JUKI PS-800-12080 User manual

PS-800-12080
INSTRUCTION MANUAL

i
CONTENTS
1. SPECIFICATIONS .............................................................................................1
2. CONFIGURATION .............................................................................................2
3. INSTALLATION..................................................................................................3
3-1. Setting up the sewing machine ..................................................................................... 3
3-1-1. Unpacking .............................................................................................................. 3
3-1-2. Setting up the X feed mechanism and the table................................................. 5
3-1-3. Setting up the table ............................................................................................... 6
3-1-4. Setting up the switches, bobbin winder and switch button (asm.) .................. 7
3-1-5. Check points and precautions before turning the power ON ........................... 8
3-2. Installing the air hose ..................................................................................................... 9
3-3. Cautions for the compressed air supply (source of supply air) facility .................. 10
3-4. Installing the bobbin winder device ............................................................................ 11
3-5. Winding the bobbin thread........................................................................................... 11
3-6. Precautions for installation of the machine ............................................................... 12
4. PREPARATION OF THE SEWING MACHINE ................................................13
4-1. Lubricating method and check of the oil quantity..................................................... 13
4-2. Attaching the needle..................................................................................................... 14
4-3. Threading the machine head ....................................................................................... 15
4-4. Bobbin replacement procedure................................................................................... 16
4-5. Adjusting the thread tension ....................................................................................... 17
4-6. Adjusting the thread take-up spring and the thread breakage detector plate ........ 18
4-7. Adjusting the thread take-up stroke............................................................................ 18
4-8. Needle-to-hook relationship ........................................................................................ 19
4-9. How to wind a bobbin................................................................................................... 21
4-10. Adjusting the position of the thread trimmer............................................................. 22
4-11. How to attach / remove the cylinder lifting plate ....................................................... 24
4-12. How to conrm the amount of oil (oil splashes) in the hook.................................... 25
4-13. Adjusting the amount of oil in the hook ..................................................................... 26
4-14. Adjusting the needle hole in the throat plate and the needle................................... 27
4-15. Setting the mechanical origin...................................................................................... 28
4-16. Adjusting the disk presser pressure........................................................................... 29
4-17. Adjusting the thread end position at the beginning of sewing ................................ 30
4-18. Adjusting the electronic intermediate presser stroke............................................... 31
4-19. Adjusting the needle thread air blower....................................................................... 32

ii
4-20. Making a template......................................................................................................... 33
4-21. Preparation for sewing................................................................................................. 35
4-22. Conguration of the operation panel.......................................................................... 37
4-23. Maintenance mode........................................................................................................39
4-24. List of parameters......................................................................................................... 40
4-25. List of error codes ........................................................................................................ 46
5. MAINTENANCE OF SAWING MACHINE .......................................................62
5-1. Troubles and corrective measures (Sewing conditions) .......................................... 67
5-2. Disposal of batteries..................................................................................................... 69
6. SUBCLASS MODEL........................................................................................70
6-1. Barcode reader.............................................................................................................. 70
6-2. Rotary knife ................................................................................................................... 75
6-2-1. Safety precautions .............................................................................................. 75
6-2-2. How to carry out coaxial adjustment................................................................. 76
6-2-3 How to adjust the timing belt tension ................................................................ 79
6-2-4 How to adjust he knife pressure ......................................................................... 79
6-2-5. Changing the moving knife .......................................................................................83
6-2-6. Adjusting the operating speed of template when the knife operates............. 83
6-2-7. Usage instructions .............................................................................................. 84
6-2-8. Denition of the electrical control buttons ....................................................... 86
6-2-9. Function-related precautions............................................................................. 86

– 1 –
1. SPECIFICATIONS
1 Sewing area (X,Y)(mm) 1200 × 800
(Cutting area Rotary knife type : 698 × 391
Laser type : 646.5 × 426.5)
2 Feed motion of feeding frame Intermittent feed (2-shaft drive by stepping motor)
3 Needle bar stroke 39.5 mm
4 Max. sewing speed [S type] 3,000 sti/min (When stitching pitch is 2.2 mm or less)
[H type] 1,800 sti/min (When stitching pitch is 3.5 mm or less)
For other stitch pitches and numbers of revolutions, refer to Fig. 1.
5 Settable stitch length 0.5 to 12.7 mm
6 Needle [S type] DB × 1 #8 (#7 to #14), DP × 5 #8 (#7 to #14)
[H type] DP17 #21
To be chosen according to the model.
7 Hook Double-capacity full-rotary hook
8 Intermediate presser stroke 4 mm (Standard)
9 Lift of intermediate presser 20 mm
10 Lift of disc presser 15 mm
11 Memory of pattern data Max. 999 patterns
12  Max. 999 patterns
13 Program input method USB
14 Data format DXF.AI.PLT.DST
15 Main shaft servomotor power [S type] 550W [H type] 750W
16 Power consumption 470VA
17 Input voltage 220V ± 10%
18 Mass (gross mass) 780 kg [Rotary knife type] 788kg [Laser type] 850kg
19 Dimensions 2,180 mm (W) × 2,185 mm (L) × 1,250 mm (H)
20 Operating temperature range 
21 Operating humidity range 35 to 85 % (No dew condensation) [Laser type] 5 to 70 %
22 Storage temperature range 
23 Storage humidity range 20 to 85 % (No dew condensation, 85 % applies to the case where the tem-

[Laser type] 20 to 85 % (No dew condensation)
24 Air pressure used 0.5 to 0.6 MPa
25 Needle highest position stop facility After the completion of sewing, the needle can be brought up to its highest
position.
26 Noise - Equivalent continuous emission sound pressure level (LpA) at the worksta-
tion :
A-weighted value of 78.0 dB ; (Includes KpA = 2.5 dB) ; according to ISO
10821- C.6.2 -ISO 11204 GR2 at 2,800 sti/min.
27 Lubricating oil #10 (Equivalent to JUKI NEW DEFRIX OIL No. 1)
#32 (Equivalent to JUKI NEW DEFRIX OIL No. 2), Lithium based grease No. 2
Grease information
Manufacturer: WERATCHE
Type and number: Lithium base 2# grease
Stitch pitch and the sewing speed
Number Stitch pitch Sewing speed Remarks
1 2.8 mm 2,800 sti/min
2 3.0 mm 2,500 sti/min
3 4.0 mm 2,200 sti/min
4 5.0 mm 1,800 sti/min
Note: The sewing machine must not run at the maximum num-
ber of revolutions continuously for more than 15 minutes. The
number of revolutions may vary even if the pitch is consistent
due to the change in the needle and material.
S type H type
Fig. 1
Stitch pitch and the sewing speed
Number Stitch pitch Sewing speed Remarks
1 3.5 mm 1,800 sti/min
2 4.0 mm 1,600 sti/min
3 4.5 mm 1,400 sti/min
4 5.0 mm 1,200 sti/min
Note: The number of revolutions may vary even if the
pitch is consistent due to the change in the needle
and material.

– 2 –
2. CONFIGURATION
❶Machine head
❷Table
❸X-axis feed mechanism
❹Y-axis feed mechanism
❺Cassette clamp device
❻Operation panel
❼Air control box
❽Electrical control box
❾Power switch (also used as the emergency
stop switch)
󱢳Thread stand
󱢴Bobbin winder device
󱢵Rotary knife device (subclass)
󱢵󱢵
❶❶
❷❷❸❸
❻❻
❾❾
󱢳󱢳
❺❺
❹❹
󱢴󱢴
❼❼
❽❽
󱢵󱢵
Rotary knife

– 3 –
3. INSTALLATION
3-1. Setting up the sewing machine
3-1-1. Unpacking
1) Lift up clamp ❶as shown in the picture.
2) Firstly remove upper cover ❷. Then,
remove the covers of the remaining four
surfaces.
If the clamp is not lifted up suf-
ciently, unpacking will not be
smoothly carried out.
❶❶

rear caster seats ❸of the sewing ma-
chine.
4) Remove the plastic cover.
❷❷
❸

– 4 –
5) Remove the parts, accessory box and
feed mechanism from the crate.
Cut the cable clip band to detach
the sewing machine parts.
* Insert the claw of
a folk lift here.

place with a folk lift. (Sewing machine
weighs 640 kg)
7) Turn the casters to check to make sure
that the sewing machine is levelled. Also
make sure that the sewing machine is
placed steadily with little wobbling.
Turn red pad ❹
❹❹
* Necessary tools are contained in the ac-
cessory box.

– 5 –
3-1-2. Setting up the X feed
mechanism and the table
1) Detach the package.

nut you have detached in the accessory
box.
3) Remove rubber plugs ❺. Tighten the
screws that are placed under the rubber
plugs with a wrench. Then, attach rubber
plugs ❺.
❺❺
4) Move the clamp to the center of the X
feed mechanism before removing six nuts
in order to prevent the clamp from inter-
fering with screws when attaching them.
5) Take care not to allow the screws from
󰀨-
taching the nuts.
Put the nuts you have removed in the
accessory box.
Pin
* Store the tools in the accessory box.
Align the pin with
the pin hole.

– 6 –
3-1-3. Setting up the table
1) Loosen the thumb screw as shown in Fig.
I when setting up the left table, right table
and front table (center).
2) Tighten the nuts and screws that are ex-
clusive to the aluminum frame as shown
in Figs. II and III when setting up the front
table (left) and the front table (right).
Fig. I
Fig. II
Fig. III

– 7 –
3-1-4. Setting up the switches, bobbin
winder and switch button
(asm.)
* Necessary tools are contained in the ac-
cessory box.
1) Secure the power switch plate to the alu-
minum frame of the front table (right) with
two Phillips head screws A.
Secure power switch Cto the plate with
two Phillips head screws B.
2) Secure switch button (asms.) Fto the
aluminum frame of the front table (right)
with T screws Eand nuts D.
Secure three switch buttons so that they
point upward.
ABB
CC
DEDE
F
3) Secure the bobbin winder to the alumi-
num plate of the front table (right) with T
screw Eand nut D.
DEDE