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JUKI DDL-9000 Engineer's Manual

High-speed 1-needle lockstitch machine with automatic thread trimmer
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HIGH-SPEED 1-NEEDLE LOCKSTITCH MACHINE WITH
AUTOMATIC THREAD TRIMMER
DDL-9000
ENGINEER'S MANUAL
29338001
No.00

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Summary of Contents for JUKI DDL-9000

  • Page 1 HIGH-SPEED 1-NEEDLE LOCKSTITCH MACHINE WITH AUTOMATIC THREAD TRIMMER DDL-9000 ENGINEER’S MANUAL 29338001 No.00...
  • Page 2 PREFACE This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance of the machine. The Instruction Manual for this machine intended for the maintenance personnel and operators at an apparel factory contains operating instructions in detail. And this manual describes “Standard Adjustment, “Adjustment Procedures”, “Results of Improper Adjustment”, and other important information which are not covered in the Instruction Manual.

  • Page 3: Table Of Contents

    CONTENTS 1. OUTLINE ..........................1 1-1 Features ................................. 1 1-2 Specifications (Table of DDL-9000 series specifications) ................ 2 1-3 Application ..............................4 1-4 Cautions when operating ..........................4 2. OPERATION ..........................5 2-1 Configuration ..............................5 2-2 Check points before trial operation and operation ................... 5 3.

  • Page 4: Outline

    8) The superior portions of JUKI existing lockstitch machines with automatic thread trimmer have been succeeded to the operation panel and the control box of these machines, and reliability and easy operability have been improved.

  • Page 5: Specifications (Table Of Ddl-9000 Series Specifications)

    1-2 Specifications (Table of DDL-9000 series specifications) SS (Minute-quantity lubrication type) DS (dry-head type) 5,000 rpm 4,000 rpm Max. sewing speed * 4,000 rpm or less when stitch length is 4 mm or more and RP hook is used. ←...
  • Page 6 (Table of DDL-9000 series specifications) DF (for extra-light-weight materials, foundation) SH for heavy-weight material) 3,500 rpm 4,500 rpm Max. sewing speed (4,000 rpm or less when stitch length is 4 mm or more.) ← Bed size 178 mm X 517 mm...

  • Page 7: Application

    1-3 Application 1) Standard type (SS) It is suited for the wide using range from light-weight general fabrics to medium- and heavy-weight fabrics. (It is especially suited for the process for which a high speed revolution of the sewing machine is required or the process for which hook lubrication is required in accordance with the nature of thread used.) 2) Dry type (DS) It is suited for the wide using range from light-weight general fabrics to medium- and heavy-weight fabrics.

  • Page 8: Operation

    2. OPERATION 2-1 Configuration (12) (13) (11) (14) (19) (16) (17) (18) (10) (15) Fig. 1 (1) Power switch (8) Touch-back switch (14) Tension release change-over screw (2) Operation panel (9) Wiper device (15) Micro-lifter screw (3) Pulley cover (10) Screw for level adjustment (16) Under cover (4) Thread stand of table/stand (Caster)
  • Page 9 (1) Power switch Power switch for motor, PSC, operation panel, etc. (2) Operation panel This panel can set automatic reverse feed stitching, pattern sewing, etc. (3) Pulley cover This is a cover for safety and prevents dust which enters inside motor. (4) Thread stand (5) PSC box Circuits to control the sewing machine and motor, output circuits to function the respective outputs (thread...
  • Page 10 (Trial operation) 1) Operation when the power is turned ON When turning ON the power switch, the sewing machine rotates up to the needle-up position excluding the case where the needle position at that time is the position other than the up-stop position and stops at needle- up position.
  • Page 11 3) Pedal operation with the pedal type auto-lifter (AK118) Pedal can be operated in five steps. High speed Low speed High speed Low speed Stop Stop (neutral) Presser foot lifting Thread trimming Presser foot lifting Thread trimming Fig. 3 ① The machine runs at low speed when you lightly depress the front part of the pedal. ②...

  • Page 12: Configuration

    3. CONFIGURATION 3-1 Adjusting the needle stop position 1) Adjusting the upper stop position (Upper stop position after thread trimming) The standrad needle stop position is obtained, when needle stops after thread trimming, by aligning the red marker dot on the machine arm with the white marker dot on the handwheel.

  • Page 13: Principle Of Thread Trimming

    3-3 Principle of thread trimming 2. Moving knife handles threads (recedes). 1. Blade point of hook scoops needle thread. Fig. 9 3. Moving knife catches needle and bobbin threads (advances). 4. Thread trimming Fig. 10 3-4 Sequence of thread trimming Knife catches thread.
  • Page 14 (Reference) 1. Marker dot on the handwheel shows the standard value of cam timing. The timing can be more advanced by 2˚ or more delayed by 5˚ than that in case of cotton thread or synthetic thread. At this time, however, confirm that moving knife securely separates two pieces of needle thread at the bottom face of throat plate.

  • Page 15: Observing And Adjusting The Thread Trimmer Cam Timing

    3-5 Observing and adjusting the thread trimmer cam timing 1) Proper observing of the thread trimmer cam timing Thread trimmer cam timing for both cotton and synthetic threads can be easily adjusted by aligning marker dot on the machine arm with that on the handwheel. Tilt the machine head, turn the handwheel by hand until the thread take-up lever goes up slightly near the upper dead point, press thread take-up picker (Fig.

  • Page 16: Adjusting The Position Of Moving Knife Movement

    3-6 Adjusting the position of moving knife movement 1) Proper movement of the moving knife The position of moving knife when it moves until it will go no further is the position where the front top end of moving knife is receded 2.5 to 3 mm from the center of the needle. When the amount of recession is excessively small, the moving knife cannot scoop needle thread or bobbin thread when trimming thread, and if the amount is excessively large, feed dog may come in contact with moving knife.
  • Page 17 ② Adjust so that the center of moving knife link pin is aligned with V groove (Fig. 15 (2)) of the center of slot in knife driving arm (Fig. 15 (3)), and tighten the lock nut to fix the pin. ③...

  • Page 18: Properly Installing The Counter Knife

    3-7 Properly installing the counter knife The dimension of proper installation of the counter knife is as shown in Fig. 17. The standard distance from thread guide for knife attached so that needle enters the center of window to the top end of counter knife blade is 0.5 At this time, a clearance of approximate 4 mm is provided between the center of needle and the top end of counter knife...

  • Page 19: Rising Amount Of The Thread Tension Disk No. 2

    Properly installing the thread guide for knife Install the thread guide for knife so that the needle enters just in the center of the window (hole). 3-8 Rising amount of the thread tension disk No. 2 1) Observing the rising amount of the thread tension disk No. 2 Lift the presser foot at the position where the thread take-up lever comes slightly to this side of its upper dead point.

  • Page 20: Replacing The Moving Knife

    ○ When the sharpness is insufficient although the blade face is enough sharpened, it is because the left and right blade faces of moving knife and counter knife do not simulataneously come in contact with each other. At this time, adjust the inclination of the counter knife.

  • Page 21: Replacing The Thread Guide For Knife

    3-11 Replacing the thread guide for knife When replacing the thread guide for knife, loosen screws (2) and (3) shown in Fig. 17, and replace it with screw (1) tightened. If the installing angle of counter knife is moved, perform re-adjustment referring to the item of 3-7 “Properly installing the counter knife”.

  • Page 22: Adjusting The Clutch Plate And The Thread Trimmer Solenoid

    3-13 Adjusting the clutch plate and the thread trimmer solenoid The stroke of thread trimmer solenoid is 6 mm. Installing positions of the clutch plate and the solenoid are the positions where the clearance of section A is 0.1 to 0.5 mm when the thread trimmer solenoid is drawn (Fig.

  • Page 23: Installing/Removing The Knife Installing Base

    Needle Moving knife Needle entry position Fig. 32 1) Press the roller arm in the direction of the arrow mark to press it to the stopper section of the thread trimmer control plate. 2) At this time, adjust with screws (1) and (2) so that the stopper section works at the position where the moving knife does not reach the needle entry position.

  • Page 24: Adjusting The Position Of The Touch-Back Switch

    3-16 Adjusting the position of the touch-back switch The height of the touch-back switch can be changed by turning push button (1). When you desire to further change the position, loosen setscrew (2) to slide it up or down, or loosen setscrew (3) to move it up or down together with switch base (4).
  • Page 25 2) Remove hinge screw (4) in knee lifter link (3), replace the link with knee lifter link (5) to which spring (6) supplied with the machine is set, and install it with hinge screw (7). At this time, tilt the machine head and check that knee lifter connecting rod (8) enters in the hole of connecting rod guide (9).
  • Page 26 7) Pass cord (16) of AK device (asm.) through the hole of the table and insert 2P connector (18) into 2P connector (19) (2P white CN9) located on the control circuit board. (20) (21) Arrange the cord with other cords using cord clamp (20) and cable band (21) so that they do not hang loose.
  • Page 27 Selecting the automatic presser lifting function 1) Pressing switch (1) in the control box, turn ON the power switch. 2) LED will be displayed (2) (FL ON) with “beep”, and the automatic presser lifting function becomes effective. 3) Turn OFF the switch once and again turn it ON. 4) Repeat operations 1) through 3), and LED display will be “FL ON.

  • Page 28: Optionals (Presser Foot Micro-Lifter)

    3-19 Optionals (Presser foot micro-lifter) When straight stitching is not performed since slip-off of fabrics occurs dut to the pressure of presser foot in case of fluffy masterials such as velevet or the like, or hard-to-sew materials, if presser foot micro-lifter (2311056) is used, the presser foot can be minutely lifted at the face plate section with ease, and sewing can be performed.

  • Page 29: Adjusting The Tension Release Change-Over

    3-23 Adjusting the tension release change-over When the sole of the presser foot is lifted 3.5 mm or more with the knee pad or AK device, the tension release works and the thread tension disk rises. As a result, tension is not applied to the needle thread. When the presser foot is lifted by the thickness of the overlapped section of the fabric instead of the knee lifter, the tension release does not work.

  • Page 30: Dimensions Of Table

    3-26 Dimensions of table The bed size of this machine is the same as that of JUKI LH model. This machine cannot be set to the table for the exising lockstitch sewing machines. Refer to the following dimensions only when JUKI exclusive table is not used since the main dimensions of the table are described below.

  • Page 31: Points Of Adjustment And Assembly Of The Feed Mechanism

    3-27 Points of adjustment and assembly of the feed mechanism (Adjusting the feed driving components) To obtain the movement in the direction of the horizontal feed, feed rocker shaft (1) is rocked by means of feed rocker cam attached to feed driving shaft (2), connecting links A (4) and B (3) of feed rocker rod (19), feed adjusting link (5), and feed rocker arm (6).
  • Page 32 (Adjusting the feed adjustment components) When there is a lateral play in feed changing shaft (16), lever snarl, or longitudinal play of the feed dog will be large. Securely tighten setscrew (17) in the feed changing shaft arm A with a rather large-sized screwdriver, and assemble the shaft with thrust collar (18) so that it smoothly turns without play.
  • Page 33 (Adjusting the feed mechanism of feed base components) [Adjusting the longitudinal position of the feed dog] 1) Adjust the marker dot of feed driving base pin (1) to the right and feed rocker base pin (2) to the upper right at approximately 45˚. 45˚...
  • Page 34 (Adjusting the feed timing and dimensions of the feed base components [Inclination and height of the feed dog] Standard adjustment value of the inclination of the feed dog : Marker dot (6) in feed rocker base pin 45˚ (3) is positioned to the upper right 45˚ and marker dot (5) in feed driving base pin (1) is positioned to the right for reference.
  • Page 35 [Locus and timing of the feed dog] ☆ Locus of feed and feed driving timing in terms of the needle can be changed by loosening setscrew (10) Standard adjustment in feed driving cam (9). Standard adjustment value is the state that marker dot (7) is aligned with marker dot (8) in the center.
  • Page 36 [Adjusting the needle and feed timing] When performing adjustment of feed driving cam timing, or inclination and height of the feed dog, the needle and feed timing will change. As a result, defective sewing or needle breakage may result. In this case, adjust the timing in the following procedure. 1) Checking the timing of lowering of the feed dog Turn the handwheel by hand and check the top end of needle eyelet in the state that the top end of the feed dog is aligned with the top surface of the throat plate at the end of feed.

  • Page 37: Points Of Adjusting And Assembling The Thread Take-Up And The Needle Bar Mechanism

    3-29 Points of adjusting and assembling the thread take-up and the needle bar mechanism [Thread take-up] * It is not necessary to lubricate to the thread take-up since the grease-sealed ball bearing is used. Defective position of the thread take-up crank largely affects the durability of thread take-up and noise occurrence. Adjust the thread take-up crank shaft in the following procedure.

  • Page 38: Replacing The Motor

    3-29 Replacing the motor 1) Lossen the setscrews in the handwheel in the order of No. 2 (2) and No. 1 (1). 2) Remove four setscrews (4) in pulley cover (3) with 4 mm hexagonal wrench key. 3) Remove the pulley cover while taking care of LED (5) of the synchronizer.

  • Page 39: Points Of Adjusting And Assembling Of The Bobbin Winder

    When the motor is separated from the coupling, set the clearance between the end face of motor and the end face of coupling to 0.5 mm when assembling them again. 2) Tilt the machine head, remove the setscrew and washer (9) located on the rear side of the machine bed, and take out connectingrod guide (10).

  • Page 40: Points Of Adjusting And Assembling Of The Lubrication Mechanism (Ss, Sh)

    In addition, minute-quantity oil is lubricated to the needle bar through oil wick. ☆ Fill oil tank with JUKI New Defrix Oil No. 1 from the oil hole up to the marker line of the oil tank using oiler supplied with the machine in the state that the machine head is tilted when the top end of the gauge of oil amount indication window comes down to the lower marker line.

  • Page 41: Applying The Exclusive Grease

    → when oil is short, open the gear box cover and suck out with vinyl pipe all oil contained inside the gear box. Then, fill the gear box with JUKI New Defrix Oil No. 2 of 140 cc.

  • Page 42: Removing/Attaching The Gear Box Cover

    Turn the setscrews one more to tighten further after tightening all setscrews to securely tighten them. 5) Remove plug (1) in the front face of machine bed, and fill JUKI Defrix Oil No. 2 of 140 cc. When attaching plug (1) , apply sealant to it.

  • Page 43: Points Of Adjuting The Sewing

    3-35 Points of adjuting the sewing Adjusting the needle and the hook Align hook blade point (1) with the center of needle (2) when the needle bar goes up from its lowest poisition and the lower end of the needle bar metal is aligned with marker line B on the needle bar. At this time, the standard clearance between the needle and the hook blade point is approximately 0.04 to 0.1 If the clearance between the hook blade point and the needle is smaller than the specified value, the hook blade point is damaged resulting in thread breakage.
  • Page 44 Points of adjusting sewing When using the plastic race hook for DS and DF, if the balance of adjustment of the thread take-up spring and the tension spring is not proper, thread breakage when sewing at high speed, thread breakage when performing reverse feed stitching, hangnail of thread, or thread breakage when performing concealed seam under stitching is likely to occur.

  • Page 45: Adjusting The Amount Of Oil In The Hook

    3-36 Adjusting the amount of oil in the hook Adjusting procedure and points of the amount of oil in the hook ★ Before adjustment ... • Perform carefully to check the amount of oil since the hook is rotating at high speed. •...
  • Page 46 ★ Amount of oil in the hook • Standard for the amount of oil in the hook and cautions are as follow : ○ Dotted line of amount of oil • • • When the oil stain is especially disliked (Caution) Hook is apt to be affected by dust or the like as described in the previous page.

  • Page 47: Troubles And Corrective Measures (Mechanical Parts)

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  • Page 53: Troubles In Sewing And Corrective Measures

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  • Page 63: Bobbin Case With Idle-Prevention Spring

    6. BOBBIN CASE WITH IDLE-PREVENTION SPRING For the DDL-9000 series, bobbin case with idle-prevention spring is used. Adjust the tension of the idle-prevention spring in the following procedure. When the bobbin runs idle Increase the tension of the idle-prevention spring.
  • Page 64 FAX : (81)3-3430-4909 • 4914 • 4984 * The description covered in this engineer's manual is subject to change for improvement of the TELEX : J22967 commodity without notice. Copyright (C) 1999 JUKI CORPORATION. All rights reserved throughout the world. 99 · 08 Printed in Japan (E)

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