JUKI PS-800-6045 Instruction Manual
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JUKI PS-800-6045 Instruction Manual

JUKI PS-800-6045 Instruction Manual

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PS-800-6045
INSTRUCTION MANUAL

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Summary of Contents for JUKI PS-800-6045

  • Page 1 PS-800-6045 INSTRUCTION MANUAL...

  • Page 2: Table Of Contents

    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.

  • Page 3: Specifications

    10821- C.6.2 -ISO 11204 GR2 at 2,800 sti/min. #10 (Equivalent to JUKI NEW DEFRIX OIL No. 1) 27 Lubricating oil #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...

  • Page 4: Configuration

    2. CONFIGURATION ❶ ❶ ❻ ❻ ❷ ❷ ❾ ❾ ❸ ❸ ❹ ❹ ❺ ❺ ❽ ❽ ❼ ❼ ❶ Machine head ❷ Table ❸ X-axis feed mechanism ❹ Y-axis feed mechanism ❺ Cassette clamp device ❻ Operation panel ❼...

  • Page 5: Installation

    3. INSTALLATION 3-1. Installing the operation panel 1) The figure given on the left shows the operation panel in the delivered state. 2) Remove fixation screws ❶ (two pieces). Also take ❶ ❶ out screws ❷ (two pieces) from the plastic bag. ❷...

  • Page 6: Installing The Power Switch And The Button Switch

    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. 2) Remove the screws (two pieces) from the under- surface of the table. Detach the button switch. 3) Shift the button switch forward and secure it with the screws (four pieces).
  • Page 7 4) Remove the screw and nut from the left side and 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 Concave Convex on the table.

  • Page 8: Installing The Air Hose

    3-3. 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 9: Installing The Thread Stand

    3-4. Installing the thread stand 1) Take out thread stand device from the electrical equipment shelf. Install the spool support (asm) ❷ onto thread stand bar (lower) ❶ that has been mounted to the table as shown in the figure. ❷...

  • Page 10: 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 11: Installing The Bobbin Winder Device

    3-6. Installing the bobbin winder device 1) Insert the bobbin deep into the bobbin winder spindle ❶ until it will go no further. ❸ ❸ ❶ ❶ 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 figure on the left.
  • Page 12 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.

  • Page 13: Precautions For Installation Of The Machine

    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- 2.

  • 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 hook maintenance cover 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 ❶ ❶ Thread tension controller No. 1 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- maining tension is produced by tension controller ❶...

  • 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 Loosen setscrew ❷ . Turn thread tension con- ❺ ❺ ❶ 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) Bring the needle bar to the position that is 2.9 ± 0.3 mm above its lower dead point.
  • Page 21 (3) Adjusting the hook timing The timing gauge is supplied for the machine as an accessory. Put the accessory timing gauge in Lower dead point Position for adjusting the such a way that the surface with the of the needle timing between the hook bar of the S type and the needle bar of the...

  • Page 22: Adjusting The Position Of The Thread Trimmer

    4-9. 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. ❶ ❶ (1) Adjusting the position of the thread trim- ming cam 1) Turn pulley ❶...
  • Page 23 2) Attaching the counter knife ❷ 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 24: How To Check The Amount Of Oil In The Hook

    4-10. How to check the amount of oil 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 25: Adjusting The Amount Of Oil In The Hook

    4-11. 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) Detach the hook maintenance cover. 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 26: Adjusting The Needle Hole In The Throat Plate And The Needle

    4-12. 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 27: Setting The Mechanical Origin

    4-13. Setting the mechanical origin 1) Slightly tighten screw ❷ on the lower shaft side. Then, turn the pulley to position screw ❶ 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 28: Adjusting The Disk Presser Pressure

    4-14. Adjusting the disk presser pressure 1) Adjust the disk presser air cylinder pressure regu- ❶ ❶ lation valve ❶ . Pull up nut ❷ . Then, turn the nut 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 ❷...

  • Page 29: Adjusting The Thread End Position At The Beginning Of Sewing

    4-15. 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. Change over the setting of the wiper function be- ❶...

  • Page 30: Adjusting The Intermediate Presser Stroke

    4-16. Adjusting the 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 31: Adjusting The Needle Thread Air Blower

    4-17. Adjusting the needle thread air blower 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- ❷ ❷ noid valve of the electrical system.

  • Page 32: Making A Template

    4-18. Making a template (1) Machining a template 6045 type template of dimensions of the maximum sewing range ・ Material of template: PVC plate ・ Template thickness: 2 mm thick PVC plate ・ Adjust the template size according to the cloths and/or pattern to be sewn. The size must not exceed the maximum dimensions of the relevant specifications.
  • Page 33 (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 34: Preparation For Sewing

    4-19. 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 35 ❺ 7) Selecting the reference 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 36: Configuration Of The Operation Panel

    PRESS key Used to move up/down the cassette holder START key Used to start sewing USB port *1 PS-800-6045 does not have this function. Reset button Used to re-start the operation panel COM port RS232C * This product is not provided with the Wi-Fi function.
  • Page 37 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 38: Maintenance Mode

    4-21. 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 39: List Of Parameters

    4-22. List of parameters Classifi- Standard Range cation of Parameter name Meaning of parameter and comment value parameters Clamp is opened after the Cassette clamp is lifted every time the Automatic Yes/No completion of automatic machining continuous sewing cycle is completed machining Number of stitches to be 0 to 8...
  • Page 40 Classifi- Standard Range cation of Parameter name Meaning of parameter and comment value parameters Automatic P172 Intermediate presser is Yes/No Intermediate presser motor is reset at reset after the completion machining the end of sewing of operation P248 Whether or not the shaft Yes/No travel is required before setting a reference...
  • Page 41 Classifi- Standard Range cation of Parameter name Meaning of parameter and comment value parameters Speed Button sewing speed 2 100 to 20000 8000 Eight direction keys are supported after the button is pressed parameter Operation speed using icon (mm/min) Button sewing speed 3 100 to 20000 1000 Eight direction keys are supported...
  • Page 42 Classifi- Standard Range cation of Parameter name Meaning of parameter and comment value parameters Reset Clamp at the time of reset- Cassette clamp comes down when Yes/No ting setting returning to origin Clamp is opened after Cassette clamp goes up when returning P264 Yes/No manual resetting...
  • Page 43 Classifi- Standard Range cation of Parameter name Meaning of parameter and comment value parameters Statistics Operation continues after Yes/No Whether the operation is continued settings the counter has reached after the sewing counter has reached the set value the set value Counter setting is enabled Yes/No Whether the sewing counter is enabled...
  • Page 44 Classifi- Standard Range cation of Parameter name Meaning of parameter and comment value parameters Energi- Presser foot is lifted at the Yes/No Presser foot goes up when turning the zation time of turning the power power ON setting Other Whether or not the air pres- Yes/No In the case of "Yes", the sewing ma- sure detection is required...

  • Page 45: List Of Error Codes

    4-23. List of error codes Fault Cause Error Error description Solution Code Click the "Reset" button to reset E001 There is no reset The machine is not reset or reset abnormally after power on E002 Couldn't find X zero signal 1.
  • Page 46 Fault Cause Error Error description Solution Code 1. Reset or redirect parameters E023 X axis driver software over- 1. The parameters are incorrect 2. Check the machinery current 2. The motor is stuck 3. Check and replace the motor 3. The motor is broken or the motor wire is damaged and short circuit- 4.
  • Page 47 Fault Cause Error Error description Solution Code E048 Z axis AD sampling module Refer to E028 Error Handling Method failure E049 Z axis overheated Refer to E029 Error Handling Method Refer to E050 Shear driver overvoltage E020 Error Handling Method 1.
  • Page 48 Fault Cause Error Error description Solution Code 1. Reset or redirect parameters E063 Main axis software over 1. The parameters are incorrect. 2. Check the machinery current 2. The motor is stuck 3. Check and replace the motor 3. The motor is broken or the motor wire is broken and short circuited 4.
  • Page 49 Fault Cause Error Error description Solution Code E084 Y servo overspeed 1. The wiring of the cable and encod- 1. Whether the wiring of the servo motor er cable is wrong power cable and encoder cable is cor- rect and damaged 2.
  • Page 50 Fault Cause Error Error description Solution Code E101 Y servo PDO parameters Spare alarm read only E102 Y Servo PDO does not Spare alarm have an index to find E103 Y servo PDO setting syn- Spare alarm chronization time out of range E104 Y servo PDO data out of Spare alarm...
  • Page 51 Fault Cause Error Error description Solution Code Refer to E121 Overload of spindle drive E026 Error Handling Method Refer to E122 Spindle braking resistor E089 Error Handling Method overload Refer to E123 Overheated spindle motor E415 Error Handling Method Refer to E124 Overheated spindle drive E416 Error Handling Method...
  • Page 52 Fault Cause Error Error description Solution Code E203 The main motor error 1. The winding is normal but the 1. See "Internal Drive Preview" - "Spindle" work occasionally reports that the - "Version Number" on the screen. If it power board software and hard- is lower than 2, you need to update the ware are too old program.
  • Page 53 Fault Cause Error Error description Solution Code 1. Zero parameter setting error 1. Change the zero parameter P687 E210 Motor foot fault 2. Check the wiring or replace the sensor 2. If it is an external zero position, the zero position sensor wiring is bad or damaged, or the installa- tion is loose 3.
  • Page 54 Fault Cause Error Error description Solution Code 1. The file is too large, the moth- E218 Waiting for the working data 1. Need to wait for a while to disappear erboard waits for the screen to automatically transfer files during processing 2.
  • Page 55 Fault Cause Error Error description Solution Code E227 The file transfer failed 1. Check the screen line 1. The screen cable interface is loose or disconnected 2. The screen or motherboard pro- 2. Upgrade the latest screen or mother- gram is too old board program 3.
  • Page 56 Fault Cause Error Error description Solution Code 1. Check the corresponding IO E242 No work IO 1. The work enable input IO signal is abnormal. 2. Turn off the “work enable input IO” func- 2. Parameter setting error tion and set the parameter value to 0 1.
  • Page 57 Fault Cause Error Error description Solution Code E402 (0x) Driver board HOC Spare alarm E403 (0x) Driver module AD mod- Spare alarm ule initial calibration failure E404 (0x) Drive board parameter 1. Abnormal memory 1. Maintenance memory storage error 2. Not enough memory 2.
  • Page 58 Fault Cause Error Error description Solution Code 1. Reset the correct parameters E419 (0x) Driver board position 1. The position deviation parameter deviation is too large is set too small 2. Replace the servo unit 2. Servo unit circuit board failure 3.
  • Page 59 Fault Cause Error Error description Solution Code E437 (0x) Driver board PDO Spare alarm communication synchroni- zation time is out of range E438 (0x) Drive board initializa- Spare alarm tion LAN9252 error Refer to E439 (0x) Driver board UVW E105 Error Handling Method short circuit E440 (0x) Drive board inertia...
  • Page 60 Fault Cause Error Error description Solution Code Refer to E474 (0x) Driver board encoder E024 Error Handling Method failure Refer to E475 (0x) Driver board is open E025 Error Handling Method Refer to E476 (0x) Drive board overload E026 Error Handling Method Refer to E477 (0x) The driver board is out E027...

  • Page 61: Maintenance Of Sawing Machine

    5. MAINTENANCE OF SAWING MACHINE WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. In addition, attach the covers which have been removed before operation back in place.
  • Page 62 Region Explanation Operating time 1. Detach cover ❶ . Lubricate the hook oil tank. If the oil level in the 2. Remove rubber plug ❷ of the oil tank drops below oil tank. the lower scale 3. Pour accessory (or specified) marker, replenish oil to the oil tank through the the oil tank with...

  • Page 63: Troubles And Corrective Measures (Sewing Conditions)

    5-1. Troubles and corrective measures (Sewing conditions) Cause Corrective measures Trouble 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 64 Cause Corrective measures Trouble 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 ◦...

  • Page 65: Disposal Of Batteries

    5-2. Disposal of batteries The operation panel has a built-in battery in order to operate the clock even when the power is turned OFF. Be sure to dispose of the battery following the local laws and regulations. ■ How to remove the battery ❸...

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