JUKI PS-800-8045 Instruction Manual
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JUKI PS-800-8045 Instruction Manual

JUKI PS-800-8045 Instruction Manual

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PS-800-8045
INSTRUCTION MANUAL

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  • Page 1 PS-800-8045 INSTRUCTION MANUAL...

  • Page 2: Table Of Contents

    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.
  • Page 3 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.

  • Page 4: Specifications

    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...

  • Page 5: Configuration

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

  • Page 6: Installation

    3. INSTALLATION 3-1. 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 7: 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 8: Installing The Bobbin Winder Device

    3-3. 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 ❷ ❸ ❸ ❶ ❶ 3-4. Precautions for installation of the machine 1.

  • Page 9: 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 10: 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 11: 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 ❶...

  • Page 12: 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 13: Adjusting The Thread Tension

    4-5. Adjusting the thread tension (1) Adjusting the needle thread tension Thread tension controller No. 1 ❶ 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 14: 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 ❺ Loosen setscrew ❷ . Turn thread tension con- 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 15: 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) 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 S type: 2.9 ±...
  • Page 16 (3) Adjusting the hook timing The timing gauge is supplied for the machine as an accessory. Adjust the hook timing according to Lower dead point Position for adjusting the the sewing type (S type / H type) of of the needle timing between the hook the sewing machine.

  • Page 17: 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 ❶ 4) Manually wind thread on bobbin ❷ by several ❷...

  • Page 18: 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 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 19: 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 ❶...
  • Page 20 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 21: 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 22: 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 23: 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 24: 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 25: Setting The Mechanical Origin

    4-16. 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 26: Adjusting The Disk Presser Pressure

    4-17. Adjusting the disk presser pressure 1) Adjust the disk presser air cylinder pressure regu- ❷ ❷ lation valve ❶ . Pull up nut ❷ . Then, turn the nut ❶ 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 27: 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 28: 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 29: Adjusting The Needle Thread Air Blower

    4-20. 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- noid valve of the electrical system. Thread end is pushed by air between the disk press- er and the pattern at the beginning of sewing.

  • Page 30: Making A Template

    4-21. Making a template (1) Machining a template 8045 type template of dimensions of the maximum sewing range ・ Material of template: PVC plate ・ Template thickness: 1.5 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 31 (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 32: 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 33 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 34: 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 35 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 36: 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 37: List Of Parameters

    4-25. List of parameters Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Automatic Clamp is opened after the Yes/No Cassette clamp is lifted every time the completion of automatic machining continuous sewing cycle is completed machining Number of stitches to be 0 to 8...
  • Page 38 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Automatic P172 Intermediate presser is Yes/No Intermediate presser motor is reset at machining reset after the completion the end of sewing of operation P248 Whether or not the shaft Yes/No travel is required before setting a reference...
  • Page 39 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Speed P174 Machine head 2 speed 0 to 2000 XY axes speed when using a laser parameter (mm/s) knife P175 Machine head 3 speed 0 to 2000 XY axes speed when using a laser (mm/s) knife...
  • Page 40 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Reset P649 Alarm in the case of a Yes/No setting resetting error P782- Output IO setting after OUT1 to OUT6 Not set Setting of IO after returning to the origin resetting P787 / Not set...
  • Page 41 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Detection Automatic detection of Yes/No In the case of "Detect", the operation is of thread thread breakage stopped and the description of error is breakage displayed. Thread breakage detection function Detection is ignored for 1 to 255...
  • Page 42 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Other Work ending position Return to 0 Return to Return to 0 (zero): All of x / y axes settings (zero) / sewing 0 (zero) coordinates return to 0 (zero); sewing starting position machine terminates sewing;...

  • Page 43: 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 44 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 45 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 46 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 47 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 48: Maintenance Of Sawing Machine

    5. MAINTENANCE OF SAWING MACHINE Region Explanation Operating time The area under the throat plate, area Clean up the surface of equipment Eight hours surrounding the hook, bobbin case and its with a tool such as an air gun. In inner portion, thread trimming area, needle particular, clean up the regions in bar area, areas inside and outside of the...
  • Page 49 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 50: 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 51 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 ◦...

  • Page 52: 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 1) Release lock ❶...

  • Page 53: Subclass Model

    6. SUBCLASS MODEL 6-1. Barcode reader WARNING : Be sure to turn OFF the power supply and air supply to the sewing machine before attaching the parts in order to protect against accidents caused by an unintended start of the sewing machine. 1.
  • Page 54 4) Take out a seal from barcode seals ❻ provided. One hundred barcode seals (with serial numbers from 001 to 100) are provided. ❻ ❻ 5) Stick the barcode seal to the cassette at the posi- 250 mm tion that is 250 mm left from the center of cassette (setup guide) and 30 mm below the upper side of 30 mm cassette.
  • Page 55 2. Setting the barcode functions ● Setting the barcode functions on the oper- ation panel 1) Press button A. 2) Press button B. In the default state, the factory-set password is provided. The password is "11111111". 3) Press button C. 4) To allow the barcode reader to recognize the template, change D from "Electronic identification label"...
  • Page 56 ● Setting the barcode number 1) Press button A. 2) Press button B. 3) Select the sewing pattern file you want to read and press button C. 4) Press button D. Save the data. – 53 –...
  • Page 57 ● Cancelling the barcode number When you want to cancel the barcode reader number, it is necessary to set the current number to the largest value (the largest one of unassigned numbers, such as 100) first. Then, change that number to "0". Example) When the number "3"...

  • Page 58: Rotary Knife

    6-2. Rotary knife 6-2-1. Safety precautions Putting a hand here is pro- hibited in order to protect against cuts and laceration. 1. Anyone other than the workers (persons concerned) is prohibited from touching the machine during installation and adjustment procedures. 2.

  • Page 59: How To Carry Out Coaxial Adjustment

    6-2-2. How to carry out coaxial adjustment Counter knife device Moving knife device ❶ ❺ ❷ ❹ ❸ ❶ 1) Turn OFF the power and air. 2) Detach upper fixing plate ❷ , lower fixing plate ❹ , timing belt cover ❶ , moving knife cover ❺ and knife clamp ❸...
  • Page 60 5) Loosen setscrews  (seven pieces) of the counter knife unit. 6) Fit the bushing jig into the moving knife shaft. Push down link  of the counter knife unit to put the coun- ter knife shaft into the bushing jig. 7) Remove reposition spring  of the moving knife.
  • Page 61 10) After resetting, proceed to the next page of the operation panel. ⇒ Press the "OUT1 (for single-substrate type machine head) / OUT 9 (for double-substrate type machine head)" to bring the tip of the counter knife shaft and that of the moving knife shaft closer to each other while fitting the bushing jig in position.

  • Page 62: How To Adjust The Timing Belt Tension

    6-2-3 How to adjust the timing belt tension Measure the belt tension ❶ Motor shaft ❶ with a thrust meter and a pair of vernier calipers. If the belt tension falls out of the specification, loosen motor fixation screws ❶ (four pieces) and adjust the position of the motor appropriately.
  • Page 63 6-2-4-3. Position of the knife pressure adjust- ment screw of the counter knife Adjust the position of the knife pressure adjustment screw so that it does not protrude the end face of the counter knife. ❶ 6-2-4-4. Position of the knife pressure adjust- ment screw of the counter knife ❶...
  • Page 64 6-2-4-5. Adjustment of the height of the counter knife and moving knife ❸ ❶ ❹ ❺ Cylinder lifting plate ❻ Interference with the top surface of the lower cassette must be prevented. Moving knife 1) Loosen setscrews ❶ and ❷ of the counter knife base. Adjust the height of the counter knife. 2) In the normally shipped state, the sewing machine has been factory-adjusted so that the height of the blade point (lower end point) of the counter knife is 3 mm above the top surface of lifting plate ❺...
  • Page 65 6-2-4-6. Adjusting the knife pressure Under the manual mode, press the axis 2 button. Turn the knife to change its direction so as to allow easy adjustment. Push a hexagonal wrench key into the slot in the set- screw (in the direction of the left arrow) and loosen the setscrew until the counter knife is aligned with the moving knife while lifting the setscrew in the direction of the up arrow to allow the counter knife to...

  • Page 66: Changing The Moving Knife

    6-2-5. Changing the moving knife Loosen two screws (rotary moving knife parts catalog number 53) on the moving knife. Detach the moving knife and change it with a new one. Then, tighten the aforementioned two screws. When you attach a moving knife, take care to attach it so that its bottom portion comes in contact with the moving knife rod without fail.

  • Page 67: Usage Instructions

    6-2-7. Usage instructions 6-2-7-1. Creating patterns When you want to create a knife pattern, take care to ensure that the shortest distance of 3 mm or more is provided from the knife locus line to the seam line. Sewing patterns are created using the Layer 1, and knife patterns are created using the Layer 2.
  • Page 68 6-2-7-3. Setting the references Start the machine and proceed to the main interface. Then, click "Next" ❶ . Click "Move frame" ❷ , "Head Offset" ❸ , and the "Head 2 displacement". Enter "98.5" in the X-axis direction field and "54.5" in the Y-axis direction field (The head 2 position should be adjusted according to the cutting position and the displacement of sewing position.

  • Page 69: Definition Of The Electrical Control Buttons

    6-2-8. Definition of the electrical control buttons OUT9 Lifting / lowering of the rotary counter knife / moving knife OUT11 Starting the cutting operation of the rotary moving knife OUT12 Lifting / lowering of the clamp foot of the rotary counter knife 6-2-9.

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