JUKI PS-800-13085 User manual

PS-800-13085
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........................................................................ 5
3-1-3. Setting up the table ............................................................................................... 7
3-1-4. Setting up the switches, bobbin thread winder and switch button (asm.) ...... 8
3-1-5. Points to be checked and precautions to be taken before turning the
power ON .....................................................................................................................9
3-2. Installing the air hose ................................................................................................... 11
3-3. Cautions for the compressed air supply (source of supply air) facility .................. 12
3-4. Installing the bobbin winder device ............................................................................ 13
3-5. Winding the bobbin thread........................................................................................... 13
3-6. Precautions for installation of the machine ............................................................... 14
4. PREPARATION OF THE SEWING MACHINE ................................................15
4-1. Lubricating method and check of the oil quantity..................................................... 15
4-2. Attaching the needle..................................................................................................... 16
4-3. Threading the machine head ....................................................................................... 17
4-4. Bobbin replacement procedure................................................................................... 18
4-5. Adjusting the thread tension ....................................................................................... 19
4-6. Adjusting the thread take-up spring and the thread breakage detector plate ........ 20
4-7. Adjusting the thread take-up stroke............................................................................ 20
4-8. Needle-to-hook relationship ........................................................................................ 21
4-9. How to wind a bobbin................................................................................................... 23
4-10. Adjusting the position of the thread trimmer............................................................. 24
4-11. How to attach / remove the cylinder lifting plate ....................................................... 26
4-12. How to conrm the amount of oil (oil splashes) in the hook.................................... 27
4-13. Adjusting the amount of oil in the hook ..................................................................... 28
4-14. Adjusting the needle hole in the throat plate and the needle................................... 29
4-15. Setting the mechanical origin...................................................................................... 30
4-16. Adjusting the disk presser pressure........................................................................... 31
4-17. Adjusting the thread end position at the beginning of sewing ................................ 32
4-18. Adjusting the electronic intermediate presser stroke............................................... 33
4-19. Adjusting the needle thread air blower....................................................................... 34

ii
4-20. Making a template......................................................................................................... 35
4-21. Preparation for sewing................................................................................................. 37
4-22. Conguration of the operation panel.......................................................................... 39
4-23. Maintenance mode........................................................................................................41
4-24. List of parameters......................................................................................................... 42
4-25. List of error codes ........................................................................................................ 48
5. MAINTENANCE OF SAWING MACHINE .......................................................64
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) 1300 × 850
(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 3,000 sti/min (When stitching pitch is 2.5 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 DB×1 #8 (#7 to #14), DP×5 #8 (#7 to #14)
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 750W
16 Power consumption 640VA
17 Input voltage 220V ± 10%
18 Mass (gross mass) 590 kg [Rotary knife type] 598 kg [Laser type] 655.7 kg
19 Dimensions 2,190 mm (W) × 2,100 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 temper-

[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 (L
pA
) at the workstation :
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 2,500 sti/min
2 3.0 mm 2,500 sti/min
3 4.0 mm 2,000 sti/min
4 5.0 mm 2,000 sti/min
Note: The sewing machine must not run at the maximum number 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.
Fig. 1

– 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)
❽❽
󱢵󱢵
󱢴󱢴
❶❶
❻❻
󱢳󱢳
❺❺
❹❹
❷❷
❸❸
❾❾
❼❼
󱢵󱢵
Rotary knife

– 3 –
3. INSTALLATION
3-1. Setting up the sewing machine
❶❶3-1-1. Unpacking
1) Lift clamp ❶as shown in the pic-
ture.
2) Detach top cover ❷
❷❷
3) Remove clamping plates of front and rear caster seats ❸from the sewing machine.
* Tools are packed in the accessory box for the sewing machine.
If the clamp is not lifted up
su󰀩ciently, unpacking will
not be smoothly carried
out.
❸❸❸❸

– 4 –
4) Remove the plastic cover.
6) Lift the sewing machine with a forklift to

the sewing machine: 500 kg)
Insert the forks of the forklift
into this portion.
5) Remove parts, accessories and feed mechanism from the wooden crate.

– 5 –
❹❹
7) Turning casters ❹, check to make sure
that the sewing machine is put horizontally
on the forks of the forklift.
Keep the sewing machine on the forks in
such a way that it does not rattle.
3-1-2. Setting up the X-feed mechanism
❶❶
1) Detach clamping plates ❶. Put the screws and nuts you have removed in the accessory box.
2) Unpack the X-feed mechanism.

– 6 –
❷❷
❸❸
3) Lay the X-feed mechanism aside the main body
of the sewing machine.
Move the clamp to the center of the X-feed mech-
anism.
4) Detach rubber plug ❷. Remove four nuts ❸on
the opposite side with a wrench key. Take care no
󰀨
after you have removed the nuts.
Put the nuts you have removed in the accessory
box.
5) Aligning the screws with the taps of the X-feed support block, tighten the screws.

– 7 –
❶❶
Fig.1
3-1-3. Setting up the table
1) Set up the left, right and front (center) tables.
Tighten the screws as illustrated in Fig. 1.
2) Set up the front tables (left) and (right).
Secure the aforementioned parts with dedicated link plates ❶and the nuts.

– 8 –
3-1-4. Setting up the switches, bobbin thread winder and switch button (asm.)
* Tools are packed in the accessory box for the
sewing machine.
1) Secure the bobbin thread winder to the alumi-
num frame of the front table (right) with T-head
screw Aand nut B.
BB
AA
CC
BB
AA
BB
AA
2) Secure the power switch plate to the alumi-
num plate of the front table (right) with T-head
screw Aand nut B.
3) For switch button (asm.) C, change round the
direction of assembly.
Then, secure it to the aluminum plate of the
front table (right) with T-head screw Aand nut
B.
Secure the switch button (asm.) so that its
three switch buttons are faced upward.

– 9 –
3-1-5. Points to be checked and precautions to be taken before turning the power ON
1) Inspect horizontality of the sewing machine.
2) Inspect whether the electrical components and
pneumatic components are correctly assembled.
3) Inspect whether the needle entry point is correctly
aligned with the center of the needle hole in the
throat plate of the sewing machine.

– 10 –
4) Detach the throat plate. Inspect the hook timing.
5) Inspect the clearance provided between the
X-feed origin detection sensor and the detection
plate.
6) Inspect whether the X-feed mecha-
nism operates smoothly.

– 11 –
3-2. Installing the air hose
1) Connecting the air hose
Connect the air hose to ❶.
WARNING :
Check to be sure that the air hose is fully inserted into the air cock before supplying the air to the
machine so as to prevent the air from being blown directly to the human body. Then, carefully open
the air cock.
2) Adjustment of air pressure
Pull up air regulating knob ❷. Then, turn it to
adjust the air pressure to 0.5 - 0.55 MPa.
Then, push down air regulator knob ❷.
Pull up air regulating knob ❸. Then, turn it to
adjust the air pressure to 0.15 MPa.
Then, push down air regulator knob ❸.
❷: Adjustment of the air pressure of the entire
sewing machine
❸: Adjustment of the air pressure of the disk
presser
❶❶
❷❷❸❸

– 12 –
3-3. Cautions for the compressed air supply (source of supply air) facility
As large as 90 % of failures in pneumatic equipment (air cylinders, air solenoid valves) are caused by "con-
taminated air."
Compressed air contains lots of impurities such as moisture, dust, deteriorated oil and carbon particles. If
such "contaminated air" is used without taking any measures, it can a cause of troubles, inviting reduction in
productivity due to mechanical failures and reduced availability.
Be sure to install the standard air supply facility shown below whenever the machine provided with pneumat-
ic equipment is used.
Mist separator
Standard air supply facility to be prepared by the user
Standard equipment supplied by JUKI
Air compressor
Auto-drain
Auto-drain
After cooler
Air tank
Main line lter
Air dryer Quality of the air supply
When the supply air contains a considerable amount of moisture
Ambient environment
When our machine is installed at a place where the temperature greatly
changes in the morning and in the evening from that in the daytime or
freeze is like to occur.
In the aforementioned cases, be sure to install an air dryer.
When the supply air contains a considerable amount of carbon
and dust
(Most troubles in the air solenoid valves are caused by carbon.)
Be sure to install a mist separator.
Filter regulator
Air solenoid valve
Air cylinder
Cautions for main piping
• Be sure to slope main piping by a falling gradient of 1 cm per 1 m in the direction of air ow.
• If the main piping is branched o󰀨, the outlet port of the compressed air should be provided at
the top part of the piping using a tee in order to prevent drain settling inside the piping from
owing out.
• Auto drains should be provided at all lower points or dead ends in order to prevent the drain
from settling in those parts.

– 13 –
3-4. Installing the bobbin winder device
❶❶
❷❷
❸❸
1) Insert bobbin winder disk mounting bar ❶into
hole ❷in the bobbin winder and secure with nut
❸.
3-5. Winding the bobbin thread
LED lamp 1,2,3,4
"+", "-", "P",
"<", ">" key Emergency
stop
Start
1. Button description
1) Red button: emergency stop, press this button for
2 seconds will be reset.
2) Green button: Start
3) "P" key: function key, Hold down "P" key for 2
seconds to enter parameter setting, after setting

keep parameter.
4) "+" key: numbers from 0 to 9
5) "-" key: numbers from 9 to 0
6) "<" key: turn left
7) ">" key: turn right
2. Indicator light
1) Parameter indicator light
2) Production failure indicator light
3) Stop indicator light
4) Work indicator light
3. Parameter setting
Hold down "P" key for 2 seconds to enter the param-
eter setting inter face.
A: The thread length setting is 0 to 99.9 meters
B: Compensate for 0 to 9.9 meters
C: The bobbin calculate to thread length 0 to 99.9
meters
D: Motor speed: F1 (fast), F2 (medium), F3 (slow)
E: LED lamp brightness: H0 (OFF), H1 (darkest), H2,
H3, H4, H5 (brightest)
4. Threading Diagram

– 14 –
3-6. Precautions for installation of the machine
1. Depending on the size of
template, the sewing ma-
chine may extend beyond
the sewing machine table
in X direction. Take care not
to allow the machine to hit
against someone standing
near the table to cause inju-
ry.
2. Be sure to secure a space
as wide as 500 mm or more
around the sewing machine
table (i.e., both in lateral and
longitudinal directions).
Sewing machine table Template
2115mm
420mm
2210mm
115mm 115mm

– 15 –
4. PREPARATION OF THE SEWING MACHINE
4-1. Lubricating method and check of the oil quantity
1. Do not use any oil other than the spec-
ied oil. After the completion of lubri-
cation, securely attach the rubber plug
and cylinder lifting plate to their original
positions.
2. When you put the sewing machine into
use for the rst time after delivery or
after having disused it for a long time,
replenish the hook with a small amount
of oil in advance.
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
Max
Min
❷❷
1) Detach cylinder lifting plate ❶.
2) Remove rubber plug ❷from the oil tank.
3) Fill the oil tank with the accessory oil (or the spec-

4) The adequate oil amount is obtained when the
oil surface stays between the oil tank indications
"Min" and "Max".
❶❶

– 16 –
4-2. Attaching the needle
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
1) Loosen screw ❶to remove the needle.
Be sure to hold the needle so that its
groove ❷faces toward blade point ❸of
the rotary hook.
2) Tighten screw ❶.
In the case of replacing the needle with a
needle which di󰀨ers in specications, be
sure to re-adjust the distance from the
rotary hook to the needle. If you neglect
this re-adjustment, the problems listed
below can occur.
1. Stitch skipping
2. Thread fray
3. Breakage of blade point of hook
4. Breakage of needle
❶❶
❷❷
❷❷
❸❸
❸❸

– 17 –
4-3. Threading the machine head
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
1) Put sewing machine thread ❶on thread stand ❷.

Lastly, draw out thread end through needle eyelet
by 50 to 60 mm.
❶❶
❷❷