JUKI PS-800SB-2850 Series User manual

PS-800SB-2850
INSTRUCTION MANUAL

i
CONTENTS
PREFACE.............................................................................................................1
1. SPECIFICATIONS............................................................................................3
2. CONFIGURATION............................................................................................4
3. INSTALLATION ................................................................................................5
3-1. Installing the panel ............................................................................................5
3-2. Installing the air hose........................................................................................6
3-3. Installing the thread stand................................................................................7
3-4. Cautions for the compressed air supply (source of supply air) facility....... 8
3-5. Installing the bobbin winder device.................................................................9
3-6. 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
4-5-1. Adjusting the needle thread tension ................................................................. 16
4-5-2. Adjusting the bobbin thread tension................................................................. 16
4-6. Adjusting the thread take-up spring and the thread take-up stroke...........17
4-7. Needle-to-hook relationship ...........................................................................18
4-8. Adjusting the needle thread presser device .................................................19
4-9. Adjusting the thread trimmer .........................................................................20
4-9-1. For checking of the thread trimming cam timing............................................. 20
4-9-2. Adjustment of the thread trimming cam timing................................................ 21
4-9-3. Checking of the knife unit .................................................................................. 22
4-9-4. Adjustment of the knife unit............................................................................... 23
4-10. LED hand light ...............................................................................................24
4-11. Adjusting the amount of oil (oil splashes) in the hook ..............................25
4-11-1. Adjusting the amount of oil in the hook.......................................................... 25
4-11-2. How to confirm the amount of oil (oil splashes) ............................................ 26
4-11-3. Sample showing the appropriate amount of oil ............................................. 26
4-12. Setting the mechanical origin.......................................................................27
4-13. Adjusting the disk presser pressure ...........................................................28
4-14. Adjusting the thread end position at the beginning of sewing .................29

ii
4-15. Adjusting the intermediate presser stroke..................................................30
4-16. Making a template..........................................................................................31
4-17. Preparation for sewing..................................................................................33
4-18. RFID (How to use the IC tag) ........................................................................35
4-19. Configuration of the operation panel...........................................................37
4-20. Maintenance mode ........................................................................................39
4-21. List of parameters..........................................................................................40
4-22. List of error codes .........................................................................................46
5. MAINTENANCE OF SAWING MACHINE......................................................62
5-1. Troubles and corrective measures (Sewing conditions) .............................64
5-2. Disposal of batteries .......................................................................................66
5-3. Draining waste oil............................................................................................68
6. Barcode reader .............................................................................................69

– 1 –
PREFACE
󰿿󰿿1) Lift clamp 󰿿as shown in the pic-
ture.
If the clamp is not lifted
up su󰀩ciently, unpack-
ing will not be smoothly
carried out.
2) Detach top cover 󱀀 rst. Then, detach the remaining covers from the four surfaces.
3) Remove clamping plates of front and rear caster
seats 󱀁 from the sewing machine.
* Tools are packed in the accessory box for the
sewing machine.
󱀀󱀀
󱀁󱀁

– 2 –
4) Remove the plastic cover.
5) Lift the sewing machine with a forklift to
bring it to the specied location. (Weight of
the sewing machine: 305 kg)
Insert the forks of the
forklift into this portion.
󱀂󱀂
6) Turning casters 󱀂, 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. SPECIFICATIONS
1Sewing area (X,Y)(mm) 280 × 500
2Feed motion of feeding frame Intermittent feed (2-shaft drive by stepping motor)
3Needle bar stroke 30.7mm
4Max. sewing speed 3,500sti/min (When stitching pitch is 2.2 mm or less)
For other stitch pitches and numbers of revolutions, refer to Fig. 1.
5Settable stitch length 0.5 to 12.7 mm
6Needle DB × 1 #8 (#7 to #14)
7 Hook Standard full-rotary hook
8Intermediate presser stroke 4 mm (Standard)
9Lift of intermediate presser 12mm
10 Lift of disc presser 10mm
11 Memory of pattern data Max. 999 patterns
12 Number of patterns that can be identied 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：293kg
19 Dimensions 1,470mm (W) × 1,150mm (L) × 1,310mm (H)
20 Operating temperature range 5 to 35℃
21 Operating humidity range 35 to 85% (No dew condensation)
22 Storage temperature range -5 to 60℃
23 Storage humidity range 10 to 85%（(No dew condensation, 85 % applies to the case where the tem-
perature is 40 ˚C or lower)
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
23.0 mm 2,500 sti/min
34.0 mm 2,200 sti/min
45.0 mm 1,800 sti/min
Note: The sewing machine must not run at the maximum
number of revolutions continuously for more than 15 min-
utes. The number of revolutions may vary even if the pitch
is consistent due to the change in the needle and material.
Fig. 1

– 4 –
2. CONFIGURATION
󰿿Machine head
󱀀Table
󱀁X-axis feed mechanism
󱀂Y-axis feed mechanism
󱀃Cassette clamp device
󱀄Operation panel
󱀅Air control box
󱀆Electrical control box
󱀇Power switch (also used as the emergency stop switch)
󱢳Thread stand
󱢴 Suction device (provided/not provided depending on specications)
󱢵 Pedal for suction device (provided/not provided depending on specications)
󱢶 Power supply for suction device (provided/not provided depending on specications)
󱢴󱢴
󱢳󱢳
󱀄󱀄
󱀃󱀃
󱀇󱀇
󱀅󱀅
󱀆󱀆
󱀂󱀂
󱀁󱀁
󱀀󱀀
󰿿󰿿
󱢶󱢶
󱢵󱢵

– 5 –
3. INSTALLATION
3-1. Installing the panel
1) This gure shows the operation panel in the
shipped state.
2) Remove xing screws 󰿿 and 󱀀.
3) Install the operation panel to the arm with screws
󰿿 and 󱀀.
4) Connect the cable to the operation panel.
󱀀󱀀
󰿿󰿿

– 6 –
3-2. Installing the air hose
1) Connecting the air hose
Connect the air hose to 󰿿.
2) Adjustment of air pressure
Pull up air regulating knob 󱀀. Then, turn it to adjust the air pressure to 0.5 - 0.55 MPa.
Then, push down air regulator knob 󱀀.
Pull up air regulating knob 󱀁. Then, turn it to adjust the air pressure to 0.15 MPa.
Then, push down air regulator knob 󱀁.
󱀀 : Adjustment of the air pressure of the entire sewing machine
󱀁 : 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.

– 7 –
3-3. Installing the thread stand
1) This gure shows the thread stand in the shipped
state.
2) Install thread stand bar (lower) 󰿿 to the table as
shown in the gure .
󱀁󱀁
󰿿󰿿
3) Assemble spool support (asm.) 󱀀 and thread
stand bar (lower) 󰿿 together as shown in the
gure.
󱀀󱀀

– 8 –
3-4. 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.

– 9 –
3-5. Installing the bobbin winder device
1) Insert the bobbin deep into the bobbin winder
spindle 󰿿 until 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
the order as shown in the gure on the left. Then,
wind clockwise the end of the bobbin thread on the
bobbin several times.
3) Press the bobbin winder trip latch 󱀀 in the direc-
tion of 󱤨 and start the sewing machine. The bobbin
rotates in the direction of
󱤩
and the bobbin thread
is wound up. The bobbin winder spindle 󰿿auto-
matically as soon as the winding is nished.
4) Remove the bobbin and cut the bobbin thread
with the thread cut retainer 󱀁.
5) When adjusting the winding amount of the bob-
bin thread, loosen setscrew 󱀂 and move bobbin
winding lever 󱀀 to the direction of 󱤪or
󱤫
. Then
tighten setscrew 󱀂.
To the direction of 󱤪 : Decrease
To the direction of
󱤫
: Increase
6) When the bobbin is not evenly wound with thread,
loosen nut 󱀃 and adjust the height of bobbin
winder tension disk 󱀆.
󱤬
󱤭
󱀄
󱀅
󱀄
󱀃
󱀄
1. When winding the bobbin thread, start the winding in the state that the thread between the
bobbin and thread tension disk 󱀄is 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.
󱀆
󱤩
󱀀
󱤨
󱤪
󱤫
󱀂
󰿿
󱀁
• It is the standard that the center of the bobbin is as high as the center of thread tension disk 󱀄.
• Adjust the position of thread tension disk 󱀄 to the direction of 󱤬 when the winding amount of the bobbin
thread on the lower part of the bobbin is excessive and to the direction
󱤭
when the winding amount of
the bobbin thread on the upper part of the bobbin is excessive.
After the adjustment, tighten nut
󱀃
.
7) To adjust the tension of the bobbin winder, turn the thread tension nut 󱀅.

– 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 –
3-6. Precautions for installation of the machine
1. Depending on the size of template, the
sewing machine 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 injury.
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).
Sewing machine table
Template
1330mm
1060mm
683mm
120.5mm
230.5mm
74.5mm

– 12 –
4. PREPARATION OF THE SEWING MACHINE
4-1. Lubricating method and check of the oil quantity
Fill the oil tank with oil for hook lubrication before
operating the sewing machine.
1) Turn ON the power switch. Remove oil hole cap
󰿿. Pour NEW Defrix Oil No. 1 (part number:
40214221 or MDFRX16000C0) supplied with the
unit or JUKI CORPORATION GENUINE OIL 7
(part number: 40102087) into the oil tank through
the oil hole.
2) When the oil tank is lled with the maximum
amount of oil, 
 is displayed on the
operation panel to warn the operator.
Stop oiling.
If the oil is lled excessively, it will leak from the
air vent hole in the oil tank or proper lubrication
will be not performed. In addition, when the oil is
vigorously lled, it may overow from the oil hole.
So, be careful.
3) When the remaining amount of oil in the oil tank runs short while the sewing machine is in operation, the
warning screen is displayed on the operation panel as shown in the gure below to warn the operator with

 。
Replenish the oil tank with oil.
After you have replenished the oil tank with oil, re-start the sewing machine.
1. When you use a new sewing machine or a sewing machine after an extended period of
disuse, use the sewing machine after performing break-in at 2,000 sti/min or less.
2. For the oil for hook lubrication, purchase JUKI NEW DEFRIX OIL No. 1 (part number :
MDFRX1600C0) or JUKI CORPORATION GENUINE OIL 7 (part number : 40102087).
3. Be sure to lubricate clean oil.
4. Do not operate the machine with the oil hole cap 󰿿removed. Never remove cap 󰿿from the
oil inlet in any case other than oiling. In addition, take care not to lose it.
WARNING :
1. Do not connect the power plug until the lubrication has been completed so as to prevent accidents
due to abrupt start of the sewing machine.
2. To prevent the occurrence of an inammation or rash, immediately wash the related portions if oil
adheres to your eyes or other parts of your body.
3. In the case of adding oil to the sewing machine while it is energized, do not place your hands into
the moving parts for the sake of safety.
󰿿󰿿

– 13 –
4-2. Attaching the needle
Use the specied needle for the machine. Use the
proper needle in accordance with the thickness of
thread used and the kinds of the materials.
1) Turn the handwheel to lift the needle bar to its
upper end.
Press the "Threading" on the operation panel.
2) Loosen screw 󱀀, and hold needle 󰿿with its
indented part 󱤨 facing exactly to the right in di-
rection 󱤩.
3) Insert the needle fully into the hole in the needle
bar in the direction of the arrow until the end of
hole is reached.
4) Securely tighten screw 󱀀.
5) Check that long groove 󱤪 of the needle is facing
exactly to the left in direction 󱤫.
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
󱤪
󱤫󱤩
󱤨
➊
❷
󰿿󰿿
󱀀󱀀

– 14 –
4-3. Threading the machine head
󱀀
󰿿
1) Put sewing machine
thread 󰿿 on thread stand
󱀀.
2) Pass the thread as illustrated in the gure.
Lastly, draw out thread end through needle eyelet by 50 to 60 mm.
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
(Note)
Do not pass this thread
through section 󱤨.
󱤨
[S type]

– 15 –
(3) Installing the bobbin case
1) Place the bobbin case in the hook with its knob 󱤨
tilted and fully push it into the hook until you hear
it click.
2) Close cover 󰿿.
If it is not fully inserted, bobbin case 󱀁
may slip o󰀨 during sewing.
If the bobbin 󱀀is 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 󱀀 into bobbin case 󱀁 in the direc-
tion shown in the gure.
2) Pass the thread through thread slit 󱤩 of bobbin
case 󱀁, 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 󱤪.
3) Pull out the thread by 50 mm from thread opening
󱤪.
50mm
󱤩
󱀁
󱀀
󱤪
Check the position of your hands and
the locations of goods before opening
/ closing cover 󰿿so as to prevent the
goods from being caught under the
cover and to prevent bodily injury.
In addition, do not push cover 󰿿with
your hands placed on it.
(1) Removing the bobbin case
1) Open cover 󰿿. Then, the bobbin can be
changed.
2) Raise latch 󱤨 of bobbin case 󱀁, and remove the
bobbin case 󱀁 and the bobbin 󱀀.
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.
󰿿󰿿

– 16 –
4-5. Adjusting the thread tension
4-5-1. Adjusting the needle thread tension
1) Turn thread tension No. 1 nut 󰿿 clockwise (in di-
rection 󱤨), to shorten the thread length remaining
on the needle after thread trimming or counter-
clockwise (in direction 󱤩), to lengthen the thread
length.
2) Turn thread tension nut 󱀀 clockwise (in direction
󱤪) to increase or counterclockwise (in direction 󱤫)
to reduce the needle thread tension.
󱀁󱤬󱤭
󰿿
󱀀
󱤨
󱤩
󱤪
󱤫
4-5-2. Adjusting the bobbin thread tension
1) Turn tension adjusting screw 󱀁 clockwise (in
direction 󱤬) to increase or counterclockwise (in
direction 󱤭) to reduce the bobbin thread tension.

– 17 –
(1) Adjusting the stroke of thread take-up spring 󰿿
1) Loosen setscrew 󱀀.
2) Turn tension post 󱀁 clockwise (in direction 󱤨), the stroke of the thread take-up spring will be increased,
and turn the post 󱀁 counterclockwise (in direction 󱤩), the stroke will be decreased.
(2) Adjusting the pressure of thread take-up spring 󰿿
1) Loosen setscrew 󱀀, and remove thread tension (asm.) 󱀃.
2) Loosen tension post setscrew 󱀂.
3) Turn tension post 󱀁 clockwise (in direction 󱤨), the pressure will be increased, and turn the post 󱀁coun-
terclockwise (in direction 󱤩), the pressure will be decreased.
(3) Adjusting the thread take-up stroke
1) When sewing heavy-weight materials, move thread guide 󱀆 to the left (in direction 󱤪) to increase the
length of thread pulled out by the thread take-up.
2) When sewing light-weight materials, move thread guide 󱀆 to the right (in direction 󱤫) to decrease the
length of thread pulled out by the thread take-up.
* Standard state of the thread guide
The standard distance between the right end face of thread guide and the screw head is as follows:
󰿿
󱤮
󱤯
󱤭󱤬
󱤫
󱤪
󱤨󱤨
󱤩󱤩
󱀄󰿿
󱀁
󱀇
󱀆
[DDL-8000A-*MS]
󱀀
To check how the thread take-up spring works, draw out the needle thread in direction 󱤭after
having adjusted the thread take-up spring pressure to check whether the thread take-up spring
exerts force to the thread up to the last moment (state 󱤮) just before the thread comes out
from 󱤬. If the spring fails to exert force to the spring until the last moment (state 󱤯), decrease
the thread take-up spring pressure. In addition, the stroke of the thread take-up spring is
excessively small, the spring does not work properly. For the general fabrics, a stroke of 10 to
13 mm is proper.
[DDL-8000A-*MS]
7
4-6. Adjusting the thread take-up spring and the thread take-up stroke