JUKI AP-876/IP-420 User manual

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ENGLISH
INSTRUCTION MANUAL
AP-876 / IP-420
* "CompactFlash(TM)" is the registered trademark of SanDisk Corporation, U.S.A.

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CONTENTS
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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. Removing the reinforcing board of the folding unit ...................................................................3
3-3. Assembling the stacker safety pipe .............................................................................................4
3-4. Assembling the safety pipe for the folding unit..........................................................................5
3-5. Installing the air hose and air gun and adjusting the pressure.................................................6
3-6. Thread stand assembly ................................................................................................................. 7
3-7. Installing the operation panel ....................................................................................................... 7
3-8. Locking the Pocket Folding Board...............................................................................................9
3-9. Connecting the power supply.......................................................................................................9
3-10. Lubrication..................................................................................................................................10
3-11. Checking the emergency stop switch......................................................................................10
3-12. Removing the foamed polystyrene from the folding unit ...................................................... 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 .................................................................................................................20
4-8. How to adjust the folding unit.....................................................................................................21
5. Emergency stop switch ........................................................................................... 24
@. OPERATION SECTION (WITH REGARD TO THE PANEL)................... 25
1. PREFACE .................................................................................................................. 25
2. WHEN USING IP-420 ................................................................................................ 29
2-1. Name of each section of IP-420 .................................................................................................. 29
2-2. Buttons to be used in common .................................................................................................. 30
2-3. Basic operation of IP-420 ............................................................................................................ 31
2-4. Liquid crystal display at the time of sewing pattern selection................................................ 32
(1) Sewing pattern data input screen ............................................................................................... 32
(2) Sewing screen ............................................................................................................................ 34
2-5. Replacing the pattern ..................................................................................................................36
2-6. How to select the sewing pattern ............................................................................................... 38
2-7. Pattern checking procedure........................................................................................................40
2-8. Changing item data......................................................................................................................41

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2-9. Performing modication of needle entry point ......................................................................... 43
2-10. Setting the MANUAL/AUTOMATIC/STEP .................................................................................44
2-11. Changing the folding timing......................................................................................................45
2-12. Changing the folding position .................................................................................................. 48
2-13. How to use temporary stop.......................................................................................................49
(1) To continue performing sewing from some point in sewing ........................................................49
(2) To perform re-sewing from the start............................................................................................50
(3) To carry out the folding operation again......................................................................................51
2-14. Lowering the presser.................................................................................................................52
2-15. Stacker operation (taking out the material).............................................................................53
(1) Taking out the material from the stacker .................................................................................... 53
(2) Adjusting the stack-full sensor ....................................................................................................53
2-16. Using counter.............................................................................................................................54
(1) Setting procedure of the counter ................................................................................................54
(2) Count-up releasing procedure .................................................................................................... 56
(3) How to change the counter value during sewing ........................................................................56
2-17. Performing new register of users’ pattern...............................................................................58
2-18. Naming users’ pattern ............................................................................................................... 59
2-19. Performing new register of pattern button..............................................................................60
2-20. LCD display section at the time of pattern button selection ................................................. 61
(1) Pattern button data input screen................................................................................................. 61
(2) Sewing screen ............................................................................................................................ 63
2-21. Performing pattern button No. selection ................................................................................. 65
(1) Selection from the data input screen .......................................................................................... 65
(2) Selection by means of the shortcut button.................................................................................. 66
2-22. Changing contents of pattern button.......................................................................................67
2-23. Copying pattern button ............................................................................................................. 68
2-24. Changing sewing mode.............................................................................................................69
2-25. LCD display section at the time of combination sewing........................................................70
(1) Pattern input screen....................................................................................................................70
(2) Sewing screen ............................................................................................................................ 72
2-26. Performing combination sewing .............................................................................................. 74
(1) How to create new combination data.......................................................................................... 74
(2) How to add combination data ..................................................................................................... 75
(3) Deleting procedure of the combination data ...............................................................................76
(4) Deleting procedure of the step of the combination data ............................................................. 76
2-27. Using the simple operation mode ............................................................................................ 77
2-28. LCD display when the simple operation is selected...............................................................78
(1) Data input screen (individual sewing) .........................................................................................78
(2) Sewing screen (individual sewing)..............................................................................................81
(3) Data input screen (combination sewing).....................................................................................84
(4) Sewing screen (combination sewing) ......................................................................................... 86
2-29. Changing memory switch data.................................................................................................88
2-30. Using information ......................................................................................................................89
(1) Observing the maintenance and inspection information.............................................................89
(2) Releasing procedure of the warning ...........................................................................................90

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2-31. Using communication function ................................................................................................ 91
(1) Handling possible data ...............................................................................................................91
(2) To conduct communication by means of the CompactFlash (TM)..............................................91
(3) Performing communication by using USB .................................................................................. 91
(4) Take-in of the data ......................................................................................................................92
(5) Taking in plural data together...................................................................................................... 93
2-32. Performing formatting of the media.........................................................................................95
3. MEMORY SWITCH DATA LIST ................................................................................. 96
4. ERROR CODE LIST .................................................................................................. 99
5. MESSAGE LIST ......................................................................................................106
#. MAINTENANCE OF SAWING MACHINE ............................................. 109
1. MAINTENANCE....................................................................................................... 109
1-1. Adjusting the height of the needle bar.....................................................................................109
1-2. Needle and hook adjustment .................................................................................................... 109
1-3. Counter knife.............................................................................................................................. 110
1-4. Positioning the counter knife and the knife thread guide...................................................... 111
1-5. Thread take-up amount adjustment ......................................................................................... 111
1-6. Holder pressure adjustment ..................................................................................................... 111
1-7. Hook oil amount (track of oil) adjustment ............................................................................... 112
1-8. Adjusting the oil amount in the face plate............................................................................... 113
1-9. Replacing the oil in the machine head..................................................................................... 114
1-10. Cleaning the vacuum lter ...................................................................................................... 114
1-11. Removing dust from the face part of the machine head ...................................................... 115
1-12. Cleaning the lter in the electrical box .................................................................................. 115
2. TROUBLE SHOOTING............................................................................................ 116
3. OPTIONAL............................................................................................................... 118
3-1. Garment body rack .................................................................................................................... 118
3-2. Marking light............................................................................................................................... 119

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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 medium
・Main body: Max. 999 patterns
・Medium: 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 : 650 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 11204 GR2 at 4,000 sti/min.
1. SPECIFICATIONS
!. MECHANICAL SECTION (WITH REGARD TO THE SEWING MACHINE)