments by intermediate presser lower turning the sensor slit so that the lines combining the center of the...
  • Page 24 (9) Intermediate presser drive arm Standard Adjustment * Refer to Instruction Manual, 4-7. Intermediate presser height. Close contact Intermediate presser bar – 19 –...
  • Page 25 Adjustment Procedures Results of Improper Adjustment 1. Turn ON the power supply and set the height of the intermediate o If there is no clearance, there will presser to 0mm. Turn OFF the power supply in the state that the be interference between the intermediate presser has been lowered.

  • Page 26: Lower Shaft Backlash Adjustment And Connection/Disconnection

    (10) Lower shaft backlash adjustment and connection/disconnection Standard Adjustment 1. Size of lower shaft backlash is 0.1mm at the tip of the driver . The shaft is required to rotate smoothly. 2. Define the stop position of the lower shaft so that the set screw settles almost in the center of the flat section...
  • Page 27 Adjustment Procedures Results of Improper Adjustment 1. Lower shaft backlash o If the backlash is excessive, the 1) Loosen the two set screws hook noise will be increased. 2) Turn the lower shaft rear metal in the direction of the arrow and adjust o If backlash is too small, the lower the backlash, keeping the metal to contact closely with Face A.

  • Page 28: Adjustment Of Hook Oil Amount

    (12) Adjustment of hook oil amount Standard Adjustment (13) Shuttle connection / disconnection and oil wick piping Procedures of disassembling 1. Loosen the three set screws 2. Cut the harness bands 3. Remove the set screw and pull the oil tank in the direction of the arrow A.
  • Page 29 Adjustment Procedures Results of Improper Adjustment o If the amount of hook lubricant is 1. Loosen the set screw and remove it. reduced too much, this can be a 2. When the adjusting screw is tightened, the quantity of oil can be cause of frictional wear of the regulated for the lubrication pipe left hook race plane or lock-up.

  • Page 30: Adjusting The Height Of The Needle Bar

    (14) Adjusting the height of the needle bar Standard Adjustment Marker line for DP x 5 Marker line for DP x 17 (with needle count higher than #22) Marker line for DP x 17 (with needle count lower than #22) –...
  • Page 31 Adjustment Procedures Results of Improper Adjustment * Turn ON the power once, and turn OFF the power again after making the intermediate presser in the lowered state. 1. Bring the needle bar down to the lowest position, loosen the needle bar connection screw and align the upper engraved line on the...

  • Page 32: Hook Adjustment

    (15) Hook adjustment Standard Adjustment : Marker line for DP x 5 needle : Marker line for DP x 17 needle (with needle count higher than #22) : Marker line for DP x 17 needle (with needle count lower than #22) DP x 17 needle DP x 17 needle When a DP x 5...
  • Page 33 Adjustment Procedures Results of Improper Adjustment * Turn ON the power once, and turn OFF the power again after making the intermediate presser in the lowered state. 1. Turn hand wheel by hand to ascend the needle bar Adjust so that lower marker line on the ascending needle bar aligns with the bottom end of the needle bar bushing lower 2.

  • Page 34: Thread Trimmer Presser Lifter Cam Connection/Disconnection

    (16) Thread trimmer presser lifter cam connection/disconnection Procedures of disassembling 1. Loosen 2 set screws securing the presser lifter and thread trimmer cam (hereafter called “cam”) 2. Loosen the two set screws and remove the sensor slit 3. Remove the four set screws and take out the presser lifting motor in the direction of the arrow.
  • Page 35 Procedures of assembling 1. Apply a proper amount of grease (Juki Grease A) to the grooved cam block of the cam , the peripheral cam block, and the rollers of the presser bar lifter link and the thread trimmer link .

  • Page 36: Adjusting The Thread Trimmer Sensor

    (18) Adjusting the thread trimmer sensor Standard Adjustment After completion of origin retrieval (at start switch on) in the test mode I07 (IP-400) or CP-6 (CP-20), press the + key 6 to 8 times, and the thread trimmer sensor is turned off (IP-400: The contents on the operation panel change from “...
  • Page 37 Adjustment Procedures Results of Improper Adjustment 1. Start the test mode I07 (IP-400) or CP-6 (CP-20). o If the thread trimmer sensor changeover takes place outside 2. Tread on the pedal to perform origin retrieval for the thread trimmer the range, the moving knife may cam.

  • Page 38: Adjustment Of The Moving Knife And Counter Knife Position

    (19) Adjustment of the moving knife and counter knife position Standard Adjustment Counter knife position : The clearance between the counter knife and the needle hole guide is 1.0mm. Moving knife position : Before thread trimmer operation (standby state), the distance from the throat plate front end to the tip of the thread cutter lever (small) is 18.5mm.
  • Page 39 Adjustment Procedures Results of Improper Adjustment 1. Counter knife position o If the clearance is less than Loosen the counter knife set screw to adjust the position. 1.0mm, thread may be cut by the counter knife blade when the 2. Moving knife position thread is pulled with the moving Loosen the screw to adjust the position.

  • Page 40: Second Thread Tension Connection / Disconnection

    (21) Second thread tension connection / disconnection Procedures of disassembling 1. Loosen the set screw 2. Remove three setscrews and take out the thread tension cap 3. Remove the nut and the tension releasing pin adjusting collar . Then take out the thread tension disc pressing plate and three thread tension disc return springs 4.
  • Page 41 Procedures of assembling 1. When mounting the second thread tension , confirm in advance that the pin block of the AT link unit (front) is exactly settling in the hole of the thread tension pressing pin . If you try to mount the second thread tension forcedly with the pin area left disengaged, this may result in breakage in the thread tension pressing pin...

  • Page 42: At Unit Connection / Disconnection

    (22) AT unit connection / disconnection Procedures of disassembling 1. Remove the set screw of the AT link unit (front) and take out the second thread tension . ((21) Refer to “Second thread tension connection / disconnection.”) 2. Draw out the cotter pin from the pin block (H type) or (S type) of the AT link unit (rear)
  • Page 43 Procedures of assembling 1. For incorporating the AT solenoid unit into the system, run the solenoid cable from the rear of the AT solenoid unit to the rear end of the machine arm. 2. The center-to-center distance between the AT joints of the AT connector rod is 299 mm for S type and 301 mm for H type.

  • Page 44: Wiper Adjustment

    (23) Wiper adjustment Standard Adjustment 1. When lowering the intermediate presser at the stop position after thread trimming (needle height from the top surface of throat plate is 17.7 mm.) and pressing wiper link section , adjust the clearance between the center of needle and the inside of V letter of the wiper to 10 mm.
  • Page 45 Adjustment Procedures Results of Improper Adjustment 1. Turn OFF the power after stopping the thread trimming, or turn ON o If the clearance between the wiper the threading switch and lower the intermediate presser and needle is too small, the (Caution) As for the height of needle when adjusting the wiper wiper comes in contact with the...

  • Page 46: Adjusting The Pre-Load Of The X-Y Table

    (24) Adjusting the pre-load of the X-Y table Standard Adjustment When removing the X-Y table assy from the sewing machine, re-adjustment of the pre-load is necessary for the X axis only. 9.8 to 39.2N – 41 –...
  • Page 47 Adjustment Procedures Results of Improper Adjustment 1. Hold down the X fixed race (rear) in the direction of the arrow to tighten 4 set screws 2. Loosen 4 set screws 3. Hold down the X fixed race (front) in the direction of the arrow to tighten 4 set screws .

  • Page 48: Adjustment Of The Tension Of The X Timing Belt

    (25) Adjustment of the tension of the X timing belt Standard Adjustment 7.84N (26) Adjustment to positions of X-motor and Y-motor (Backlash adjustment to gear) Standard Adjustment 1. Hold down the X motor in the direction of Arrow A and secure it. 2.
  • Page 49 Adjustment Procedures Results of Improper Adjustment 1. Move the race table to the left end (in the direction of the arrow). o If the tension is excessive, it will 2. Tighten the adjusting screw and fix the nut so that the load cause timing belt breakage.

  • Page 50: Adjusting Of The Presser Lower Arm (Motor Type Only)

    (27) Adjusting of the presser lower arm (Motor type only) Standard Adjustment Close contact Close contact (28) Adjustment when the presser plate sheet is replaced (Motor type only) Standard Adjustment Unevenness: No good Apply grease – 45 –...
  • Page 51 Adjustment Procedures Results of Improper Adjustment 1. Secure the presser lower arm A so that the clearance between the o If the angle of the presser lower holding arm and machine arm becomes 0.3 mm with 2 set screws arm A and B is not equal, it will cause loosening the arm asm.
  • Page 52 (29) Height of the slider and pasting of the presser plate sheet (Pneumatic type only) Standard Adjustment 1. Follow the dimensions in the drawing below for pasting the presser plate sheet on the presser plate Apply grease after pasting the sheet. 2.
  • Page 53 Adjustment Procedures Results of Improper Adjustment 1. Remove 4 set screws to remove the presser plate , and replace o If the position where the presser the old presser plate sheet with new one. plate sheet was pasted is 2. After mounting the presser plate , adjust the height of the slider wrong, abrasion of related with 4 set screws...

  • Page 54: Adjusting The Speed Of The Work Clamp Feet (Pneumatic Type Only)

    (30) Adjusting the speed of the work clamp feet (Pneumatic type only) Standard Adjustment 1. Adjust the knob 1 and the knob 2 of the speed controller mounted on the solenoid valve and make adjustments as described below. • Presser lifting (tube label: 1-A, 2-A) and presser lowering (tube label: 1-B, 2-B). •...
  • Page 55 Adjustment Procedures Results of Improper Adjustment 1. Adjust the speed referring to Standard Adjustment. o When the work clamp foot comes 2. To increase the speed of lowering/raising the work clamp foot, turn down, the noise is big. the knob 1 counterclockwise.

  • Page 56: Making The Origin Setting Gauge

    (31) Making the origin setting gauge Standard Adjustment Hole ø4 for positioning pin 16 mm 36 mm Tap M4 for setscrew Origin marking for 1316 , 2206 Origin marking for 1510 , 2210 (32) Adjusting the X origin sensor Standard Adjustment When the feed is in the mechanical origin, align the tip of the needle with the lateral position of the engraved dot of the origin.
  • Page 57 Adjustment Procedures Results of Improper Adjustment 1. Make an origin setting gauge as shown in the figure, and attach it to the work clamp foot Adjustment Procedures Results of Improper Adjustment 1. Start the test mode I06 (IP-400), or CP-2 (CP-20). 2.

  • Page 58: Adjusting The Y Origin Sensor

    (33) Adjusting the Y origin sensor Standard Adjustment When the feed is in the mechanical origin, align the tip of the needle with the longitudinal position of the engraved dot of the origin. B Main motor side (rear) Operator side (front) –...
  • Page 59 Adjustment Procedures Results of Improper Adjustment 1. Start the test mode I06 (IP-400) or CP-2 (CP-20). 2. When the pedal is trodden on, the feed moves to the mechanical origin and then stops. 3. Lower the needle and check the front-rear displacement from the engraved marking of the origin.

  • Page 60: Adjustment Of The Bobbin Winder Driving Wheel Position

    (34) Adjustment of the bobbin winder driving wheel position Standard Adjustment The distance is 139.5 mm between the measuring plane of the bobbin winder driving wheel and the cover mounting plane of the sewing machine frame 139.5mm (35) Adjusting the bobbin winder amount Standard Adjustment The position of the bobbin winder lover is based on the standard that it is 14 mm apart from the bobbin...
  • Page 61 Adjustment Procedures Results of Improper Adjustment o If the distance of 139.5mm is 1. Loosen the two set screws to adjust the position (139.5mm) of the insufficient, rubber ring wear may bobbin winder driving wheel and fix it with the two set screws occur in the bobbin winder unit.

  • Page 62: Adjustment Of The Shuttle Upper Spring And Lower Thread Holder Position

    (36) Adjustment of the shuttle upper spring and lower thread holder position Standard Adjustment 1. Shuttle upper spring : In regard to the right and left positioning, secure coincidence between the center of the needle and that of the groove width C. For the front-rear positioning, join the needle rear end and the corner block.
  • Page 63 Adjustment Procedures Results of Improper Adjustment o If there is a front and rear 1. Remove the work feed bar, feed plate, and the throat plate. Adjust displacement or a right and left the positioning of shuttle upper spring with the set screws pcs.).

  • Page 64: Shape Of The Shuttle Race Ring

    (38) Shape of the shuttle race ring Standard Adjustment If wear seems to be too much around the pointed tip of the inner hook, release the shuttle race ring confirm that the dimensions of the hatched area on the rear side are 0.3 x 8mm. (39) Adjustment of thread take-up spring Standard Adjustment Stroke : The movable distance of the needle thread when the needle thread is pulled in the direction...
  • Page 65 Adjustment Procedures Results of Improper Adjustment 1. If the dimensions of 0.3 x 8mm are not secured, retouching is re- quired with the aid of an oil stone. Dimension A Part No. Name of part Remarks (mm) 14103253 Shuttle race ring A Optional 14103352 Shuttle race ring B...

  • Page 66: Needle Thread Clamp Device Connection/Disconnection

    (40) Needle thread clamp device connection/disconnection Procedures of disassembling 1. Remove the hinge screw * If the hinge screw cannot be seen from the open part of the needle thread clamp device , try to move the needle thread clamp connector link by hand in the direction of A or B.
  • Page 67 Procedures of assembling 1. Push the needle thread clamp device in the direction of A and fix it with the four set screws . Tighten the hinge screw 2. Turn on the power supply and press the key twice so that the needle thread clamp support plate complete is positioned at the far advanced end.

  • Page 68: Adjusting The Needle Thread Clamp Sensor

    (41) Adjusting the needle thread clamp sensor Standard Adjustment When the needle thread clamp support plate complete is withdrawn by 3 to 4 pulses from the needle thread clamp position (Caution 1., 2.) the clearance A toward the needle thread clamp becomes 0.
  • Page 69 Adjustment Procedures Results of Improper Adjustment In the first place, confirm that the setting value of the memory switch o If there are too many pulses used U69 is [0] for S Type and [1] for H Type. Since then, make the until the clearance A becomes 0, adjustments as specified below.

  • Page 70: Adjusting The Needle Thread Clamp Notch

    (42) Adjusting the needle thread clamp notch Standard Adjustment 1. Needle thread clamp notch R position • When the needle thread clamp link complete is pressed in Direction A, and Part B of the needle thread clamp support plate complete and the needle thread clamp begins to open, the distance between the needle thread clamp...
  • Page 71 Adjustment Procedures Results of Improper Adjustment 1. Needle thread clamp notch R adjustment o If the distance is too long between the needle thread clamp 1) Loosen the two set screws the needle thread clamp base 2) Press the needle thread clamp link complete in Direction A so that the needle thread release timing the distance between the needle thread clamp...

  • Page 72: Memory Switch

    4. Memory switch (1) Start and change To change the memory switch (level 2): The sewing machine operation can be changed by changing the setting of the memory switch. For IP-400: (1) To call up the screen showing the memory switch data (level 2) list: Hold down the switch for approx.
  • Page 73 2. For CP-20: 1. Press the key when the sewing LED is off to activate the user setting mode (Level 1)of the memory switch. Hold down the key for 6 seconds to activate the service setting mode (Level 2) of the memory switch. (Caution) A 3-second and a 6-second buzzers Lower 2 figures indicate Upper 3 figures indicate a...

  • Page 97: Explanation Of Each Function

    5. Supplemental remarks of each function number and explanation of each function (1) Feeding frame operational sequence setup For the AMS-210E, it is possible to change the method of feeding frame and pedal operation by means of a memory switch. 1.
  • Page 98 [(5) List of feeding frame and pedal setup] For pulse motor driving Setup Contents Preference Explanation United clamp – Lowered to the bottom by Pedal 1. United clamp, Lowered to the intermediate position by Pedal 1 (right). – 2-step stroke Lowered to the bottom by Pedal 2 (left).
  • Page 99 3. Feeding frame lifting setup at the end of sewing Using the memory switch U37, it is possible to set up the timing for feeding frame lifting at the end of sewing. Setup Contents Explanation After the start of The feeding frame is lifted after the movement sewing reset from the end of sewing to the start of sewing.
  • Page 100 6. Presser pedal setup Using the memory switches U84 ~ U87 below, it is possible to set up the method of pedal operation. U84 : Used to set up the method of pedal operation for Pedal 1. (Standard pedal, PK47 right) U85 : Used to set up the method of pedal operation for Pedal 2.

  • Page 101: Fixed Refuge Position Setup

    (2) Fixed refuge position setup Irrespective of the second origin in the pattern data, a memory switch is available to set up the second origin (fixed refuge position) that is common to each pattern. When the use of the fixed refuge position has been set up with the memory switch K90, the fixed refuge position becomes enabled, which has been set up with the fixed refuge position Coordinate X of Memory Switch K117 and the fixed refuge position Coordinate Y of Memory Switch K118.

  • Page 102: Bank Function Setup

    (3) Bank function setup The bank function means a function of sewing effected through changeover to a pattern by an external signal, which is registered in multiple pattern buttons in cases of cassette discrimination and others. For sewing by the bank function, an external signal input is entered before the feeding frame is lowered at the time of pedal treading-on.
  • Page 103 (2) External input terminal setup The input terminal numbers to be used for the bank function are set up. 1. IP-400 1) Bank function setup screen display When the number of K130 bank connection select terminals is preset for the memory switch data (Level 2), the bank function button (A) is displayed on the mode changeover screen.
  • Page 104 When the bank function setup screen is closed and the data input screen is displayed, a pictograph (F) for indicating the ON status is displayed if the bank function is turned ON. When the key is pressed, the bank mode screen is displayed.
  • Page 105 2. CP-20 The bank input terminals 0 to 3 (input Nos. 3 to 6) are assigned to arbitrary input terminals of the memory switches Nos. 300 ~ 331. 1) When the key is continuously pressed for 6 seconds in the state that the sewing LED is unlit, the service setup mode is assumed for the memory switches and the bank mode is set up.

  • Page 106: Port I/O Setup

    (4) Port I/O setup This sewing machine is provided with the machine control functions that are enabled only by the machine main body through the generation of signal outputs to the outside and the reception of signal inputs from the outside, without the intervention by any appropriative I/O unit and other devices.
  • Page 107 2. Output terminal setup Output No. Contents Explanation No output For the actuator Feeding frame 1 Feeding frame right lifting Feeding frame 2 Feeding frame left lifting Feeding frame 3 (Feeding frame right 2-stage stroke) Feeding frame 4 Feeding frame left 2-stage stroke (Intermediate presser) (Signal output) Void...
  • Page 108 Output No. Contents Explanation Bobbin status Bobbin key → Bobbin status Main unit input status Main unit input key → Main unit input status Pattern check status Pattern check, thread tension / intermediate presser height command setup Last mode status Last mode status (Sewing machine revolutions / output / XY / presser thread cutter / thread clamp / intermediate presser test mode) Presser SW input effective...
  • Page 109 [Normal Status Diagram of the Port I/O] G: Second origin C: Midway stop O: Origin 57: Setting condition READY SW ON 58: Ready operation state 59: Ready state 60: Sewing state 61: Sewing forwarded 62: Sewing machine driving 63: Sewing start point reset 64: Midway stop 65: Sewing error display stop 66: Sewing temporary stop...
  • Page 110 [Error Status Diagram of the Port I/O] 57: Setting condition 58: Ready operation state 59: Ready state 60: Sewing state 61: Sewing forwarded 62: Sewing machine driving 63: Sewing start point reset 64: Midway stop Reset SW ON Reset SW ON Reset SW ON Reset SW ON 65: Sewing error display stop...
  • Page 111 [Miscellaneous Status Diagram of the Port I/O] 57: Setting condition Ready SW ON Ready SW ON Test sewing SW → Test sewing Ready SW ON Test sewing SW OFF 58: Ready operation state 59: Ready state 60: Sewing state 61: Sewing forwarded 62: Sewing machine driving 63: Sewing start point reset 64: Midway stop...
  • Page 112 [Sewing Machine Driving Status Diagram of the Port I/O] 49: Needle upper position 50: Needle lower position 51: Needle upper dead point position 52: Needle lower dead point position 53: Thread trimming signal 50ms 54: During rotation 120ms 55: Sewing machine brake 120ms 102: Sewing machine start 103: Sewing machine stop...
  • Page 113 3. Setup procedures (1) IP-400 1) Display of the port I/O screen When the switch is continuously pressed for about 6 seconds and the page changeover button is pressed, the port I/O setup button (A) is displayed. When this button is pressed, the port I/O setup screen is displayed.
  • Page 114 3) Port I/O setup To make output number setting, input number set- ting, and virtual I/O number setting, the setup button (G) is pressed to enter an input of the setting function number (H) in the selected terminal through the ten key (I). The signal type is selected from High (J) and Low (K).

  • Page 117: Simplified Program Setup

    (5) Simplified program setup This machine is provided with the simplified program functions, which can make the programming of various addi- tional devices (stacker, unit, etc.) according to sewing machine operation. In conjunction with the port I/O output functions, modification into such additional devices can be carried out in the main unit of the sewing machine. 1.
  • Page 118 4. Operational Procedures (1) Simplified program selection screen display When the key is continuously pressed for 3 seconds, the simplified program button (A) is displayed on the mode changeover screen. When this button is pressed, the simplified program selec- tion screen is displayed. (2) Simplified program effective / ineffective The simplified program comes in five patterns.
  • Page 119 In the simplified program editing screen, the editing step is selected with the use of the step forwarding button (D) and the step return button (E). For each selected step, it is possible to carry out command port I/ O setting and parameter setting. A maximum of 99 steps can be entered.
  • Page 120 On the port setup screen, current setting items are dis- played at the top left of the screen. : Output information (High) setup screen : Output information (Low) setup screen : Input information (High) setup screen : Input information (Low) setup screen Using the page turning buttons (M, L), the displayed port type can be changed.
  • Page 121 3) Parameter input Corresponding to the selected command, the param- eter input button is displayed. When the parameter input button (Q) is pressed, the parameter input screen is displayed. Enter a numerical input through the ten key (R) and press the Enter button (S).
  • Page 122 5) Step deletion It is possible to delete the step that has been dis- played. When the step deletion button (V) is pressed, the deletion check screen is displayed. When the Enter button (W) is pressed, the displayed step is deleted and the step standing behind is shifted forward.
  • Page 123 5. To use the simplified program with CP-20 (1) Simplified program ON/OFF 1) When the power supply is turned on with the key kept pressed, the unit is started in simplified program mode. 2) When the key is pressed, the simplified program number and the ON/OFF status are displayed. Using the key, it is possible to select the simplified program number.
  • Page 124 3) Select data Write or Read with the key. : Reading : Writing 4) Using the key, it is possible to select the file number. 1. For data reading It is possible to select only the file number registered in the smart media. 2.

  • Page 131: Version Display

    (6) Version display 1. To display the version information screen: Hold down the key for 3 seconds to call up the version information button, (A) on the screen. Press this button to display the version information screen. The version information screen shows the version information of your sewing machine.

  • Page 132: Keylock Setup

    (7) Keylock setup 1. To call up the keylock screen: Hold down the key for 3 seconds to call up the keylock button, (A) on the screen. Press this button to display the keylock setting screen. The current status appears on the keylock button. : Keylock is inactivated.

  • Page 133: Communication Screens Of The Maintenance Personnel Level (Program Rewrite)

    (8) Communication screens of the maintenance personnel level (Program rewrite) The data types allowed to be handled in the communication screens can differ according to the ordinarily used levels and the specific levels that are used by the maintenance personnel. 1.
  • Page 134 2. Reading/Writing of adjustment data and all sew- ing machine data (For the IP-400) (1) Display of the communication screen of the main- tenance personnel level When the key (A) is continuously pressed for 3 seconds, the top left image is turned into the orange color (B) and a communication screen of the mainte- nance personnel level is displayed.
  • Page 135 (3) Program rewrite start When the start of communication button (H) is pressed, program rewriting is started. (Caution) Never turn off the power or open/shut the smart media cover during the work. Oth- erwise, the main body can be destroyed. Data deleting screen Data writing screen Ending screen...
  • Page 136 4. Reading/Writing of the adjustment data and all sewing machine data in the smart media (For the CP-20) (1) When the power is turned on with the key kept pressed, the adjustment data mode is started. When the adjustment data mode is started, the pattern number LED is lit up. When the power is turned on with the key kept pressed, the all sewing machine data mode is started.
  • Page 137 5. Program rewriting (For the CP-20) (1) When the power is turned on with the key kept pressed, the rewriting mode of the simplified panel program is started. When the rewriting mode of the simplified panel program is started, the Y scale LED is lit up. When the power is turned on with the key kept pressed, the rewriting mode of the main program is started.
  • Page 138 6. Use of smart media other than those packed together When the contents of the smart media card packed together are going to be copied on another smart media card, the smart media card of the copying destination should be formatted with IP400. Since then, the following directory configuration should be established with a personal computer.

  • Page 139: Information Screen At The Maintenance Personnel Level

    (9) Information screen at the maintenance personnel level 1. Error history (1) To display the information screen at the mainte- nance personnel level: Hold down the information key, (A) for approx. 3 seconds in the switch sheet section on the data in- put screen to call up the information screen at the maintenance personnel level.
  • Page 140 2. Cumulative operating information (1) To call up the information screen at the mainte- nance personnel level: Hold down the information key , i for approx. 3 seconds in the switch sheet section on the data in- put screen to call up the information screen at the maintenance personnel level.

  • Page 141: Test Sewing Function

    (10) Test sewing function Connecting your PC to the sewing machine allows you to perform test sewing based on data created with PM-1 (sewing data creating and editing software). IP400 IP400 Data transmission P M - 1 P M - 1 Connect your PC and transmit data to the sewing machine after creating it with PM-1, and IP-400 automatically shows the test sewing screen when the data input screen is called up.
  • Page 142 (3) Modification to data Press the button, A, B, or C to be changed to call up the numeric keypad. Enter a new value and press the enter button (D). (4) Test sewing Press the ready-to-go switch (E) to call up the test sewing screen.
  • Page 143 2. Color chart indicating thread tension values An indicated needle positioning drawing varies with thread tensions adjusted for needle entry positions. The follow- ing chart shows the colors of lines for thread tensions. Thread tension Color 0 to 20 : Gray 21 to 40 : Purple 41 to 60...

  • Page 144: Test Mode

    6. Test mode (1) Start (CP-20) When the check program is started, maintenance and inspection can be carried out. 1) Check program start 1. When the key is continuously pressed for 3 seconds in the state that the sewing LED is unlit, a buzzer sound is heard and the user setup mode is assumed for the memory switch.
  • Page 145 Check program number Check program Contents Output check The wiper and air outputs are generated. Presser, thread cutter motor/ The status of inching operation of the presser and origin sensor check thread trimmer motor, operation of origin retrieval, and he presser origin / presser sensors is displayed. Needle thread clamp motor/ The status of inching operation of the needle thread origin sensor check clamp motor, operation of origin retrieval, and the needle...

  • Page 146: Display Output Test (Cp-20)

    (2) Display output test (CP-20) After the movement to a check program, the display output test is started. The following LEDs are lit at the intervals of one second. – 141 –...

  • Page 147: Method Of Confirmation According To Each Test Program No. (Cp-20)

    (3) Method of confirmation according to each test program No. (CP-20) 1) CP-1 (Input signal check) It is possible to check the input status of the operation panel keys, pedal switches, and various sensors. Display of input No. The input number is updated by +1 each time the keys are pressed simultaneously.
  • Page 148 2) CP-2 (XY motor / origin sensor check) The status of inching operation of the X/Y motor, operation of origin retrieval, and the X/Y origin sensors is displayed. 1. In the first place, press the key to carry out needle thread clamping and origin retrieval for the presser and thread trimmer motor.
  • Page 149 3. Presser lifting, Lowering frequency vertical times setup Press the keys to set up the presser vertical times. B0: Ineffective (Initial value) B1 ~ B10: 1 to 10 times After setting, press the key. The ordinary display is recovered. 4. Continuous operation After the completion of setting, regular operation like pattern number setup and others should be carried out.
  • Page 150 4) CP-4 (Main motor rpm check) Set up the rpm number of the sewing machine, drive only the main motor of the sewing machine at the preset rpm level, and display the measured rpm number. 1. READY operation In the first place, press the key for the origin retrieval of the needle thread clamp and the presser and thread trimmer motor.
  • Page 151 5) CP-5 (Output check) 1. Operation An output is generated while the key is pressed. The checking items can be changed with the keys. In regard to the items, refer to the section of IP-400 output check. 6) CP-6 (Presser and thread trimmer motor / origin sensor check) The status of inching operation of the presser and thread trimmer motor, operation of origin retrieval, and the presser origin and thread trimmer sensors is displayed.
  • Page 152 7) CP-7 (Needle thread clamp motor / origin sensor check) The status of inching operation of the needle thread clamp motor, operation of origin retrieval, and the thread clamp origin and needle thread clamp sensors is displayed. 1. Operation According to the status of the needle thread clamp sensor, “0” or “1” is dis- played.
  • Page 153 9) CP-9 (Software version display) The software versions of the PANEL Board, the MAIN Board, and the SDC Board are displayed. Each version is expressed in a format of RR, VV, LL-xx. xx is used to indicate the specifications for special orders, etc.

  • Page 154: For Ip-400

    (4) For IP-400 1) Display of the check program screen When the key is continuously pressed for 3 seconds, the check program (A) is displayed on the screen. When this button is depressed, the check program screen is displayed. The check program comes in the ten items as specified below.
  • Page 155 Presser and thread trimmer motor / origin sen- sor check → The status of inching operation of the presser and thread trimmer motor, operation of origin retrieval, and the presser origin and presser sensor is dis- played. Needle thread clamp motor / origin sensor check →...
  • Page 156 2) Touch panel correction 1. Display of the touch panel correction screen When the touch panel correction button (A) of the check program screen is pressed, the touch panel correction screen is displayed. 2. Pressing the bottom left position Press the red circle (C) located at the bottom left of the screen.
  • Page 157 4. Pressing the top left position Press the red circle (E) located at the top left of the screen. To complete correction, press the cancel button (B). 5. Pressing the top right position Press the red circle (F) located at the top left of the screen.
  • Page 158 3) LCD check 1. Display of the LCD check screen When the LCD check button (A) is pressed on the check program screen, the LCD check screen is displayed. 2. Confirmation of LCD dot missing The LCD check screen is displayed only in one color. In this state, the LCD should be checked to freedom from dot missing.
  • Page 159 4) Method of input signal check 1. Display of the input signal check screen When the input signal check button (A) is pressed on the check program screen, the sensor check screen is displayed. Input signal check In the input signal check screen, the input condi- tions of various sensors can be confirmed.
  • Page 160 The sensors provide the following 43 types of conditions: Pictograph Contents of sensor Pictograph Contents of sensor DIPSW2-1 SDET sensor DIPSW2-2 Head fall SW DIPSW2-3 Air pressure SW DIPSW2-4 Thread breakage sensor SW Start SW (Pedal) X motor origin sensor Presser 1 SW (Pedal) Y motor origin sensor Presser 2 SW (Pedal)
  • Page 161 Pictograph Contents of sensor Pictograph Contents of sensor External input 6 External input 12 External input 7 External input 13 External input 8 External input 14 External input 9 External input 15 External input 10 External input 16 External input 11 –...
  • Page 162 5) Main motor rpm check 1. Display of the main motor rpm check screen When the main motor rpm check button (A) is pressed on the check program screen, the main motor rpm check screen is displayed. 2. Main motor operation and measured rpm value check Using the –/+ buttons (B, C), the rpm...
  • Page 163 6) Method of output check 1. Display of the output check screen When the output check button (A) is pressed on the check program screen, the output check screen is displayed. 2. Output check The output check screen can be used for the output check of each position.
  • Page 164 The output check display provides the following 17 types of positions: Pictograph Contents Pictograph Contents Wiper Air output 9 Air output 1 Air output 10 Air output 2 Air output 11 Air output 3 Air output 12 Air output 4 Air output 13 Air output 5 Air output 14...
  • Page 165 7) Method of XY motor / origin sensor check 1. Display of the XY motor / origin sensor check screen When the XY motor / origin sensor check button (A) is pressed on the check program screen, the XY motor / origin sensor check screen is dis- played.
  • Page 166 8) Method of presser and thread trimmer motor / origin sensor check Display of the presser and thread trimmer mo- tor / origin sensor check screen When the presser and thread trimmer motor / origin sensor check button (A) is pressed on the check program screen, the presser and thread trim- mer motor / origin sensor check screen is displayed.
  • Page 167 9) Method of needle thread clamp motor / origin sen- sor check 1. Display of the needle thread clamp motor / origin sensor check screen is displayed. When the needle thread clamp motor / origin sensor check button (A) is pressed on the check program screen, the needle thread clamp motor / origin sensor check screen is displayed.
  • Page 168 10) Method of continuous operation 1. Display of the continuous operation screen When the continuous operation button (A) is pressed on the check program screen, the continu- ous operation screen is displayed. 2. Continuous operation In the continuous operation screen, the continuous operation mode is set up.
  • Page 169 11) Method of intermediate presser motor / origin sensor check 1. Display of the intermediate presser motor / ori- gin sensor check screen When the intermediate presser motor / origin sensor check button (A) is pressed on the check program screen, the intermediate presser motor / origin sensor check screen is displayed.

  • Page 170: Printed Wiring Board And Dip Switch

    7. Printed wiring board and dip switch (1) Various printed wiring boards 1) FLT-T board Single-phase 100V~120V 3-phase 200V~240V Pulse generation is carried out for the purposes of power supply rectification, noise reduction, and the detection of a CN1 : Power input ← Power switch momentary interruption In the signal-phase mode, the power supply is connected to...
  • Page 171 2) FLT-S board Single-phase 200V~240V Pulse generation is carried out for the purposes of power supply rectification, noise reduction, and the detection of a momentary interruption CN1: Power input ← Power switch S i n c e s i n g l e - p h a s e s p e c i f i c a t i o n s a r e adopted, the power supply is connected to Pins 4-5.
  • Page 173 4) LED3 for SDC board error check No. of LED3 flashes Error description Display of operation panel Remarks Turn on Dimly turn on in ordinary state Main shaft motor lock E007 Failure in revolving for 2 seconds Error in phase Z E303 Failure in phase Z detection About 1.5 turns...

  • Page 178: Dipswitch Setup

    (2) Dipswitch setup 1. The penetration force is increased when “4” of SDC board Dipswitch SW1 is turned ON on the SDC board 2. If the penetration force is insufficient for thick materi- als, this switch should be turned ON. 3.

  • Page 179: Table Of Exchanging Gauge Parts According To Sewing Specifications And Needle Size Used

    8. Table of exchanging gauge parts according to sewing specifications and needle size used In accordance with the sewing condition, exchange the gauges referring to the following table. Sewing spec. S type when Knit. H type when When thick and needle size used delivered.

  • Page 180: Option List

    9. Option list Name of parts Type Part No Size (mm) 1. needle hole guide Needle hole guide (A) for light- B242621000A øA=1.6 weight material Needle hole guide (B) for medium- B242621000B øA=2.0 weight material Needle hole guide (C) for knitwear B242621000C øA=1.6 Needle hole guide (D) for heavy-...
  • Page 181 Name of parts Type Part No Size (mm) 5. Feed plate blank Sheet A for work clamp (Velboren) B259522000A A x B x t (Velboren) 1,000 x 675 x 1 Sheet B for work clamp B259522000B A x B x t (Velboren) 1,000 x 675 x 3 Sheet C for work clamp...
  • Page 182 Name of parts Type Part No Size (mm) 8. Blank for processing Separated type right blank of outer 40035609 A x B x t frame with knurl 97 x 81.5 x 4 Separated type outer frame blank 40035608 A x B x t without knurl 97 x 81.5 x 4 (Left and right are common.)
  • Page 183 Name of parts Type Part No Size (mm) 10. Compressor unit CU-01 11. Economy type presser milling MU-12 unit 12. Inverting clamp unit (Caution) For the head of S type, it FU-05 is necessary to provide 40036596 for the AMS-210E air set separately.
  • Page 184 Name of parts Type Part No Size (mm) 15. Inverting intermediate presser Without bearing D431421WJ0B A x B installing base 5 x 24 D430121XB00 A x B 7 x 20 D431421WZ00 A x B 7 x 24 D431421WK00 A x B 8 x 24 D431421YF00 A x B...
  • Page 185 Name of parts Type Part No Size (mm) 17. Pedal switch 3-step pedal (PK47) GPK470010AB Relay cable for 3-step pedal 40033875 2-step pedal (PK78) 40033831 18. Needle cooler (Caution) For the head of S type, it 40035692 is necessary to provide for the AMS-210E air set separately.
  • Page 186 Name of parts Type Part No Size (mm) 20. Pedal SW cable set This is a kit intended to change (40040138) (Set Item No.) the tandem pedal (PK78) into the 3-switch pedal. Switch assembly 40040130 For further details, refer to [(1) Method of pedal switch cable set connections].

  • Page 187: Method Of Pedal Switch Cable Set Connections

    (1) Method of pedal switch cable set connections 1. Parts Pedal switch cable set (Item No.: 40040138) Item name Item No. Quantity Presser micro switch plate 11102308 Micro switch setscrew SL4031691SC ∗ Switch assembly Limit switch HA001900000 Heat contraction tube ø5 (15mm) E8760452G00 Heat contraction tube ø...
  • Page 188 5. Operation control items o The moving switch does not function unless the right pedal is trodden first. o For more details, refer to [6. Switch mounting position diagram]. 6. Switch mounting position diagram. (Caution) The micro switch shall be mounted in parallel to the upper plane of the pedal.

  • Page 189: Method Of Mechanical Valve Unit Connections

    (2) Method of mechanical valve unit connections 1. Remove once two setscrews , two washers (small) , two spring washers and two washers (large) attached to mechanical valve unit . Refer to the figure, and install 2-pedal (PK78) type into hole A of mechanical valve unit 2.

  • Page 190: Maintenance

    10. Maintenance (1) Replacing the fuse The machine uses the following three fuses: (SDC Board) For pulse motor power supply protection 15A(time-lag fuse) For solenoid and pulse motor power supply pro- tection 3.15A (time-lag fuse) For control power supply protection 2A (fast-blow type fuse) –...

  • Page 191: Changing The Voltage Specification

    (2) Changing the voltage specification It is adaptable to the voltage of single phase 100V to 120V/3-phase 200V to 240V by changing the voltage changeover connector mounted on FLT-T p.c.b. (Caution) When the changing procedure is wrong, the control box will be broken. So, be very careful. Changing procedure of the changeover connector 1.

  • Page 192: Greasing • Lock-Tight Parts

    10g tube JUKI Part No.: 40006323 500g (IE-22) JUKI Part No.: 23640204 JUKI Grease B •••• Used, in particular, for the specific areas with highly loaded parts. Important: this grease must be replenished at the specified intervals of period, according to “(5) Grease-up procedures for the specified position.”...

  • Page 193: Parts To Which Grease • Lock-Tight Is Applied

    (4) Parts to which grease • lock-tight is applied o MAIN SHAFT & NEEDLE BAR COMPONENTS A : JUKI Grease A B : JUKI Grease B C : Grease – 188 –...
  • Page 194 PRESSER MECHANISM & PRESSER VARIABLE COMPONENTS (1) ∗ B : JUKI Grease B ∗ : Lock-tight 241 – 189 –...
  • Page 195 PRESSER MECHANISM & PRESSER VARIABLE COMPONENTS (2) B : JUKI Grease B C : Grease o WIPER MECHANISM COMPONENTS C : Grease – 190 –...
  • Page 196 PRESSER PLATE & MANUAL PRESSER MECHANISM COMPONENTS A : JUKI Grease A B : JUKI Grease B C : Grease o TENSION RELESASE & THREAD TENSION COMPONENTS C : Grease – 191 –...
  • Page 197 SHUTTLE DRIVER SHAFT COMPONENTS A : JUKI Grease A o FRAME & MISCELLANEOUS COVER COMPONENTS (2) A : JUKI Grease A – 192 –...
  • Page 198 TENSION RELEASE & THREAD TRIMMER MECHANISM COMPONENTS A : JUKI Grease A C : Grease o THREAD CLAMP COMPONENTS C : Grease – 193 –...
  • Page 199 X-Y COMPONENTS B : JUKI Grease B C : Grease D : Grease D – 194 –...
  • Page 200 CLOTH FEED MECHANISM COMPONENTS (FOR AMS-210EHS, ESS) B : JUKI Grease B C : Grease o CLOTH FEED MECHANISM COMPONENTS (FOR AMS-210EHL, ESL) B : JUKI Grease B C : Grease – 195 –...

  • Page 201: Replenishing The Designated Places With Grease

    No. 245 is changed to “0”. 2. Use grease tube (JUKI grease B Part No. : 40013640) supplied as accessories to replen- ish the designated places below with grease. If grease other than the designated one is replenished, damage of components will be caused.
  • Page 202 2. Supplement JUKI grease B to the felt section (3 places) and the hinge screws around them. 4) Grease supplement to X guide shaft bearing 1. At the same time, apply JUKI grease B to the rear faces of X guide shaft and presser plate...

  • Page 203: Error Code List

    11. Error code list Error code Pict Description of error How to recover Place of recovery E001 Data is initializes Turn OFF (EEPROM of MAIN CPU) the power E007 Main shaft motor-lock Turn OFF When large needle resistance sewing product is sewn the power E008 Head connector abnormality Turn OFF...
  • Page 204 Error code Pict Description of error How to recover Place of recovery E017 EEP-ROM capacity over Possible to Previous When the mounted EEP-ROM is different in type. re-start after screen reset. E018 Type of EEP-ROM is different. Previous When the mounted EEP-ROM is different in type. screen E019 File size over...
  • Page 205 Error code Pict Description of error How to recover Place of recovery E032 File interchanging error Possible to Data input File cannot be read. re-start after screen reset. E040 Sewing area over Possible to Sewing When the sewing area is exceeded re-start after screen reset.
  • Page 206 Error code Pict Description of error How to recover Place of recovery E302 Confirmation of tilt of machine head Possible to Previous When tilt of machine head sensor is OFF. re-start after screen reset. E303 Phase Z detection error Turn OFF Detection of the upper dead point is impossible for the power.
  • Page 207 Error code Pict Description of error How to recover Place of recovery E438 Execution cannot be performed. Possible to Previous re-start after screen reset. E441 Back-up data does not exist. Possible to Previous re-start after screen reset. E703 Panel is connected to the machine other than Possible to Commnunication supposed.
  • Page 208 Error code Pict Description of error How to recover Place of recovery E903 Abnormality of stepping motor power Turn OFF When stepping motor power of servo control p.c.b. the power. fluctuates ±15% or more. E904 Abnormality of solenoid power Turn OFF When solenoid power of servo control p.c.b.
  • Page 209 Error code Pict Description of error How to recover Place of recovery E918 MAIN board overheat Turn OFF Overheat of MAIN board the power. Turn ON the power again after taking time. E925 Intermediate presser motor origin retrieval error Turn OFF Origin sensor of intermediate presser motor does not the power.

  • Page 210: Message List

    12. Message list Message No. Display Display message Description M520 Erase confirmation of User’s pattern Erase is performed. OK? M521 Erase confirmation of pattern button Erase is performed. OK? M522 Erase confirmation cycle pattern Erase is performed. OK? M523 Erase confirmation of backup data Pattern data is not stored in memory.
  • Page 211 Message No. Display Display message Description M532 Overwriting confirmation of vector data on personal computer/M3 data/sewingstandard format data/ simplified program data Overwriting is performed. OK? M534 Overwriting confirmation of adjustment data of smart media and all machine data Overwriting is performed. OK? M535 Overwriting confirmation of adjustment data on personal...
  • Page 212 Message No. Display Display message Description M546 Data corresponding to personal computer does not exist. Data does not exist. M547 Overwriting prohibition on pattern data Overwriting cannot be performed since data exists. M548 Overwriting prohibition on smart media data Overwriting cannot be performed since data exists.

  • Page 233: Circuit Diagrams

    14. Circuit diagrams (1) Block diagram A – 228 –...

  • Page 234: Power Supply Circuit Diagram A

    (2) Power supply circuit diagram A FLT-T BOARD SDC BOARD MAIN BOARD POWER SWITCH 200V CONNECTIONS White Green White Green Black Yellow Black White White Orange Black Black Black White Black Brown White Yellow – 229 –...

  • Page 235: Power Supply Circuit Diagram B

    (3) Power supply circuit diagram B FLT-T BOARD SDC BOARD MAIN BOARD POWER SWITCH 100V CONNECTIONS White Green/ Green White Yellow Gray Black Yellow Gray White Orange Black Black Black White Black Brown White Yellow – 230 –...

  • Page 236: Power Supply Circuit Diagram C

    (4) Power supply circuit diagram C FLT-S BOARD SDC BOARD MAIN BOARD POWER SWITCH White Green/ Green/Yellow White Yellow Brown Brown Yellow Light Blue Light Blue Orange Black Black Black White Black Brown White Yellow – 231 –...

  • Page 237: Servo Motor Circuit Diagram

    (5) Servo motor circuit diagram AC SERVO MOTOR SDC BOARD White (Drain line) Black Orange Blue Purple ENCODER Light Blue Pink Yellow Black White Green + Yellow – 232 –...

  • Page 238: Sensor-Pedal Circuit Diagram

    (6) Sensor-pedal circuit diagram (Red) X feed origin sensor White Black MAIN BOARD (Yellow) Brown Black (White) Y feed origin sensor Blue (Black) White Lifting the work clamp foot origin sensor Black (Yellow) Brown Black Needle thread clamp origin sensor Blue Brown Black...

  • Page 239: Main•Panel Board Circuit Diagram

    (7) MAIN•PANEL board circuit diagram MAIN BOARD PANEL BOARD – 234 –...

  • Page 240: Motor•Solenoid Circuit Diagram

    (8) Motor•solenoid circuit diagram (Red) Orange X feed motor Yellow (Yellow) Blue White Black AT solenoid Black (White) (White) Orange Y feed motor Black Yellow Blue Wiper solenoid White Black (White) Orange Blue Thread trimmer lifting the work clamp foot motor Yellow MAIN BOARD (Blue)

  • Page 241: Air System Circuit Diagram

    (9) Air system circuit diagram FU-05 (Option) FU-05 (Option) Feeding frame cylinder (left) Hose elbow Feeding frame cylinder (right) Hose nipple Elbow union Inverting cylinder Speed controller T type tee Solenoid valve Plug Barrel nipple ø 4 Air tube Manifold Filter regulator Regulator One-touch joint plug...

  • Page 242: Drawing Of The Table

    15. Drawing of the table Z-Z (2pcs.) Control box mounting hole Leg mounting hole (Rear side: 2 positions, drill depth 10) Draw stopper mounting position (1 position on rear side) 9 drill, 20 depth Counterbore depth 17 4 x 8 drill Top of table 17 drill 30 drill, 51 depth Counterbore...
  • Page 243 Please do not hesitate to contact our distributors or agents in your area for further information when necessary. * The description covered in this engineer's manual is subject to change for improvement of the Copyright © 2006 JUKI CORPORATION. commodity without notice.

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