JUKI APW-896N/IP-420 Instruction Manual
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JUKI APW-896N/IP-420 Instruction Manual

Automatic welting machine
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APW-896N/IP-420

INSTRUCTION MANUAL

* "CompactFlash(TM)" is the registered trademark of SanDisk Corporation, U.S.A.

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Summary of Contents for JUKI APW-896N/IP-420

  • Page 1: Instruction Manual

    APW-896N/IP-420 INSTRUCTION MANUAL * "CompactFlash(TM)" is the registered trademark of SanDisk Corporation, U.S.A.

  • Page 2: Table Of Contents

    CONTENTS I. CAUTIONS BEFORE OPERATION ..................1 II. CONFIGURATION OF THE MACHINE ................2 III. SPECIFICATIONS ......................3 1. MECHANICAL SPECIFICATIONS ....................... 3 2. ELECTRICAL SPECIFICATIONS ......................3 IV. INSTALLATION .......................4 1. REMOVING PACKING MATERIALS ....................4 2. SECURING THE MACHINE........................4 3. CONNECTING THE FOOT PEDAL ...................... 5 4.
  • Page 3 (3) Input screen (Alternate sewing mode) .................... 31 (4) Sewing screen (Alternate sewing mode) ..................32 (5) Input screen (Cycle sewing mode)....................33 (6) Sewing screen (Cycle sewing mode) ..................... 34 4. USING THE COUNTER ........................35 (1) Setting procedure of the counter..................... 35 (2) Releasing procedure of count-up ....................
  • Page 4 VII. MAINTENANCE ......................99 1. INSPECTION ............................99 (1) Maintenance and inspection of the pneumatic device ..............99 (2) Maintenance and inspection related to the sewing machine ............99 (3) With regard to the waste oil of the hook oil ................... 100 (4) With regard to the cleaning of the hook shaft base...............

  • Page 5: Cautions Before Operation

    I. CAUTIONS BEFORE OPERATION Following items have to be checked every working day before the operation of the machine and before the start of work hours. Ascertain that the sewing machine is filled with the predetermined amount of oil. Never operate the machine unless the lubricating part in the hook has been filled up with oil. Ascertain that the pressure gauge indicates the designated air pressure of 0.5 MPa.

  • Page 6: Configuration Of The Machine

    II. CONFIGURATION OF THE MACHINE The APW-896N consists mainly of the following units. A Frame and structural components (Framesewing table, covers, foot switch, etc.) B Clamp foot unit and feed mechanism C Corner knife unit D Binder unit (Binder components and its driving components) E Pneumatic control unit (Pneumatic control devices and pipings) F Stacker unit (Optional) G Sewing machine head...

  • Page 7: Specifications

    Machine operation is automatically stopped if the cloth feed mechanism error detector, 14 Safety mechanism the needle thread breakage detector or any of the various safety devices is actuated. 15 Lubricating oil JUKI New Defrix Oil No. 1 16 Operating air pressure 0.5 MPa 17 Air consumption Approx.

  • Page 8: Installation

    IV. INSTALLATION 1. REMOVING PACKING MATERIALS Remove the upper cover and remove Remove the string that has fixed the the string and packing materials that binder unit. have fixed the clamp foot. Remove the string and packing materials that have fixed the clamp Wooden table bar stacker.

  • Page 9: Connecting The Foot Pedal

    3. CONNECTING THE FOOT PEDAL CAUTION When installing the pedal, perform the work paying attention to the overhead table. ① Install the pedal base to the machine frame with screws ❷ . ② Connect pedal bases A and B with two screws ❶...

  • Page 10: Connecting The Power Plug

    5. CONNECTING THE POWER PLUG CAUTION To prevent possible accidents caused by leakage or dielectric strength, an appropriate power plug shall be installed by a person who has an expert knowledge of electricity. Be sure to connect the pow- er plug to the receptacle that is well grounded. Connection of the power plug to the power depends on the specifications of the product.

  • Page 11: Assembling The Thread Stand And Attaching It To The Machine

    6. ASSEMBLING THE THREAD STAND AND ATTACHING IT TO THE MACHINE Putting nut and washer between main unit frame ❶ and fix the thread stand as illustrated in the left-hand figure. Washer ❶ Spring washer − 7 −...

  • Page 12: Installing Sp-46N (Clamp Bar Stacker) (Optional Part No. : 40149301)

    7. INSTALLING SP-46N (CLAMP BAR STACKER) (OPTIONAL PART NO. : 40149301) Clamp bar stacker is delivered in the state that it is fixed in the frame at the time of delivery with the clamp bar stacker mounted. It is necessary to change the installing position to the nor- mal using position.

  • Page 13: Installing Sp-47N (Roller Stacker) (Optional Part No. : 40149302)

    8. INSTALLING SP-47N (ROLLER STACKER) (OPTIONAL PART NO. : 40149302) (1) Adjusting the position ① Confirming parallelism Make sure that stacker table ❹ and rubber roller ❷ ❸ are installed parallel with each other. If not, loosen four set- ❺ screws ❷...

  • Page 14: Removing The Head Fixing Plate

    9. REMOVING THE HEAD FIXING PLATE Remove fixing screws ❷ of head fixing plate ❶ . Be sure to fix the machine and the frame when performing re-transportation. ❷ ❶ 10. INSTALLING THE SUB-TABLE Install the sub-table with four screws ❶ as shown in the figure.

  • Page 15: Lubricating The Oil Tank

    Fill the oil tank with the oil for hook lubrication before operating the sewing machine. ① Remove oil cap ❶ and fill the oil tank with JUKI MACHINE OIL No. 1 (Part No. : MD- FRX1600C0) using the oiler supplied with the ❶...

  • Page 16: Installing Sa-120N (Interlining Supplying Device) (Optional Part No. : 40149798)

    13. INSTALLING SA-120N (INTERLINING SUPPLYING DEVICE) (OPTIONAL PART NO. : 40149798) CAUTION Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. ① Fix interlining installing plate ❶ to the machine ❷...

  • Page 17: Adjustment Of Sa-120N (Interlining Supplying Device) (Optional Part No. : 40149798)

    14. ADJUSTMENT OF SA-120N (INTERLINING SUPPLYING DEVICE) (OPTIONAL PART NO. : 40149798) CAUTION Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. ① Adjustment of the interlining feeding amount is performed with memory switch ( However, perform further fine adjustment with the speed controller ❷...

  • Page 18: Preparation Of The Sewing Machine

    V. PREPARATION OF THE SEWING MACHINE 1. HOW TO OPERATE THE SEWING MACHINE HEAD (1) How to attach the needles CAUTION • Turn OFF the power before starting the work so as to prevents accidents caused by abrupt start of the sewing machine.

  • Page 19: How To Pass The Needle Thread

    (3) How to pass the needle thread CAUTION Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. ① Lift binder ❶ in the direction A, Hold section B by hand and turn the whole binder in the direc- tion C.

  • Page 20: How To Remove The Sewing Table

    2. HOW TO REMOVE THE SEWING TABLE CAUTION Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. (1) When replacing the bobbin thread ① Move the clamp foot to the rear end of its stroke. ②...

  • Page 21: Cautions To Be Taken When The Sewing Tables Are Removed

    (2) Cautions to be taken when the sewing tables are removed CAUTION Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. When you remove the sewing tables ❶ and ❷ , be sure to accurately set them by following the points below. ①...

  • Page 22: How To Wind The Bobbins

    3. HOW TO WIND THE BOBBINS CAUTION To prevent damage, avoid contact with bobbins while the machine is in operation. ① Put bobbin into the thread winder shaft until it will go no further. ② Pass thread through thread guide ❹...

  • Page 23: How To Thread The Bobbin Case

    4. HOW TO THREAD THE BOBBIN CASE ① Hold in hand a bobbin in the way that it spins clockwise and put it into the bobbin case. Bobbin case ② Pass the thread through slot ❶ in the bobbin case. ③...

  • Page 24: How To Adjust The Thread Tension

    6. HOW TO ADJUST THE THREAD TENSION ① Adjusting bobbin thread tension Bobbin case Turn bobbin thread tension adjustment screw clockwise to increase the bobbin thread tension or turn the screw counterclockwise to decrease it. Bobbin Bobbin thread tension adjustment screw As shown in the left-hand figure, standard bobbin thread tension is 0.25 to 0.35N when...

  • Page 25: Setting The Material To Be Sewn

    7. SETTING THE MATERIAL TO BE SEWN Use a garment body that is larger than the garment body clamp rub- ber piece adhered under the right and left garment body clamps. If a garment body of which size is smaller than the garment body clamp rubber piece, the rubber piece can come off or the machine can malfunction.

  • Page 26: How To Use The Operation Panel

    VI. HOW TO USE THE OPERATION PANEL 1. PREFACE To use the data for APW-895N/896N (EPD data) on APW-896N To use the EPD data on the APW-896N, read the data into the IP-420. Insert the relevant medium into the IP-420. Select pattern number xxx from EPD data. Folder structure of the media Store each file in the directories below of the media.
  • Page 27 ■ Removing the CompactFlash (TM) Hold the panel by hand, open the cover, and press the media ❷ removing lever ❶ . The me- dia is eject. When the lever ❶ is strongly pressed, ❶ the media ❷ may be broken by protrud- ing and falling.
  • Page 28 • Some type of the USB device may not be properly recognized by this sewing machine. • JUKI does not compensate for loss of data stored on the USB device caused by using it with this sewing machine. • When the panel displays the communication screen or pattern data list, the USB drive is not recognized even if you insert a medium into the slot.

  • Page 29: Basic Operation Of The Operation Panel (Ip-420)

    2. BASIC OPERATION OF THE OPERATION PANEL (IP-420) (1) Configuration of IP-420 [ Front ] [ Right side ] ❻ ❼ ❽ ❾ ❶ ❷ ❸ ❹ ❺ Symbol Name Description ❶ TOUCH PANEL, LCD display section Change-over of the data input screen and the sewing screen ❷...

  • Page 30: Buttons Used In Common

    (2) Buttons used in common Buttons that perform common operation in the respective screens of IP-420 are as described below. Pictograph Name Description Pop-up screen is closed. In case of the data change screen, the CANCEL button data during changing can be cancelled. ENTER button Data changed are determined.

  • Page 31: Start Sewing

    ② Select pattern No. you desire to sew. C is pressed, the pattern No. When PATTERN NO. button can be selected. For the selecting procedure of pattern No., see "VI-7.(1) Performing the selection of pattern" p. At the time of your purchase, pattern Nos. 1 to 10 have been reg- istered.
  • Page 32 At this time, the error screen is displayed to inform that stop switch F is pressed, the error is is pressed. When RESET button released and the screen returns to the input screen. ⑤ Depress back the pedal at the time of mounting the breast box device.

  • Page 33: Explanation Of The Basic Screen

    3. EXPLANATION OF THE BASIC SCREEN (1) Input screen (Independent sewing mode) Symbol Name of button Description NEW CREATION button Independent sewing pattern new creation screen is displayed and new register of the pattern data can be performed. COPY button Independent sewing copy source pattern list screen is displayed and the pattern can be copied.

  • Page 34: Sewing Screen (Independent Sewing Mode)

    (2) Sewing screen (Independent sewing mode) Symbol Name of button Description INTERLINING SUPPLY button When this button is pressed, interlining is supplied. * This is displayed when “With” of , automatic interlining supplying device is set with the optional setting. TYPE OF WELT CHANGE-OVER button Type of welt change-over screen is displayed and change-over of type of welt and adjustment of parallelism of the binder can be performed.

  • Page 35: Input Screen (Alternate Sewing Mode)

    (3) Input screen (Alternate sewing mode) Symbol Name of button Description NEW CREATION button Alternate sewing data new creation screen is displayed and new register of data can be performed. COPY button Alternate sewing data copy source No. list is displayed and alternate sewing data can be copied. CHARACTER INPUT button Character input screen is displayed and name input can be performed n the alternate sewing data.

  • Page 36: Sewing Screen (Alternate Sewing Mode)

    (4) Sewing screen (Alternate sewing mode) Symbol Name of button Description INTERLINING SUPPLYING button When this button is pressed, interlining is supplied. * This is displayed when “With” of , automatic interlining supplying device is set with the optional setting. TYPE OF WELT CHANGE-OVER button Type of welt change-over screen is displayed, and change-over of type of welt and adjust- ment of parallelism of the binder can be performed.

  • Page 37: Input Screen (Cycle Sewing Mode)

    (5) Input screen (Cycle sewing mode) Symbol Name of button Description NEW CREATION button Cycle sewing data No. new creation screen is displayed and new register of cycle sewing data can be performed. COPY button Cycle sewing data copy source No. list screen is displayed and cycle sewing data can be copied.

  • Page 38: Sewing Screen (Cycle Sewing Mode)

    (6) Sewing screen (Cycle sewing mode) Symbol Name of button Description INTERLINING SUPPLYING button When this button is pressed, interlining is supplied. * This is displayed when “With” of , automatic interlining supplying device is set with optional setting. TYPE OF WELT CHANGE-OVER button Type of welt change-over screen is displayed, and change-over of type of welt and adjust- ment of parallelism of the binder can be performed.

  • Page 39: Using The Counter

    4. USING THE COUNTER (1) Setting procedure of the counter ① Display the counter setting screen. Press MODE CHANGEOVER key from the input screen and A is displayed on the screen. COUNTER SETTING button Press this button and “COUNTER SETTING screen (screen A)” is displayed.
  • Page 40 C In “Count- Press NUMBER OF PCS. COUNTER button er setting screen (screen A)”, and “number of pcs. setting screen (screen C)” is displayed. Then the kind of counter can be set. Counter setting screen (Screen A) [ Number of pcs. counter ] UP counter : Every time one of finished products is sewn, the existing value is counted up.
  • Page 41 ③ Changing the target value of the counter D, and in case In case of the sewing counter, press button E, and “ Nu- of the number of pcs. counter, press button merical setting pop-up screen (screen D)” Is displayed. Then the target value of counter can be set.

  • Page 42: Releasing Procedure Of Count-Up

    (2) Releasing procedure of count-up During the sewing work, the count-up condition is reached the count- up screen is displayed and the buzzer sounds. Press CLEAR button A to reset the counter, and the screen returns to the sewing screen. And, counting starts again. (3) Counter value changing procedure during sewing ①...

  • Page 43: Using The Bobbin Thread Amount Adjustment Counter

    5. USING THE BOBBIN THREAD AMOUNT ADJUSTMENT COUNTER (1) Setting procedure of the bobbin thread remaining amount adjustment counter ① Display the counter setting screen Press MODE CHANGEOVER key from the input screen, A is displayed on the screen.. COUNTER SETTING button Press this button and “Counter setting screen (screen A)”...
  • Page 44 ③ Set the bobbin thread remaining amount adjustment value Press BOBBIN THREAD REMAINING AMOUNT ADJUSTMENT C and the bobbin thread remain- VALUE SETTING button ing amount adjustment value setting screen (screen B) is dis- played. Counter setting screen (Screen A) Here, input the bobbin thread remaining amount adjustment value (0 to 9).

  • Page 45: Releasing Procedure Of The Bobbin Thread Remaining Amount Detection Count-Up

    ＊ Setting of the bobbin thread remaining amount adjustment counter ＊ Set the bobbin thread remaining amount adjustment counter to the value shown in the table below. Start the sewing to perform regular sewing. In case of test sewing, adjust the sewing length to that to be sewn in the actual process.

  • Page 46: Changing The Sewing Mode

    6. CHANGING THE SEWING MODE ① Display the sewing mode selection screen A and the Press SEWING MODE CHANGEOVER key mode change-over screen is displayed. ② Select the sewing mode Press MODE SELECTION button B and the indication of button is changed. When the independent When the alternate sewing When the cycle sewing is...

  • Page 47: Using The Sewing Pattern

    7. USING THE SEWING PATTERN (1) Performing the selection of pattern ① Display the input screen When the input screen of independent sewing mode, alternate sewing mode and cycle sewing mode is displayed, the selection of pattern can be selected. By customizing the sewing screen, the selection of pattern can be performed from the sewing screen as well.

  • Page 48: Performing The New Creation Of Pattern

    (2) Performing the new creation of pattern ① Display the input screen When the input screen of independent sewing mode, alternate sewing mode and cycle sewing mode is displayed, the new creation of pattern can be performed. ② Call the sewing pattern new creation screen A, and the pattern new creation screen is dis- Press NEW CREATION button played.

  • Page 49: Copying The Pattern

    (3) Copying the pattern The pattern which has been already registered can be copied to the sewing pattern which has not registered yet. Copying of overwriting of pattern is prohibited. So, when you desire to overwrite, perform it after erasing the pattern once.
  • Page 50 ③ Select the pattern of copy source Select the pattern of copy source from PATTERN LIST button B. C and the copy destination input screen Next, press COPY DESTINATION NO. INPUT button (screen B) is displayed. Copy destination No. input screen (screen A) ④...

  • Page 51: Erasing The Pattern

    (4) Erasing the pattern ① Display the input screen When the input screen of independent sewing mode, alternate sewing mode and cycle sewing mode is displayed, it is possible to erase the pattern. ② Call the pattern list screen A and the pattern No. list screen (screen A) is dis- Press PATTERN LIST button played.

  • Page 52: Naming The Pattern

    (5) Naming the pattern ① Display the input screen When the input screen of independent sewing mode, alternate sewing mode and cycle sewing mode is displayed, it is possible to input the name to the pattern data. ② Call the character input screen A and the character input screen (screen B) is displayed.

  • Page 53: Editing Procedure Of The Cycle Sewing Data

    (6) Editing procedure of the cycle sewing data ① Display the cycle sewing input screen When the input screen of cycle sewing ode is displayed, it is pos- sible to edit the cycle sewing data. Cycle sewing input screen (Screen C) ②...
  • Page 54 ③ Erase the registered pattern data E and the pattern data which is dis- Press ERASE button played with white emphasis is erased. Select the pattern data you desire to erase with UP/DOWN SCROLL buttons F and erase it. The pattern data which is displayed with white emphasis is the pattern data to be sewn next.

  • Page 55: Changing The Sewing Data

    8. CHANGING THE SEWING DATA (1) Changing procedure of the sewing data ① Display the input screen When the input screen of independent sewing mode, alternate sewing mode and cycle sewing mode is displayed it is possible to change the swing data. The sewing data which are frequently used can be registered to SEWING DATA SHORTCUT button B in the input screen and be set directly.

  • Page 56: Sewing Data List

    (2) Sewing data list ① Items that are displayed in the data input screen Setting range Item Initial value Edit unit Motion mode change-over - - - With/without of motion of sewing machine motor, center knife and corner knife is selected. Cloth feed, sewing Cloth feed mode machine thread trimming...
  • Page 57 Setting range Item Initial value Edit unit ※ Flap concealed stitching data (Right sewing end) –9.9 to 9.9 0.0mm Position of sewing end of right-hand flap is adjusted. 0.1mm * It is possible to set only when is set to flap sewing. Changeover of deflection direction at the start of sewing - - - Changeover of deflection direction at the start of sewing is performed.
  • Page 58 Setting range Item Initial value Edit unit Setting of right width of corner knife at the start of sewing –1.0 to 0.5mm Right width of corner knife at the start of sewing is set. 1.5mm 0.1mm Setting of left width of corner knife at the start of sewing –1.0 to 0.5mm Left width of corner knife at the start of sewing is set.
  • Page 59 Setting range Item Initial value Edit unit Setting of (left) corner knife motion position at the start of sewing –9.9 to 0.0mm Motion (longitudinal) position of left corner knife at the start of sewing is set. 9.9mm 0.1mm Setting of (right) corner knife motion position at the start of sewing –9.9 to 0.0mm Motion (longitudinal) position of right corner knife at the start of sewing is...
  • Page 60 Setting range Item Initial value Edit unit Automatic detection function of deflection at the start of sewing - - - Flap is read at the start of sewing using two flap sensors and deflection is automatically set. * When Right flap angle detection device is not mounted, left flap (double welt and single welt with one side flap) only can be used.
  • Page 61 ② Items that are displayed in the sewing data list screen Setting range Item Initial value Edit unit ※ Flap priority sewing selection - - - Flap priority sewing mode is selected. * It is possible to set only when alternate sewing mode is set. Flap priority sewing pro- Flap priority sewing hibited...
  • Page 62 Setting range Item Initial value Edit unit ※ Condensation pitch at sewing start 0.5 to 1.5 1.0mm Condensation sewing pitch at sewing start is set. * It is possible to set only when is set to selection of condensation. 0.1mm ※...
  • Page 63 Setting range Item Initial value Edit unit ※ First stitch pitch of return of back tack at sewing start 0.1 to 3.0 2.0mm First stitch pitch of return section of back tack sewing at sewing start is set. * It is possible to set only when is set to selection of back tack.
  • Page 64 Setting range Item Initial value Edit unit ※ The last stitch pitch of condensation 0.1 to 1.5 1.0mm The last stitch pitch of condensation sewing at sewing end is set. * It is possible to set only when is set to selection of condensation. 0.1mm * It is possible to set only when is set to selection of condensation/...
  • Page 65 Setting range Item Initial value Edit unit ※ Second stitch pitch of return of back tack sewing at sewing end 0.1 to 3.0 2.0mm Second stitch pitch of return section of back tack sewing at sewing end is set. * It is possible to set only when is set to selection of back tack.
  • Page 66 Setting range Item Initial value Edit unit 3 to 10 Jump feed speed up to the position of sewing start Jump feed speed up to the position of sewing start is set. 3 to 10 Jump feed speed up to the position of corner knife Jump feed speed up to the position of corner knife is set.

  • Page 67: Copying Function Of The Upper And Lower Alternate Sewing Data

    (3) Copying function of the upper and lower alternate sewing data ① Display the alternate sewing input screen. When the input screen of the alternate sewing mode is displayed, it is possible to copy the upper and lower data. ② Call the sewing mode changeover screen. Press SEWING MODE SETTING button to display the sewing mode changeover screen.
  • Page 68 ④ Start copying. When ENTER button is pressed in the copy confirmation screen, the left and right sewing data are inversely copied. When CANCEL button is pressed, the screen returns to the original sewing mode changeover screen without copying. * The sewin data below are inversed from the left to the right at the time of copying. (Other sewing data are copied without inversion.) Item S003...

  • Page 69: Changing The Memory Switch Data

    9. CHANGING THE MEMORY SWITCH DATA (1) Changing procedure of the memory switch data ① Display the memory switch data list screen Press MODE CHANGE-OVER key and the memory switch A is displayed. When this button is pressed, the button memory switch data list (screen A) is displayed.

  • Page 70: Memory Switch Data List

    (2) Memory switch data list ① Level 1 Memory switch data (level 1) are the motion data that the sewing machine has in common and the data that operate on all sewing patterns in common. Setting range Item Initial value Edit unit Change-over of the position of clamp foot after sewing end - - -...
  • Page 71 Setting range Item Initial value Edit unit ※ Stacker timer 4 0.00 to 0.00 sec. Time to advance timing to release the sewing product by lifting clamp 9.99 foot is set. When clamping a short sewing product, the amount to drop by tare is 0.01 sec.
  • Page 72 Setting range Item Initial value Edit unit Clamp foot down order change-over - - - Lowering order of clamp foot is selected. From right From left Right/left at the same time * When right and left are simultaneously actuated with customizing of pedal setting, this parameter is neglected and the right and left are simultaneously actuated.
  • Page 73 Setting range Item Initial value Edit unit - - - Changeover of compensation of flap concealed stitching position using deflection detection When the automatic deflection detection of left flap is not set, compen- sation of flap concealed stitching is automatically performed using the second flap sensor.
  • Page 74 ② Level 2 Memory switch data (level 2) are the motion data that the sewing machine has in common and the data that operate on all sewing patterns in common. The data are for the maintenance personnel and possi- ble to edit by pressing the mode switch as long as 6 seconds. Setting range Item Initial value...
  • Page 75 Setting range Item Initial value Edit unit L size data range enlargement - - - Enlarging/not enlarging L size data range to max. 220 mm + 15 mm is set. In case of the long and wide type, the size is enlarged to 250 mm + 50 mm. Not enlarging Enlarging Selection of sewing speed of sewing machine setting...
  • Page 76 Setting range Item Initial value Edit unit - - - Back tack control method selection Sewing pattern of back tack can be selected. 1st mode (standard) Sewing first the longer seams (Emphasis is put on sewing quality.) 2nd mode Sewing first the shorter seams (Emphasis is put on produc- tivity.) 3rd mode 1st mode and 2nd mode are changed over according to...
  • Page 77 Setting range Item Initial value Edit unit Center knife lowering time 10 to 100 Center knife lowering time is set. Center knife one-shot motion prohibition setting - - - With/without one-shot motion to properly cut the cutting position of cen- ter knife on the side of the end of sewing is selected.

  • Page 78: Performing Optional Setting

    10. PERFORMING OPTIONAL SETTING (1) Changing procedure of the optional setting ① Displaying the 2nd screen of the operation-mode changeover screen. When you keep operation-mode changeover key held A is displayed pressed for six seconds, right-scroll button on the screen. When you press this button, the 2nd screen (screen A) of the op- eration-mode changeover screen is displayed.

  • Page 79: Optional Setting List

    (2) Optional setting list By setting the optional mounted state, it is possible to perform the respective optional operations. Setting range Item Initial value Edit unit Clamp bar stacker mounting/not mounting is set - - - Not mounting Mounting Not mounting Roller stacker mounting/not mounting is set.

  • Page 80: Changing The Device Setting

    11. CHANGING THE DEVICE SETTING (1) Changing procedure of the device setting ① Displaying the 2nd screen of the operation-mode changeover screen. When you keep operation-mode changeover key held A is displayed pressed for six seconds, right-scroll button on the screen. When you press this button, the 2nd screen (screen A) of the op- eration-mode changeover screen is displayed.

  • Page 81: Device Setting List

    (2) Device setting list By setting the type of device, it is possible to operate according to the type. Setting range Item Initial value Edit unit Gauge size 8 to 20 10 mm Gauge size of sewing machine is set. ( 22 to 32 ) * Corner knife motion is changed according to the set value of gauge size.

  • Page 82: Customizing The Pedal Operation

    12. CUSTOMIZING THE PEDAL OPERATION Operation functions of “Binder down”, “Flap presser down”, etc. in terms of the number of the respective de- pressing steps of the pedal can be optionally registered in accordance with the using conditions. In addition, the customized pedal operation data can have as many as 5 kinds. Select and use them. (1) Method to select and use the customized data ①...

  • Page 83: Customizing The Pedal Operation Data

    (2) Customizing the pedal operation data ① Press button A, and set whether to make the clamp foot recede or not with the pedal depressed to the reverse step. Display Description To make clamp foot recede Not to make clamp foot recede ②...
  • Page 84 ⑤ Functions below can be registered from first step in order. Func- tions that can be registered are in the state of button as , and displayed in order. When the button is pressed, the color changes and the function is registered. The number of pedal steps is ad- E.

  • Page 85: Customizing The Data Input Screen

    13. CUSTOMIZING THE DATA INPUT SCREEN Buttons displayed in the data input screen can be customized in accordance with the customers’ using con- ditions. ① Display the customizing screen of the input screen Keep pressing MODE CHANGEOVER key for three sec- A is displayed on the screen.
  • Page 86 ③ Register the sewing data to SEWING DATA CUSTOMIZING button Up to 4 sewing data can be registered to SEWING DATA CUS- TOMIZE buttons N. Register and use the sewing data that are frequently used. When pressing CUSTOMIZING button N you desire to register, the sewing data list (screen A) is displayed.

  • Page 87: Performing The Customizing Setting Of The Sewing Screen

    14. PERFORMING THE CUSTOMIZING SETTING OF THE SEWING SCREEN Buttons displayed in the data input screen can be customized in accordance with the customers’ using condi- tions. ① Display the customizing screen of the sewing screen Keep pressing MODE CHANGEOVER key for three sec- A is onds and SEWING SCREEN CUSTOMIZING button...
  • Page 88 ③ Register the direct pattern. When DIRECT PATTERN REGISTER button N is pressed, the direct pattern register list screen (screen A) is displayed. In the direct pattern list screen, the pattern data of independent sewing/alternate sewing/cycle sewing can be freely registered up to 30.

  • Page 89: Using The Information

    15. USING THE INFORMATION There are three functions below, in the information function. ① Display the information screen A of the switch seat section in Press INFORMATION key the input screen and the information screen (screen A) is dis- played. Ⓐ...

  • Page 90: Observing The Maintenance Inspection Information

    (1) Observing the maintenance inspection information ① Display the maintenance information screen Press MAINTENANCE INSPECTION INFORMATION SCREEN A of the information screen. DISPLAY button Three items of the information below are displayed in the mainte- nance inspection information screen. • Needle replacement (1,000 stitches) : •...

  • Page 91: Releasing Procedure Of The Warning

    ③ Display the threading diagram E displayed in the maintenance Press THREADING button inspection information screen and the needle thread threading screen is displayed. See when performing threading. (2) Releasing procedure of the warning When the specified inspection time is reached, the warning screen is displayed.

  • Page 92: Observing The Production Control Information

    (3) Observing the production control information It is possible to designate the start, display the number of pieces of production from the start to the existing time, display the number of pieces of production target, etc. in the production control screen. There are two kinds of display ways for the production control screen.
  • Page 93 [ In case of displaying from the sewing screen ] ① Display the sewing screen A in the input screen and the sewing Press READY key screen is displayed. ② Display the production control screen B in the sewing screen and the Press INFORMATION key production control screen is displayed.

  • Page 94: Performing Setting Of The Production Control Information

    (4) Performing setting of the production control information ① Display the production control screen Refer to "VI-15.(3) Observing the production control information" p. 88 and display the production control screen. ② Input the final target value First, input the number of pieces of the target of production in the process to which sewing is performed from now on.
  • Page 95 ⑤ Start the count of number of pieces of production I and the count of number of pieces Press START button of production is started. ⑥ Stop the count Display the production control screen referring to "VI-15.(3) Observing the production control information" p. J is When the count is being performed, STOP button J is pressed, the count is...

  • Page 96: Observing The Operation Measurement Information

    (5) Observing the operation measurement information ① Display the operation measurement screen Press OPERATION MEASUREMENT SCREEN DISPLAY button A in the information screen. The operation measurement screen (screen A) is displayed. Information on the following 5 items is displayed in the operation measurement screen.
  • Page 97 ③ Start the measurement C, and the measurement of each data Press START button is started. ④ Stop the count Display the operation measurement screen referring to Items ① and ② of "VI-15.(5) Observing the operation measurement information" p. When the measurement is being performed, STOP button D is displayed.

  • Page 98: Using The Communication Function

    16. USING THE COMMUNICATION FUNCTION Communication function can download the sewing data created with other sewing machine . In addition, the function can upload the aforementioned data to the media or personal computer. As the means of communication, a media slot and USB are prepared. (1) Handling possible data Data name Extension...

  • Page 99: Take-In Of The Data

    (4) Take-in of the data ① Display the communication screen When COMMUNICATION key of switch seat section is pressed in the input screen, the communication screen (screen A) is displayed. ② Select the communication procedure There are four communication procedures as described below. A Writing data from media to panel B Writing data from personal computer (server) to panel C Writing data from panel to media...

  • Page 100: Take-In Of Plural Data Together

    (5) Take-in of plural data together It is possible for the sewing data to select plural data to be written and write all together. Pattern No. of writ- ing destination is the same No. of the selected data No. No.99 and after of the media cannot perform the plural selection. ①...
  • Page 101 Data No. during communication, total number of writing data and number of data that have finished the data communication are displayed in the during communication screen. * When performing writing to the pattern No. that already exists, the overwriting confirmation screen is displayed before writing. When performing overwriting, press ENTER button When performing overwriting to all without displaying the overwrit- G in...

  • Page 102: Performing Formatting Of The Media

    17. PERFORMING FORMATTING OF THE MEDIA When re-formatting the media, be sure to perform it with IP-420. The media that have been formatted with the personal computer cannot be read with IP-420. ① Display the media format screen Keep pressing MODE CHANGEOVER key for three sec- A is displayed on the onds and MEDIA FORMAT button...

  • Page 103: Maintenance

    • Check the sharpness of center knife and corner knife before the work, and try to replace it in good time. • For the lubrication of the sewing machine, be sure to use the designated oil JUKI MACHINE OIL No. 1 (MDFRX1600C0).

  • Page 104: With Regard To The Waste Oil Of The Hook Oil

    (3) With regard to the waste oil of the hook oil CAUTION To prevent accidents caused by abrupt start of the sewing machine, start the work after turning OFF the power. Turn and remove the oil can, and drain the waste oil when the waste oil gathered in approximately half of oil can ❶...

  • Page 105: Marking Light

    2. MARKING LIGHT WARNING 1. If the laser light directly enters the eye, eyesight trouble may be caused. Do not look into the laser inlet/outlet. 2. Never perform installing/removing of the marking lamp with the power turning ON. In addition, do not use the light other than marking. DANGER: Use of controls or adjustments or performance of procedures other than those specified here in may result in hazardous radiation exposure.

  • Page 106: Adjusting The Marking Light Irradiation Position

    (3) Adjusting the marking light irradiation position 1) Press button A in the input screen and the marking light setting screen is displayed. Then the irradiation position of marking light can be adjusted. 2) Lateral line irradiation position of marking light is determined by the sewing type, and the irradiation position is automatically moved by B change-over of sewing start irradiation/sew-...

  • Page 107: Replenishing Grease To The Designated Place

    3. REPLENISHING GREASE TO THE DESIGNATED PLACE * When “Grease-up warning E220” or “Grease-up error E221” is displayed, or when the machine has been used for one year, be sure to perform replenishing of grease. When turning ON the power after the sewing machine has operated up to 40 million stitches, “grease-up warning E220”...
  • Page 108 ② Loosen two screws ❸ (SM4050655SP) and move face plate cover ❹ to the left side. At this time, be careful of moving the cover along es- cape A of the cover so that it does not come in contact with plate spring ❺ . ❺...
  • Page 109 ⑥ Fix the screws to be symmetrical to the center of slot  so as to keep the clearance (approx- imately 1 mm) between wiper  and arm  open. Operator's side ⑦ Remove the rubber cap and apply new grease to the inside of the hole after removing old grease adhered to the inside of hole B.

  • Page 110: Consumable Replacement Components

    4. CONSUMABLE REPLACEMENT COMPONENTS The components below are the consumable ones. Periodically replace them. • Thread guide felt (Part No. : 40034444) The part where thread passes is worn out and rough motion of thread is apt to occur unless it is periodi- cally replaced.

  • Page 111: Tilting The Machine

    5. TILTING THE MACHINE CAUTION • Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. • When tilting/raising the machine, be careful not to allow your hands, fingers or any other part of your body to be caught in the related parts.

  • Page 112: Standard Of Replacing Time Of The Gas Spring

    [ Do not use anything other than JUKI genuine gas spring (Part No. : 40023177). ] 5. To avoid personal injuries, do not use with the gas spring removed.

  • Page 113: Replacing Procedure Between Double-Welt And Single-Welt

    7. REPLACING PROCEDURE BETWEEN DOUBLE-WELT AND SINGLE-WELT CAUTION To prevent accidents caused by abrupt start of the sewing machine, start the work after turning OFF the power. (1) Replacing procedure between double-welt and single-welt ① Turn ON the power and advance the clamp foot. ②...

  • Page 114: Replacing The Binder

    • Fine adjustment of single-welt type ① , ③ ① Move the position of garment body clamp to inside (direction A) on the panel. ② It is possible to perform the fine adjustment of Garment body the position with adjustment knob for single-welt Garment body clamp (left) clamp (right)

  • Page 115: Adjusting The Corner Knife

    8. ADJUSTING THE CORNER KNIFE CAUTION 1. Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 2. Do not touch your fingers or hands to the blade section of knife. so as to prevent fatal accidents. 3.

  • Page 116: Adjusting The Corner Knife

    (2) Adjusting the corner knife CAUTION Be careful not to slip your hand since the adjustment work is performed with a screwdriver. Knife base Ⓒ Knife base Ⓐ Knife base Ⓑ Knife base Ⓓ Fig.1 ❷ ❷ ❷ ❷ ❸ ❸...

  • Page 117: Corner Knife Adjustment Function Screen

    (3) Corner knife adjustment function screen This mode is the mode to adjust the installation of the corner knife. For the actual adjustment procedure of the knife, refer to "VII-8.(2) Adjusting the corner knife" p. 112. In the state of the delivery from the factory, the corner knives have been adjusted to ±0.5 mm longitudinally and 0.0 mm laterally at the setting of size L = 150 mm using a piece of the trial sewing cloth attached to the sewing machine.
  • Page 118 ② Display the corner knife adjustment sewing screen. When pressing the pattern button you desire to adjust, the corner knife adjustment sewing screen (A) is displayed. Corner knife adjustment sewing screen (A) When READY key is pressed, the corner knife adjustment sewing screen (B) is displayed.

  • Page 119: Corner Knife Actuating Position Setting Procedure

    (4) Corner knife actuating position setting procedure By pressing corner knife actuating position setting button (A or B), it is possible to set the corner knife actu- ating position. Independent sewing mode Alternate sewing mode / cycle sewing mode ① Setting of corner knife actuating position at the start of sew- For the setting of corner knife actuating position at the start of sewing, there are 4 kinds of right width C, left width D, left side front and rear E and right side front and rear F, and it is possible...

  • Page 120: Feature Of The Corner Knife Actuating Position Setting

    (5) Feature of the corner knife actuating position setting Corner knife of APW-896N has the features below. • Left and right corner knives are independent and the corner knife actuating positions of left and right cor- ner knives can be separately adjusted. •...
  • Page 121 In the standard state of delivery, the deflection of corner knife can be used only up to 8.0 mm. When desiring to perform the deflection setting of more than 8.0 mm, change the setting of deflec- tion following the procedure next. The following is an example of deflection setting of 10.0 mm. 1) Adjust the long corner knife so that the cutting length of the outside knife becomes from 4.0 mm to 6.0 mm.

  • Page 122: Deflection Amount Setting

    (6) Deflection amount setting Automatic deflection detection function By pressing the button of automatic deflection detection function, the flap is read using two flap sensors and the deflection can be automatically set. However, when Right flap angle detection device is not mounted, left flap (double welt and single welt with one side flap) only can be used.

  • Page 123: Center Knife

    9. CENTER KNIFE (1) Center knife actuating position setting procedure It is possible to set the center knife actuating position by pressing CENTER KNIFE MOTION POSITION SETTING button A. Independent sewing mode Alternate sewing mode / cycle sewing mode ① Setting of the center knife actuating position There are two kinds of the center knife actuating positions, SEW- ING START B and SEWING END C and it is possible to sepa- rately set.

  • Page 124: Feature Of The Center Knife Actuating Position Setting

    (2) Feature of the center knife actuating position setting • In case of the slant sewing setting, whether the corner knife performs indexing or not makes the setting of center knife actuating position as follows. Center knife actuating position at the start of sew- Center knife actuating position : ing : Index : With...
  • Page 125 [Setting of center knife actuating position at the end of sewing] In case of normal setting (corner knife does not perform indexing), screen C is displayed. When the corner knife performs indexing the same as the center knife actuating position at the start of sew- ing setting, screen D instead of screen C is displayed.

  • Page 126: Adjusting The Position Of The Sensor For Detecting Flaps

    10. ADJUSTING THE POSITION OF THE SENSOR FOR DETECTING FLAPS ① Adjust the positions of both right and left sen- sors for detecting flaps to outside of 4.5 to 5 mm from the needle entry and the sewing direction (longitudinal direction) of both right and left sen- sors to the position of 37 mm from the needle entry on the operator side.

  • Page 127: Causes And Corrective Measures Against Troubles With The Bobbin Thread Remaining Amount Detecting Device

    11. CAUSES AND CORRECTIVE MEASURES AGAINST TROUBLES WITH THE BOBBIN THREAD REMAINING AMOUNT DETECTING DEVICE Phenomenon Cause Corrective measure ① The bobbin thread remaining ○ Check the specified data on the bobbin The bobbin thread remaining amount amount adjusting counter has been thread remaining adjusting counter “...

  • Page 128: How To Adjust The Foot Pedal

    12. HOW TO ADJUST THE FOOT PEDAL The foot pedal of this device is so designed that an analog type pedal sensor detects the depressing depth of the foot pedal and the detected voltage value is taken as the operation step of the pedal. However, the voltage value of the pedal sensor changes with a lapse of time.
  • Page 129 ② When FOOT PEDAL ADJUSTMENT button B is pressed, the foot pedal adjustment screen is displayed and the number of steps in terms of the depressing depth of the foot pedal is set. ③ Pedal sensor voltage value in the present pedal depressing state is displayed in the range of 0 to 99 in the volume bar indication C.

  • Page 130: Error Code List

    13. ERROR CODE LIST Error code Description of error How to recover E001 Initialization of EEP-ROM of MAIN CPU Turn OFF the power. E007 Machine-lock Turn OFF the Main shaft of the sewing machine does not rotate due to some power.
  • Page 131 Error code Description of error How to recover E027 Read error Possible to re- Data read from server cannot be performed. start after reset. E028 Write error Possible to re- Data write from server cannot be performed. start after reset. E029 Lid of media slot is open.
  • Page 132 Error code Description of error How to recover A203 Oil replacement time warning Possible to re- When operation time of the sewing machine is reached to the oil start after reset. replacement time that is set from the panel. E220 Grease-up warning Possible to re- When number of stitches of operation is reached to 40 million...
  • Page 133 Error code Description of error How to recover E358 Corner knife on the moving side, right is held lifted. Possible to re- start after reset. Corner knife on the fixing side, left is held lifted. E359 Possible to re- start after reset. E360 Corner knife on the fixing side, right is held lifted.
  • Page 134 Error code Description of error How to recover E370 Roller stacker lower end sensor is gone past. Possible to re- start after reset. E371 Clamp bar stacker material presser sensor is gone past. Possible to re- start after reset. Clamp bar stacker material sweeper origin sensor is gone E372 Possible to re- past.
  • Page 135 Error code Description of error How to recover E381 Flap rear end cannot be detected (forced stop). Possible to re- Error is displayed after end of sewing. start after reset. E382 Flap dust detection error Possible to re- start after reset. Flap front end cannot be detected.
  • Page 136 Error code Description of error How to recover E393 Binder bottom detection error Automatic recovery by sensor input Binder top detection error E394 Automatic recovery by sensor input E398 Corner knife drawer detection error Possible to re- start after reset. E399 Binder open detection error Possible to re-...
  • Page 137 Error code Description of error How to recover E475 Flap priority sewing mode selection at the time of slant flap Possible to re- sewing is disapproved. start after reset. At the time of independent sewing or cycle sewing, when flap priority sewing is selected with slant flap, error occurs.
  • Page 138 Error code Description of error How to recover E486 Flap sewing data cannot be sewn. Possible to re- start after reset. E487 Both long presser and endless zipper are simultaneously Possible to re- selected. start after reset. E488 The gauge size exceeds the input range. Possible to re- start after reset.
  • Page 139 Error code Description of error How to recover E496 Condensation at sewing end length over Possible to re- When condensation pitch X number of stitches exceeds 15.0 mm start after reset. Back tack at sewing end length over E497 Possible to re- When back tack pitch X number of stitches exceeds 6.0 mm start after reset.
  • Page 140 Error code Description of error How to recover E811 Overvoltage of power error Turn OFF the When input power is more than the specified value power. Low voltage of power error E813 Turn OFF the When input power is less than the specified value power.
  • Page 141 Error code Description of error How to recover E983 Center knife motor lock detection Turn OFF the power. E984 Center knife motor abnormality Turn OFF the power. E985 Clamp foot motor step-out error Possible to re- start after reset. E986 Clamp foot stepping motor origin retrieval error Possible to re- start after reset.

  • Page 142: Input Number Table

    14. INPUT NUMBER TABLE Name Connecting connector No. Air pressure detection MAIN CN-30 Origin sensor on marking light fine adjustment side MAIN CN-36-6 Corner knife motor origin sensor MAIN CN-37-6 Back tack motor origin sensor MAIN CN-38-6 Thread breakage detection (left) INTA CN62A-2 Thread breakage detection (right) INTA CN63A-2...

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