JUKI PS800-8045 User manual

PS-800-8045
INSTRUCTION MANUAL

i
CONTENTS
1. SPECIFICATIONS .............................................................................................1
2. CONFIGURATION .............................................................................................2
3. INSTALLATION..................................................................................................3
3-1. Installing the air hose ..................................................................................................... 3
3-2. Cautions for the compressed air supply (source of supply air) facility .................... 4
3-3. Installing the bobbin winder device .............................................................................. 5
3-4. Precautions for installation of the machine ................................................................. 5
4. PREPARATION OF THE SEWING MACHINE ..................................................6
4-1. Lubricating method and check of the oil quantity....................................................... 6
4-2. Attaching the needle....................................................................................................... 7
4-3. Threading the machine head ......................................................................................... 8
4-4. Bobbin replacement procedure..................................................................................... 9
4-5. Adjusting the thread tension ....................................................................................... 10
4-6. Adjusting the thread take-up spring and the thread breakage detector plate ........ 11
4-7. Adjusting the thread take-up stroke............................................................................ 11
4-8. Needle-to-hook relationship ........................................................................................ 12
4-9. How to wind a bobbin................................................................................................... 14
4-10. Adjusting the needle bar height .................................................................................. 15
4-11. Adjusting the position of the thread trimmer ............................................................. 16
4-12. How to attach / remove the cylinder lifting plate ....................................................... 18
4-13. How to conrm the amount of oil (oil splashes) in the hook.................................... 19
4-14. Adjusting the amount of oil in the hook ..................................................................... 20
4-15. Adjusting the needle hole in the throat plate and the needle................................... 21
4-16. Setting the mechanical origin...................................................................................... 22
4-17. Adjusting the disk presser pressure........................................................................... 23
4-18. Adjusting the thread end position at the beginning of sewing ................................ 24
4-19. Adjusting the electronic intermediate presser stroke............................................... 25
4-20. Adjusting the needle thread air blower....................................................................... 26
4-21. Making a template......................................................................................................... 27
4-22. Preparation for sewing................................................................................................. 29
4-23. Conguration of the operation panel.......................................................................... 31
4-24. Maintenance mode........................................................................................................33
4-25. List of parameters......................................................................................................... 34
4-26. List of error codes ........................................................................................................ 40
5. MAINTENANCE OF SAWING MACHINE .......................................................45
5-1. Troubles and corrective measures (Sewing conditions) .......................................... 47
5-2. Disposal of batteries..................................................................................................... 49

ii
6. SUBCLASS MODEL........................................................................................50
6-1. Barcode reader.............................................................................................................. 50
6-2. Rotary knife ................................................................................................................... 55
6-2-1. Safety precautions .............................................................................................. 55
6-2-2. How to carry out coaxial adjustment................................................................. 56
6-2-3 How to adjust the timing belt tension ................................................................ 59
6-2-4 How to adjust he knife pressure ......................................................................... 59
6-2-5. Changing the moving knife .......................................................................................63
6-2-6. Adjusting the operating speed of template when the knife operates............. 63
6-2-7. Usage instructions .............................................................................................. 64
6-2-8. Denition of the electrical control buttons ....................................................... 66
6-2-9. Function-related precautions............................................................................. 66

– 1 –
1. SPECIFICATIONS
1 Sewing area (X,Y)(mm) 800 × 450
(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 550W
16 Power consumption 500VA
17 Input voltage 220V ± 10%
18 Mass (gross mass) 380 kg [Rotary knife type] 388kg [Laser type] 448.5kg
19 Dimensions 1,200 mm (W) × 1,325 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 –
Rotary knife
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
󱢴󱢴
❾❾
❼❼
❷
❸
❻❻
󱢳󱢳
❺❺❹❹
󱢵󱢵

– 3 –
3. INSTALLATION
3-1. 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.
❶❶
❷❷❸❸2) 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

– 4 –
3-2. 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.

– 5 –
3-3. 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.
3-4. 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
1200mm
270mm
1320mm
250mm 250mm

– 6 –
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
❶❶
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".
❷❷

– 7 –
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

– 8 –
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.
❶❶
❷❷
1) Put sewing machine thread ❶on thread stand ❷.

Lastly, draw out thread end through needle eyelet
by 50 to 60 mm.

– 9 –
(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.
2) Close cover 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.
2) Raise latch 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
❶❶
❸
❷
A

– 10 –
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.
Fig. C: Needle thread tension is too high or bobbin
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.
Recommended value: Approximately 25 g
The bobbin case will come down slowly by its
-
ure.
A
B
❺
❶❶
❷❷
❸❸
❹❹
Fig. A
Fig. B
Fig. C

– 11 –
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

– 12 –
1) For the S type, the relation between the needle
bar height and the hook position should be adjust-
ed when the needle bar goes up from its lower
dead point by 2.9 ± 0.3 mm. For the H type, it
should be adjusted when the needle bar goes up
from its lower dead point by 2.4 ± 0.3 mm.
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
S type: 2.9 ± 0.3 mm
H type: 2.4 ± 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.

– 13 –
(3) Adjusting the hook timing
The timing gauge is supplied for the machine as an accessory.
Lower dead point
of the needle
bar of the S type
sewing machine
Position for adjusting the
timing between the hook
and the needle bar of the
S type sewing machine
Position for adjusting the
timing between the hook
and the needle bar of the
H type sewing machine
Lower dead point
of the needle bar of
the H type sewing
machine
Adjust the hook timing according to
the sewing type (S type / H type) of
the sewing machine.
Turn the timing gauge upside down
according to the sewing machine

left.
For the S type :
Position the timing gauge
with its S inscription
turned up
For the H type :
Position the timing gauge
with its H inscription
turned up
Needle bar connection setscrew
1) Put the timing gauge on the resin cover. Then,

2) Then, turn the timing gauge by 180 degrees of an
angle longitudinally. Adjust the hook timing posi-
tion.
When adjusting the hook timing, it is necessary to
put the jig on the left side of the needle to prevent
the jig from coming in contact with the needle bar
thread guide.
Align the timing gauge with the end
surface of the needle bar.
Loosen needle bar connection
setscrew. Adjust the height of
the needle bar.

– 14 –
1) Put bobbin ❷on bobbin winder shaft ❸.
2) Pass sewing thread ❻through spool rest rod.

4) Manually wind thread on bobbin ❷by several
turns clockwise.
5) Press button ❹to start winding thread on the
bobbin.
6) When the bobbin thread amount wound on the
bobbin reaches the set amount (80 %), the bob-
bin winder automatically stops turning. Or, press
button ❺to stop the bobbin winder.
7) Trim the thread with thread trimmer ❶. Detach
bobbin ❷.
4-9. How to wind a bobbin
❶❶
❷❷
❸❸
❹❹
❺❺
❻❻

– 15 –
❶❶Turn pulley ❶counterclockwise to lower the nee-
dle bar to its lower dead point.
4-10. Adjusting the needle bar height
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
Needle
Inner hook
Needle eyelet
At this time, the needle bar connecting rod and
the needle bar are located on the straight line as

S type
Expose a half of the needle eyelet from the inner
hook (standard position).
Determine the needle bar height accord-
ing to the material to be used.
1. Since woven fabric in general con-
sists of two or three layers of material,
expose a half of the needle eyelet from
the inner hook.
2. For the resilient materials such as knit
or comparatively heavy-weight materi-
als, expose two-thirds of needle eyelet
from the inner hook.
3. The appropriate needle bar height
varies depending on the type and/or
thickness of material.
H type
18.4 ± 0.3 mm
H type
 
bar to the throat plate to 18.4 ± 0.3 mm. Expose
two-thirds of the needle eyelet from the inner
hook.

– 16 –
4-11. Adjusting the position of the thread trimmer
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the
sewing machine.
❶❶
❷❷
❸❸
The moving knife is in
parallel with the moving
knife base
Blade point of moving knife
is aligned with the needle
Blade point of
moving knife
❶
(1) Adjusting the position of the thread trim-
ming cam
1) Turn pulley ❶to engage needle bearing ❸of the
thread trimmer connecting rod with groove ❷in
the thread trimming cam.
 -
gle setting parameter has been factory-adjusted
to 290 at the time of shipment. Finely adjust the
󰀨
(2) Adjusting the position of the moving knife
and counter knife
1) Attach the moving knife to the moving knife base.
Push the moving knife to the right to make the
tail of the moving knife in parallel with the moving
knife base. At this time, the blade point of moving
knife is aligned with the needle. Tighten moving
knife clamping screw ❶.

– 17 –
❷❷
❸❸
Mark both sides of the moving
knife with a black marker pen.
Black markers on both sides of
the moving knife are rubbed by
the counter knife simultaneously.
2) Attaching the counter knife
The tail portion of the counter knife has a hole.
Inserting 2.5 hexagonal wrench key ❷into that

knife while aligning the tail portion of the counter
knife with the hexagonal wrench key.
3) Mark the 5-mm position of the moving knife blade
with a black marker pen. Adjust the counter knife
pressure with counter knife pressure adjustment
screw ❸.
After you have completed adjustment, push down
the moving knife to re-adjust the moving knife
pressure in repetition until both sides, with black
markers, of the moving knife are simultaneously
rubbed by the counter knife without fail. In addi-
tion, the friction force between the moving knife
and the counter knife can be minimized by trim-
ming three used machine-sewing threads.