JUKI AVP-875S User manual

Automatic Pocket Setter For Jeans
AVP-875S
AVP-875A (With an automatic bobbin winding and feeding device AW-2)
AVP-875A
High-performance machine that folds pockets with sharp,
crisp-looking edges and sews at the high speeds needed for
optimal pocket attachment to jeans.

A wider sewing table is prepared for
large-sized garment bodies.
A wider sewing table is prepared for
large-sized garment bodies.
The operation panel is specifically
designed to facilitate easy operation.
The exclusive machine head
finishes beautiful seams.
Crease-folding unit helps produce
pockets of upgraded quality.
AVP-875A
The machine demonstrates improved
productivity.
The machine automatizes a series of pocket-setting
processes, concurrently folding and sewing sequential pocket
cloths in the production line, thereby resulting in substantial labor
savings. With its newly developed large-hooked zigzag-stitching
lockstitch machine head, the machine run at a maximum sewing
speed of 4,000rpm and executes all of its operations with split-
second response. The sum result: dramatically reduced cycle time
and increased productivity.
The machine folds pocket cloths
with beautiful, sharp creases and
absolutely no material slippage.
A pocket cloth is folded on the table surface and
properly tensed by a pocket style jig to create sharp creases
without material slippage or bulging. The pocket cloth is vertically
shifted and pulled to the suitable tautness for placement on the
garment body. This prevents the pocket cloth from slipping out of
the correct position and makes it easy to adjust folding timing. With
this pocket-folding and pocket-positioning mechanism, the machine
is widely adaptable to various materials.
The machine is ready for large
garment bodies.
The folding unit is sufficiently spaced from the machine
head. This means large garment bodies never interfere with each
other even when right and left garment bodies are alternately
processed on the machine. The machine widely adapts to
materials of various sizes and many different sewing specifications.
The machine achieves consistent
seam quality.
The work clamp plate clamps the pocket cloth at the
center of the sewing area so that the entire pocket cloth is pressed
down evenly, thereby preventing the cloth from flopping. In
addition, by installing JUKI's unique hook-driving-shaft offset
mechanism in the machine head, the machine produces beautiful
seams with consistency while preventing the stitch skipping or
thread breakage that is liable to occur when the needle throws to
the right and left.
12
45
JUKI automatic pocket setter is a highly advanced machine that
automatically performs pocket setting procedures for jeans ranging
from folding the hip pocket piece, setting it onto the garment body,
sewing it, and stacking the finished product. The result is even more consistent quality and
higher productivity.
When the machine is equipped with the optional jig for a pre-folded pocket style, pocket
pieces folded in advance, upstream from the machine's standard pocket-setting functions,
can be sewn onto the garment body while disabling only the pocket-piece folding function.
This production style using the optional pocket style jig makes it possible to apply the
machine for the production of various products in small lots at a reduced cost.
The machine can be used in two different ways, i.e., as a regular pocket setter when the production
lot is large, or as a pre-folded pocket setter when the lot is small. In this way, the AVP-875 offers
increased availability.
AVP-875
AVP-875

●Denim • Blade-shape
bottom type ●Corduroy • Round- shape bottom type
Hand pulley
Needle entry point and needle-to-hook
timing can be easily adjusted when
setting the sewing data.
Needle-thread-breakage detector
2-step thread tension controller
Needle thread tension can be
changed over during sewing.
Hand pulley
Needle entry point and needle-to-hook
timing can be easily adjusted when
setting the sewing data.
Needle-thread-breakage detector
The large-hooked zigzag stitching lockstitch machine head runs at
a maximum sewing speed of 4,000rpm and comes with JUKI's
unique offset mechanism for the hook driving shaft.
Pocket style jigs can be replaced with no tools. A new pocket
style jig can be installed in the machine and fully adjusted in
only about five minutes. After replacing the pocket style jig, the folding position of
the pocket cloth can be finely adjusted via the operation
panel in a few short moments.
The stacker provides a capacity of 64 pieces of
finished products. In addition, the stacker is equipped
as standard with a stacker-capacity detector.
JUKI's unique hook driving shaft offset mechanism
The position at which the
blade point of the hook tacks
the needle thread varies at the
leftmost position and rightmost
position of zigzag stroke.
The position at which the
blade point of the hook tacks
the thread is almost uniform.
The center of the hook
driving is moved away from
the center of the needle.
AVP-875
(Hook-driving shaft offset.)
Regular state
Hook
Needle
position
The needle and
hook are concentric.
Locus of the
blade point of
the hook
Left Right Left Right
The blade point of the hook tucks the thread at a
constant position even if the needle throws to the right
and left, thereby helping reduce stitch skipping and
thread breakage.
The pocket style jig can be easily
replaced and adjusted.
Replacing the pocket style jig, including adjustment, takes only
about five minutes. The pocket style jig can be attached/removed without
the use of any tools. By reducing the downtime required for pocket style jig
replacement, the machine can respond more flexibly to small-lot production.
The folding position after the replacement can be finely adjusted with a few
easy modifications of the sewing data on the operation panel, and a series
of operating procedures can be checked step by step by changing over the
operation mode.
3
Needle
Blade point of
the hook

●Thanks to a sophisticated design pooling all of JUKI's available technologies,
the automatic bobbin thread winding and feeding device (AW-2) can
automatically execute all steps of bobbin replacement, including
removal/installation of the bobbin, removal of the thread remaining on the
bobbin, and threading of the bobbin case. There are absolutely no manual
steps required to replace the bobbin - the operator is entirely free.
●Bobbin replacement by the automatic bobbin thread winding and feeding device
is fully synchronized with the sewing operation of the AVP-875. With this device,
the operator can operate the machine rhythmically, fully concentrating his or her
attention on the sewing work. The downtime conventionally associated with
bobbin replacement has been eliminated.
●The automatic bobbin thread winding and feeding device also controls the
amount of thread remaining on the bobbin during replacement to eliminate
thread waste.
●When the AVP-875 is equipped with the AW-2, the AW-2 increases production
capacity by as much as 10%.
(Note: Increases in productivity with the AVP-875 vary with the operating conditions.)
Productivity is increased Automatic bobbin winding
and feeding cycle
A trial calculation of productivity
Trial calculation conditions
Thread: Span #20
Bobbin thread consumption: 1.2 m/pocket
Time required to manually replace the bobbin: 25 sec/case
Cycle time: 10.5 sec/pocket
Allowance rate (excluding bobbin replacement): 15 %
Time lost due to
causes other than
bobbin replacement
Time lost due to
bobbin replacement
Total time lost in one
day (allowance rate)
Daily production
(8-hour operation)
Effect of introduction
of AW-2
AVP-875A
3,946 seconds in
8 hours
0 seconds in
8 hours
3,946 seconds in
8 hours (16 %)
2,367 pockets
AVP-875S
3,775 seconds in
8 hours
2,664 seconds in
8 hours
6,421 seconds in
8 hours (29 %)
2,131 pockets
Production: Increase by 236 pockets in
8 hours (11 % increase)
Time lost: Reduced by 2,475 seconds in
8 hours (39 % reduction)
Allowance rate: 13 % decrease
＊The time lost for the AVP-875 includes the time required to
operate the AW-2 (189 seconds in 8 hours).
＊Daily production and effect of introduction of the AW-2 vary
with sewing conditions.
Automatic Bobbin Winding and Feeding Device
AW-2
Automatic bobbin thread replacement has been a desired
function since the manufacture of the very first lockstitch
machines many years ago. This is the world's first automatic
bobbin thread winding and feeding device that fully
automatizes the bobbin thread replacement procedure.
Saving the time ordinarily required for bobbin thread
replacement, this device helps the pocket setter for jeans
maximize its already excellent production capacity.
The world's first automatic bobbin thread winding and feeding device
that fully automatizes the bobbin thread replacement procedure.
AVP-875A

Replacement parts for pocket style jig
Creasing gauge Presser plate Form plate
Pre-folded pocket style (Optional)
Label-inserting device
(optional)
A label can be inserted either into the
right- or left-hand side of a pocket cloth.
A cylinder-type label-inserting device that
can be directly mounted on the pattern
board is also available. When placing an
order for a pocket style jig, specify a label-
inserting device, if necessary.
Folded of the pocket and label Label-inserting device
Clamp frame (asm.)
Clamp upper plate (machined)
Clamp lower plate (machined)
[Clamp designed specifically for pre-folded pockets]
Part No.:
Clamp frame (asm.) G6132-875-0A0
Clamp upper plate blank (asm.) G6133-875-0A0
(Clamp upper plate/lower plate, combined)
Magnet mounting plate (asm.) G6131-875-0A0
(Magnet for retaining the upper plate)
●This is a pocket style jig to be used exclusively for sewing pocket pieces onto the
garment body after they have been folded in a separate process.
●The pre-folded pocket style jig consists of three components, i.e., the “clamp frame,”
“clamp upper plate” and "clamp lower plate." Changes in pocket size and design are
accommodated by replacing the clamp upper plate and lower plate with appropriate
ones. The clamp upper plate and lower plate are less expensive than the conventional
pocket style jigs. The use of the pre-folded pocket jig in highly flexible small-lot
production reduces the running costs of the AVP-875.
●The clamp upper plate and lower plate can be attached and removed to and from the
clamp frame quickly and easily.
●Even when using the pre-folded pocket style jig, the machine can sew at speeds as
high as 4,000rpm, dramatically boosting productivity.
●The folding mechanism of the pocket setter does not support a trapezoidal-design
pocket. With the pre-folded pocket style jig, however, this type of pocket piece can be
sewn onto a garment body if it has been folded into a trapezoidal shape in advance.
＊If you want to use a pre-folded pocket style jig with your AVP-875, you
may have to change the system ROM of the main AVP unit. When
placing an order for a pre-folded pocket style jig, please confirm with the
distributor in your area whether you will need to replace the system ROM.
■Set the folded pocket piece on the pre-folded pocket jig.
＊When the magnet for the retaining upper plate is used with the jig,
you can set a pocket on the jig using both hands.

Main unit
Stacker
1,860
1,160
700
830
INTERNATIONAL SALES H.Q.
8-2-1, KOKURYO-CHO, CHOFU-SHI,
TOKYO 182-8655, JAPAN
PHONE : [phone]〜4
FAX : [phone]
TELEX : J22967
http://www.juki.co.jp
✽ Specifications and appearance are subject to change without prior notice for improvement.
✽ Read the instruction manual before putting the machine into service to ensure safety.
AUGUST, 2001 Printed in Japan(T)
Handy programming device
PGM-6
If the handy programming device is
connected to the main unit of the pocket
setter, sewing data can be established
and modified.
Marking light
(Part number: G9001-875-0A0)
The marking light helps you easily
position a pocket and garment body on
the machine.
AVP-875 S
■SPECIFICATIONS ■OPTIONS
■WHEN YOU PLACE ORDERS
(unit: mm)
●To order, please contact your nearest JUKI distributor.
＊
The automatic bobbin thread winding and feeding device (AW-2) cannot be mounted on the AVP-875S after setup.
Garment put base
(Part number: G9011-875-0B0)
When mounted on the main unit, the
garment put base is quite helpful of
sewing either right or left garment bodies
in succession.
AVP-875S AVP-875A
High-speed, 1-needle, lockstitch, zigzag stitching machine
(exclusive machine head)
4,000rpm
250mm (L)×240mm (W)
0.1〜6.0mm
35mm
SCHMETZ 134SES SERV7 (Nm130)
Horizontal-axis full-rotary hook
Model name
Machine head
Max. sewing speed
Sewing area
Stitch length
Needle bar stroke
Needle (at the time of delivery)
Hook
Automatic bobbin winding
and feed device (AW-2)
Size of bobbin
and bobbin case
Bobbin thread replacement
Needle thread breakage
detection
Stacking capacity
Number of patterns that
can be stored in memory
Memory medium
Feeding method
Lubrication
Lubricating oil
Power requirement
Power consumption
Compressed air
Air consumption
Total weight
Dimensions
−

1.7 fold
Manual
Provided as standard
1.4 fold (specifically designed
for the AW-2)
Automatic (AW-2)
＊
Provided as standard
Max. 64 pieces of jeans bodies
Max. 691 pattern
2DD/2HD 3.5" micro-floppy disk
AC servomotor, X-Y clamp drive
Automatic (machine head)
JUKI New Defrix Oil No.1 (equivalent to ISO VG7)
Single-phase 200〜240V, 3-phase 200V, 200〜240V, 380〜440V
600VA
0.5MPa (5.0kgf/cm2)
120N /min 220N /min (max.)
600kg
Please note when placing orders, that the model name should be written as follows:
Type
Standard
With AW-2
Code
S
A
Single-
phase
3-phase
Code
E
P
N
M
200〜240V
200〜240V
380〜440V
200V for CE
Power supply
Pocket style jig
Configuration
Not used
Round-bottom type
Blade-shape bottom type
Trapezoidal-bottom type
Bilge-shaped-bottom type
Square-bottom type
Others
Code
Z
A
B
C
D
E
X
Kind
999
Label-inserting
device
Not provided
Code
Z
001 〜998
for each
configuration
Not provided : Z
Provided : A
Option
Marking light
Not provided
Not provided
Provided
Provided
Code
Z
A
B
C
Garment put
base
Not provided
Provided
Not provided
Provided