JUKI APW-895 Quick start guide

40052509
No.E375-00
ENGINEER’S MANUAL
Lockstitch, Automatic Welting Machine
APW-895(Parallel Pocket with Flap Sewing)
®

PREFACE
This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance
of the machine.
The Instruction Manual for these machines intended for the maintenance personnel and operators at an apparel
factory contains operating instruction in derail. And this manual describes “Standard Adjustment”, “Adjustment
Procedures”, “Results of Improper Adjustment”, and other important information which are not covered in the
Instruction Manual.
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 “StandardAdjustment” on the former page under which the most basic adjustment value is
described, and on the latter page “Results if Improper Adjustment” under which stitching errors and troubles
arising from mechanical failures and “Hoe to adjust” are described.

CONTENTS
1. Specifications ........................................................................................................ 1
(1) Machinical specifications........................................................................................................ 1
(2) Electric specifications ............................................................................................................. 1
2. Configuration of the machine ................................................................................ 2
3. Standard adjustment .............................................................................................. 3
(1) Machine head .......................................................................................................................... 3
1) How to change the timing belt.........................................................................................................3
2) Adjustment of needle bar height.....................................................................................................5
3) Front or rear adjustment of needle bar rocking base ...................................................................5
4) Adjustment of mounting position for needle thread trimming unit .............................................7
5) Adjustment of needle thread trimmer sharpness..........................................................................7
6) Replacement of needle thread knife ...............................................................................................7
7) Adjusting the bobbin thread trimming knife ..................................................................................9
8) Height adjustment of center knife.................................................................................................11
9) Adjustment of center knife link .....................................................................................................11
10)Adjustment of center knife motion stop.......................................................................................13
11)Timing adjustment of needle and hook ........................................................................................13
12)Adjustment of clearance between needle and hook ...................................................................15
13)Installing and removing of hook ...................................................................................................15
14)Opener adjustment .........................................................................................................................15
15)Wiper adjustment............................................................................................................................17
16)Hook oil amount..............................................................................................................................19
17)Adjustment of thread take-up spring............................................................................................21
18)Adjustment of floating amount of the thread tension disk.........................................................23
19)Adjustment the bobbin thread remaining amount detection .....................................................25
20)Lower shaft area .............................................................................................................................27
(2) Unit and related sections ..................................................................................................... 29
1) Binder adjustments ........................................................................................................................29
2) Clamp foot operation......................................................................................................................35
3) Tension adjustment of clamp foot feed belt ................................................................................37
4) Stop position adjustment for forward end or backward end of clamp foot feed......................37
5) Positioning adjustment of welting patch folding plate ...............................................................39
6) Adjustment of parallelism of welting patch folding ....................................................................39
7) Positioning adjustment of right and left garment body clamp...................................................41
8) Adjustment of parallelism of right and left garment body clamp and pocket bag scale .........41
9) Adjustment of released presser height ........................................................................................43
10)Positioning adjustment of the flap presser..................................................................................43
11)Positioning adjustment of flap scale and flap stopper ...............................................................43
12)Corner knife mechanism................................................................................................................45
13)Height adjustment of corner knife ................................................................................................47
14)Tension adjustment of corner knife feeding belt........................................................................47
15)Adjustment of origin position of corner knife..............................................................................49
16)Centering adjustment of corner knife...........................................................................................51
17)Adjustment of corner knife right and left bends..........................................................................51
18)Adjustment of parallel sewin .........................................................................................................53
19)Fine adjustment for stitches..........................................................................................................53
20)Pedal and related sections ............................................................................................................55
21)Marking light and related sections................................................................................................57

(3) Optional sections.................................................................................................................. 59
1) SA-117 (dart stretcher unit) ...........................................................................................................59
2) SA-118 (shim unit) ..........................................................................................................................61
3) SA-119 (suction unit)......................................................................................................................65
4) SA-120 (automatic interlining feeder unit) ...................................................................................71
5) SA-121 (pattern matching marking light unit)..............................................................................75
6) SA-127 (suction motor unit)...........................................................................................................77
7) SP-46 (clamp bar stacker unit) ......................................................................................................81
8) SP-47 (roller stacker unit) ..............................................................................................................95
4. Operation panel and related parts....................................................................... 97
(1) Configuration of IP-310 ........................................................................................................ 97
(2) Memory switch...................................................................................................................... 98
(3) Memory switch data list ....................................................................................................... 99
(4) Optional setting list ............................................................................................................ 106
5. Supplemental remarks of each function number and
explanation of each function ............................................................................. 107
(1) Version display ................................................................................................................... 107
(2) Keylock setup ..................................................................................................................... 108
(3) Communication screens of the maintenance personnel level ....................................... 109
(4) Information screen at the maintenance personnel level................................................. 113
(5) Check program ................................................................................................................... 115
(6) Pedal volume adjustments ................................................................................................ 134
6. Control box......................................................................................................... 137
(1) Description of each constitutive part ............................................................................... 137
1) Function of boards in the control box and installation position............................................. 137
2) Function of boards in the operation panel (IP-310) and installation position ........................137
3) Function of INT board (relay board) and installation position .................................................138
4) Function of PMDC board (optional component) and installation position ............................ 138
(2) Replacement of part ........................................................................................................... 139
1) Replacement of fuses.................................................................................................................. 139
2) Replace the board.........................................................................................................................139
(3) Description of dip switches ............................................................................................... 143
1) MAIN board dip switch ................................................................................................................ 143
2) SDC board dip switch.................................................................................................................. 143
3) PANEL board dip switch ............................................................................................................. 143
4) PMDC board dip switch (For roller stacker)...............................................................................143
(4) Modification of the source voltage specifications .......................................................... 144
7. Names of switches and switch sensors and installation places .................. 145
8. Maintenance....................................................................................................... 151
(1) Machine head maintenance-related matters .................................................................... 151
(2) Application of grease and Locktight................................................................................. 152
(3) Spots where grease • adhesive agents are used ............................................................ 153
(4) Replenishing grease to the designated place.................................................................. 176
(5) Consumable replacement components............................................................................ 178
9. Error code list .................................................................................................... 179
10.Troubles and corrective measures .................................................................. 189
(1) Machine head ...................................................................................................................... 189
(2) Equipment and related matters ......................................................................................... 194
(3) Electrical matters................................................................................................................ 196

11. Air circuit diagram............................................................................................. 202
12.Circuit diagrams ................................................................................................ 203
(1) Block diagram ..................................................................................................................... 203
(2) Connection diagram ...........................................................................................................204
1) Diagram 1 ......................................................................................................................................204
2) Diagram 2 ......................................................................................................................................205
3) Diagram 3 ......................................................................................................................................206
4) Diagram 4 ......................................................................................................................................207

– 1 –
No. Application
APW-895
1Sewing machine LH-895 model of 2-needle, lockstitch machine with a center knife
2Sewing speed Max: 3,000 rpm
Lockstitch : 2.0 to 3.4mm (standard :2.5mm)
Condensation stitch : 0.5 to 1.5mm (standard : 1.0mm)
Back tuck stitch : 0.5 to 3.0mm (standard : 2.0mm)
Condensation/Back tuck stitch selectable
Parallel duble welt, parallel single welt
Each with flap or without flap
Possible to set in increments of 0.1mm ithin the range of 18mm (min.) to 220mm (max.) (Needle gage: 8 to 20mm)
Note that the pocket length is 35mm at the minimum when using the corner knife
5 (50mm in case of 14mm gauge or more and 21mm by adding a solenoid valve)
For the longer type (optonal), the maxmimum sewing length will be 250mm (Needle gage: 22 to 32mm)
(Possible up to 300mm wihiout entering corner knife)
Welting width 8, 10, 12, 14, 16, 18 and 20mm
(Needle gauge) (Optional : 22, 24, 26, 28, 30 and 32mm)
7 Needles ORGAN DP X 17 #14 to #18 (standard #16), SCHMETZ 190R #100 to #110 (standard #100)
8Thread Spun thread #60 (Recommended)
9Hook Vertical-axis 1.7-fold capacity hook
10 Thread take-up lever Slide thread tak-up lever
11 Needle bar stroke 33.3mm
12 Cloth feed mechanism Driver by stepping motor
13 Control By a micro-computer
Machine operation is automatically stopped if the cloth feed mechanism error detector, the needle
thread breakage detector or anu of the various safety devices is actuated.
15 Lubricating oil JUKI New Defrix Oil No. 1 (equivalent to ISO VG7)
16 Grease 1. JUKI Grease A. 2. JUKI Grease B
17 Operating air pressure Standard : 0.5MPa
18 Air consumption 40dm3/min(ANR)
Dimensions of Width: 1,095 mm Length: 1,500 mm Height: 1,200 mm
machine (Width: 1,580 mm, including stacker) (Height: 1,800 mm, including thread stand)
20 Weight 238.5kg
21 Temperature: 5°C to 35°C, Humidity: 35 to 85% (no condensation)
1. Specifications
(1) Machinical specifications
3Stitch length
4Types of welt
Pocket lip length
(Welt length)
6
19
(2) Electric specifications
Once setting has been made, data can be retained (for 100 hours) by the built-in battery cell even after Power OFF
unless this setting is canceled, thanks to the function of the built-in microcomputer.
No. Application
APW-895
1No. of patterns for stored single sewing 99 (1 to 99)
2No. of patterns for stored alternate sewing 20 (1 to 20)
3No. of stored cycles 20 (1 to 20)
Single phase/3-phase 200 V, 220 V, 230 V, 240 V (option 380 V)
4Input voltage/frequency 50/60 Hz
Power voltage fluctuation Rated voltage ±10% or less
5Power consumption 200VA
Model name
Item
Model name
Item
14 Safety mechanism
Working temperature/
humidity

– 2 –
The APW-895 consists mainly of the following units.
AFrame and structural components (Frame sewing table, covers, foot switch, etc.)
BClamp foot unit and feed mechanism
CCorner knife unit
DBinder unit (Binder components and its driving components)
EPneumatic control unit (Pneumatic control devices and pipings)
FStacker unit (Optional)
GSewing machine head
HElectric control unit (Control panel)
IOperation panel
JPower switch
KTemporary stop switch
With this machine consisting of the aforementioned 11 units, you can do desired welting work simply by setting
materials (garment body, interlining piece, welting patch, etc.) in place and operating the switches on the operation
panel.
In addition, when temporary stop switch Kis pressed during operation of the device, tthe device stops.
A
H
J
I
G
DK
E
B
F
C
2. Configuration of the machine

3. Standard Adjustment
(1)Machine head
1) How to change the timing belt
– 3 –
Flat in
front
Arm inner diameter
Up dead position
No. 1 screw
Flat
Flat
0.5mm
Arm hole
Driving
Standard Adjustment
Parts no. : 40029049

– 4 –
1. Remove the four set screws of the motor.
2. Loosen the two set screws of the coupling.
3. Remove the motor and coupling from the lower shaft .
4. Remove the six set screws , and remove the window plate .
5. Remove the timing belt from the pulley .
6. Loosen the two setscrews from arm hole.
7. Loosen the two setscrews of the pulley , and remove the pulley
.
8. Tap the rear bearing from inside and pull out this rear bearing .
9. Pass the timing belt through the bearing hole of the arm and
remove (pull out) the timing belt via the main shaft .
10. Install a new timing belt .
11. Degrease the outer diameter of the rear bearing and the inner
diameter of the arm, apply a sealant of medium or higher strength,
and drive the rear bearing until it stops in the interior.
12. Tighten two setscrews from the armhole. (There is no flat section.)
13. Join the flat section of the main shaft with the first screw of the
pulley , and mount the pulley .
At that time, the clearance should be about 0.5mm between the pulley
and the arm.
14. Turn the pulley and let the needle bar stay in the UP dead
position.
At that time, the timing belt is hung in the position where the flat
section of the lower shaft faces the front.
15. Join the flat section of the lower shaft with the first screw of the
coupling, and tighten two setscrews .
16. Tighten four motor setscrews to fix the motor .
17. Fix the window plate with six setscrews .
Adjustment Procedures Results of Improper Adjustment

2) Adjustment of needle bar height
– 5 –
3) Front or rear adjustment of needle bar rocking base
Lower dead point marker
of needle bar
Blindstitch marker
of hook blade tip
Eccentricity
Origin position
Standard Adjustment
Standard Adjustment

1. Turn the pulley until the needle bar comes to the lower dead point.
2. Loosen the needle bar connection screw .
3. Based on the upper engraved marker line of the needle bar lower
dead point, tighten the needle bar connection screw .
4. The needle shall be positioned in the center of the throat plate
hole.
– 6 –
1. When the motor shaft is rotated, the needle bar rocking link
makes a rocking motion by the effect of the eccentric cam .
2. Turn the power OFF, rotate the motor shaft , and confirm that the
needle makes a uniform rocking motion in the oblong hole of the
throat plate .
3. If the needle motion is not uniform, insert a tool from the hole on the
top surface of machine arm and loosen the needle bar rocking arm
setscrew for adjustments.
4. In the case of eccentricity to the left, confirm whether the sensor slit
is located in the edge position of the sensor .
5. In the case of deflection, loosen the sensor slit setscrew or the
sensor setscrew for adjustments.
* For fine adjustments, use of the sensor setscrew is adequate.
6. After the power is ON, the needle comes in the center of the
throat plate hole.
To make sure, examine [(11) Needle and Hook Timing Adjustments
and (12) Needle and Hook Clearance Adjustments] (Hook
Adjustment).
Adjustment Procedures Results of Improper Adjustment
Adjustment Procedures Results of Improper Adjustment

4) Adjustment of mounting position for needle thread trimming unit
– 7 –
5mm
30 to 32mm
Clearance
5) Adjustment of needle thread trimmer sharpness
6) Replacement of needle thread knife
Same surface
Standard Adjustment
Standard Adjustment
Standard Adjustment

✩The knife is driven by the air cylinder. Therefore, relieve the air
pressure before adjustments.
1. Loosen two setscrews and maintain the clearance toward the
throat plate at 5mm in the state that the moving knife is advanced
to the extreme front. Adjust the distance toward the needle to 30
to 32 mm and tighten the two setscrews .
In this case, confirm that a proper clearance is secured between the
center knife and the spreader .
– 8 –
1. Loosen two setscrews of the counter knife and push both right
and left blades of the counter knife uniformly against the moving
knife . Then tighten the two setscrews again.
2. Check the motion of the cylinder shaft . Confirm that it can work to
accomplish cutting assuredly at 17.6N (1.8kgf) or less.
3. After thread cutting, the holding force for needle thread clamp is
more than 2.9N (300g) both right and left.
In the case when this force is not secured, select an adequate spacer
.
[The spacer has four types of thickness: 0.2mm, 0.4mm, 0.6mm,
and 0.8mm]
1. Loosen the setscrew and remove the pin . Then, the moving
knife can be pulled off downwards.
2. Install a new moving knife and insert the pin .
At that time, the pin should be held almost in the same plane of
the moving knife . Tighten the setscrew .
*The needle thread trimming unit has some mounting parts that can
change with the gauge size. Refer to the table below for details.
No. 8mm 10mm 12mm 14mm 16mm 18mm 20mm 22mm 24mm 26mm 28mm 30mm 32mm
1Counter knife 16409906 16411308 40039788
2Moving knife 40033814 40023020 40033809 40033810 40033811 40033812 40033813
3Clamp plate 40033815 16411407 40039783
Size
Name of parts
Adjustment Procedures Results of Improper Adjustment
Adjustment Procedures Results of Improper Adjustment
Adjustment Procedures Results of Improper Adjustment

7) Adjusting the bobbin thread trimming knife
– 9 –
A
B
Standard Adjustment

1. How to join the throat plate and the bobbin thread trimming
knife
(1) Hold the bobbin thread trimming knife perpendicular to the throat
plate. Install it to avoid any twisting motion during operation.
(2) Loosen the setscrew of the left bobbin thread trimmer and actuate
the bobbin thread trimmer knife cylinder .
(3) Loosen the setscrew of the right bobbin thread trimmer and actuate
the bobbin thread trimmer knife cylinder .
(4) Set the left bobbin thread trimmer base where the bobbin thread
trimming knife does not cause twisting motion, and fix the setscrew
.
(5) Set the right bobbin thread trimmer base where the bobbin thread
trimming knife does not cause twisting motion, and fix the setscrew
.
2. Adjustment of bobbin thread trimming knife position and height
(1) Join the upper surfaces of both right and left bobbin thread trimming
knives with the upper surface of the throat plate in the same plane.
Make adjustments so that the groove of throat plate meets in parallel
to that of the bobbin thread trimming knife when the bobbin thread
trimmer is actuated.
(2) Loosen the setscrew of the left bobbin thread trimmer and make
adjustments so that the upper surfaces of the throat plate and the
bobbin thread trimming knife are joined in the same plane.
(3) Loosen the setscrew of the right bobbin thread trimmer and make
adjustments so that the upper surfaces of the throat plate and the
bobbin thread trimming knife are joined in the same plane.
(Caution) Be aware that the bobbin thread trimming knife should
be below the top surface of the throat plate.
(4) Push the bobbin thread trimming knife cylinder of the left bobbin
thread trimmer in DirectionAand adjust its position so that the groove
of the bobbin thread trimming knife meets in parallel to that of the
throat plate.
(5) Push the bobbin thread trimming knife cylinder of the right bobbin
thread trimmer in Direction B and adjust its position so that the groove
of the bobbin thread trimming knife meets in parallel to that of the
throat plate.
(6) Tighten the right and left setscrews and .
3. Replacement of the bobbin thread trimming knife
(1) When the setscrews and are loosened, the right and left bobbin
thread trimming knives can be pulled off downwards.
4. Adjustment of bobbin thread trimming knife sharpness
(1) Adequately push the thread clamp pushing spring against the
bobbin thread trimming knife to adjust its sharpness.
(2) The pushing force should be kept as light as possible, to a degree
the thread can be cut assuredly. Then, the
– 10 –
Adjustment Procedures Results of Improper Adjustment

8) Height adjustment of center knife
– 11 –
9) Adjustment of center knife link
Knife bar connection
Screw hole
0 to 0.3mm
Tightening
screw hole
Level
Metal
Standard Adjustment
Standard Adjustment

✩Relieve the air pressure during adjustment.
1. Insert a tool from the hole of the knife bar connecting screw and
loosen the knife bar connecting setscrew .
2. Turn the motor shaft to move the center knife to the lower
dead point.
At that time, tighten the knife bar connecting setscrew where the
throat plate and the center knife assume a condition of 0 to
0.3mm as illustrated.
– 12 –
1. Remove the four set screws , and remove the face plate .
2. Confirm that Link A is maintained level at the lower dead point of
the center knife.
3. If the horizontality of Link A is not secured, insert a tool from the
tightening screw hole and loosen the driving arm tightening screw
. Where Link A is maintained level, tighten the driving arm
tightening screw again.
At that time, the driving arm should have been moved to the metal
side during screw tightening.
Adjustment Procedures Results of Improper Adjustment
Adjustment Procedures Results of Improper Adjustment

10) Adjustment of center knife motion stop
– 13 –
11)Timing adjustment of needle and hook
Protruded
Coincidence of
shaft centers
1.3
±
0.2mm
Blade point
3.5mm
Withdrawn
Lifting position
Needle
Blade point
0 to -0.05mm
0 to 0.03mm
Standard Adjustment
Standard Adjustment

1. While the cylinder is withdrawn, the knife bar is in the state of
motion. While it is protruded, the knife bar remains in the state of
stop.
2. While this cylinder is protruded, confirm that the shaft center of
Link A coincides with that of Screw A .
3. If no coincidence is perceived, loosen the nut of the adjusting
screw and adjust the adjusting screw to the position where
the shaft centers coincide with each other. When coincidence is
secured, fix the nut .
– 14 –
1. Timing adjustment of the needle and hook
(1) Remove the throat plate. When the needle is raised by 3.5mm from
the lowermost point (needle bar engraved line alignment), let the
blade points of the right and left hooks coincide with the needle
centers.At that time, the clearance between the needle side surface
and the hook holder shall be 0 to -0.05mm, the clearance between
the needle side surface and the blade point shall be 0 to 0.03mm,
and the distance between the upper end of the needle hole and the
blade point shall be 1.3±0.2mm.
2. Adjustment of hook timing
(1) Loosen three setscrews of small gears located on the hook shaft
and turn the hook. When the needle center coincides with the blade
point, tighten the setscrews . In this case, the three setscrews
should be tightened in the specified order. To avoid the occurrence
of vertical rattling in the hook shaft, try to tighten the setscrews
while the hook is pushed down and the small gears are somewhat
raised.
(2) Check whether the main shaft torque is applied after adjustment of
the hook timing.
Adjustment Procedures Results of Improper Adjustment
Adjustment Procedures Results of Improper Adjustment

12) Adjustment of clearance between needle and hook
13) Installing and removing of hook
14) Opener adjustment
– 15 –
0.2 to 0.3mm
Standard Adjustment