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JUKI AMS-221EN Series, Engineer'S Manual

Introducing the JUKI AMS-221EN Series Engineer's Manual, your essential companion for unlocking the full potential of your JUKI sewing machine. Download this comprehensive manual for free from manualshive.com, empowering you to optimize your machine's performance and tap into seamless creativity. Perfect for engineers and enthusiasts alike.

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– 44 –

Belt tension mete

 (measurement value)

(28) Adjustment of the tension of the X timing belt

Standard Adjustment

A

B

A

2mm

9.8N

(Example: 2516)

M
W
S

003.4g/m
025 mm/R
0315 mm

TENSION

400.0N

(Example: 2516)

Belt tension meter

(set value)

Summary of Contents for AMS-221EN Series

Page 1: ...40087241 No E389 00 ENGINEER S MANUAL Computer controlled Cycle Machine With Input Function AMS 221EN Series ...

Page 2: ...n 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 Standard Adjustment on the form...

Page 3: ...ent of the moving knife and counter knife position 34 22 Floating amount of the thread tension disk 34 23 Second thread tension connection disconnection 36 24 AT unit connection disconnection 38 25 Wiper adjustment 40 26 Backlash adjustment for the X motor 42 27 Backlash adjustment for the Y motor 42 28 Adjustment of the tension of the X timing belt 44 29 Adjustment of the tension of the Y timing ...

Page 4: ...iring boards 169 2 Dipswitch setup 177 8 Table of exchanging gauge parts according to sewing specifications and needle size used 178 9 Option list 179 1 Method of pedal switch cable set connections 186 10 Maintenance 188 1 Replacing the fuse 188 2 Changing the voltage specification 189 3 Greasing lock tight parts 190 4 Parts to which grease Locktight is applied 191 5 Replenishing the designated pl...

Page 5: ...6M 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 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 When the patter...

Page 6: ...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 Air regulator ...

Page 7: ...mation 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 switc...

Page 8: ... 4 3 Standard adjustment 1 Adjustment of the throat plate auxiliary cover height Standard Adjustment Within 0 3mm 1 2516 2 3020 0 8 to 1 0mm ...

Page 9: ...r plate mounting plate under the conditions that the throat plate aux cover is positioned higher than throat plate and its step difference is kept within 0 3mm Since then fix the setscrews 2 pcs and the setscrews 12 pcs Confirm that the clearance maintains its length at 0 8 to 1mm throughout the moving range in Direction X o The feed plate is caught by the stepped part of the throat plate and the ...

Page 10: ...ment of the X movement top cover Standard Adjustment Auxiliary cover rail stop plate 2 Adjustment of the feed base auxiliary cover rail X Standard Adjustment X movement bottom cover asm X movement bottom cover asm ...

Page 11: ...per amount of grease on the sliding parts of the Y guide rail holder o If there is any rattling this can be a cause of noise o If the rattling condition is removed extremely this can be a cause of abrasion developed in the X movement top cover asm Adjustment Procedures Results of Improper Adjustment 1 Loosen 16 setscrews 2 Lightly push the feed base auxiliary cover rail X in the direction of the a...

Page 12: ...Refer to 3 5 Removal of the main shaft motor and coupling 4 Loosen 2 setscrews On this occasion be aware that the balancer may rotate due to loosened setscrews 5 Loosen 2 setscrews 6 Loosen 2 setscrews On this occasion completely remove No 1 setscrew of the setscrews from the flat part of the main shaft 7 Loosen 2 setscrews and 2 setscrews 8 Pull out the main shaft in the direction of Arrow C Scre...

Page 13: ...crews and 2 setscrews Make sure that No 1 setscrew touches the flat part of the main shaft 5 Mount the main shaft motor and coupling Refer to 3 5 Removal of main shaft motor and coupling 6 Secure the eccentric cam of the intermediate presser with 2 setscrews Refer to 3 8 Adjustment of intermediate presser cam 7 Press the hand pulley in the direction of Arrow F to engage the hand pulley gear A with...

Page 14: ...tor 2 For removal of the coupling from the main shaft motor loosen 2 setscrews on the main shaft motor side Caution The screw hole that can be seen first is No 1 setscrew when the main shaft is turned in the forward direction A A A A A For loosening loosen No 2 setscrew first and for tightening tighten No 1 setscrew first No 1 setscrew No 1 setscrew 0 7mm A No 2 setscrew Procedures of disassemblin...

Page 15: ...al 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 setscrew 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 setscrew No 1 setscrew on the main shaft motor side between 2 setscrews on the main shaft side and engage...

Page 16: ...age No 1 setscrews 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 4 Main shaft connection disconnection and remove the crank rod unit 22 1 to 22 6mm Face B No 2 setscrew No 1 setscrew C A E D Procedures of disassembling No 1 setscrew No 2 set screw ...

Page 17: ...ft Lightly press the oscillator shaft in the direction of arrow C and the thrust collar in the direction of Arrow D and tighten 2 setscrews Make sure that No 1 setscrew touches the flat section of the oscillator shaft 5 Secure the oscillator according to 3 14 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 ...

Page 18: ...wers and the clearance between the needle bar connecting and needle bar lower bushing is 4 6 mm 2 setscrews of the crank balancer becomes horizontal position Axial direction Bring the main shaft eccentric cam into contact with the crank balancer Standard Adjustment B A 4 6mm ...

Page 19: ...re the crank balancer with 2 setscrews under the condi tions that 2 setscrews 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 setscrews tighten them alternately Adjustment Procedures Results of Improper Adjustment o If the mounting angle of the crank balancer is wrong ...

Page 20: ... 16 8 Adjustment of intermediate presser cam 9 Adjustment of intermediate presser bar 13 5mm Standard Adjustment Standard Adjustment Align Align ...

Page 21: ...ew after ensuring that the needle passes through the center of the intermediate pressure Caution Be aware that the tightening pressure of the setscrew should be from 2 16 to 2 75 N m 22 to 28 kgf cm o An excessive thrusting distance of the intermediate presser bar may damage the intermediate presser spring or cause poor presser lifting o Excessive tightening pressure may deform the intermediate pr...

Page 22: ...tely 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...

Page 23: ...ft in this order and pass this assembly through the frame Mount the E ring on the intermediate presser lifting shaft 7 Pressing the intermediate presser lifting shaft in the direction of the Arrow C press the thrust collar in the direction of the Arrow G and tighten the two setscrews 8 Fix the intermediate presser lifting cam by means of the 2 setscrews so that the clearance becomes 0 5mm between ...

Page 24: ... press the X key after the completion of origin search to withdraw from the Test Mode I10 Start the Test Mode I10 again no origin search and press the key 5 times Even though the power supply is turned off after that the intermediate presser cam shall not rotate After the completion of origin search press the X key to withdraw from the Test Mode I10 Start the Test Mode I10 again no origin search a...

Page 25: ...ithdraw from the Test Mode I10 Start the Test Mode I10 again no origin search and press the key 3 times When the power supply is turned off after that the intermediate presser cam shall not rotate This process is finished when the above mentioned conditions have been satisfied Otherwise loosen the setscrews 2 positions of the drive bevel gear and move the bevel gear in Direction C Turn the interme...

Page 26: ... 22 12 Intermediate presser drive arm Standard Adjustment Refer to Instruction Manual 4 7 Intermediate presser height Close contact Intermediate presser bar Approx 3 6mm ...

Page 27: ...al 4 After the setscrew has been tightened confirm that there is no backlash in the intermediate presser adjusting arm in the forward and backward directions 5 Finally make adjustments of the intermediate presser stroke Refer to Instruction Manual III MAINTENANCE OF SAWING MA CHINE 1 4 Adjusting the vertical stroke of the intermediate presser o If there is no clearance there will be interference b...

Page 28: ...he stop position of the lower shaft so that the setscrew settles almost in the center of the flat section of the lower shaft 14 Oscillator gear positioning 1 When the oscillator is lightly swung by a finger in the direction of the arrow the oscillator is fixed in the center position of swinging No 1 screw No 2 screw No 1 screw A Standard Adjustment Standard Adjustment Face A C 0 01 to 0 1mm throug...

Page 29: ... cause of the lock up of oscillator or the crank rod 1 Loosen the 2 setscrews and increase the backlash of the lower shaft gear Caution 1 If the lower shaft gear has insufficient backlash the oscillator does not swing correctly In such a case refer to 13 Lower shaft backlash adjustment and connection disconnection and provide a suffi cient backlash 2 The 3 setscrews should have been loosened in ad...

Page 30: ...tion pipes and Take them out of the oil tank 4 Loosen 2 setscrews of the clamp in the waste oil pipe and remove the clamp and the setscrew 5 Loosen the setscrew and take out the driver 6 Loosen the setscrew 7 Remove the setscrew and pull out the shuttle race adjust shaft 8 Pull the shuttle in the direction of the arrow C and take it out Standard Adjustment Procedures of disassembling Top surface o...

Page 31: ...uch this can be a cause of frictional wear of the hook race plane or lock up 1 Pass the two lubrication pipes and and the oil drain pipe through the frame and mount the shuttle 2 Hold the lubrication pipes and with the pipe holder and fix them with the setscrews 3 Fix the two lubrication pipes and with the cord clamps and the setscrews At that time make sure not to permit the lubrication pipes and...

Page 32: ...7 Adjusting the height of the needle bar Standard Adjustment Maker line for 134 DP x 5 Maker line for 135 x 17 DP x 17 No 140 or more 22 or more Marker line for 135 x 17 DP x 17 No 140 less than 22 less than ...

Page 33: ... torque is even after adjustment At that time check the clearance toward the wiper If the clearance seems to be narrow readjust this sec tion If adjustments are carried out with the needle bar positioned too low o Feed timing causes mismatching and this can be a cause of needle breakage o Interference occurs with the inner hook while the needle is lowering and this can be a cause of needle blunt o...

Page 34: ...134 DP x 5 is used Maker line for 135 x 17 DP x 17 No 140 or more 22 or more is used Maker line for 134 DP x 5 Maker line for 135 x 17 DP x 17 No 140 or more 22 or more Marker line for 135 x 17 DP x 17 No 140 less than 22 less than Maker line for 135 x 17 DP x 17 No 140 less than 22 less than is used ...

Page 35: ...ustment of the driver 2 When the driver is used for a long time the driver may be open to increase the clearance In such a case replace it with a new one or adjust the clear ance 7 Loosen the set screw securing the shuttle and adjust the front rear position of the shuttle by rotating the shuttle adjusting shaft so that the clearance between the needle and the blade point of the inner hook becomes ...

Page 36: ...t seem to be tightly coupled Pull out the motor shaft in the direction of the arrow straightforward in order not to hurt the bearing At that time the cam may come down Handle it with care not to damage it 20 Thread trimmer and presser origin sensor adjustment Standard Adjustment Procedures of disassembling A Flat section When origin retrieval at start switch on is conducted in the test mode I07 th...

Page 37: ...rigin sensor adjustment and make sensor adjustments Adjustment Procedures Results of Improper Adjustment Procedures of assembling 1 Start the test mode I07 2 Tread on the pedal for the retrieval of the thread trimmer and presser bar lifter cam origin 3 Make sure that the standard holes A ø3 and B of the thread trimming motor stand are aligned with the standard hole C of the thread trimmer and pres...

Page 38: ...e shall be a proper clearance toward the moving knife tip during needle thread clamp and feed forward 22 Floating amount of the thread tension disk When the sewing machine power supply is turned off AT solenoid is OFF the gap between AT thread tension and thread tension disc is 1 6mm for S type and 1 1mm for H type Close contact Standard Adjustment Standard Adjustment 4 mm or less A B H 1 1 0 1mm ...

Page 39: ...section should not be engaged with the incomplete thread section of the thread tension releasing pin The thrusting distance of the thread o If the amount of disc floating is too less the residual thread length can be changed or shortened when the thread is thick o If the amount of disc floating is too much the thread tension discs cannot close completely and nor mal thread tension may fail to be c...

Page 40: ... 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 Pull out the second thread tension to remove it Arrow A 5 For reassembly follow the steps of 4 to 1 above Procedures of disassembling A ...

Page 41: ...essing 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 or malfunction 2 After the completion of mounting make adjustments of 19 Floating amount of the thread tension disk and 38 Adjustment of thread take up spring 1 Stroke adjustments Procedures of assembling ...

Page 42: ...the AT link unit rear Be careful not to drop the washer at that time 3 Lift the AT joint block of the AT unit upward to remove the block from the pin block H type or S type of the AT link unit rear 4 Draw out the AT link unit front from the plane side in the direction of the arrow E and remove it 5 Remove the 2 setscrews and take out the AT solenoid unit 6 For reassembly follow the steps of 5 to 1...

Page 43: ...correct and that the front and rear of the AT joints are parallel Failure to observe this may cause AT malfunction resulting in incorrect thread tension When the AT joint is turned 4 times the feed move amount comes to attain 2mm 3 For the pin block of the AT link unit rear use the pin block for H type and the pin block for S type The wrong pin position may cause AT malfunction resulting in incorr...

Page 44: ... phase of the intermediate presser A Throat plate top surface Height of Intermediate Presser 1mm or more 10mm 15 to 20 V letter 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 A adjust the clearance between the center of needle and the inside of V letter of the wiper to...

Page 45: ... tighten setscrew Caution After the modification of the needle bar height needle size boldness and intermediate presser height adjust the wiper without fail Length of the needle can change according to the needle tip shape and needle size boldness o If the clearance between the wiper and needle is too small the wiper comes in contact with the needle due to uneven stop position of the main shaft ca...

Page 46: ...Backlash adjustment for the X motor 27 Backlash adjustment for the Y motor Standard Adjustment Standard Adjustment Motor installing base Y drive gear thrust bearing Bed Flat section 40 7 to 40 8mm Flat section ...

Page 47: ...the Y feed stepping motor with the position of the setscrew At that time confirm that the Y drive bevel gear does not move in the axial direction 3 Install the Y feed stepping motor on the bed 4 Press the Y trailing gear in the direction of the arrow to reduce the backlash to zero and tighten 2 setscrews At that time join the flat section of the Y drive shaft with the position of the setscrew o If...

Page 48: ...sion mete measurement value 28 Adjustment of the tension of the X timing belt Standard Adjustment A B A 2mm 9 8N Example 2516 M W S 003 4g m 025 mm R 0315 mm TENSION 400 0N Example 2516 Belt tension meter set value ...

Page 49: ... the tip of a tool that does not hurt the finger or the belt A measured value is indicated For more detailed use of the tension meter refer to the relevant manual of the tension meter If the belt tension meter is not available at your hand If no belt tension meter is available at your hand the procedure below can substitute for the confirmation of tension according to the above procedure 2 In such...

Page 50: ...tment of the tension of the Y timing belt Standard Adjustment Example 2516 M W S 003 4g m 025 mm R 0190 mm TENSION 300 0N A B A 2mm 9 8N Belt tension mete measurement value Belt tension meter set value Example 2516 ...

Page 51: ...one by means of the tip of a tool that does not hurt the finger or the belt A measured value is indicated For more detailed use of the tension meter refer to the relevant manual of the tension meter If the belt tension meter is not available at your hand If no belt tension meter is available at your hand the procedure below can substitute for the confirmation of tension according to the above proc...

Page 52: ...from the Y drive shaft 31 Phase adjustment for the Y timing belt Standard Adjustment Standard Adjustment 1mm A Flat section Flat section Y timing belt Y LM guide Y drive shaft thrust bearing Y timing belt Y LM guide Flat section B ...

Page 53: ...ghten 2 setscrews At that time 1 of the setscrews should be aligned with the flat section of the Y drive shaft o If there is any rattling this can be a cause of feed error 1 Loosen 4 setscrews 2 Move the X movement base forward and backward two or three times 3 Tighten 4 setscrews When the Y timing belt is adjusted phase adjustments of this Y timing belt should be carried out without fail Caution ...

Page 54: ... 50 32 Adjustment of the X Y mechanism Make adjustments to the dimensions specified below Standard Adjustment 70mm 300 8mm 70mm Face B 300 8mm Butt Face A Butt 70mm 192mm Butt 3020 only Face A ...

Page 55: ...ce to 300 8mm between the Y LM guide and the Y aux LM guide and secure the parallelism 3 Fix the Y aux LM guide with seven screws 4 Temporarily fasten four fixing screws of the X trailing bracket base and join it with the Y aux rail bracket with two screws 5 Tighten four fixing screws of the X trailing bracket base Adjust the belt tension after installation After the above mentioned X Y LM guides ...

Page 56: ...ould be positioned toward the front SM6050660TP The thinner side should be positioned toward the front When the presser foot slide plate is moved vertically and then the slide plate bearing comes in contact with the spring pin the startup torque slippage torque will be 0 98 to 7 84N 100 to 800g ...

Page 57: ... setscrew is tightened pressure kept applied to the slide plate bearing is changed Therefore when the setscrew is tightened examine the amount of the slippage torque 2 The pressure adjusting screw is not attached to the sewing machine Adjustment Procedures Results of Improper Adjustment o If normal pressure is too strong vertical movement of the presser cannot be accomplished normally o If normal ...

Page 58: ...center to center distance is 119 5 0 3mm between the ø5 hole of the presser cylinder and the ø5 hole of the cylinder knuckle Adjust the center to center distance to 111 5 0 3mm between the 2 step stroke fulcrum shaft and the connecting shaft of the intermediate stop cylinder knuckle when the intermediate stop cylinder 2 step stroke cylinder assumes a state of maximum stroke 111 5 0 3 at the maximu...

Page 59: ...etely As a result the material cloth cannot be held tight and displacement of materials can occur 1 Pull the knuckle so that the 2 step stroke cylinder can attain the maximum stroke 2 Loosen the nut and turn the knuckle so that the center to center distance is adjusted to 111 5 0 3mm 3 Fix the nut assuredly o If the center to center distance is insufficient the amount of presser rise cannot attain...

Page 60: ...d tighten the nut Standard adjusting value of the speed controller for the 2 step stroke cylinder 1 Loosen the nut and once turn the knob fully in Direction A Then turn this knob in Direction B by one turn and tighten the nut Standard Adjustment For presser cylinder right For presser cylinder left Type L 2 step presser with 2 step stroke For 2 step stroke cylinder For presser cylinder right For pr...

Page 61: ...ncrease the vertical presser speed turn the knob in Direction B o To decrease the vertical presser speed turn the knob in Direction A o Too much noise is generated when the presser is lowered o The presser does not rise Adjustment Procedures Results of Improper Adjustment ...

Page 62: ... cylinder right can rise at the same time Then tighten the nut 2 At that time confirm that the pressure reducer of for the presser cylinder right has reduced the pressure to 0 10 to 0 17Mpa If the pressure seems to deviate from this range check the torque at the working section of the feed bracket and readjust this deviation Caution For Type S specification for united presser only the pressure red...

Page 63: ...to the standard adjusting values o To reduce the pressure turn the knob in Direction B o To raise the pressure turn the knob in Direction A o The presser cannot be lowered by hand Adjustment Procedures Results of Improper Adjustment ...

Page 64: ... gauge 39 Adjusting the X origin sensor 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 A D C Standard Adjustment Standard Adjustment Origin marking for 2516 B Y movement base 174mm 3020 116mm 3020 Origin marking for 3020 ...

Page 65: ...e 2 setscrews 5 When the engraved marking of the origin is found to be displaced in Direction B from the needle tip loosen the 2 setscrews and adjust the sensor mounting plate in Direction D After adjustments tighten the 2 setscrews Caution After the adjustment make sure that the slit plate does not interfere with the sensor Adjustment Procedures Results of Improper Adjustment Adjustment Procedure...

Page 66: ... 40 Adjusting the Y origin sensor 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 Standard Adjustment A B C D Sensor Y ...

Page 67: ... the origin is found to be displaced in Direction A from the needle tip adjust the sensor mounting plate in Direction C Loosen the setscrews and fix the setscrews after adjustments 5 When the engraved marking of the origin is found to be displaced in Direction B from the needle tip adjust the sensor mounting plate in Direction D Loosen the setscrews and fix the setscrews after adjustments Adjustme...

Page 68: ... bobbin winder amount The position of the bobbin winder lover is based on the standard that it is 14 mm apart from the bobbin winder shaft Try to perform bobbin winding actually and make fine adjustments of the bobbin lever set screw in the directions of the arrows A and B so that the amount of thread winding becomes adequate recommended value 80 to 90 of the bobbin Standard Adjustment Standard Ad...

Page 69: ...the amount of winding 1 If the amount of winding seems to be too much adjust the bobbin winder lever in the direction of the arrow B 2 If the amount of winding seems to be too less adjust the bobbin winder lever in the direction of the arrow A 3 If the winding state of the thread around the bobbin winder seems to be uneven loosen the nut and adjust the height of the thread tension control Example ...

Page 70: ...he direction of the arrow E After the best positioning has been secured fasten the 2 setscrews Caution If Part B B B B B and F F F F F is damaged this is the cause of thread breakage hangnail of thread stain on thread etc Therefore this part should be polished by the use of a buff or the like In particular the rear side should be handled with care 44 Shuttle felt Two pieces of the shuttle felt are...

Page 71: ...ustment Procedures Results of Improper Adjustment Adjustment Procedures Results of Improper Adjustment 1 If the shuttle felt seems to be protruded or it has been replaced with a new one push it in by means of tweezers or the like Caution Do not push it in excessively Align the height and the plane of the shuttle race 2 Confirm that the shuttle packing has been mounted assuredly Caution When the ho...

Page 72: ... A 0 3m m Stroke The movable distance of the needle thread when the needle thread is pulled in the direction A until the thread take up spring stops 12 to 15 mm for S type 12 to 18 mm for H type Tension Adjust the thread take up spring tension in accordance with the thread tension Actually sew a material and adjust the thread take up spring tension to an appropriate value Standard Adjustment Stand...

Page 73: ...of remaining needle thread is shortened causing the needle thread to slip off the needle at the sewing start o If the stroke of the thread take up spring is smaller than the speci fied value Needle thread breakage will oc cur at the time of thread trimming when using a thin thread Caution If the thread take up spring interferes with the L shaped thread guide the thread take up spring may fail to r...

Page 74: ...inge 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 2 Remove the three set screws of the needle thread clamp base and take out the needle thread clamp device Open part A B ...

Page 75: ...ove the needle thread clamp sensor behind in the direction of the arrow A according to 41 Adjusting the needle thread clamp sensor and make readjustment from 3 above 5 Confirm that the distance between the needle thread clamp release plate and the needle center is A 2 0 2mm and B 2 0 2mm respectively 6 If the distance seems to be inadequate loosen the three set screws and move the needle thread cl...

Page 76: ...mp device and the needle thread clamp base becomes 17 5mm common to S and H type 2 Needle thread clamp notch F position When the needle thread clamp link complete is pushed in Direction C and Part B of the needle thread clamp release plate and the needle thread clamp device begins to open the distance between the needle thread clamp device and the needle thread clamp base becomes 22mm common to S ...

Page 77: ...e of unthreading at the beginning of sewing o If the distance is too short be tween the needle thread clamp and the needle thread clamp base the needle thread release tim ing is delayed and this can be a cause of needle thread end re maining on the rear side of the material When the needle thread clamp notch is adjusted improperly o The notch position cannot stay in the standard range even after t...

Page 78: ...e thread clamp position is known as the position returned by one step from the most advanced position when the key is pressed after the origin retrieval by the Test Mode I08 2 According to the thread clamp specifications the memory switch U069 may change S Type 0 H Type 1 49 Adjusting the needle thread clamp sensor Standard Adjustment C B A B 2 0 2mm A 2 0 2mm Needle thread clamp motor sensor Need...

Page 79: ...clearance A becomes 0 After the adjustment of the clearance in the thread clamping position try to pass a line of thread actually to examine how the thread slips smoothly If it seems to be caught by anything readjust the clearance or confirm the thread path finish 7 Tread on the pedal for needle thread clamp origin retrieval and define the most advanced position by pressing the key once 8 Confirm ...

Page 80: ...racket position Fix the lifter brackets A and B in four positions by means of screws washers spring washers and nuts Section C Section D Check 3 Check 2 Check 1 Section B Check 5 Check 4 A X direction Y direction Gas spring Lifter blacket Rod section Lifter blacket Gas spring Lifter blacket Table ...

Page 81: ...ifter bracket Adjustments in Direction Y Check 2 3 There shall be no interference around Section C gas spring and stud Adjustments in Direction X Check 3 4 There shall be no interference around Section D gas spring and table Adjustments in Direction X Check 4 5 When the sewing machine is raised in the maintenance position the gas spring shall stay free There is a clearance between the upper end of...

Page 82: ...long groove section of the stopper plate enters the pin smoothly when the release lever is moved in Direction A 3 Adjustment of spring tension for falling stopper ON OFF The assembly size B of the spring hanger and the spring hanger bracket shall be as specified below Guide A 6 0 5mm Guide B 6 5 0 5mm Guide C 5 5 0 5mm B A Guide C Guide B Guide A ...

Page 83: ...o persons 3 Adjustment of spring tension for falling stopper ON OFF Turn the nut in the state that the spring is hung on the spring hanger In this condition adjust Size B After adjustments fasten the nut It is necessary to hold the sewing machine because it may fall down during adjustments This work should be carried out by at least two persons o The stopper does not work even though the release l...

Page 84: ...ent of the gas spring When the sewing machine is lifted the force of more than 20kg may be required in the tip of the head grip In such a case there is possibility of gas leakage at the gas spring Replace the gas spring in the procedures specified below Widen the clearance by 0 2mm A ...

Page 85: ...d section of the gas spring at the time of reassembly work Fix the thrust collar with an opening of 0 2mm in the thrust direction and confirm that the gas spring smoothly moves up and down Apply Juki Grease B Part No 40013610 to the shaft section and the thrust collar end plane 5 Attach the hinge screw washer and the spacer to the top of the gas spring as illustrated Fix them by means of the nut A...

Page 86: ...t the memory switch button to be changed Select the data item D to be changed using the up and down scroll buttons C 3 To change memory switch data level 2 Memory switch data level 2 has 2 types of data items one is where a value is changed and the other is where a pictograph is selected The data items where a value is changed are colored pink and num bered such as and the value can be changed wit...

Page 87: ...itch 200 to 2800sti min 100sti min 2800 In case of with thread clamp 7 Thread tension of 1st stitch 0 to 200 1 200 In case of with thread clamp 8 Thread tension setting at the time 0 to 200 1 0 of thread trimming 9 Thread tension changeover timing 6 to 4 1 4 0 setup at the time of thread trimming 10 Sewing speed of 1st stitch 200 to 1500sti min 100sti min 200 In case of without thread clamp 11 Sew...

Page 88: ...it setting of feeding frame at the time of 2 step stroke 10 to 300 1 70 20 Selection of buzzer sound Valid Invalid 21 1 to 7 1 2 22 10 to 0 1 0 23 Valid Invalid selection of thread clamp control 24 Setting of feed operation timing 8 to 16 1 3 1 4 No Item Setting range Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 84 HL 2516 FU SL 2516 FU Smallest change able unit Setting of number of stitc...

Page 89: ... retrieval combination sewing Every time 1 pattern is finished Every time 1 cycle is finished 29 Presser rise Presser rise with presser switch Up position 30 Selection of needle bar stop position Upper dead point 31 Normal Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 85 HL 2516 FU SL 2516 FU Smallest change able unit Selection of rising operation Valid Invalid for feeding frame at the end...

Page 90: ...g input procedure Actual size input 36 Setup of thread tension output time 0 to 20 1 sec 0 No 1 20 at needle thread tension setting thread tension output 37 Selection of bend position of thread 0 S type 1 S type 0 H type 1 clamp 1 H type thin thread 50 to 8 2 H type intermediate 3 H type thick threas 5 to 2 Front 38 Selection of thread clamp position Rear Valid Invalid selection of thread Disabled...

Page 91: ...parated 42 Feeding frame control presser In the order Procedure setting for feeding fram of left to right 1 0 5 0 6 operation with pedal operation under 4 to 7 Special type 1 normal conditions 8 Solid presser 9 Solid presser 2 step stroke 10 Right left separated presser 2 step stroke Without right left separation 11 Right left separated presser 2 step stroke Order of right to left 12 Right left se...

Page 92: ...peration at 4 to 7 Special type 1 temporary stop 8 Solid presser 9 Solid presser 2 step stroke 10 Right left separated presser 2 step stroke Without right left separation 11 Right left separated presser 2 step stroke Order of right to left 12 Right left separated presser 2 step stroke Order of left to right 13 to 99 Solid presser 1 This is an option 44 Selection of the presence of pedal Without SW...

Page 93: ...move Second origin specified later Without motion 50 With motion Without 51 With Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 89 HL 2516 FU SL 2516 FU Smallest change able unit Selection of the presence of pedal SW2 latch Selection of the presence of pedal SW3 latch Selection of the presence of pedal SW4 latch Presence of retainer compensation motion Selection of valid invalid refuge to n...

Page 94: ... of intermediate presser with sewing data control during operation Enabled lowering during feeding front and feeding back Immediately before 55 Selection of Intermediate presser sewing machine lowering timing head activation Synchronization with last feeding frame Above intermediate presser 56 Intermediate presser wiper sweeping Above intermediate wiper sweeping position presser intermediate press...

Page 95: ...guage selection Italian Not selected yet English French German Portuguese Turkish Vetnamese Korean Indonesian Russian English Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 91 HL 2516 FU SL 2516 FU Smallest change able unit Setting limit range of the intermediate presser height Upper limit setting Selection of valid invalid of needle cooler control Selection of presence of air pressure dete...

Page 96: ...net wiper on 10 to 500ms 10ms 50 10 Setup of delay time of magnet wiper off 10 to 500ms 10ms 80 Level 2 Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 92 HL 2516 FU SL 2516 FU Smallest change able unit Selection of feeding frame lowering speed at motor presser operation Selection of feeding frame rising speed at motor presser operation Selection of pulse motor drive speed at thread trimmer ...

Page 97: ...ser 19 Selection of feeding frame drive type Pneumatic presser 20 Setup of pneumatic presser lowering delayed time 0 to 1000ms 10ms 100 Disabled with motor presser selected 21 Procedure setup for feeding frame operation at Full open 1 0 automatic lifting and lowering of feeding frame control full holding Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 93 Selection of wiper output timing when...

Page 98: ...under normal conditions return to origin Y axis X axis X axis Y axis Standard Inversion 25 Route selection of origin retrieval at mealing return to origin Y axis X axis X axis Y axis 26 Setup of thread trimming timing 2 to 2 1 0 Disabled backup 27 data enabled Enabled Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 94 Valid Invalid selection of media pattern reading at ready state HL 2516 FU...

Page 99: ...t Rest time setup at the top position of jump command Setup of timeout period of input command Temporary stop control at sewing end position Valid Invalid selection Selection of XY feed synchronized control extension of main motor Setup of intermediate presser lowering speed Setup of intermediate presser rising speed Selection of the presence of material end detection control Selection of the pres...

Page 100: ...00pps 10pps 2000 48 XY feed moving speed at origin retrieval 100 to 10000pps 10pps 2000 49 XY feed moving speed direction dependence 100 to 10000pps 10pps 10000 first region X axis neighborhood 50 XY feed moving speed direction dependence 100 to 10000pps 10pps 10000 second region Y axis neighborhood 51 XY feed moving speed direction dependence 100 to 10000pps 10pps 10000 third region 45 neighborho...

Page 101: ...iation error 10 to 50 1 33 56 Threshold setting of Y deviation error 10 to 50 1 33 Ineffective 57 Effective Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 97 Valid Invalid selection of bank and barcode mode HL 2516 FU SL 2516 FU Smallest change able unit Selection of the presence of feeding frame lifter at temporary stop error Selection of XY deviation error code timing Selection of effecti...

Page 102: ... completion of sewing Auto deceleration and limit cancellation No automatic deceleration Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 98 HL 2516 FU SL 2516 FU Smallest change able unit Common data setting of thread tension standard value Common data setting for height standard value of intermediate presser Selection of display screen when shifting sewing mode Setting of changing amount of...

Page 103: ...Y feed acceleration limit Effective 68 Model classification 1 0 1 2 3 5 6 7 0 to 7 8 and above Optional Initial value SS HS SL HL HS 2516 2516 2516 2516 3020 HL 2516 FU SL 2516 FU Smallest change able unit Main shaft speed sensitivity during XY feed operation ...

Page 104: ...frame ON OFF operational sequence by ordinary pedal operation Using the memory switch U081 it is possible to set up the operational sequence of the feeding frame by ordinary pedal operation In regard to the setup items refer to the 5 List of feeding frame and pedal setup 3 Feeding frame ON OFF operational sequence by a temporary stop command Using the memory switch U082 it is possible to set up th...

Page 105: ...red to the bottom by Pedal 3 left treading on Right left separation Lowering enabled The right feeding frame is lowered to the bottom by clamp from the right or left Pedal 1 right then the left feeding frame is lowered 5 left 2 step stroke to the intermediate position by Pedal 2 left intermedi ate The left feeding frame is lowered to the bottom by Pedal 3 left treading on Right left separation Low...

Page 106: ...pedal and the sewing after resetting at the starts by pressing the start pedal sewing start 4 Feeding frame lifting setup at the time of temporary stop Using the memory switch U041 it is possible to set up the timing for feeding frame lifting when it has been set up with a temporary stop command in the pattern data Setup Contents Explanation Lifting The feeding frame is lifted immediately with the...

Page 107: ...7 left intermediate U086 Used to set up the method of pedal operation for Pedal 3 PK47 left treading on U087 Used to set up the method of pedal operation for Pedal 4 Not used Setup Contents Explanation The feeding frame is lowered only if the pedal is trodden on It is lifted when the Non latch pedal is released The feeding frame is lowered when the pedal is trodden on once It is left lowered ven w...

Page 108: ...The fixed refuge position is not used disabled Fixed refuge position The fixed refuge position is used enabled 2 Fixed refuge position coordinates setup Using the memory switch K117 it is possible to set up the fixed refuge position Coordi nate X Setup Contents Explanation Coordinate X Coordinate X of the Coordinate X of the fixed refuge position is fixed refuge position set up within the feeding ...

Page 109: ...ry to set up the memory switch K090 because the fixed refuge position mode is automati cally secured for the bank function 2 The fixed refuge position defined by the fixed refuge position Coordinate X of Memory Switch K117 and the fixed refuge position Coordinate Y of Memory Switch K118 is regarded as the standby position of the feeding frame for the bank function In standard setting the feeding f...

Page 110: ...played 2 Registration of the direct pattern number When the direct pattern number registration button C is pressed for a setting input terminal num ber B the direct pattern number selection screen is displayed However the selectable direct pattern num bers are limited only for the individual sewing The direct pattern number to be registered for the input terminal is selected as indicated by D 3 Ba...

Page 111: ...utomatically changed over if there is coincidence of an input with the relevant input terminal F F Relationship between bank input terminals and bank numbers Input terminal Input terminal Input terminal Input terminal 3 2 1 0 3 2 1 0 3 2 1 0 3 2 1 0 H H H H Bank No 1 H L H H Bank No 5 L H H H Bank No 9 L L H H Bank No 13 H H H L Bank No 2 H L H L Bank No 6 L H H L Bank No 10 L L H L Bank No 14 H H...

Page 112: ...tive with the External Input 8 com mand of the pattern data 42 External input 9 Sewing is suspended until the input terminal becomes active with the External Input 9 com mand of the pattern data 43 External input 10 Sewing is suspended until the input terminal becomes active with the External Input 10 com mand of the pattern data 44 External input 11 Sewing is suspended until the input terminal be...

Page 113: ...ut 14 command of the pattern data 48 External output 15 Reverse signal output with the External Output 15 command of the pattern data Status of sewing machine head 49 Needle upper position Upper stop position 40 to 62 Always ON shortly after Power ON 50 Needle lower position Internal signal 80 to 123 Always OFF shortly after Power ON 51 Needle upper dead point position Reverse rotation needle lift...

Page 114: ...Sheet counter carryover being displayed OFF by counter reset For the trigger 97 READY operation start When the READY key is accepted ON for 100ms 98 READY operation end After moving to READY key sewing start point ON for 100ms 99 Sewing start When the Start switch is accepted Normal Midway stop Temporary stop ON for 100ms 100 Before sewing start point reset Before sewing start point reset after pa...

Page 115: ...w 6 Low 6 Low 6 Low 6 Low Initial value SS HS SL HL HS SL HL 2516 2516 3020 2516FU Terminal setup High Low Terminal setup High Low Terminal setup High Low Terminal setup High Low I01 0 to 199 High Low 0 Low 0 Low 0 Low 0 Low I02 0 to 199 High Low 0 Low 0 Low 0 Low 0 Low I03 0 to 199 High Low 0 Low 0 Low 0 Low 0 Low I04 0 to 199 High Low 0 Low 0 Low 0 Low 0 Low I05 0 to 199 High Low 0 Low 0 Low 0 L...

Page 116: ... OUT 0 IN 0 IN 0 IN 0 IN V11 0 to 199 IN OUT 0 IN 0 IN 0 IN 0 IN V12 0 to 199 IN OUT 0 IN 0 IN 0 IN 0 IN V13 0 to 199 IN OUT 0 IN 0 IN 0 IN 0 IN V14 0 to 199 IN OUT 0 IN 0 IN 0 IN 0 IN V15 0 to 199 IN OUT 0 IN 0 IN 0 IN 0 IN V16 0 to 199 IN OUT 0 IN 0 IN 0 IN 0 IN Item Setting range Virtual I O terminal Initial value SS HS SL HL HS SL HL 2516 2516 3020 2516FU High Low High Low High Low High Low Pr...

Page 117: ...t reset 102 Sewing machine start 103 Sewing machine stop 104 XY feed start 106 Total presser lowering 107 Total presser lifting 64 Midway stop C 66 Sewing temporary stop 65 Sewing error display stop 105 Origin reset start 68 Origin reset 69 Presser lowering state 70 Bobbin state 71 Main unit input state 72 Shape check state 73 Check program state 76 Temporary stop SW stopped 78 Air pressure loweri...

Page 118: ... sewing start point reset 102 Sewing machine start 103 Sewing machine stop 104 XY feed start 106 Total presser lowering 107 Total presser lifting 64 Midway stop 66 Sewing temporary stop 65 Sewing error display stop 68 Origin reset 105 Origin reset start 76 Temporary stop SW stopped 78 Air pressure lowering stop 79 Stop on account of another error 77 Thread breakage error stop 59 Ready state 80 Sew...

Page 119: ... 100 Before sewing start point reset 101 After sewing start point reset 102 Sewing machine start 103 Sewing machine stop 104 XY feed start 106 Total presser lowering 107 Total presser lifting 72 Shape check state 73 Check program state 105 Origin reset start 67 Jump feed 68 Origin reset 76 Temporary stop SW stopped 78 Air pressure lowering stop 79 Stop on account of another error 77 Thread breakag...

Page 120: ... SW ON Intermediate presser check program SW Start SW ON Ready SW ON Reset SW ON Presser thread trimming check program SW ON Needle thread clamp check program SW ON XY check program SW ON 57 Setting condition 74 Presser SW input effective 75 Start SW input effective 102 Sewing machine start 103 Sewing machine stop 104 Jump feed start 106 Total presser lowering 107 Total presser lifting 73 Check pr...

Page 121: ...he port I O setup screen is displayed 2 Selection of the port I O screen For port I O setup four I O setup screens are avail able A required function number can be set on a relevant screen B Output number setting C Input number setting D Virtual I O number setting E Switch operation prohibition setting Setup screen changeover is possible with the right and left scroll buttons F located on the top ...

Page 122: ... 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 In the case of virtual I O number setting it is selected from output and input To make switch operation setting the setup button L is pressed to select the signal type from High M and Low N B G F E L J K H I N M ...

Page 123: ...housing HK01651009B ELCO 60 8263 3098 15 002 10P housing HK01651010B ELCO 60 8263 3108 15 002 12P housing HK01651012B ELCO 60 8263 3128 15 002 Use CN79 and CN81 for switch input Use CN80 and CN82 for sensor or switch input CN79 5V 1 2 3 4 5 6 7 8 9 10 4 7K 5V 4 7K I 01 GND I 02 GND I 03 GND I 04 GND I 05 GND 1 2 3 4 5 6 7 8 I 09 GND I 10 GND I 11 GND I 12 GND CN82 5V 3 2 1 4 5 6 7 8 9 10 11 12 4 7...

Page 124: ... housing HK01651011A ELCO 60 8263 3118 15 001 12P housing HK01651012A ELCO 60 8263 3128 15 001 The drive transistor is used with 0 5 A rated current Make sure that the total current is equal or less than 1 A CN84 24V 24V O 01 24V O 06 24V O 11 24V O 12 24V O 13 24V O 14 24V O 15 24V O 16 24V O 07 24V O 08 24V O 09 24V O 10 24V Ic 0 5A 24V Ic 0 5A 24V Ic 0 5A O 02 24V O 03 24V O 04 24V O 05 Black B...

Page 125: ... from the sewing machine control side Caution The virtual I O port is an internal signal of the sewing machine It cannot be brought out directly to the outside 3 Control operation At the start of simplified program execution operation is sequentially carried out starting from Step No 1 at the intervals of 1ms for each step At the beginning of step execution the con tents of output information setu...

Page 126: ...simplified program comes in five patterns In the initial state all the patterns are set at OFF When the simplified program setup button B is used each program can be made effective or ineffective Simplified program effective Simplified program ineffective 3 Simplified program editing Simplified program No and the registered num ber of steps are displayed on the program editing button C When this b...

Page 127: ...ion screen is displayed The command that is being selected is displayed on the button On the command selection screen the command button G is displayed Press the selecting command button and then press the Enter button H In regard to command descriptions refer to 4 list of simplified program commands 2 Port I O information setup The port status can be set up for the four items as specified below I...

Page 128: ...n be changed The port comes in the four types as specified below Output port No Input port No Virtual I O port No etc Presser SW 1 to 4 Start SW Temporary stop SW The port No button is displayed on the screen Press the button that corresponds to current setting The selection status button is displayed in gray After selection press the Enter button O M L O For output setting press the output button...

Page 129: ...key R and press the Enter button S In regard to the parameters that correspond to the commands refer to 4 list of simplified program com mands Q R S T U 4 Step insertion It is possible to insert a step before the displayed step When the step insertion button T is pressed the command selection screen is displayed Select the command that is required to be inserted and press the Enter button U Then t...

Page 130: ...sewing screen The simplified program button A is displayed in the sewing screen if this simplified program is avail able The simplified program select screen is pre sented and the effective simplified program button B is displayed Select the simplified program number the status of which is being checked and press the ENTER but ton C The simplified program confirmation screen is pre sented and the ...

Page 131: ...nation 1 to 99 steps Number of 0 to 9999 stitches Moving to the next step after the lapse of the preset for No of stitches No stitches number of stitches Jumping to the step specified by the skip destination No within the range of the preset number of stitches when either condition specified by input setting is satisfactory OR input 7 JUMP Jump repetition counter Effective Ineffective Skip destina...

Page 132: ...als directly generate outputs with the aid of the simplified program Port I O setting is disabled Simplified Program Setup End DELy o01H to o16H o01L to o16L Delay time Unit of 1ms And or o01H to o16H o01L to o16L i01H to i16H i01L to i16L Pn Program No Number of stitches Unit of 1 stitch STiA Stio v01H to v16H v01L to v16L v01H to v16H v01L to v16L Sn Step No JUMP Rest p1H to p4H sH eH p1L to p4L...

Page 133: ...ified program input i07 Stacker material clamp sensor Simplified program input i08 Virtual I O I O Contents Remarks v01 Output 61 Sewing forwarded v02 Output 102 Sewing machine started v03 Output 100 Before sewing start point reset v04 Output 101 After sewing start point reset v05 Output 105 Before origin reset v06 Input 55 Feeding frame lift lower wait v07 v08 Caution For the descriptions in the ...

Page 134: ...ng till sewing machine start 2 or o06L v03L v05L d 0 Stacker movement ON Waiting till sewing start point reset or origin reset 3 And v03L Sn 11 d 1 To Step 11 if there is no sewing start point reset 4 And v06L v04L d 0 Feeding frame lifting wait ON Waiting till sewing start point reset 5 And i06 d 0 Waiting till stacker movement sensor ON 6 And o07L i07 d 0 Stacker material clamp ON Waiting till s...

Page 135: ...o06 o07 o08 o09 o10 o11 o12 o13 o14 o15 o16 6 Port I O setup sheet Terminal Contents Remarks input i01 i02 i03 i04 i05 i06 i07 i08 i09 i10 i11 i12 i13 i14 i15 i16 Virtual I O I O Contents Remarks v01 v02 v03 v04 v05 v06 v07 v08 v09 v10 v11 v12 v13 v14 v15 v16 ...

Page 136: ...tio v01H to v16H v01L to v16L v01H to v16H v01L to v16L Sn Step No JUMP Rest p1H to p4H sH eH p1L to p4L sL eL d Delay time c Numberofstitches r Repetition counter Step No Co Command Output information High Output information Low Input information High Input information Low Parameter 1 Parameter 2 Remarks 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 7 Simplified program setup sheet ...

Page 137: ...ruction Manual The data to be copied come in the following contents put in a single file PRO1 PRO2 PRO3 PRO4 PRO5 Port I O setup Cautions 1 Port I O setup data of PRO1 to 5 are put in a single file They cannot be saved individually 2 When copying the data into other sewing machines data writing can be performed only for the machines where connections to the I O connectors are made in the same stat...

Page 138: ...gram version C Main program version D Main shaft program version Pressing the cancel button E closes the ver sion information screen and calls up the mode screen 2 To display the detail screen Press the detail screen button F to call up the panel program detail screen G Module H RVL I Checksum Pressing the cancel button J closes the detail screen and calls up the version information screen Pressin...

Page 139: ...operation mode is changed to the key lock state To change the quick operation mode to key lock state press the button D The quick operation mode is changed to the key lock state 7 Keylock setup 1 To call up the keylock screen Hold down the key for about 6 seconds The page shift button A is displayed on the upper part of the screen Press the page shift button to dis play the next page Press the key...

Page 140: ...in put screen Close the mode screen The data input screen is displayed and pictograph E for indicating the key lock status is displayed on the right of pattern No indication Only the buttons available even in the state of key lock are displayed E E E E ...

Page 141: ...mized key lock data is stored in the panel It is also possible to copy the customize data to another panel Refer to 5 9 Communication screens of the maintenance personnel level for further details 1 Procedure to customize the key lock Displaying the selection screen to customize the key lock Press the customize button A for the normal operating mode or the customize button B for the quick operatin...

Page 142: ... selecting the di rect pattern Data input screen combination sewing Sewing screen when selecting the user pattern and media pattern Sewing screen when selecting the direct pattern Sewing screen combination sewing Mode changeover screen Customizable screen list for normal operation mode Button Screen Data input screen independent sewing Data input screen combination sewing Sewing screen independent...

Page 143: ...re G However such buttons cannot be customized as those that may cause some problems in sewing machine operation by making the operation disabling setup or no display setup When the button is pressed further for about 1 second in the state of no display setup the frame only display turns into an original display and the operation enabling setup becomes available Caution When the setup conditions o...

Page 144: ...d even though a button of operation disabling setup or no display setup is pressed 5 Determine the customize setup Press the switch after completion of customize The customized setting is performed and the screen returns to the selection screen to customize the key lock The customized setting is not saved if the power supply is turned off before pressing the switch Press this button ...

Page 145: ...ressed button stays in the frame only display C Caution This indicates that all buttons in all the screens changed from the pressed button are set to the no display setup 3 If the button is kept pressed for about one second in the state that the frame only button is displayed all buttons in all the screens transferred from the pressed button are set to the factory shipment setup and the customize ...

Page 146: ...mode independently of each other Press the button A for the initialization of the normal operation mode and press the button B for the quick operation mode The checking screen for the key lock customize initialization is displayed 2 Initialization When Button C is pressed in the key lock customize initialize checking screen the customize setup conditions are initialized in the state of shipment fr...

Page 147: ... is pressed the panel is established with the backup data When Button B is pressed the key lock customize data of both the normal operation mode and the quick operation mode are initialized into the state of shipment from the factory 2 If the backup data are broken If the backup data are also found to be destroyed the screen shown at left is displayed When this screen is displayed the key lock cus...

Page 148: ... Model name 00XXX MSW Data of the memory switches 1 and 2 Example AMS00001 MSW All sewing machine data Model name 00XXX MSP All data maintained by the sewing machine Example AMS00001 MSP Panel program data BP RVL 6 digits HED Program data and display data of the panel BP RVL 6 digits PXX BM RVL 6 digits IXX Main program data MA RVL 6 digits PRG Main program data Servo program data MT RVL 6 digits ...

Page 149: ...l level the data selection screen is displayed In this state it becomes possible to select the ad justing data and all sewing machine data 3 Program rewriting 1 Selection of the data type When the data classification button C is pressed in a communication screen of the mainte nance personnel level the data selection screen is displayed In this state select the panel program data D 2 Selection of a...

Page 150: ...been completed If any data writing error screen should be displayed im mediately turn off the power supply and check the check ing items specified below Then take the setup actions again Checking items 1 Did you open the media cover in the middle of data communication from the media card 2 Data of the media card are incorrect or there is no data file 3 The contact point of the media card is contam...

Page 151: ...rectory configuration should be established with a personal computer Information about the method of media card formatting is obtainable from the Instruction Manual 2 28 Performing formatting of the media Route directory PROG AMS221EN BPxxxxxx prg Servo program MAxxxxxx prg Main program AMSEN BPxxxxxx BPxxxxxx hed BPxxxxxx p01 BMxxxxxx i01 BMxxxxxx i10 BMxxxxxx i11 BMxxxxxx i12 BMxxxxxx i21 BMxxxx...

Page 152: ... buttons 2 To call up the error history screen Press the error history button B on the infor mation screen to call up the error history screen The error history screen shows the error history of your sewing machine C Chronological recording number D Error code E Cumulative energizing time during error hour Pressing the cancel button G closes the error history screen and calls up the information sc...

Page 153: ...hanges from blue to or ange and there are 5 buttons 2 To display cumulative operating information Press the cumulative operating information button A on the information screen to call up the cu mulative operating information screen The following 4 items are indicated on the cumula tive operating information screen B Cumulative operating time hour C Cumulative thread trimming count D Cumulative ene...

Page 154: ...ing from PM 1 When data vector type for test sewing is transmit ted from PM 1 the screen shown at right appears and a needle positioning drawing of transmitted data appears in the center of the screen The color of the needle positioning drawing changes depending on thread tension If the stitch count of transmitted data is too large a needle positioning drawing does not appear 2 Edit of vector para...

Page 155: ...to call up the registration screen Enter the user pattern number to which the test sew ing data is registered with the numeric keypad G 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 D 4 Test sewing Press the ready to go switch E to call up the test sewing screen Test sewing is ready 7 data entry screen Af...

Page 156: ...ead 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 Blue 61 to 80 Light blue 81 to 100 Green 101 to 120 Yellowish green 121 to 140 Orange 141 to 160 Red 161 to 180 Pink 181 to 200 Black ...

Page 157: ...t mode 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 A ...

Page 158: ...eval and the X Y origin sen sor is displayed 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 The status of inching operation of the needle thread clamp motor operation of origin retrieval an...

Page 159: ... 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 To complete correction press the can cel button B 3 Pressing the bottom right position Press the red circle D located at the bottom right of the screen To complete correction press the cancel button B B D B A C ...

Page 160: ...reen To complete correction press the cancel button B 6 Data saving When all the four points have been pressed the cor rection data are saved At that time the Power OFF Prohibition screen is displayed The power supply must not be turned off while the above mentioned screen is displayed If the power supply is carelessly turned off no cor rection data are saved After data saving the check program sc...

Page 161: ...e 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 After this confirmation press a proper position on the screen The LCD check screen is closed and the check program screen is displayed A ...

Page 162: ...ensor check screen is displayed 2 Input signal check In the input signal check screen the input condi tions of various sensors can be confirmed For each sensor the input status is displayed as indicated by B The ON OFF conditions are displayed as shown below ON condition OFF condition Using the UP DOWN buttons C display the sensor that has been confirmed A B C ...

Page 163: ...1 SW Pedal Y motor origin sensor Presser 2 SW Pedal Presser motor origin sensor Presser 3 SW Pedal Needle thread clamp motor origin sensor Presser 4 SW Pedal Intermediate presser motor origin sensor Temporary stop SW Presser motor sensor AUDET sensor Needle thread clamp motor sensor ADDET sensor External input 1 DDET sensor External input 2 UDET sensor External input 3 TG sensor External input 4 P...

Page 164: ...ensor applications No Sensor data Applications 11 AU DET sensor For needle bar reverse revolution 5 to 30 12 AD DET sensor For needle bar DOWN stop 209 to 239 13 D DET sensor Not used For thread cutting timing of former models 14 U DET sensor For needle bar UP stop 40 to 62 15 TG sensor ON OFF by dividing one turn of the main shaft into 45 portions 16 P DETsensor For feed timing 17 S DET sensor No...

Page 165: ...e main motor rpm check screen is displayed 2 Main motor operation and measured rpm value check Using the buttons B C the rpm number can be set up When the button D is pressed the sewing machine is operated at the pre set speed At that time the measured rpm value is displayed at E When the SET button F is pressed the sewing machine is stopped A B C E F D ...

Page 166: ...ck 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 Try to press the output check button B While this button is pressed the ON sta tus output is kept generated A B ...

Page 167: ...ions No Pictograph Contents No 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 Air output 6 Air output 15 Air output 7 Air output 16 Air output 8 ...

Page 168: ...XY motor origin sensor check screen is dis played 2 XY motor origin sensor check According to the status of the X Y origin sensor the ON OFF condition of the sensor is displayed in the position of B When the Arrow Mark button C is pressed the X Y motor can be driven by 0 05mm in the direction Caution 1 Using the Start SW origin retrieval of the X Y motors is effected for both shafts A B C ...

Page 169: ...n sensor is displayed in the position of C Using the and keys D E the presser thread trimmer motor can be driven by one pulse When the fixed position moving button F is pressed the presser thread trimmer motor is driven to any of the following fixed positions A pictograph indicating this position is displayed in gray G Presser lifting position H Presser lowering position lowering position during p...

Page 170: ...he needle thread clamp origin sensor the ON OFF condition of the needle thread clamp sensor is displayed in the position of B Using the and buttons D E the needle thread clamp motor can be driven by one pulse When the fixed position moving button F is pressed the needle thread clamp motor is driven to any of the following fixed positions A pictograph in dicating this position is reversed and displ...

Page 171: ...inuous operation 1 Display of the continuous operation setup screen When the continuous operation button A is pressed on the check program screen the continu ous operation setup screen is displayed 2 Continuous operation mode setup In the continuous operation setup screen the con tinuous operation mode is set up B Intervals of operation rest time C Origin retrieval at the end of sewing 0 No 1 Ever...

Page 172: ... interme diate presser origin sensor is displayed in the posi tion of B Using the and buttons C D the intermediate presser motor can be driven by one pulse When the fixed position moving button E is pressed the intermediate presser motor is driven to any of the following fixed positions A pictograph in dicating this position is reversed and displayed F Lower position at the height of 7mm during lo...

Page 173: ...240V In the signal phase mode the power supply is connected to Pins 4 5 In the 3 phase mode the power supply is connected to Pins 4 5 6 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 momentary interruptio...

Page 174: ...wer supply rectification noise reduction and the detection of a momentary interruption C 10 C 9 4 CN1 Power input Power switch CN3 Momentary interruption detection signal MAIN board CN2 Power output MAIN board Since single phase specifications are adopted the power supply is connected to Pins 4 5 ...

Page 175: ...ationa and error check CN14 For Main shaft encoder Main shaft motor DIPSW 1 1 For testing off 1 2 For testing off 1 3 For testing off 1 4 Penetration force off DIPSW 2 1 For weiting off 2 2 For mode setting off 2 3 For mode setting off 2 4 For mode setting off CN15 For Main communication Main board CN16 For Main shaft motot power Main shaft motor CN17 For power supply FLT board LED2 For power supp...

Page 176: ... error E731 Logical error in U V W 5 IPM error E901 Error output generation from IPM 6 Undervoltage E813 Source voltage 20 or more 7 Motor reverse rotation E733 Irregular motor revolutions 8 Overvoltage E811 Source voltage 20 or more 9 Power interruption Display disabled Power interruption of 40ms or more 10 Not used 11 85V power system error E903 SDC board fuse F1 blow off 12 33V power system err...

Page 177: ...de Black CN54 Y feed encode White DIPSW 2 1 Not used OFF 2 2 Not used OFF 2 3 For FRAM clearing OFF 2 4 Not used OFF DIPSW 3 1 For writing OFF 3 2 For writing OFF 3 3 For writing OFF 3 4 Not used OFF CN53 X feed encode Red CN43 Intermediate pressr pulse motor Blue CN41 Y feed pulse motor White CN35 Sub circuit board Control signal CN51 Foot switch White CN40 X feed pulse motor Red CN52 For pneumat...

Page 178: ... 174 CN22 Needle thread clamp pulse motor White CN21 Control signal MAIN board CN20 Power supply MAIN board 5V 15V 85V 6 SUB board Controls of the pulse motor for a signale shaft performed ...

Page 179: ...or Red Option CN71 CN72 CN73 24V Option CN70 Intermediate presser origin sensor white CN69 Temporary stop Black CN64 Thread trimmer origin sensor Black CN68 Thread trimming detection Yellow CN67 Safety switch Red CN63 Y feed origin sensor Yellow CN62 X feed origin sensor Red CN65 Thread clamp origin sensor Yellow Thrad clamp position sensor ...

Page 180: ...t management CN100 Connector for main body connection SW2 DIP SW2 Normal setting state 1 1 OFF Disabling switch for the media detector switch 1 2 OFF Always used in OFF position CN113 USB connector host side CN113 USB connector function side CN118 Connector for LCD BZ 1 Buzzer CN109 Connector for touch panel LD1 Status display LED CN120 Connector for LCD backlight BT1 Backup battery CN122 External...

Page 181: ...he media detector switch 1 2 OFF Always used in OFF position SW1 DIPSW 1 for production check Normal setting state 1 1 ON 1 2 ON 1 3 OFF 1 4 OFF Caution 2 Do not change the settings normally IP 420 Panel Board Caution 1 If the panel cannot be used due to an error of media cover open caused as a result of media cover destruction or the like the media detector switch can be disabled by turning this ...

Page 182: ...edle hole guide B242621000A B242621000C B242621000B B242621000D B242621000G ø1 6 ø1 6 ø2 0 ø2 4 ø3 0 For knit B242621000F With counter bore ø3 0 Inner hook presser asm 14103352 14103659 B1817210DAD Needle guard 1 3 mm Needle guard Needle guard 1 7 mm 1 9 mm Shuttle 40014964 40061991 Intermediate presser 40023632 B1601210D0BA B1601210D0CA ø2 2 ø2 7 ø3 5 Tension controller No 2 asm 40010508 40029411...

Page 183: ...ork clamp B2591220000 A x B x t preventing slipping 250 x 200 x1 5 Sponge sheet for work clamp B2564223C00 A x B x t 450 x 300 x 1 5 Work clamp material A B2587220000 A x B x t 380 x 240 x 1 Work clamp material B B2588220000 A x B x t 380 x 240 x 1 5 3 Feed plate blank for Feed plate blank with knurl 40052341 A x B x t processing AMS 221EN 2516 239 x 353 x 1 2 Feed plate blank without knurl 400523...

Page 184: ...t 140 8 x 72 5 x1 Aluminum feed plate inner plate GMU12037000 A x B x t 140 6 x 72 5 x 1 6 Cassette holder Cassette holder fixing plate asm 40052328 AMS 221EN 2516 Cassette holder fixing plate asm 40053782 AMS 221EN 3020 Cassette holder assy B25822210A0 AMS 221EN 2516 Cassette holder assy 40053777 AMS 221EN 3020 7 Feeding frame blank Plastic blank AMS 221EN 2516 For united presser 40035093 AMS 221...

Page 185: ...C 14103659 A 1 7 D B1817210DAD A 1 9 B A t B A t B A t A No Part No Part name Q ty 1 40032837 Presser foot asm left 1 2 40032835 Presser foot asm right 1 3 SM6061200SP Presser foot setscrew 4 4 WP0651056SD Presser foot washer 4 5 SS7150910TP Outer frame setscrew 4 6 WP0651056SD Outer frame washer 4 7 SM8060812TP Outer frame height adjusting screw 2 8 NM6060003SC Outer frame height adjusting nut 2 ...

Page 186: ...rmediate presser relay Specific presser foot left asm B26302150A0 A x B x t metal fittings Relay metal fittings used to install 66 x 58 x 4 the presser of the ASM 206 and 210 Specific presser foot right asm B2630215AA0 A x B x t 66 x 58 x 4 13 Inverting clamp unit FU 40048659 14 Inverting intermediate presser Reversal intermediate presser blank B4317220000 A x B x t blank large with knurl 206 x 12...

Page 187: ... installing base B 8 x 24 x 15 This item is required when the reversal intermediate presser blank small B4319220000 is used Reversal intermediate presser small SS1090750SP setscrew 16 Reversal crank shaft Reversal crank shaft B B4326220000 A x B x ø C 26 x 71 x 7 17 Wiper Side sweeping wiper assy 40035867 Side sweeping wiper repeater cable 40036668 assy ...

Page 188: ...of parts Type Part No Remarks 18 Pedal switch 3 step pedal PK47 GPK470010AB Relay cable for 3 step pedal 40033875 2 step pedal PK78 40033831 19 Needle cooler 40092717 When the crosswise wiper asm 40035867 is used ...

Page 189: ...is 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 Micro switch plate 11102308 Micro switch setscrew SL4031691SC 2 pcs ...

Page 190: ...1013110000 1 Cabtyre cable 2 core 1830mm HW500140000 1 Pin terminal female HK03464000A 2 o The item number of the switch assembly in the above table is 40040130 o For more details of the pedal switch cable set in the above table refer to 3 Switch assembly and 6 Switch mounting position diagram 2 Switch mounting position For more details refer to 6 Switch mounting position diagram 3 Switch assembly...

Page 191: ...upper plane of the pedal The switch is fixed in the ON state CN88 Connector Connector pin No 2 Connector pin No 7 Black No 7 White No 2 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 ...

Page 192: ...The machine uses the following three fuses SDC Board For pulse motor power supply protection 5A 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 193: ... on the side of the Box Side of the control box Connect the crimp style terminal of AC input cord to the power plug as shown in the figure Caution Securely perform the insulation treatment to the red terminal which is not used with insulation tape or the like When the in sulation is insufficient there is a danger of electric shock or leakage current C In case of using with single phase 200V to 240...

Page 194: ...ltinok 2 Epinok 2 Kyodo Oil Co Ltd Lisonix 2 Idemitsu Petrochemical Co Ltd Coronex 2 2Templex N2 Grease D Used for the feeding gear block 10g tube JUKI Part No 13525506 3JUKI Grease A Used for high speed sliding parts and their peripheral parts 10g tube JUKI Part No 40006323 100g tube JUKI Part No 23640204 4 JUKI Grease B Used in particular for the specific areas with highly loaded parts Important...

Page 195: ... 191 4 Parts to which grease Locktight is applied o FRAME MISCELLANEOUS COVER COMPONENTS 3 A JUKI Grease A C Grease D Templex Locktight 241 C C A C D ...

Page 196: ... 192 A Inside A A A B C C B B B B o MAIN SHAFT NEEDLE BAR COMPONENTS A JUKI Grease A B JUKI Grease B C Grease A Inside A Bothe sides ...

Page 197: ... 193 B B B B B B B B B B B B B B B B B Both sides B Both sides B B B B B B B B B B B B A o PRESSER MECHANISM PRESSER VARIABLE COMPONENTS 1 A JUKI Grease A B JUKI Grease B Lock tight 241 ...

Page 198: ... 194 C C C C C C C o PRESSER MECHANISM PRESSER VARIABLE COMPONENTS 2 o WIPER MECHANISM COMPONENTS C Grease B JUKI Grease B C Grease B B C B B B B B B B B C C B C B B B B ...

Page 199: ... 195 o SHUTTLE DRIVER SHAFT COMPONENTS o TENSION RELESASE THREAD TENSION COMPONENTS A JUKI Grease A C Grease C C C A A A ...

Page 200: ... 196 C C C C C C C C C A A A C A o TENSION RELEASE THREAD TRIMMER MECHANISM COMPONENTS o THREAD CLAMP COMPONENTS A JUKI Grease A C Grease C Grease A C C ...

Page 201: ... 197 F F E F F F F F F F F o X Y COMPONENTS 1 E Three Bond 3060G Lock tight 241 F Grease for LM guide It shall be applied to the V groove section on the side surface 3020 only ...

Page 202: ... 198 o X Y COMPONENTS 2 D D C C C D C C D C Grease D Grease D Locktight 241 ...

Page 203: ... 199 C Grease D Grease D D C D C C D C D D C C D D D D D C D C o CLOTH FEED MECHANISM COMPONENTS D ...

Page 204: ...rease up error is displayed be sure to replenish the designated places below with grease Then call the memory switch U245 press CLEAR but ton A and set NUMBER OF STITCHES D to 0 When RESET key B is pressed without replenish ing the designated places with grease error code E221 Grease up warning is displayed every time the power is re turning ON afterwards and the sewing machine fails to operate So...

Page 205: ...ease B JUKI Grease A When the grease runs short be sure to purchase new grease Grease type Capacity Spare parts No JUKI Grease A 10g tube 40006323 JUKI Grease A 100g tube 23640204 JUKI Grease B 10g tube 40013640 2 Points to be applied with JUKI Grease A Caution Use grease tube A part number 40006323 in light blue supplied with the unit for adding grease to any points other than the points specifie...

Page 206: ...rmediate presser bar bushing grease hole Put JUKI Grease A through inlet Tighten screw to fill inside the bushing with JUKI Grease A The setscrew is used for a detent plug for grease replenishment It should be tightened softly to a degree that it is not loosened due to vibration of the sewing machine Caution 1 Do not wipe off the grease applied onto the periphery of needle bar inside the frame If ...

Page 207: ...d with the unit for adding grease to any points other than the points specifies below If any grease other than the specified one is used the related components can be damaged 3 Points to be applied with JUKI Grease B o Adding grease onto the eccentric cam section 1 Tilt the machine head and remove the grease cover 2 Fill coupling supplied with the unit with grease through JUKI Grease B tube 3 Remo...

Page 208: ... 204 1 Apply the Juki Grease B to the rear side of the holder plate 4 Grease replenishment to the holder plate ...

Page 209: ...011 External media not inserted Media is not inserted Possible Previous External media is not inserted to re enter screen after reset E012 Read error external Data cannot be read Possible Previous Data read from media cannot to re start screen be performed after reset E013 Write error external Data cannot be written Possible Previous Data write from media cannot to re start screen be performed aft...

Page 210: ...E027 Read error Data cannot be read Possible to Previous Data read from server cannot re start after screen be performed reset E028 Write error Data cannot be written Possible to Previous Data write from server cannot re start after screen be performed reset E029 Media slot release error Cover of Media slot is Possible to Previous Lid of media slot is open open re start after screen reset E030 Mis...

Page 211: ...ocessed after reset E050 Stop switch Temporary stop switch is Possible to Step screen When stop switch is pressed pressed re start after during machine running after reset E052 Thread breakage detection Thread breakage is Possible to Step screen error detected re start after When thread breakage is after reset detected E061 Memory switch data error Memory switch data error Turn OFF Memory switch d...

Page 212: ...or cannot be detected the power screen The thread trimmer knife is not in the regular position E306 Thread clamp position error Thread clamp sensor Turn OFF Thread clamp unit is not in the cannot be detected the power regular position E307 External input command time There is not input for a Possible to Data input out error certain period of time with re start after screen Input is not performed f...

Page 213: ...not proper in the initial communication communication switch E704 Inconsistency of system Version of program Possible to Communication version incompatible rewrite program screen System software version is pressing inconsistent in the initial communication communication switch E730 Main shaft motor encoder Sewing machine motor is Turn OFF defectiveness defective the power When encoder of the sewin...

Page 214: ...Turn OFF SERVO CONTROL p c b P c b is to high the power Turn ON the power again after taking overheat time of SERVO CONTROL p c b E907 X feed motor origin retrieval Origin X motor cannot be Turn OFF error found the power When origin sensor signal is not X origin sensor inputted at the time of origin retrieval motion E908 Y feed motor origin retrieval Origin Y motor cannot be Turn OFF error found t...

Page 215: ...rature Turn OFF Overheat of MAIN p c b to high the power Turn ON the power again after taking time E925 Intermediate presser motor Origin of intermediate Turn OFF origin retrieval error presser cannot be found the power Origin sensor of intermediate Intermediate presser presser motor does not change origin sensor change at the time of origin retrieval E926 X motor position slip error X feed motor ...

Page 216: ...tor overload Turn OFF is excessive the power E933 Thread trimming motor Thread trimming motor Turn OFF overload error overload is excessive the power E935 Intermediate presser Intermediate presser Turn OFF motor overload error motor overload is the power excessive E936 X Y motor out of range Feed motor position has Turn OFF error exceeded the sewing the power area E943 MAIN CONTROL p c b trouble M...

Page 217: ...ackup data Pattern data is not stored in memory Erase is OK M528 Overwriting confirmation of users pattern Overwriting is performed OK M529 Overwriting confirmation of media Overwriting is performed OK M530 Overwriting confirmation of vector data of panel M3 data sewing standard format data simplified program data Overwriting is performed OK M531 Overwriting confirmation of vector data of media M3...

Page 218: ...performed OK M535 Overwriting confirmation of adjustment data on personal computer and all machine data Overwriting is performed OK M537 Delection confirmation of thread tension command Delecting is performed OK M538 Delection confirmation of intermediate presser increase decrease value Delecting is performed OK M542 Format confirmation Formatting is performed OK M544 Data corresponding to panel d...

Page 219: ...iting cannot be performed since data exists M550 Backup data information on main body input There is back up data of body input M554 Key lock customization data Customized data initialization have been initialized notice Customized key lock data has been initialized M555 Key lock customization data Customized data breakage are broken Customized key lock data has broken Initializing is OK Initializ...

Page 220: ...lay Display message Description M653 During formatting Formatting is performed M669 During data reading Data is being read M670 During data writing Data is being written M671 During data converting Data is being converted ...

Page 221: ...height is inadequate 5 C Inadequate adjustment of the Adjust the feeder bar auxiliary cover rail X feeder bar auxiliary cover rail X 2 6 Traveling torque in X direction 6 A Parallelism of the Y_LM Adjust the mounting position of the Y LM guide or Y or Y direction is excessive guide or the Y_aux LM auxiliary LM guide guide is not secured 6 B There is interference between Adjust the throat plate aux...

Page 222: ... or lowered pressure reducer 6 2 Defective board 2 A The board is out of order Replace the board 2 B Connector connections are Check the connector connections improper 6 3 There are inadequate fitting Examine the positions for greasing conditions among the work feed bar the link and the face plate The sewing material is not pressed completely by the outer frame as a whole 6 4 Supply air pressure i...

Page 223: ...djusted 8 3 Intermediate presser pulse 3 A Intermediate presser pulse Replace the intermediate presser pulse motor motor malfunction motor is out of order 3 B Connection of intermediate Check the connector connections presser pulse motor is improper 8 4 Defective board 4 A The board is out of order Replace the board 4 B Connector connections are Check the connector connections improper 8 5 The int...

Page 224: ...n of the thread breakage detecting detecting plate is wrong plate 11 Even though the needle thread is 11 1 Position of the thread Adjust the position of the thread breakage detecting broken the sewing machine does breakage detecting plate is plate not stop wrong 12 Wiper cannot spread a thread 12 1 Interference between wiper 1 A Wiper mounting position is Adjust the wiper position and needle inade...

Page 225: ...le guide and the counter knife is excessively high 2 F Needle thread tension is high Adjust the needle thread tension and the thread is excessively stretched 2 G Thread spreading section of Polish the thread spreading section of the moving the moving knife has scratches knife with buff or replace the knife 1 3 Length of bobbin thread re 3 A Level difference between the Adjust the height of the cou...

Page 226: ...nife ing knife is inadequate 2 Needle breakage 2 1 Inadequate clearance between Adjust the clearance between needle and shuttle driver the shuttle driver and the needle 2 2 Inadequate clearance between Adjust the clearance between the needle and the the needle and the inner hook inner hook 2 3 Feed timing is defective 3 A Too late feed timing for cloth Change the feed timing by the use of the memo...

Page 227: ... needle 7 A The tension of the thread Increase the tension of the thread take up spring thread length is long after take up spring is deficient thread trimming the needle While the needle is passing thread end caught by the through the cloth at the first needle thread clamp is stitched stitch the thread take up at the second stitch Stitch spring has too much stroke skipping at the second stitch an...

Page 228: ... to 1000sti min 8 E The setting conditions of the Memory switch U069 Changes of 1 2 and 2 3 needle thread clamp device do not conform to the thread characteristics H type only 4 Needle thread breakage 4 1 Stratches on the inner hook 1 A Scratches on section A After polishing the blade point of the inner hook with Contact of the inner hook with oilstone polish it with polishing powder Properly adju...

Page 229: ...e inner hook is too small driver and the inner hook 4 5 Scratches on the needle hole Remove the scratches and polish with buff or replace guide the needle hole guide 4 6 Finish of the needle hole is rough Replace the needle 4 7 Thread take up spring is 7 A Stroke of the thread take up Properly adjust the thread take up spring maladjusted spring is too large 7 B Thread take up spring tension Proper...

Page 230: ...he counter knife is too high moving knife 5 5 Clearance between the needle 5 A Thread is cut before trimming Properly adjust the position of counter knife hole guide and the counter with the blade section of the knife is too small moving knife 5 6 Lower face of the needle hole 6 A Thread is cut with the needle Remove the scratches and polish with buff or replace guide has scratches hole guide the ...

Page 231: ...ve the scratches The shape of the thread trimmed becomes and thread waste remains 6 3 Moving knife does not spread 3 A Initial position of the moving Adjust the initial position of the moving knife threads knife is maladjusted 3 B Thread trimmer cam position Adjust the thread trimmer cam position is inadequate 3 C Position of the shuttle upper Adjust the position of shuttle upper spring spring is ...

Page 232: ...with a thicker one used is improper 7 6 Selection of the needle hole 6 A Hole diameter of the needle Replace the needle hole guide with a new one having guide is improper hole guide to the needle to be a larger needle hole used and thread is small 7 7 Shape of the feed plate is 7 A Material to be sewn is stiff and Raise the material to be sewn by means of the feed defective closely contacted with ...

Page 233: ...mall Needle thread clamp device ON 8 4 Stitch skipping due to the heat 4 A Sewing speed is too fast Change the maximum speed electrical components 4 B Needle is too thin Use a thicker needle Raise the number of needle to be used 4 C Loop of the needle thread falls down Attach the needle with the long groove orienting slightly to the right approximately 20 8 5 Uneven stitch tightness due 5 A Sewing...

Page 234: ...pply of the MAIN board supply 1 2 85V 3 24V 4 5V 5 33V 6 7 8 GND Check the output voltage in the SDC board unit 1 E The operation panel has no Check if there is shortcircuiting in the 24V power power supply system for the operation panel Check the connection between CN34 of the MAIN board and the panel 1 2 Detection of a momentary 2 A No momentary interruption Check the connection between CN3 of t...

Page 235: ...tor is out of order Measure the resistance of the motor winding If there is any abnormality replace the motor 4 Error E029 4 1 The switch signal is not received 1 A The slot OPEN OFF switch Check the cover to examine whether the switch pin Media slot open error is not pressed can be pressed If there is any abnormality replace the cover Confirm the switch pin whether it is normal If there is any ab...

Page 236: ...t tester Replace the switch 1 C Switch is defective Check it by means of a circuit tester Replace the switch 1 D Switch fails to properly work Check the switch mounting conditions 11 Error E303 11 1 Phase Z signal upper shaft 1 A The encoder cord is broken Confirm whether each signal is delivered to CN14 Upper shaft motor Phase Z motor is not received or the motor encoder circuit of the SDC board ...

Page 237: ...14_7 Phase B CN14_2 GND Replace the motor if there is no signal change as a result of manual turning 1 B The signal input circuit is out Replace the SDC board of order 15 Error E731 15 1 Main shaft motor No signal 1 A The motor is out of order Confirm whether each signal is delivered to CN14 of Main shaft motor encoder error B entry in Phase U Phase V the SDC board LED3 on SDC board Flashing and P...

Page 238: ...imes 1 B Blown out of the F4 fuse of Replace the SDC board the SDC board 21 Error E904 21 1 No 33V power output of 1 A Blown out of the F2 fuse of Check if there is shortcircuiting in the 33V power Abnormal solenoid power the SDC board available the SDC board system for the MAIN board LED3 on SDC board Flashing Replace the MAIN board 12 times 1 B Blown out of the F5 fuse of Replace the SDC board t...

Page 239: ...k CN62 of INT board 2 C Input circuit is out of order Replace the MAIN board 24 Error E908 24 1 Irregular motor rotations 1 A There are irregularities in the Check the mechanism and look for the section that Y feed motor origin retrieval error mechanism such as is particularly overloaded that is any holdup overloading etc 1 B Motor leads are broken Check the resistance of the motor winding Replace...

Page 240: ...sm such as is particularly overloaded that is any holdup or retrieval error overloading etc whether screws are loose 1 B Motor leads are broken Check the resistance of the motor winding The motor is out of order Replace the motor as required 1 C The driver circuit is out of order Replace the MAIN board 26 2 No sensor signal entry 2 A The sensor is out of order or Check the sensor with the test pro...

Page 241: ...chanism such as is particularly overloaded that is any holdup retrival error verloading etc 1 B Motor leads are broken Check the resistance of the motor winding Replace the motor as required 1 C The driver circuit error MAIN board CN56 Check encoder of intermediate presser motor MAIN board CN43 Check motor Replace the MAIN board 31 2 No sensor signal entry 2 A The sensor is out of order or Check t...

Page 242: ...r position cannot be read Replace the MAIN board out accurately 37 Error E930 Mispositioning error of inter Replace the encoder mediate presser motor 38 Error E931 38 1 The motor current has 1 A The motor torque is Check the mechanism and look for the section that Overload error of X motor exceeded the tolerable insufficient is particularly overloaded that is any holdup range 39 Error E932 Check t...

Page 243: ... Black Black MAIN board B asm 40081590 White White For Analog pedal Red Switch Input x 5 Red Sensor Input x 3 Red Switch Input x 4 Red Sensor Input x 3 For ICE Red For PLD White For external IF For LK_BR White White SUB P C B MOTOR CABLE 40083869 MOTOR CABLE 40083865 ENCODER CABLE 40083870 MOTOR CABLE 40083866 ENCODER CABLE 40083871 MOTOR CABLE 40083867 ENCODER CABLE 40083872 MOTOR CABLE 40083868 ...

Page 244: ...ly circuit diagram A 240 POWER SWITCH Green Black White Red FLT T BOARD 200V CONNECTIONS SDC BOARD MAIN BOARD Green Black White Red White White Yellow Red Orange Black Black Black Red White Black Brown White Yellow ...

Page 245: ...ly circuit diagram B 241 POWER SWITCH Green Yellow Gray Gray FLT T BOARD 100V CONNECTIONS SDC BOARD MAIN BOARD Green Black White Red White White Yellow Red Orange Black Black Black Red White Black Brown White Yellow ...

Page 246: ...ply circuit diagram C 242 POWER SWITCH Green Yellow Brown Light Blue FLT S BOARD SDC BOARD MAIN BOARD Green Yellow Brown Light Blue White White Yellow Red Orange Black Black Black Red White Black Brown White Yellow ...

Page 247: ... 5 Servo motor circuit diagram 243 ENCODER SDC BOARD AC SERVO MOTOR Black Red White Green Yellow White Drain line Black Orange Blue Purple Light Blue Pink Red Yellow ...

Page 248: ...ack Temporary stop Thread breakage detection Red White Black Brown Black Blue Red White Black White Black Black White Red White White White White White White White White White Yellow Black White Red Yellow Black Yellow Red Brown Yellow Green White Red Black Red Brown Yellow Green White Red Black Brown Yellow Green White Red Black Black Brown Yellow Green White Red Black Yellow White Black White Wh...

Page 249: ... 7 MAIN PANEL board circuit diagram 245 PANEL BOARD MAIN BOARD ...

Page 250: ... 1ø Thread trimmer lifting the work clamp foot motor R 0 45Ω 1ø Needle thread clamp motor R 1 5Ω 1ø Intermediate presser motor R 1 5Ω 1ø Black White CN47 White MAIN BOARD Yellow Blue Red Orange CN40 Red Yellow Blue Red Orange CN41 White Yellow Blue Red Orange CN42 Black Yellow Blue Red Orange CN43 Blue Yellow Blue Red Orange CN22 White SUB BOARD ...

Page 251: ... for presser left Pneumatic source 2 step stroke solenoid valve Solenoid valve for presser left 2 step presser specifications with 2 step stroke AMS 221ENSL 2516 AMS 221ENHL 2516 Solenoid valve for presser right Exhaust solenoid valve Pneumatic source Exhaust solenoid valve Feeding frame cylinder right Feeding frame cylinder left Feeding frame cylinder right 2 step stroke cylinder ...

Page 252: ...terbore depth 17 R 2 a l l p e r i p h e r y 248 2 pcs Top of table 11 drill 2 x 11 drill 30 drill 4 x 11 drill R 2 a l l p e r i p h e r y 2 x 2 drill depth 14 3 drill depth 8 2 x 11 drill 17 drill 10 drill 2 x 50 depth 0 0 5 0 5 0 2 x 3 5 drill depth 10 4 pcs ...

Page 253: ...perates an environmental management system to promote and conduct the following as the company engages in the research development design sales distribution and maintenance of industrial sewing machines household sewing machines industrial robots etc and in the provision of sales and maintenance services for data entry systems 1 The development of products and engineering processes that are safe t...

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