JUKI AP-874/IP-420 User manual

1
ENGLISH
INSTRUCTION MANUAL
AP-874 / IP-420
* "CompactFlash(TM)" is the registered trademark of SanDisk Corporation, U.S.A.

i
CONTENTS
I. MECHANICAL SECTION (WITH REGARD TO THE SEWING MACHINE) 1
1. SPECIFICATIONS ....................................................................................................... 1
2. CONFIGURATION ....................................................................................................... 2
3. INSTALLATION ........................................................................................................... 3
3-1. Setting up the machine..................................................................................................................3
3-2. Assembling the stacker safety pipe .............................................................................................3
3-3. Installing the air hose and air gun and adjusting the pressure................................................. 5
3-4. Thread stand assembly ................................................................................................................. 6
3-5. Installing the operation panel ....................................................................................................... 6
3-6. Locking the Pocket Folding Board...............................................................................................8
3-7. Connecting the power supply.......................................................................................................8
3-8. Installing the foot pedal.................................................................................................................9
3-9. Lubrication....................................................................................................................................10
3-10. Checking the emergency stop switch......................................................................................10
3-11. Removing the styrene foam of the pocket setting plate......................................................... 11
3-12. Installing the label vacuum device........................................................................................... 11
3-13. Mounting the Pattern ................................................................................................................. 11
3-14. Installing the guide bar..............................................................................................................12
3-15. Break-in operation .....................................................................................................................12
4. OPERATION .............................................................................................................. 13
4-1. How to install the needle.............................................................................................................13
4-2. Threading the needle thread.......................................................................................................14
4-3. Installing / removing the bobbin case........................................................................................15
4-4. Setting a bobbin into the bobbin case.......................................................................................15
4-5. Winding a bobbin.........................................................................................................................16
4-6. Thread tension .............................................................................................................................18
4-7. Thread take-up spring .................................................................................................................19
4-8. Adjustment procedure for the pocket setting device ............................................................... 20
4-9. Operation procedure....................................................................................................................22
5. EMERGENCY STOP SWITCH .................................................................................. 23
II. OPERATION SECTION (WITH REGARD TO THE PANEL) .................... 24
1. PREFACE .................................................................................................................. 24
2. WHEN USING IP-420 ................................................................................................ 28
2-1. Name of each section of IP-420 .................................................................................................. 28
2-2. Buttons to be used in common ..................................................................................................29
2-3. Basic operation of IP-420 ............................................................................................................ 30
2-4. Liquid crystal display at the time of sewing pattern selection................................................ 31
(1) Sewing pattern data input screen ...............................................................................................31
(2) Sewing screen ............................................................................................................................33
2-5. Replacing the pattern ..................................................................................................................35
2-6. How to select the sewing pattern ............................................................................................... 37
2-7. Pattern checking procedure........................................................................................................39

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2-8. Changing item data......................................................................................................................40
2-9. Performing modication of needle entry point ......................................................................... 42
2-10. Setting the AUTOMATIC/STEP .................................................................................................. 43
2-11. How to change the setting position..........................................................................................44
2-12. How to use temporary stop.......................................................................................................45
(1) To continue performing sewing from some point in sewing ........................................................ 45
(2) To perform re-sewing from the start............................................................................................46
(3) Re-starting the setting operation................................................................................................. 47
2-13. Lowering the presser.................................................................................................................48
2-14. Stacker operation (taking out the material)............................................................................. 49
(1) Taking out the material from the stacker .................................................................................... 49
(2) Adjusting the stack-full sensor ....................................................................................................49
2-15. Using counter.............................................................................................................................50
(1) Setting procedure of the counter ................................................................................................50
(2) Count-up releasing procedure ....................................................................................................52
(3) How to change the counter value during sewing ........................................................................52
2-16. Performing new register of users’ pattern............................................................................... 54
2-17. Naming users’ pattern ...............................................................................................................55
2-18. Performing new register of pattern button.............................................................................. 56
2-19. LCD display section at the time of pattern button selection ................................................. 57
(1) Pattern button data input screen................................................................................................. 57
(2) Sewing screen ............................................................................................................................59
2-20. Performing pattern button No. selection ................................................................................. 61
(1) Selection from the data input screen ..........................................................................................61
(2) Selection by means of the shortcut button.................................................................................. 62
2-21. Changing contents of pattern button.......................................................................................63
2-22. Copying pattern button .............................................................................................................64
2-23. Changing sewing mode.............................................................................................................65
2-24. LCD display section at the time of combination sewing........................................................ 66
(1) Pattern input screen....................................................................................................................66
(2) Sewing screen ............................................................................................................................68
2-25. Performing combination sewing ..............................................................................................70
(1) How to create new combination data.......................................................................................... 70
(2) How to add combination data .....................................................................................................71
(3) Deleting procedure of the combination data ...............................................................................72
(4) Deleting procedure of the step of the combination data .............................................................72
2-26. Using the simple operation mode ............................................................................................73
2-27. LCD display when the simple operation is selected...............................................................74
(1) Data input screen (individual sewing) .........................................................................................74
(2) Sewing screen (individual sewing)..............................................................................................77
(3) Data input screen (combination sewing).....................................................................................80
(4) Sewing screen (combination sewing) .........................................................................................82
2-28. Changing memory switch data.................................................................................................84
2-29. Using information ......................................................................................................................85
(1) Observing the maintenance and inspection information.............................................................85
(2) Releasing procedure of the warning ...........................................................................................86

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2-30. Using communication function ................................................................................................87
(1) Handling possible data ...............................................................................................................87
(2) To conduct communication by means of the CompactFlash (TM)..............................................87
(3) Performing communication by using USB ..................................................................................87
(4) Take-in of the data ...................................................................................................................... 88
(5) Taking in plural data together...................................................................................................... 89
2-31. Performing formatting of the media.........................................................................................91
3. MEMORY SWITCH DATA LIST ................................................................................. 92
4. ERROR CODE LIST .................................................................................................. 95
5. MESSAGE LIST ...................................................................................................... 102
III. MAINTENANCE OF SAWING MACHINE.............................................. 105
1. MAINTENANCE....................................................................................................... 105
1-1. Adjusting the height of the needle bar..................................................................................... 105
1-2. Needle and hook adjustment .................................................................................................... 105
1-3. Counter knife..............................................................................................................................106
1-4. Positioning the counter knife and the knife thread guide...................................................... 107
1-5. Thread take-up amount adjustment ......................................................................................... 107
1-6. Holder pressure adjustment .....................................................................................................107
1-7. Hook oil amount (track of oil) adjustment ............................................................................... 108
1-8. Adjusting the oil amount in the face plate...............................................................................109
1-9. Replacing the oil in the machine head..................................................................................... 110
1-10. Cleaning the vacuum lter ...................................................................................................... 110
1-11. Removing dust from the face part of the machine head ...................................................... 111
1-12. Cleaning the lter in the electrical box .................................................................................. 111
2. TROUBLE SHOOTING............................................................................................ 112
3. OPTIONAL............................................................................................................... 114
3-1. Garment body rack .................................................................................................................... 114
3-2. Marking light............................................................................................................................... 115

– 1 –
1) Sewing area : X (lateral) direction 250 mm, Y (longitudinal) direction 250 mm
 2) Max.sewingspeed :4,000sti/min(accordingtosewingspecications)
3) Stitch length : 0.1 to 6.0 mm (Minimum resolution: 0.05 mm)
4) Main shaft of machine head drive unit : AC servo motor
5) Presser plate travel : Continuous feed (Stepping motor with an encoder)
6) Needle bar stroke : 35 mm
7) Needle : SCHMETZ 134 SERV 7 Nm : 130
8) Hook : Full-rotary exclusive hook (forced lubrication)
9) Bobbin case : Bobbin case exclusively designed for a full-rotary 1.7-fold hook
(provided with an idling prevention spring)
10) Lubrication oil : Machine head : New Defrix Oil No. 1
11) Thread trimming mechanism : Scissors cutting mechanism using a counter knife and a moving knife
(Driven by grooved cam motor)
12) Pattern data stored in memory : Main body and a media
・Main body: Max. 999 patterns
・Media: Max. 999 patterns
13) Dimensions : 1,890 mm (W) x 1,510 mm (L) x 1,155 mm (H)
(excluding the thread stand)
14) Temporary stop function : It is possible to stop the sewing machine during sewing.
15) Bobbin counter : Up/down method (0 to 9999)
16) Sewing counter : Up/down method (0 to 9999)
17) Stitch number counter : Up/down method (0 to 9999)
18) Memory backup amount : Patterns are automatically stored in memory at the time of power
shutdown.
19) Mass (Total weight) : 558 kg
20) Power consumption : 820 VA
21) Working temperature range : 5°C to 35°C
22) Working humidy range : 35% to 85% (with no dew condensation)
23) Supply voltage : Rating ±10% 50 / 60 HZ
24) Compressed air : 0.5 MPa
25) Air consumption : 220 dm 3/min (ANR)
26) Noise : - Equivalent continuous emission sound pressure level (LpA) at the
workstation :
A-weighted value of 83.0 dB; (Includes KpA = 2.5 dB); according to
ISO 10821- C.6.3 -ISO 11204 GR2 at 4,000 sti/min.
- Sound power level (LWA) ;
A-weighted value of 90.5 dB; (Includes KWA = 2.5 dB); according to
ISO 10821- C.6.3 -ISO 3744 GR2 at 4,000 sti/min.
1. SPECIFICATIONS
I. MECHANICAL SECTION (WITH REGARD TO THE SEWING MACHINE)

– 2 –
❶Sewing machine head
❷Pocket setting plate
❸Presser plate
❹Operation panel
❺Conveyor and X-Y unit
❻Pocket cloth holding board
❼Electrical box
❽Power switch
❾Stacker
󱢳Bobbin winder
󱢴Thread stand
󱢵Presser arm
󱢶Start switch
󱢷Emergency stop switch
󱢸Temporary stop switch
󱢹Presser plunger
󱢺Pedal
2. CONFIGURATION
* If emergency stop switch 󱢷 is pressed while the device is in operation, the blower motor will not stop, but the power
to the device will be turned OFF and the device will stop.
❶
❸
❷
❹
❻
❼
❽
❾
󱢳
󱢴
󱢸
󱢵
󱢶
󱢷
❺
󱢹
󱢺

– 3 –
1) Installthemachineonaatplacewithleveled.
2) Loosen nut 󰿿and turn level adjuster 󱀀to lift the
machine until caster 󱀁idles.
3) After the machine has been set up properly, tighten
nut 󰿿andxleveladjuster󱀀.
3. INSTALLATION
3-1. Setting up the machine
󰿿
󱀀
󱀁
1） Fix stacker safety pipe 󰿿on the main body by means of pipe clamp 󱀀and setscrews 󱀁.
2） Insert two pipes into pipe joint 󱀂andxwithscrews󱀃and nuts 󱀄.
󰿿
󱀂
󱀃
󱀄
󱀁
󱀀
󱀁
󱀀
3-2. Assembling the stacker safety pipe

– 4 –
(1) Removing the sewing product
1） To remove the sewing product from the sewing ma-
chine, press stacker lever release button 󱤨
on the sewing screen to release the stacker presser
lever.
The screen changes over to “stacker release
screen”.
When the cancel butto 󱤩is pressed after
the removal of the sewing product, the screen is
changed over to the sewing screen and the stacker
presser lever closes.
Sewing screen Stacker release screen
󱤨 󱤩
2） Adjust the stacking quantity by loosening the screw
of sensor 󱀀of work clamp cylinder 󰿿and chang-
ing the sensor position. Stacking quantity will be
increased by moving the sensor position upward.
The sensor should be adjusted so that
approximately 60 sewing products are
stacked on the stacker.
󱀀
󰿿

– 5 –
󰿿󱀀
󱀃
󱀂
󱀁
󱀆
󱀄
When opening valve 󱀃, be aware that the air-supplied mechanism is partly activated.
If the air supply source pulse is too large, even at the above setting value the emergency
signal might go off.
3-3. Installing the air hose and air gun and adjusting the pressure
(Open) (Shut)
󱢵
󱢳
󱢴
󱤨
󱤩
󱤪
󱤫
󱀅
󱀇
󱢶
(1) Connecting the air
hose
1) Connect fitting 󰿿to plug
󱀀. At this time, wrap
sealing tape or the like
round the screw.
2) Insert air hose 󱀁into fit-
ting 󰿿and fasten them
with hose band 󱀂.
(Use the correct air hose
tomatchthetting.)
(2) Connecting the air gun
Insert the coil tube of air gun 󱀅into quick-coupling joint 󱀆and put the air gun on
L-shapedtting󱀇.
(3) Opening/closing the valve
To open/close valve 󱀃, turn the valve until it will go no further (by 90 degrees of an
angle).
(4) Adjusting the supply air pressure
1) The operating air pressure should be set to 0.5 MPa.
2) Deliberately open valve 󱀃.
3) Lift regulator knob 󱀄in direction 󱤨. Turning it in this state will change the sup-
ply air pressure. Turn knob in direction 󱤪(+) or in direction 󱤫(–) so that black
point of pressure gauge 󱢳indicates 0.5 MPa. After the adjustment, lower knob
󱀄in direction 󱤩to securely lock it.
(5) Pressure drop signal adjustment
1) Set the pressure at which an emergency signal will go off if the pressure drops below it.
2) The normal setting value is 0.4 MPa.
3) Insert a small screwdriver into cap 󱢴of pressure gauge 󱢳, and adjust screw 󱢵which is inside. Turn the
screw with the screwdriver until the green pointer points to 0.4 MPa.
(6) Discharging the drainage
1) Remove the drain from regulator before use to discharge water (by loosening knob 󱢶).
2) Water adversely affects the air control components. It is therefore necessary to carefully remove the water.
3) If the air pressure in regulator drops, the pressure gauge switch comes on to cause an error.

– 6 –
1) Set the thread stand in the hole at the right corner
of the table.
2) Insert thread stand rob 󱀁into thread stand thread
guide 󱀀.
3) Tighten lock nut 󰿿so that the thread stand will not
be able to move.
4) If ceiling wiring is possible, pass the power cord
through thread stand rod 󱀀.
3-4. Thread stand assembly
3-5. Installing the operation panel
1) Loosen cord clamp 󰿿. Remove panel cord 󱀀.
󰿿
󱀀
󱀁
󰿿
󱀀