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JUKI PS-800-12080 Instruction Manual

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INSTRUCTION MANUAL

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Summary of Contents for JUKI PS-800-12080

  • Page 1 PS-800-12080 INSTRUCTION MANUAL...

  • Page 2: Table Of Contents

    CONTENTS 1. SPECIFICATIONS ........................1 2. CONFIGURATION ........................2 3. INSTALLATION ......................... 3 3-1. Setting up the sewing machine ....................3 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.

  • Page 3: Specifications

    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...

  • Page 4: Configuration

    2. CONFIGURATION ❶ ❻ ❸ ❷ ❹ ❺ ❼ ❽ ❾ ❶ Machine head ❷ Table ❸ X-axis feed mechanism ❹ Y-axis feed mechanism ❺ Cassette clamp device ❻ Operation panel ❼ Air control box ❽ Electrical control box ❾ Power switch (also used as the emergency stop switch)  Thread stand  Bobbin winder device...

  • Page 5: Installation

    3. INSTALLATION 3-1. Setting up the sewing machine 3-1-1. Unpacking ❶ 1) Lift up clamp ❶ as shown in the picture. If the clamp is not lifted up suf- ficiently, unpacking will not be smoothly carried out. ❷ 2) Firstly remove upper cover ❷ . Then, remove the covers of the remaining four surfaces.
  • Page 6 Cut the cable clip band to detach the sewing machine parts. 5) Remove the parts, accessory box and feed mechanism from the crate. 6) Move the sewing machine to the specified place with a folk lift. (Sewing machine weighs 640 kg) * Insert the claw of a folk lift here.
  • Page 7 3-1-2. Setting up the X feed mechanism and the table 1) Detach the package. 2) Detach the fixing plate. Put the screw and nut you have detached in the accessory box. 3) Remove rubber plugs ❺ . Tighten the ❺ screws that are placed under the rubber plugs with a wrench.
  • Page 8 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.
  • Page 9 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 C to the plate with two Phillips head screws B.
  • Page 10 3-1-5. Check points and precautions be- fore turning the power ON 1) Inspect the levelness of the sewing ma- chine. 2) Inspect that the electric components and pneumatic components of the sewing machine have been securely assembled. 3) Inspect the alignment between the needle entry point and the center of needle hole in the throat plate of the sewing machine.

  • Page 11: Installing The Air Hose

    3-2. Installing the air hose 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.

  • Page 12: Cautions For The Compressed Air Supply (Source Of Supply Air) Facility

    When the supply air contains a considerable amount of carbon Mist separator and dust (Most troubles in the air solenoid valves are caused by carbon.) Be sure to install a mist separator. Standard equipment supplied by JUKI Filter regulator Air solenoid valve Air cylinder Cautions for main piping •...

  • Page 13: Installing The Bobbin Winder Device

    3-4. Installing the bobbin winder device 1) Insert bobbin winder disk mounting bar ❶ into hole ❷ in the bobbin winder and secure with nut ❸ . ❷ ❸ ❶ 3-5. Precautions for installation of the machine 1. Depending on the size of template, the sewing ma- chine may extend beyond the sewing machine table...

  • Page 14: Preparation Of The Sewing Machine

    4. PREPARATION OF THE SEWING MACHINE 4-1. Lubricating method and check of the oil quantity WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Detach cylinder lifting plate ❶ . ❶...

  • Page 15: Attaching The Needle

    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 ❶ to remove the needle. Be sure to hold the needle so that its ❷...

  • Page 16: Threading The Machine Head

    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 ❶ on thread stand ❷ . ❶ ❷...

  • Page 17: Bobbin Replacement Procedure

    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. (1) Removing the bobbin case 1) Open cover ❶ . Then, the bobbin can be changed.

  • Page 18: Adjusting The Thread Tension

    4-5. Adjusting the thread tension (1) Adjusting the needle thread tension Thread tension controller No. 1 ❶ ❶ When the tension disk of thread tension controller No. 2 ❸ is loosened, such a small tension as to control the thread trimmer has to remain. The re- ❷...

  • Page 19: Adjusting The Thread Take-Up Spring And The Thread Breakage Detector Plate

    4-6. Adjusting the thread take-up spring and the thread breakage detector plate 1) Adjusting the stroke ❺ Loosen setscrew ❷ . Turn thread tension con- ❶ troller ❸ . Turning it clockwise will increase the stroke of the thread take-up spring ❶ and the thread drawing amount will increase.

  • Page 20: Needle-To-Hook Relationship

    4-8. Needle-to-hook relationship 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 1) Lift the needle bar from its lower dead point by 2.9 ±...

  • Page 21: How To Wind A Bobbin

    4-9. How to wind a bobbin 1) Put bobbin ❷ on bobbin winder shaft ❸ . 2) Pass sewing thread ❻ through spool rest rod. 3) Pass the thread as illustrated in the figure. ❶ 4) Manually wind thread on bobbin ❷ by several ❷...

  • Page 22: Adjusting The Needle Bar Height

    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. Turn pulley ❶ counterclockwise to lower the nee- ❶ dle bar to its lower dead point. At this time, the needle bar connecting rod and the needle bar are located on the straight line as illustrated in the figure.

  • Page 23: Adjusting The Position Of The Thread Trimmer

    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. (1) Adjusting the position of the thread trim- ❶ ming cam 1) Turn pulley ❶...
  • Page 24 2) Attaching the counter knife ❷ The tail portion of the counter knife has a hole. Inserting 2.5 hexagonal wrench key ❷ into that hole, tighten the fixation screw of the counter knife while aligning the tail portion of the counter knife with the hexagonal wrench key.

  • Page 25: How To Attach / Remove The Cylinder Lifting Plate

    4-12. How to attach / remove the cylinder lifting plate 1) While the power to the sewing machine is turned ON, press switch ❶ . ❶ 2) Cylinder lifting plate ❷ comes off upward. Re- move it. (The cylinder pushes up the lifting plate.) 3) To install cylinder lifting plate ❷...

  • Page 26: How To Confirm The Amount Of Oil (Oil Splashes) In The Hook

    4-13. How to confirm the amount of oil (oil splashes) in the hook WARNING : Be extremely careful about the operation of the machine since the amount of oil has to be checked by turning the hook at a high speed. (1) How to confirm the amount of oil (oil splashes) ❶...

  • Page 27: Adjusting The Amount Of Oil In The Hook

    4-14. Adjusting the amount of oil in the hook WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Remove the cylinder lifting plate. 2) The oil amount is increased by turning screw ❶ in the direction of arrow A, or decreased by turning it in the direction of arrow B.

  • Page 28: Adjusting The Needle Hole In The Throat Plate And The Needle

    4-15. Adjusting the needle hole in the throat plate and the needle WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. In the case the needle does not come down to the center of needle hole in The throat plate, the position of the throat plate can be adjusted with screw ❶...

  • Page 29: Setting The Mechanical Origin

    4-16. Setting the mechanical origin 1) Slightly tighten screw ❶ on the lower shaft side. Then, turn the pulley to position screw ❷ on the main shaft motor so that it is levelled and faces upward. ❸ on the main 2) Holding the pulley, press screen of the electrical box.

  • Page 30: Adjusting The Disk Presser Pressure

    4-17. Adjusting the disk presser pressure 1) Adjust the disk presser air cylinder pressure regu- ❷ lation valve ❶ . Pull up nut ❷ . Then, turn the nut ❶ clockwise to increase the disk presser pressure or turn it counterclockwise to decrease it. The air pressure has been factory-set to 0.15 MPa at the time of shipment.

  • Page 31: Adjusting The Thread End Position At The Beginning Of Sewing

    4-18. Adjusting the thread end position at the beginning of sewing It is possible to set the needle thread end posi- tion at the beginning of sewing to top side ❶ or underside ❷ of material. The condition of the needle thread end is ❶...

  • Page 32: Adjusting The Electronic Intermediate Presser Stroke

    4-19. Adjusting the electronic intermediate presser stroke It is necessary to adjust the intermediate presser stroke (A) appropriately since there would be the need for preventing stitch skipping depending on thickness or type of the material. ❶ on the main screen of electrical 1) Press box.

  • Page 33: Adjusting The Function For Holding The Thread By Blowing Air Upward

    4-20. Adjusting the function for holding the thread by blowing air upward Blow-up pipe ❶ blows air to blow up the thread end trailing from the needle to bring it under disk presser ❷ at the beginning of sewing by controlling the sole- noid valve of the electrical system.

  • Page 34: Making A Template

    Normally, it is set to 8 mm. 3. The width of slits in the knife machining area must be at least 10 mm. 4. This figure only applies to the PS-800-12080 provided with sewing area of "1200 x 800" and the knife.
  • Page 35 (2) Attaching the templates Machine the upper and lower templates based on ❶ ❷ ❸ ❹ the design. 1) Put the upper template on the lower template, as shown in the figure, and adjust so that sewing slits A on the upper and lower templates are aligned. Affix exclusive template tape (36 mm wide) to por- tions ❶...

  • Page 36: Preparation For Sewing

    4-22. Preparation for sewing 1) Turning ON the main power switch. Press button ❶ to turn ON the main power switch. 2) Turning ON the main air source switch Move main air valve ❷ to the right to open the main air source.
  • Page 37 7) Selecting the reference ❺ In order to align the locus of sewing pattern with the sewing slits of the pattern, it is necessary to set a reference. Specifically, set the reference re- ferring to the Instruction Manual for the electrical system scanner.

  • Page 38: Configuration Of The Operation Panel

    4-23. Configuration of the operation panel LCD portion of the touch panel PAUSE key Used to temporarily stop sewing OPEN key Used to move up/down the top plate PRESS key Used to move up/down the cassette holder START key Used to start sewing USB port Reset button Used to re-start the operation panel...
  • Page 39 Explanation of the operation panel screen ❶ ❷ ❸ ❹ ❺ ❻ ❼ ❽ ❾ Buttons / display Description ❶ Lock key Used to lock the sewing pattern ❷ Threading key Used to thread the machine head ❸ Main shaft speed change key Used to change the sewing machine main shaft speed ❹...

  • Page 40: Maintenance Mode

    4-24. Maintenance mode The maintenance mode is the mode under which the notice telling that the duration of use of the sewing machine has reached the time requiring maintenance is provided in order to extend the product life of the sewing machine.

  • Page 41: List Of Parameters

    4-25. List of parameters Classifica- Standard tion of pa- Parameter name Range Meaning of parameter and comment value rameters Automatic Pressing plate is lifted Provided / not provid- Provided Cassette clamp is lifted every time the machining after the completion of continuous sewing cycle is completed automatic machining Number of stitches sewn...
  • Page 42 Classifica- Standard tion of pa- Parameter name Range Meaning of parameter and comment value rameters Startup First stitch startup speed 100 to 3000 First stitch sewing speed speed (sti/min) Second stitch startup 100 to 3000 Second stitch sewing speed speed (sti/min) Third stitch startup speed 100 to 3000 1400...
  • Page 43 Classifica- Standard tion of pa- Parameter name Range Meaning of parameter and comment value rameters Limited speed for the 100 to 1800 limited number of reverse feed stitches Platen set- Prohibition of sewing Provided / not provid- Provided Prohibition of sewing during lifting of the ting during lifting of the clamp cassette clamp...
  • Page 44 Classifica- Standard tion of pa- Parameter name Range Meaning of parameter and comment value rameters Setting of Automatic thread trim- Provided / not provid- Provided stop ming at stop Needle bar position at Upper stop position / Upper stop stop Lower stop position position Crimp board rise at stop...
  • Page 45 Classifica- Standard tion of pa- Parameter name Range Meaning of parameter and comment value rameters Detection of bottom line 0.01-255.00 Thread breakage handling is carried out after the set time has elapsed after the confirmation of thread breakage Open QEP2 Provided / not provid- Not provid- Sewing machines, in part, measures the...
  • Page 46 Classifica- Standard tion of pa- Parameter name Range Meaning of parameter and comment value rameters Cyclic machining time 1 to 65535 1440 Cyclic machining total time: When the (min) set time has elapsed, cyclic machining is stopped Cyclic machining interval 0 to 20 Interval from the completion of machin- ing to re-starting of machining under the...

  • Page 47: List Of Error Codes

    4-26. List of error codes Error code Error description Solution E001 No reset Click the [Reset] button to reset. E002 No X zero signal Inspect the X sensor for poor contact or breakage E003 No Y zero signal Inspect the Y sensor for poor contact or breakage E004 No Z zero signal Inspect the Z sensor for poor contact or breakage...
  • Page 48 Error code Error description Solution E056 Thread trimmer overload E057 Position out of the thread trimming shaft allowable range E058 Thread trimmer AD sampling failed E059 Thread trimming shaft overheat E060 Spindle overpressure E061 Spindle undervoltage E062 Spindle hardware overcurrent E063 Spindle software overcurrent E064...
  • Page 49 Error code Error description Solution E099 Communication between the Y servo DSP and ESC is interrupted E100 Communication between the Y servo net- work cable and host is interrupted E101 Exclusive for reading the Y servo PDO com- munication parameter E102 Y servo PDO communication has no index E103...
  • Page 50 Error code Error description Solution E217 Work file is not found It is necessary to re-scan or change over the graphics file. E218 Waiting for the work data Queuing time for processing graphic data differs with the size of graphic E219 Electrical failure.
  • Page 51 Error code Error description Solution ① Work enable input IO signal is abnormal. E242 No job IO ② Shut down the "Work enable input IO" function. Set the parameter value to 0 (zero). E243 Input waiting IO Waiting for the input IO signal in the graphics file. E244 Delay is executed Delay command is executed with the graphics file.

  • Page 52: Maintenance Of Sawing Machine

    5. MAINTENANCE OF SAWING MACHINE Region Explanation Operating time The area under the throat plate, Clean up the surface of equipment Eight hours area surrounding the hook, bobbin with a tool such as an air gun. In case and its inner portion, thread particular, clean up the regions in trimming area, needle bar area, which the aforementioned thread...
  • Page 53 Region Explanation Operating time 1. Detach rubber plug ❶ . Lubricate the machine through X-di- According to the usage rection ball screw nut oil hole. 2. Enter the frame travel screen environment, the sewing from the operation panel. Press machine may sew 100 ❽...
  • Page 54 Region Explanation Operating time Lubricate two Y-direction linear 1. Fully open the grip of the grease 1. Replenish the ma- guide sliders through their four oil gun (Fig. 1). Align grease gun chine with lubricating nozzle ❶ with four oil holes ❷ , holes.
  • Page 55 Region Explanation Operating time 1. Loosen screw ❶ of the face Apply grease to the upper and lower 1. Replenish the ma- covers of needle bar, needle bar plate. Detach the face plate. chine with lubricating 2. Loosen and remove screw ❷ of slide groove, guide frame groove of grease again after the the presser bar, presser bar, etc.
  • Page 56 Region Explanation Operating time 1. Remove four screws ❶ . Detach Adding the lubricating oil to the gear Replenish the gear box hook cover ❷ . box. with No. 32 white oil if the Remove six screw ❸ . Detach oil surface shown on the gear box cover ❹...

  • Page 57: Troubles And Corrective Measures (Sewing Conditions)

    5-1. Troubles and corrective measures (Sewing conditions) Trouble Cause Corrective measures ① Stitches are slipped at the start. ◦ Adjust the clearance provided between the nee- 1. The needle thread slips off at the dle and the hook. ◦ Set soft-start sewing at the beginning of sewing. start of bar-tack- ②...
  • Page 58 Trouble Cause Corrective measures ① Stitch skipping at the 1st stitch. ◦ Increase the length of needle thread remaining at 8. Thread end of the 1st stitch comes the needle after thread trimming. ② Needle used and thread used are thick ◦...

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