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

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ENGLISH
APW-896/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-896/IP-420

  • Page 1: Instruction Manual

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

  • Page 2: Table Of Contents

    CONTENTS !. CAUTIONS BEFORE OPERATION ................1 @. CONFIGURATION OF THE MACHINE ................2 #. SPECIFICATIONS ......................3 1. MECHANICAL SPECIFICATIONS ......................3 2. ELECTRICAL SPECIFICATIONS ......................3 $. 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) .................... 30 (4) Sewing screen (Alternate sewing mode) ..................31 (5) Input screen (Cycle sewing mode)....................32 (6) Sewng screen (Cycle sewng mode) ..................... 33 4. USING THE COUNTER ........................34 (1) Setting procedure of the counter..................... 34 (2) Releasing procedure of count-up ....................
  • Page 4 17. PERFORMING FORMATTING OF THE MEDIA ................. 97 &. MAINTENANCE ......................98 1. INSPECTION ............................98 (1) Maintenance and inspection of the pneumatic device ..............98 (2) Maintenance and inspection related to the sewing machine ............98 (3) With regard to the waste oil of the hook oil ..................99 (4) With regard to the cleaning of the hook shaft base ................

  • Page 5: Cautions Before Operation

    !. 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

    @. CONFIGURATION OF THE MACHINE The APW-896 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 Lubrcatng ol JUKI New Defrix Oil No. 1 16 Operatng ar pressure 0.5MPa 17 Air consumption Approx.

  • Page 8: Installation

    $. 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 2 . 2 Connect pedal bases A and B with two screws 1 .

  • 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 power 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 Itto The Machine

    6. ASSEMBLING THE THREAD STAND AND ATTACHING IT TO THE MACHINE Putting nut and washer between main unit frame 1 and fix the thread stand as illustrated in the left- hand figure. Washer Spring washer 7. INSTALLING SP-46 (CLAMP BAR STACKER) (OPTIONAL PART NO.

  • Page 12: Installing Sp-47 (Roller Stacker) (Optional Part No. : 40058953)

    8. INSTALLING SP-47 (ROLLER STACKER) (OPTIONAL PART NO. : 40058953) (1) Adjusting the position 1 Confirming parallelism Make sure that stacker table 4 and rubber roller 3 are nstalled parallel wth each other. If not, loosen four setscrews 2 to adjust. 2 Confirming the clearance Make sure that the clearance between...

  • Page 13: Removing The Head Fixing Plate

    9. REMOVING THE HEAD FIXING PLATE Remove fixing screws 2 of head fixing plate 1 . Be sure to fix the machine and the frame when performing re-transportation. 10. INSTALLING THE SUB-TABLE Install the sub-table with four screws 1 as shown in the figure.

  • Page 14: Lubricating The Oil Tank

    Fill the oil tank with the oil for hook lubrication before operating the sewing machine. 1 Remove ol cap 1 and fill the oil tank with JUKI MACHINE OIL No. 1 (Part No. : MDFRX1600C0) using the oiler supplied with the machne as accessores.

  • Page 15: Installing Sa-120 (Interlining Supplying Device) (Optional Part No. : 40045772)

    13. INSTALLING SA-120 (INTERLINING SUPPLYING DEVICE) (OPTIONAL PART NO. : 40045772) CAUTION Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1 Fx nterlnng nstallng plate 1 to the machine frame with two screws 2 .

  • Page 16: Adjustment Of Sa-120 (Interlining Supplying Device) (Optional Part No. : 40045772)

    14. ADJUSTMENT OF SA-120 (INTERLINING SUPPLYING DEVICE) (OPTIONAL PART NO. : 40045772) 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 (U003).

  • Page 17: Preparation Of The Sewing Machine

    %. 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 18: 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 1 in the direction A, Hold section B by hand and turn the whole bnder n the drecton C.

  • Page 19: 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.

  • Page 20: CautOns To Be Taken When The SewNg 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, be sure to accurately set them by following the points below. 1 Securely fit the pins, rear (left) (right) over the Pins, rear pn holes.

  • Page 21: 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 plate 8 , open thread tenson dsk 7 and put the thread into the slit of thread tenson rod 4 .

  • Page 22: How To Thread The Bobbin Case

    4. HOW TO THREAD THE BOBBIN CASE 1 Hold n hand a bobbn n the way that t spns clockwse and put t nto the bobbn case. Bobbin case 2 Pass the thread through slot 1 n the bobbn case. 3 Pull the thread to pass it under the tension sprng.

  • Page 23: 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 clockwse to ncrease the bobbn thread tenson or turn the screw counterclockwse to decrease t. Bobbin Bobbin thread tension adjustment screw As shown in the left-hand figure, standard bobbn thread tenson s 0.25 to 0.35N when...

  • Page 24: Setting The Material To Be Sewn

    7. SETTING THE MATERIAL TO BE SEWN (1) Setting a garment body U s e a g a r m e n t b o d y t h a t i s larger than the garment body clamp rubber pece adhered under the right and left garment body clamps.

  • Page 25: How To Use The Operation Panel

    ^. HOW TO USE THE OPERATION PANEL 1. PREFACE 1) To use the data for APW895/896 (EPD data) on APW-896 To use the EPD data on the APW-896, read the data into the IP-420. Insert the relevant medium into the IP-420. Select pattern number xxx from EPD data. 2) Folder structure of the media Store each file in the directories below of the media.
  • Page 26 ■ Removing the CompactFlash (TM) Hold the panel by hand, open the cover, and press the meda 2 removng lever 1 . The media is eject. When the lever 1 is strongly pressed, the media 2 may be broken by protruding and falling.
  • Page 27 • 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 ma- chne. •...

  • Page 28: 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 ] Name Symbol Description TOUCH PANEL, LCD display section Change-over of the data input screen and the sewing screen is READY key performed.

  • Page 29: Buttons Used N Common

    (2) Buttons used in common Buttons that perform common operation in the respective screens of IP-410 are as described below. Pictograph Name Description Pop-up screen is closed. In case of the data change screen, the data during CANCEL button changng can be cancelled. ENTER button Data changed are determned.

  • Page 30: Start Sewing

    2 Select pattern No. you desire to sew. When PATTERN NO. button C s pressed, the pattern No. can be selected. For the selecting procedure of pattern No., see “^-7. (1) Performing the selection of pattern”p.42. At the time of your purchase, pattern Nos. 1 to 10 have been regstered.
  • Page 31 5 Depress back the pedal at the time of mounting the breast box device. At the time of mounting the breast box devce, when depressng back the pedal n the green sewng screen (screen B), the confirmation screen as shown on the left side is displayed. When the clamp foot moves to the back by depressing back the pedal, it retreats with the flap presser closed.

  • Page 32: 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 33: Sewing Screen (Independent Sewing Mode)

    (2) Sewing screen (Independent sewing mode) Symbol Name of button Description INTERLINING SUPPLY button When ths button s pressed, nterlnng s suppled. ＊ This is displayed when “With” of , automatc nterlnng supplyng devce s set wth the optonal settng. 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 34: 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 coped.

  • Page 35: Sewing Screen (Alternate Sewing Mode)

    (4) Sewing screen (Alternate sewing mode) Symbol Name of button Description INTERLINING SUPPLYING button When ths button s pressed, nterlnng s suppled. ＊ This is displayed when “With” of , automatc nterlnng supplyng devce s set wth the optonal settng. 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 36: 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 sewng data copy source No. lst screen s dsplayed and cycle sewng data can be coped.

  • Page 37: SewNg Screen (Cycle SewNg Mode)

    (6) Sewing screen (Cycle sewing mode) Symbol Name of button Description INTERLINING SUPPLYING button When ths button s pressed, nterlnng s suppled. ＊ This is displayed when “With” of , automatc nterlnng supplyng devce s set wth optonal settng. 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 38: 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 COUNTER SETTING button A s dsplayed on the screen. Press this button and “COUNTER SETTING screen (screen A)” is dsplayed.
  • Page 39 Press NUMBER OF PCS. COUNTER button C In “Counter 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 40 3 Changing the target value of the counter In case of the sewing counter, press button D , and n case of the number of pcs. counter, press button E , and “ Numerical setting pop-up screen (screen D)” Is displayed. Then the target value of counter can be set.

  • Page 41: 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 Display the counter value change screen When you desre to change the counter value durng the sewng...

  • Page 42: 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, COUNTER SETTING button A s dsplayed on the screen.. Press this button and “Counter setting screen (screen A)”...
  • Page 43 3 Set the bobbin thread remaining amount adjustment value Press BOBBIN THREAD REMAINING AMOUNT ADJUSTMENT VALUE SETTING button C and the bobbn thread remanng amount adjustment value setting screen (screen B) is displayed. Counter setting screen (Screen A) Here, input the bobbin thread remaining amount adjustment value (0 to 9).

  • Page 44: 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 n the actual process.

  • Page 45: Changing The Sewing Mode

    6. CHANGING THE SEWING MODE 1 Display the sewing mode selection screen Press SEWING MODE CHANGEOVER key A and the 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 cycle sewing is When the independent When the alternate sewing...

  • Page 46: 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 47: 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 Press NEW CREATION button A , and the pattern new creaton screen s dsplayed.

  • Page 48: CopyNg The Pattern

    (3) Copying the pattern The pattern whch has been already regstered can be coped to the sewng pattern whch has not registered yet. Copying of overwriting of pattern is prohibited. So, when you desire to overwrite, perform it after erasing the pattern once. “^-7.
  • Page 49 3 Select the pattern of copy source Select the pattern of copy source from PATTERN LIST button B . Next, press COPY DESTINATION NO. INPUT button C and the copy destination input screen (screen B) is displayed. Copy destination No. input screen (screen B) 4 Input the pattern No. of copy destination Input the pattern No. of copy destination with ten keys B .

  • Page 50: ErasNg 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 dsplayed, t s possble to erase the pattern. 2 Call the pattern list screen Press PATTERN LIST button A and the pattern No.

  • Page 51: NamNg 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 dsplayed, t s possble to nput the name to the pattern data. 2 Call the character input screen Press CHARACTER INPUT button A and the character nput screen (screen B) s dsplayed.

  • Page 52: 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 possble to edt the cycle sewng data. Cycle sewing input screen (Screen C) 2 Register the pattern data Press BLANK button A and the pattern lst screen (screen...
  • Page 53 3 Erase the registered pattern data Press ERASE button E and the pattern data whch s dsplayed wth whte emphass s erased. Select the pattern data you desire to erase with UP/DOWN SCROLL buttons F and erase t. The pattern data which is displayed with white emphasis is the pattern data to be sewn next.

  • Page 54: 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 dsplayed t s possble to change the swng 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 55: SewNg Data LSt

    (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 machne thread trmmng...
  • Page 56 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 57 Setting range Item Initial value Edit unit Setting of right width of corner knife at the start of sewing –1.0 to 0.5mm 1.5mm Right width of corner knife at the start of sewing is set. 0.1mm Setting of left width of corner knife at the start of sewing –1.0 to 0.5mm 1.5mm...
  • Page 58 Setting range Item Initial value Edit unit Setting of (left) corner knife motion position at the start of sewing –9.9 to 0.0mm 9.9mm Motion (longitudinal) position of left corner knife at the start of sewing is set. 0.1mm Setting of (right) corner knife motion position at the start of sewing –9.9 to 0.0mm 9.9mm...
  • Page 59 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 automatcally 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 60 2 Items that are displayed in the sewing data list screen Setting range Item Initial value Edit unit Flap priority sewing selection - - - Flap prorty sewng mode s selected. ＊ It is possible to set only when alternate sewing mode is set. Flap prorty sewng Flap prorty sewng mode prohbted...
  • Page 61 Setting range Item Initial value Edit unit Number of condensation stitches at sewing start 3 to 19 5 sttches Number of condensation stitches at sewing start is set. 1 sttch ＊ It is possible to set only when is set to selection of condensation. Condensation pitch at sewing start 0.5 to 1.5 1.0mm...
  • Page 62 Setting range Item Initial value Edit unit Back tack tie stitch pitch at sewing start –2.0 to 2.0 –1.5mm Back tack te sttch at sewng start s set. 0.1mm ＊ It is possible to set only when is se to selection of back tack. First stitch pitch of return of back tack at sewing start 0.1 to 3.0 2.0mm...
  • Page 63 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. 0.1mm ＊ It is possible to set only when is set to selection of condensation. ＊...
  • Page 64 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. 0.1mm ＊ It is possible to set only when is set to selection of back tack.
  • Page 65 Setting range Item Initial value Edit unit Jump feed speed up to the position of corner knife 3 to 10 Jump feed speed up to the position of corner knife is set. Dart stretcher device stop/motion change-over - - - Stop/motion of dart stretcher device is selected.

  • Page 66: 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, t s possble 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 67 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 s pressed, the screen returns to the orgnal sewng mode changeover screen wthout copyng. * The sewin data below are inversed from the left to the right at the time of copying. (Other sewing data are coped wthout nverson.) Item S003...

  • Page 68: 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 swtch button A s dsplayed. When ths button s pressed, the memory switch data list (screen A) is displayed.

  • Page 69: Memory SwTch Data LSt

    (2) Memory switch data list 1 Level 1 Memory swtch data (level 1) are the moton data that the sewng machne has n common and the data that operate on all sewng patterns n common. Setting range Item Initial value Edit unit Change-over of the position of clamp foot after sewing end - - -...
  • Page 70 Setting range Item Initial value Edit unit Stacker timer 3 0.00 to 0.70 sec. 9.99 Motion time of material sweeping bar is set. ＊ It is possible to set only when clamp bar stacker opton s 0.01 sec. used. Stacker timer 4 0.00 to 0.00 sec.
  • Page 71 Setting range Item Initial value Edit unit Clamp foot down order change-over - - - Lowering order of clamp foot is selected. From rght From left Right/left at the same tme ＊ When right and left are simultaneously actuated with customizing of pedal setting, this parameter is neglected and the right and left are smultaneously actuated.
  • Page 72 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, compensation of flap concealed stitching is automatically performed using the second flap sensor. ＊...
  • Page 73 2 Level 2 Memory swtch data (level 1) are the moton data that the sewng machne has n common and the data that operate on all sewing patterns in common. The data are for the maintenance personnel and possible to edt by pressng the mode swtch as long as 6 seconds. Setting range Item Initial value...
  • Page 74 Setting range Item Initial value Edit unit Change-over of flap concealed stitching data edit reference - - - Making the flap concealed stitching data that is set from panel the compensation value from the flap detecting end or the distance from detectng sensor to sewng start s selected.
  • Page 75 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 productivity.) 3rd mode 1st mode and 2nd mode are changed over accordng to the deflection amount.
  • Page 76 Setting range Item Initial value Edit unit Corner knife motor origin compensation −5.0 to 0.0mm Origin of corner knife motor is compensated. 0.1mm Marking light origin compensation (just under) −500 to 0pulse Origin of marking light motor is compensated. Origin is in the state that it irradiates light just under and located at the position of 230 mm from 1pulse needle.

  • Page 77: 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 pressed for six seconds, right-scroll button A s dsplayed on the screen. When you press this button, the 2nd screen (screen A) of the operation-mode changeover screen is displayed.

  • Page 78: OptOnal SettNg LSt

    (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 mountng Not mountng Mountng Roller stacker mounting/not mounting is set.

  • Page 79: 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 pressed for six seconds, right-scroll button A s dsplayed on the screen. When you press this button, the 2nd screen (screen A) of the operation-mode changeover screen is displayed.
  • Page 80 (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 10mm Gauge size of sewing machine is set. ＊ Corner knife motion is changed according to the set value of gauge sze.

  • Page 81: 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 depressing 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 Display the pedal customizing screen Press MODE CHANGEOVER key...

  • Page 82: CustomZNg The Pedal OperatOn Data

    (2) Customizing the pedal operation data 1 Press button A , and set whether to make the clamp foot recede or not wth the pedal depressed to the reverse step. Display Description To make clamp foot recede Not to make clamp foot recede 2 Press button B , and set whether or not the nterlnng presser actuate wth the pedal depressed to the reverse step.
  • Page 83 5 Functions below can be registered from first step in order. Functions that can be registered are in the state of button as , and dsplayed n order. When the button s pressed, the color changes and the function is registered. The number of pedal steps s advanced wth ▲▼...

  • Page 84: 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 condtons. (1) Customizing procedure 1 Display the customizing screen of the input screen Keep pressing MODE CHANGEOVER key for three seconds, and CUSTOMIZE button A s dsplayed on the...
  • Page 85 3 Register the sewing data to SEWING DATA CUSTOMIZING button Up to 4 sewing data can be registered to SEWING DATA CUSTOMIZE buttons N . Register and use the sewing data that are frequently used. When pressing CUSTOMIZING button N you desre to regster, the sewing data list (screen A) is displayed.

  • Page 86: 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 condtons. (1) Customizing procedure 1 Display the customizing screen of the sewing screen Keep pressing MODE CHANGEOVER key for three seconds and SEWING SCREEN CUSTOMIZING button s dsplayed on the screen.
  • Page 87 3 Register the direct pattern. When DIRECT PATTERN REGISTER button N s 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 88: Using The Information

    15. USING THE INFORMATION There are three functions below, in the information function. 1 Display the information screen Press INFORMATION key A of the switch seat section in the input screen and the information screen (screen A) is dsplayed. A Maintenance inspection information Oil replacement (grease-up) time, needle replacement time, cleaning time, etc.

  • Page 89: Observing The Maintenance Inspection Information

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

  • Page 90: Releasing Procedure Of The Warning

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

  • Page 91: 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 92 [ In case of displaying from the sewing screen ] 1 Display the sewing screen Press READY key A n the nput screen and the sewng screen s dsplayed. 2 Display the production control screen Press INFORMATION key B n the sewng screen and the producton control screen s dsplayed.

  • Page 93: Performing Setting Of The Production Control Information

    (4) Performing setting of the production control information 1 Display the production control screen “^-15-(3) Observing the production control Refer to information” p.87 and dsplay the producton 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 94 5 Start the count of number of pieces of production Press START button I and the count of number of pieces of production is started. 6 Stop the count “^-15-(3) Display the production control screen referring to Observing the production control information” p.87.

  • Page 95: 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 96 3 Start the measurement Press START button C , and the measurement of each data s started. 4 Stop the count Display the operation measurement screen referring to Items 1 and 2 of “^-15-(5) Observing the operation measurement information” p.91. When the measurement is being performed, STOP button D is displayed.

  • Page 97: 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 ×××...

  • Page 98: 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) s dsplayed. 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 99: 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 writing destination is the same No. of the selected data No. No.99 and after of the media cannot perform the plural selection. 1 Display the writing file selection screen Press PLURAL SELECTION button A and the data No.
  • Page 100 Data No. during communication, total number of writing data and number of data that have finished the data communication are dsplayed n the durng communcaton 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 overwriting confirmation screen, press OVERWRITING button...

  • Page 101: 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 seconds and MEDIA FORMAT button A s dsplayed on the...

  • Page 102: 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 103: 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 ol can, and dran the waste ol when the waste ol gathered n approxmately half of oil can 1 located on the machne bed cover.

  • Page 104: 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. (1) Marking light for sewing reference setting The light of marking light on the front side observed from the operator side is used for longitudinal line reference setting...

  • Page 105: 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 106: Grease-Up Procedure

    (1) Grease-up procedure 1 Loosen two screws 1 (SM6040602TP) and move wiper cylinder 2 to the right side. 2 Loosen two screws 3 (SM4050655SP) and move face plate cover 4 to the left side. At this time, be careful of moving the cover along escape A of the cover so that it does not come in contact with plate spring 5 .
  • Page 107 4 Replenishment of grease to the needle bar secton Apply grease to thread take-up lever !4 , felt !5 , needle bar bracket !1 , needle bar !2 and square block !3 . 5 After applying grease in the face plate, install the face plate cover by reversing the removing procedure.

  • Page 108: 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 s worn out and rough motion of thread is apt to occur unless it is perodcally replaced.

  • Page 109: 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 110: 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 111: 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 Press button A to display the type of welt setting screen.

  • Page 112: 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 Garment body the position with adjustment knob for single-welt clamp (left) clamp (right) Move it clockwise to inside (direction A) and...

  • Page 113: Corner Knife

    8. 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 114: 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. Fig.1 Knife base C Knife base A Knife base B Knife base D Knife fixing plate [ Adjusting the open angle of knife ] Loosen angle adjustment screws 2 , adjust knife bases A and B , C , D and fix the screws.

  • Page 115: 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 "(2) Adjusting the corner knife" of "Instruction Manual (this manual) for APW-896", p.110. 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 116 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 When READY key is pressed, the corner knife adjustment sewng screen (B) s dsplayed.

  • Page 117: 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 actuatng poston. Independent sewing mode Alternate sewing mode / cycle sewing mode 1 Setting of corner knife actuating position at the start of sewing For the setting of corner knife actuating position at the start of...

  • Page 118: Feature Of The Corner Knife Actuating Position Setting

    (5) Feature of the corner knife actuating position setting Corner knife of APW-896 has the features below. • Left and right corner knives are independent and the corner knife actuating positions of left and right corner knives can be separately adjusted. •...
  • Page 119 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 deflection 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 120: 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 121: 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, SEWING START B and SEWING END C and t s possble to...

  • Page 122: 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 Center knife actuating position : sewng : Index : With...
  • Page 123 [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 sewing setting, screen D instead of screen C is displayed.

  • Page 124: 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 sensors 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 sensors to the position of 37 mm from the needle entry on the operator sde.

  • Page 125: 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 The bobbn thread 1 The bobbn thread remanng ○ Check the specified data on the bobbin remanng amount amount adjusting counter has been thread remaining adjusting counter “B008”.

  • Page 126: 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 127 2 When FOOT PEDAL ADJUSTMENT button B s 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 128: Error Code List

    13. ERROR CODE LIST Error code Description of error How to recover Initialization of EEPROM of MAIN CPU E001 Turn OFF the power. Machine-lock E007 Turn OFF the Main shaft of the sewing machine does not rotate due to some power.
  • Page 129 Error code Description of error How to recover Read error E027 Possible to Data read from server cannot be performed. re-start after reset. Write error E028 Possible to Data write from server cannot be performed. re-start after reset. E029 Lid of media slot is open. Possible to re-start after reset.
  • Page 130 Error code Description of error How to recover Oil replacement time warning A203 Possible to When operation time of the sewing machine is reached to the oil re-start after replacement time that is set from the panel. reset. Grease-up warning E220 Possible to When number of stitches of operation is reached to 40 million...
  • Page 131 Error code Description of error How to recover Corner knife on the moving side, right is held lifted. E358 Possible to re-start after reset. Corner knife on the fixing side, left is held lifted. E359 Possible to re-start after reset. Corner knife on the fixing side, right is held lifted.
  • Page 132 Error code Description of error How to recover E370 Roller stacker lower end sensor is gone past. Possible to re-start after reset. Clamp bar stacker material presser sensor is gone past. E371 Possible to re-start after reset. Clamp bar stacker material sweeper origin sensor is gone E372 Possible to past.
  • Page 133 Error code Description of error How to recover Flap dust detection error E382 Possible to re-start after reset. E383 Flap front end cannot be detected. Possible to re-start after reset. Corner knife fixing side bottom detection error E386 Possible to re-start after reset.
  • Page 134 Error code Description of error How to recover Corner knife drawer detection error E398 Possible to re-start after reset. E399 Binder open detection error Possible to re-start after reset. E401 Copy disapproved Possible to When trying to perform overwriting copy on the pattern No. which recover wth has been already regstered CANCEL...
  • Page 135 Error code Description of error How to recover E478 Deflection direction of corner knives on the moving side Possible to error re-start after reseat. E479 Deflection direction of corner knives on the fixing side error Possible to re-start after reseat. E480 Max.
  • Page 136 Error code Description of error How to recover Combination data other than right/left flap sewing is set at E489 Possible to the time of flap priority setting of alternate sewing mode. re-start after reset. It is not possible to feed up to corner knife position. E490 Possible to When flap is put on this side in case of the long type...
  • Page 137 Error code Description of error How to recover CPU runaway detection E702 Turn OFF the When program abnormality has occurred in CPU power. Panel is connected to the sewing machine which is not E703 Possible to supposed (Machine type error) re-start after When the machne type between panel and sewng machne s reset.
  • Page 138 Error code Description of error How to recover E904 Solenoid power (33V) abnormality Turn OFF the When solenoid power of SERVO CONTROL circuit board power. fluctuates more than ± 15% E905 Heat sink temperature for SERVO CONTROL circuit board Turn OFF the abnormality power.
  • Page 139 Error code Description of error How to recover Back tack motor origin retrieval error E987 Possible to re-start after reset. Pocket bag flap detecting motor origin-retrieval error E988 Possible to re-start after reset. Corner knife motor origin-retrieval error E992 Possible to re-start after reset.

  • Page 140: 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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