JUKI PS800-8045 User manual

PS-800-8045

INSTRUCTION MANUAL

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. PREPARATION OF THE SEWING MACHINE ..................................................6

4-1. Lubricating method and check of the oil quantity....................................................... 6

4-2. Attaching the needle....................................................................................................... 7

4-3. Threading the machine head ......................................................................................... 8

4-4. Bobbin replacement procedure..................................................................................... 9

4-5. Adjusting the thread tension ....................................................................................... 10

4-6. Adjusting the thread take-up spring and the thread breakage detector plate ........ 11

4-7. Adjusting the thread take-up stroke............................................................................ 11

4-8. Needle-to-hook relationship ........................................................................................ 12

4-9. How to wind a bobbin................................................................................................... 14

4-10. Adjusting the needle bar height .................................................................................. 15

4-11. Adjusting the position of the thread trimmer ............................................................. 16

4-12. How to attach / remove the cylinder lifting plate ....................................................... 18

4-13. How to conrm the amount of oil (oil splashes) in the hook.................................... 19

4-14. Adjusting the amount of oil in the hook ..................................................................... 20

4-15. Adjusting the needle hole in the throat plate and the needle................................... 21

4-16. Setting the mechanical origin...................................................................................... 22

4-17. Adjusting the disk presser pressure........................................................................... 23

4-18. Adjusting the thread end position at the beginning of sewing ................................ 24

4-19. Adjusting the electronic intermediate presser stroke............................................... 25

4-20. Adjusting the needle thread air blower....................................................................... 26

4-21. Making a template......................................................................................................... 27

4-22. Preparation for sewing................................................................................................. 29

4-23. Conguration of the operation panel.......................................................................... 31

4-24. Maintenance mode........................................................................................................33

4-25. List of parameters......................................................................................................... 34

4-26. List of error codes ........................................................................................................ 40

5. MAINTENANCE OF SAWING MACHINE .......................................................45

5-1. Troubles and corrective measures (Sewing conditions) .......................................... 47

5-2. Disposal of batteries..................................................................................................... 49

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. Changing the moving knife .......................................................................................63

6-2-6. Adjusting the operating speed of template when the knife operates............. 63

6-2-7. Usage instructions .............................................................................................. 64

6-2-8. Denition of the electrical control buttons ....................................................... 66

6-2-9. Function-related precautions............................................................................. 66

– 1 –

1. SPECIFICATIONS

1 Sewing area (X,Y)(mm) 800 × 450

(Cutting area Rotary knife type : 698 × 391

Laser type : 646.5 × 426.5)

2 Feed motion of feeding frame Intermittent feed (2-shaft drive by stepping motor)

3 Needle bar stroke 39.5 mm

4 Max. sewing speed [S type] 3,000 sti/min (When stitching pitch is 2.2 mm or less)

[H type] 1,800 sti/min (When stitching pitch is 3.5 mm or less)

For other stitch pitches and numbers of revolutions, refer to Fig. 1.

5 Settable stitch length 0.5 to 12.7 mm

6 Needle [S type] DB × 1 #8 (#7 to #14), DP × 5 #8 (#7 to #14)

[H type] DP17 #21

To be chosen according to the model.

7 Hook Double-capacity full-rotary hook

8 Intermediate presser stroke 4 mm (Standard)

9 Lift of intermediate presser 20 mm

10 Lift of disc presser 15 mm

11 Memory of pattern data Max. 999 patterns

12  Max. 999 patterns

13 Program input method USB

14 Data format DXF.AI.PLT.DST

15 Main shaft servomotor power 550W

16 Power consumption 500VA

17 Input voltage 220V ± 10%

18 Mass (gross mass) 380 kg [Rotary knife type] 388kg [Laser type] 448.5kg

19 Dimensions 1,200 mm (W) × 1,325 mm (L) × 1,250 mm (H)

20 Operating temperature range 

21 Operating humidity range 35 to 85 % (No dew condensation) [Laser type] 5 to 70 %

22 Storage temperature range 

23 Storage humidity range 20 to 85 % (No dew condensation, 85 % applies to the case where the tem-



[Laser type] 20 to 85 % (No dew condensation)

24 Air pressure used 0.5 to 0.6 MPa

25 Needle highest position stop facility After the completion of sewing, the needle can be brought up to its highest

position.

26 Noise - Equivalent continuous emission sound pressure level (LpA) at the worksta-

tion :

A-weighted value of 78.0 dB ; (Includes KpA = 2.5 dB) ; according to ISO

10821- C.6.2 -ISO 11204 GR2 at 2,800 sti/min.

27 Lubricating oil #10 (Equivalent to JUKI NEW DEFRIX OIL No. 1)

#32 (Equivalent to JUKI NEW DEFRIX OIL No. 2), Lithium based grease No. 2

Grease information

Manufacturer: WERATCHE

Type and number: Lithium base 2# grease

Stitch pitch and the sewing speed

Number Stitch pitch Sewing speed Remarks

1 2.8 mm 2,800 sti/min

2 3.0 mm 2,500 sti/min

3 4.0 mm 2,200 sti/min

4 5.0 mm 1,800 sti/min

Note: The sewing machine must not run at the maximum num-

ber of revolutions continuously for more than 15 minutes. The

number of revolutions may vary even if the pitch is consistent

due to the change in the needle and material.

S type H type

Fig. 1

Stitch pitch and the sewing speed

Number Stitch pitch Sewing speed Remarks

1 3.5 mm 1,800 sti/min

2 4.0 mm 1,600 sti/min

3 4.5 mm 1,400 sti/min

4 5.0 mm 1,200 sti/min

Note: The number of revolutions may vary even if the

pitch is consistent due to the change in the needle

and material.

– 2 –

Rotary knife

2. CONFIGURATION

❶Machine head

❷Table

❸X-axis feed mechanism

❹Y-axis feed mechanism

❺Cassette clamp device

❻Operation panel

❼Air control box

❽Electrical control box

❾Power switch (also used as the emergency

stop switch)

󱢳Thread stand

󱢴Bobbin winder device

󱢵Rotary knife device (subclass)

󱢵󱢵

❽❽

󱢴󱢴

❾❾

❼❼

❷

❸

❻❻

󱢳󱢳

❺❺❹❹

󱢵󱢵

– 3 –

3. INSTALLATION

3-1. Installing the air hose

1) Connecting the air hose

Connect the air hose to ❶.

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.

❶❶

❷❷❸❸2) Adjustment of air pressure

Pull up air regulating knob ❷. Then, turn it to

adjust the air pressure to 0.5 - 0.55 MPa.

Then, push down air regulator knob ❷.

Pull up air regulating knob ❸. Then, turn it to

adjust the air pressure to 0.15 MPa.

Then, push down air regulator knob ❸.

❷: Adjustment of the air pressure of the entire

sewing machine

❸: Adjustment of the air pressure of the disk

presser

– 4 –

3-2. Cautions for the compressed air supply (source of supply air) facility

As large as 90 % of failures in pneumatic equipment (air cylinders, air solenoid valves) are caused by "con-

taminated air."

Compressed air contains lots of impurities such as moisture, dust, deteriorated oil and carbon particles. If

such "contaminated air" is used without taking any measures, it can a cause of troubles, inviting reduction in

productivity due to mechanical failures and reduced availability.

Be sure to install the standard air supply facility shown below whenever the machine provided with pneumat-

ic equipment is used.

Mist separator

Standard air supply facility to be prepared by the user

Standard equipment supplied by JUKI

Air compressor

Auto-drain

After cooler

Air tank

Main line lter

Air dryer Quality of the air supply

When the supply air contains a considerable amount of moisture

Ambient environment

When our machine is installed at a place where the temperature greatly

changes in the morning and in the evening from that in the daytime or

freeze is like to occur.

In the aforementioned cases, be sure to install an air dryer.

When the supply air contains a considerable amount of carbon

and dust

(Most troubles in the air solenoid valves are caused by carbon.)

Be sure to install a mist separator.

Filter regulator

Air solenoid valve

Air cylinder

Cautions for main piping

• Be sure to slope main piping by a falling gradient of 1 cm per 1 m in the direction of air ow.

• If the main piping is branched o󰀨, the outlet port of the compressed air should be provided at

the top part of the piping using a tee in order to prevent drain settling inside the piping from

owing out.

• Auto drains should be provided at all lower points or dead ends in order to prevent the drain

from settling in those parts.

– 5 –

3-3. Installing the bobbin winder device

❶❶

❷❷

❸❸

1) Insert bobbin winder disk mounting bar ❶into

hole ❷in the bobbin winder and secure with nut

❸.

3-4. Precautions for installation of the machine

1. Depending on the size of

template, the sewing ma-

chine may extend beyond

the sewing machine table

in X direction. Take care not

to allow the machine to hit

against someone standing

near the table to cause inju-

ry.

2. Be sure to secure a space

as wide as 500 mm or more

around the sewing machine

table (i.e., both in lateral and

longitudinal directions).

Sewing machine table Template

1200mm

270mm

1320mm

250mm 250mm

– 6 –

4. PREPARATION OF THE SEWING MACHINE

4-1. Lubricating method and check of the oil quantity

1. Do not use any oil other than the spec-

ied oil. After the completion of lubri-

cation, securely attach the rubber plug

and cylinder lifting plate to their original

positions.

2. When you put the sewing machine into

use for the rst time after delivery or

after having disused it for a long time,

replenish the hook with a small amount

of oil in advance.

WARNING :

Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the

sewing machine.

Max

Min

❶❶

1) Detach cylinder lifting plate ❶.

2) Remove rubber plug ❷from the oil tank.

3) Fill the oil tank with the accessory oil (or the spec-



4) The adequate oil amount is obtained when the

oil surface stays between the oil tank indications

"Min" and "Max".

❷❷

– 7 –

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 ❶to remove the needle.

Be sure to hold the needle so that its

groove ❷faces toward blade point ❸of

the rotary hook.

2) Tighten screw ❶.

In the case of replacing the needle with a

needle which di󰀨ers in specications, be

sure to re-adjust the distance from the

rotary hook to the needle. If you neglect

this re-adjustment, the problems listed

below can occur.

1. Stitch skipping

2. Thread fray

3. Breakage of blade point of hook

4. Breakage of needle

❶❶

❷❷

❸❸

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