JUKI PS-800-6045 User manual

PS-800-6045
INSTRUCTION MANUAL

i
CONTENTS
1. SPECIFICATIONS .............................................................................................1
2. CONFIGURATION .............................................................................................2
3. INSTALLATION..................................................................................................3
3-1. Installing the operation panel........................................................................................3
3-2. Installing the power switch and the button switch......................................................4
3-3. Installing the air hose.....................................................................................................6
3-4. Installing the thread stand ............................................................................................7
3-5. Cautions for the compressed air supply (source of supply air) facility ....................8
3-6. Installing the bobbin winder device..............................................................................9
3-7. Precautions for installation of the machine ...............................................................11
4. PREPARATION OF THE SEWING MACHINE................................................12
4-1. Lubricating method and check of the oil quantity.....................................................12
4-2. Attaching the needle.....................................................................................................13
4-3. Threading the machine head .......................................................................................14
4-4. Bobbin replacement procedure...................................................................................15
4-5. Adjusting the thread tension .......................................................................................16
4-6. Adjusting the thread take-up spring and the thread breakage detector plate........17
4-7. Adjusting the thread take-up stroke............................................................................17
4-8. Needle-to-hook relationship ........................................................................................18
4-9. Adjusting the position of the thread trimmer.............................................................20
4-10. How to check the amount of oil in the hook...............................................................22
4-11. Adjusting the amount of oil in the hook .....................................................................23
4-12. Adjusting the needle hole in the throat plate and the needle...................................24
4-13. Setting the mechanical origin......................................................................................25
4-14. Adjusting the disk presser pressure...........................................................................26
4-15. Adjusting the thread end position at the beginning of sewing ................................27
4-16. Adjusting the intermediate presser stroke.................................................................28
4-17. Adjusting the needle thread air blower.......................................................................29
4-18. Making a template.........................................................................................................30
4-19. Preparation for sewing.................................................................................................32
4-20. Conguration of the operation panel..........................................................................34
4-21. Maintenance mode........................................................................................................36
4-22. List of parameters.........................................................................................................37
4-23. List of error codes ........................................................................................................43
5. MAINTENANCE OF SAWING MACHINE .......................................................59
5-1. Troubles and corrective measures (Sewing conditions) ..........................................61
5-2. Disposal of batteries.....................................................................................................63
5-3. Draining waste oil .........................................................................................................63

– 1 –
1. SPECIFICATIONS
1 Sewing area (X,Y)(mm) 600 × 450
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 2.2 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)
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 550W
16 Power consumption 500VA
17 Input voltage 220V ± 10%
18 Mass (gross mass) Standard type : 320 kg
19 Dimensions 1,200 mm (W) × 1,570 mm (L) × 1,624 mm (H)
20 Operating temperature range 
21 Operating humidity range 35 to 85 % (No dew condensation)
22 Storage temperature range 
23 Storage humidity range 10 to 85 % (No dew condensation, 85 % applies to the case where the tem-

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

27 Lubricating oil 



Type and number: Lithium base 2# grease
Stitch pitch and the sewing speed
Number Stitch pitch Sewing speed 
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.
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
󱢴󱢴󱢳󱢳
❻❻
❺❺
❾❾
❼❼❽❽
❹❹
❸❸
❷❷
❶❶

– 3 –
3. INSTALLATION
3-1. Installing the operation panel
❶❶
❷❷
❶❷❶❷
❶❷❶❷

panel in the delivered state.
❶ (two pieces). Also take
out screws ❷(two pieces) from the plastic bag.
3) Adjust the position of the operation panel as

operation panel on the table by tightening four
screws ( ❶and ❷) you have removed in the
aforementioned step of procedure.
4) Adjust the inclination angle of the operation panel
as you like for ease of use.
(When you operate the sewing machine standing,
󰀨
the operation panel and the table is 60° to 70°.
When you operate the sewing machine sitting, the
󰀨
is 80° to 90°.)

– 4 –
3-2. Installing the power switch and the button switch
Delivered state
1) Take out the rubber plugs (six pieces) from the
table with a thin screwdriver.
-
surface of the table. Detach the button switch.
3) Shift the button switch forward and secure it with
the screws (four pieces).

– 5 –

loosen the nut on the right side.
5) Adjust the orientation of the power switch and
tighten the screw and nuts.
6) Put the rubber plugs (six pieces) back into place
on the table.
Concave Convex
Take care not to allow the rubber plug
head to project the table surface.
The rubber plug has a convex and
concave portions. Be sure to face the
convex portion upward.
Concave Convex

– 6 –
3-3. Installing the air hose
1) 
 ❶.
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
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.
❸❸
❶❶
❷❷

– 7 –
3-4. Installing the thread stand
1) Take out thread stand device from the electrical
equipment shelf. Install the spool support (asm)
❷onto thread stand bar (lower) ❶that has been

2) Attach collar with tapped hole ❸to thread stand
bar (lower) ❶.
❸❸
❶❶
❷❷
3) Put thread stand arm (asm.) ❺and thread stand
thread guide ❻over thread stand bar (upper) ❹,
and install thread stand bar (upper) ❹to collar ❸

Then, put thread stands into the holes in the
thread stand bars (upper and lower) and tighten
them with a thin screwdriver.
❹❹
❻❻
❺❺

– 8 –
3-5. 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."

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.

– 9 –
3-6. Installing the bobbin winder device
1) Insert the bobbin deep into the bobbin winder
spindle ❶until it will go no further.
2) Pass the bobbin thread pulled out from the spool
rested on the right side of the thread stand following

wind clockwise the end of the bobbin thread on the
bobbin several times. (In case of the aluminum bob-
bin, after winding clockwise the end of the bobbin
thread, wind counterclockwise the thread coming
from the bobbin thread tension several times to wind
the bobbin thread with ease.)
3) Press the bobbin winder trip latch ❷in the direc-
tion of Aand start the sewing machine. The bobbin
rotates in the direction of Cand the bobbin thread
is wound up. The bobbin winder spindle ❶auto-


with the thread cut retainer ❸.
5) When adjusting the winding amount of the bob-
bin thread, loosen setscrew ❹and move bobbin
winding lever ❷to the direction of Aor B. Then
tighten setscrew ❹.
To the direction of A: Decrease
To the direction of B: Increase
6) When the bobbin is not evenly wound with thread, loosen nut ❺and adjust the height of bobbin winder
tension disk ❻.
• It is the standard that the center of the bobbin is as high as the center of thread tension disk ❻.
• Adjust the position of thread tension disk ❻to the direction of Dwhen the winding amount of the
bobbin thread on the lower part of the bobbin is excessive and to the direction Ewhen the winding amount
of the bobbin thread on the upper part of the bobbin is excessive.
After the adjustment, tighten nut
❺
.
7) To adjust the tension of the bobbin winder, turn the thread tension nut ❼.
1. When winding the bobbin thread, start the winding in the state that the thread between
the bobbin and thread tension disk ❻is tense.
2. When winding the bobbin thread in the state that sewing is not performed, remove the
needle thread from the thread path of thread take-up and remove the bobbin from the hook.
3. There is the possibility that the thread pulled out from the thread stand is loosened due to
the inuence (direction) of the wind and may be entangled in the handwheel. Be careful of the
direction of the wind.
❻
❼
❻
❺
❻
E
D
❶❶
❷❷
❹❹
❸❸
BB
AA
CC

– 10 –
8) Before you wind a bobbin, remove the
needle thread from the thread take-up
lever and detach the bobbin case.
9) Press the "Next page" button on the main
screen to call up the test mode screen.
10) Adjust the bobbin winding speed. Then,
press the start button of the sewing machine
to start winding the bobbin.
11) After the completion of winding of the bob-
bin, press the stop button to stop the sewing
machine and restore the screen to the main
screen.

– 11 –
3-7. 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 250 mm or more
around the sewing machine
table (i.e., both in lateral and
longitudinal directions).
1570mm
165mm
1200mm
270mm
100mm
Sewing machine table Template

– 12 –
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 lubricating the hook,
securely attach the rubber plug and the
hook maintenance cover.
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.
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".
1) Detach hook maintenance cover ❶.
Max
Min
❶❶
❷❷

– 13 –
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

– 14 –
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.
2) Pass the thread as illus-

Lastly, draw out thread
end through needle eyelet
by 50 to 60 mm.
❷
❶

– 15 –
(3) Installing the bobbin case
1) Place the bobbin case in the hook with its knob A
tilted and fully push it into the hook until you hear
it click.
❶.
If it is not fully inserted, bobbin case ❸
may slip o󰀨 during sewing.
If the bobbin ❷is installed in the bobbin
case orienting the reverse direction, the
bobbin thread pulling out will result in an
inconsistent state.
(2) Installing the bobbin
1) Set the bobbin ❷into bobbin case ❸in the direc-

2) Pass the thread through thread slit Bof bobbin
case ❸, and pull the thread as it is. By so doing,
the thread will pass under the tension spring and
be pulled out from thread hole C.
3) Pull out the thread by 50 mm from thread opening
C.
Check the position of your hands and the
locations of goods before opening / clos-
ing cover ❶so as to prevent the goods
from being caught under the cover and
to prevent bodily injury.
In addition, do not push cover ❶with
your hands placed on it.
(1) Removing the bobbin case
1) Open cover ❶. Then, the bobbin can be
changed.
Aof bobbin case ❸, and remove the
bobbin case ❸and the bobbin ❷.
4-4. Bobbin replacement procedure
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
50mm
B
❸
❷
C
❸
❷
A
❶❶

– 16 –
4-5. Adjusting the thread tension
(1) Adjusting the needle thread tension
Thread tension controller No. 1 ❶
When the tension disk of thread tension controller
No. 2 ❸is loosened, such a small tension as to
control the thread trimmer has to remain. The re-
maining tension is produced by tension controller
❶. It is possible to determine the length of thread
trailing from the needle after automatic thread
trimming by adjusting nut ❷of the thread tension
controller. The length of thread trailing from the
needle is reduced by turning nut ❷clockwise (+).
It is increased by turning nut ❷counterclockwise
(-).
Thread tension controller No. 2 ❸
The tension (applied to the thread coming from
the needle) controlled with thread tension con-
troller No. 2 ❸should be set as low as possible
so that the needle thread and bobbin thread are
interlaced together at the center of material thick-
ness (Fig. A). If the thread tension is excessively
high when sewing a light-weight material, the ma-
terial may become wrinkled or thread may break.
The tension applied to the thread coming from the
needle is increased by turning nut ❹clockwise
(+).
It is decreased by turning nut ❹counterclockwise
(-).
Fig. A: Threads are interlaced together accurately at
the center of material thickness.
Fig. B: Needle thread tension is too low or bobbin
thread tension is too high.

thread tension is too low.
(2) Adjusting the bobbin thread tension
1) Turn tension adjusting screw ❺clockwise (in
direction A) to increase or counterclockwise (in
direction B) to reduce the bobbin thread tension.
 
The bobbin case will come down slowly by its
-
ure.
A
B
❺
Fig. A
Fig. B
Fig. C
❶❶
❷❷
❸❸❹❹

– 17 –
4-6. Adjusting the thread take-up spring and the thread breakage detector plate
4-7. Adjusting the thread take-up stroke
1) Adjusting the stroke
Loosen setscrew ❷. Turn thread tension con-
troller ❸. Turning it clockwise will increase the
stroke of the thread take-up spring ❶and the
thread drawing amount will increase.
2) Adjusting the pressure
To change the pressure of the thread take-up
spring ❶, insert a thin screwdriver into the slot of
thread tension post ❹while screw ❷is tightened,
and turn it. Turning it clockwise will increase the
pressure of the thread take-up spring ❶. Turning
it counterclockwise will decrease the pressure.
3) Adjusting the thread breakage detector plate
Loosen setscrew ❻. Adjust the position of thread
breakage detection plate ❺so that the contact
depth between thread breakage detection plate
❺and thread take-up spring ❶becomes 0 to 0.2
mm.
1) When sewing heavy-weight materials, move
thread guide ❶to the left (in direction A) to
increase the length of thread pulled out by the
thread take-up.
2) When sewing light-weight materials, move thread
guide ❶to the right (in direction B) to decrease
the length of thread pulled out by the thread take-
up.
3) Normally, thread guide ❶is positioned in a way
that the center of elongated hole is aligned with
the center of the screw.
Adjust so that thread breakage detector
plate ❶does not touch any adjacent
metallic parts other than thread take-up
spring ❷. If the thread breakage detec-
tion plate comes in contact with any oth-
er metal part, a maloperation can occur.
❶
BA
❷❷
❶❶❺❺
❹❹
❻❻
❸❸

– 18 –
1) Bring the needle bar to the position that is 2.9 ±
0.3 mm above its lower dead point. At this posi-
tion, adjust the height of the needle bar and the
position of the hook.
2) When observing from the front face of the sewing
machine, the blade point of hook seems to over-
lap with the center of needle.
3) When observing from the side face of the sewing
machine, the clearance provided between the
blade point of hook and the scarf of needle is 0.05
to 0.2 mm.
4-8. Needle-to-hook relationship
If thread breakage occurs, the thread can
be tangled in the hook. In such a case,
remove the thread being tangled in the
hook carefully. Then, re-start sewing.
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
(1) Needle and hook, and angle setting
0.05 to 0.2 mm
Front face Side face
2.9 ± 0.3 mm
(2) Position of the needle and the inner hook holder

setting QEP value displayed on the operation
panel becomes 570 to 575.
Longitudinal position of the inner hook holder and
needle: The front end of needle is aligned with the
inner hook.
Lateral position of the inner hook holder and needle:
The rightmost end of projection of inner hook holder
is aligned with the right side of needle.