JUKI DDL-8000AS Instruction Manual
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JUKI DDL-8000AS Instruction Manual

JUKI DDL-8000AS Instruction Manual

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DDL-8000AS, AB
INSTRUCTION MANUAL

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  • Page 1 DDL-8000AS, AB INSTRUCTION MANUAL...

  • Page 2: Table Of Contents

    CONTENTS 1. SPECIFICATIONS ......................1 1-1. Specifications of the sewing machine head ..............1 1-2. Specifications of the control box ..................1 2. SET UP ..........................2 2-1. Drawing of table ........................2 2-2. Cautions when setting up the sewing machine ..............3 2-2-1.
  • Page 3 4-2. Operation panel ......................... 26 4-3. Audio guidance ........................28 4-4. Setting the clock ........................ 29 4-5. Operating procedure of the sewing pattern ..............30 4-5-1. Reverse feed stitching pattern ....................30 4-5-2. Overlapped stitching pattern ....................31 4-5-3. Polygonal-shape stitching pattern ..................32 4-6.

  • Page 4: Specifications

    Needle 134 Nm65 to 110 (DP × 5 #9 to 18) 134 Nm125 to 160 (DP × 5 #20 to 23) Lubricating oil JUKI NEW DEFRIX OIL No.1 or JUKI CORPORATION GENUINE OIL 7 Motor AC servo motor *MS ;...

  • Page 5: Set Up

    2. SET UP 2-1. Drawing of table – 2 –...

  • Page 6: Cautions When Setting Up The Sewing Machine

    2-2. Cautions when setting up the sewing machine Thank you very much for the purchase of JUKI Industrial Sewing Machine this time. Make sure of items 2-1 through 2-13 before operating to use this sewing machine with ease. 2-2-1. How to carry the sewing machine Carry the sewing machine while holding the machine arm with two persons as shown in the figure.

  • Page 7: Installing The Pedal Sensor

    4) Securely attach head support rod ❹ to the table until it goes no further. Be sure to mount the machine head sup- port rod ❹ on the machine table so that its height from the table surface becomes 56 to 60 mm. ❹...

  • Page 8: Connecting The Connector

    2-5. Connecting the connector WARNING : • To protect against personal injury resulting from abrupt start of the sewing machine, be sure to turn the power OFF, unplug the machine and wait for five minutes or more before installing the pedal sensor.

  • Page 9: Installing The Reactor Box [Only For The Eu Type Models]

    2-6. Installing the reactor box [Only for the EU type models] * For the EU-type models, install the reactor box that is supplied with the sewing machine. 1) Detach reactor cover ❷ from reactor box ❶ to separate from reactor base asm. ❸ . * The reactor cover can be detached with ease by inserting a tool that has a thin flat tip such as a flat-blade screwdriver between the cover...
  • Page 10 4) Connect the connector ❼ of the power cord that is fixed to reactor base asm. ❸ to the connector of reactor ❺ . Be sure to insert the former fully into the latter until the connector is locked. ❺ ❼...
  • Page 11 9) Fit reactor cover ❷ over reac- tor base asm. ❸ . ❸ ❷ Take care not to allow the cord to be caught under reactor cover ❷ . Pass the power cord through cord bushing  . Then, insert the power cord into the slit portion of reactor cover ❷...

  • Page 12: Installing The Power Switch

    2-7. Installing the power switch WARNING : 1. Be sure to attach the ground wire (green/yellow) to the specified location (on the ground side). 2. Take care not to allow terminals to come in contact with each other. 3. When closing the power switch cover, take care not to allow the cord to be caught under it. 2-7-1.
  • Page 13 4) Securely fix the terminals of the AC input cord by tightening the screws at the specified locations. 1. Be sure to prepare the power plug • 1ø 220-240V which conforms to the safety stan- Blue dard. AC 220-240V Brown 2.

  • Page 14: Installing The Thread Stand

    2-8. Installing the thread stand 1) Assemble the thread stand unit, and in- sert it in the hole in the machine table. 2) Tighten nut ❶ . ❶ 2-9. Attaching the connecting rod WARNING : To protect against possible personal injury due to abrupt start of the machine, be sure to start the following work after turning the power off and a lapse of 5 minutes or more.

  • Page 15: Adjustment Of The Pedal

    2-10. Adjustment of the pedal WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 2-10-1. Installing the connecting rod 1) Move pedal ❸ to the right or left as illustrated by the arrows so that motor control lever ❶...

  • Page 16: Power Switch

    2-12. Power switch * The switch configuration differs with the specifications. 1) Turning the power ON with the power switch Single phase The power to the sewing machine is placed in the 220 to 240V ON state when the "|" mark side of power switch ❶...
  • Page 17 2) When you depress the back part of pedal, the needle bar and the presser lifting motor carry out their initial oper- ation to allow the sewing machine to start sewing. If you attempt to start sew- ing without depressing the back part of pedal, the warn- ing message screen shown <...

  • Page 18: Lubrication

    2,000 sti/min or less. 2. For the oil for hook lubrication, purchase JUKI NEW DEFRIX OIL No. 1 (part number : MD- FRX1600C0) or JUKI CORPORATION GENUINE OIL 7 (part number : 40102087).

  • Page 19: Preparation Before Sewing

    3. PREPARATION BEFORE SEWING 3-1. 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. Use the specified needle for the machine. Use the proper needle in accordance with the thickness of thread used and the kinds of the materials.

  • Page 20: Winding The Bobbin Thread

    3-3. Winding the bobbin thread 1) Insert the bobbin deep into the bobbin winder ❽ spindle ❶ until it will go no further. 2) Pass the bobbin thread pulled out from the spool rested on the right side of the thread stand follow- ing the order as shown in the figure on the left.

  • Page 21: Threading The Machine Head

    3-4. 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. ❶ [NB type] [0B type] ❸ ❾ ❾ ❷ ❹ (Note) (Note) Do not pass this thread Be sure to pass the thread through section A.

  • Page 22: Presser Foot Pressure

    3-6. Presser foot pressure WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Loosen nut ❷ . As you turn presser spring regula- tor ❶ clockwise (in direction A), the presser foot ❶...

  • Page 23: Changing The Sewing Speed

    3-8. Changing the sewing speed ❻ on the normal sewing screen. The sewing speed can be changed with ❻ [How to change the sewing speed] 1) The sewing speed change screen is dis- ❻ on the played by pressing normal sewing screen. On the sewing speed change screen, the sewing speed can be changed.

  • Page 24: Led Hand Light

    3-9. LED hand light WARNING : In order to protect against personal injury due to unexpected start of the sewing machine, never bring hands near the needle entry area or place foot on the pedal during the adjustment of intensity of the LED.

  • Page 25: Adjusting The Amount Of Oil (Oil Splashes) In The Hook

    3-11. Adjusting 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. 3-11-1. Adjusting the amount of oil in the hook ❹...

  • Page 26: How To Confirm The Amount Of Oil (Oil Splashes)

    3-11-2. How to confirm the amount of oil (oil splashes) Amount of oil (oil splashes) confirmation paper Position to confirm the amount of oil (oil splashes) Hook driving shaft front bushing Hook Approx. 70 mm * Use any paper available regardless of the material.

  • Page 27: Adjusting The Thread Take-Up Spring And The Thread Take-Up Stroke

    3-12. Adjusting the thread take-up spring and the thread take-up stroke ❺ ❹ [DDL-8000A-*MS] [DDL-8000A-*SH,*SJ] ❽ ❾ ❾ ❽ ❻ ❻ ❶ ❶ ❶ ❸ ❸ ❷ ❷ (1) Adjusting the stroke of thread take-up spring ❶ 1) Loosen setscrew ❷ . 2) Turn tension post ❸...

  • Page 28: For The Operator

    4. FOR THE OPERATOR 4-1. How to set the machine head and to initialize data (the factory-set state at the time of shipment) * This item has been factory-adjusted at the time of shipment. Carry out the machine head setting procedure in the case the control box is replaced, or in any case where it is necessary.

  • Page 29: Operation Panel

    4-2. Operation panel ❼ -A ❻ -A ❼ -B ❻ -B ❽ ❹ ❶ ❷ ❸ ❺ ❾ How long the key Function must be pressed Short time Used to changing over the automatic reverse feed stitching at the begin- ning of sewing to: Reverse feed stitching / Double reverse feed stitching / ❶...
  • Page 30 How long the key Function must be pressed Short time Used to set the number of reverse feed stitches (ABCD) at the beginning and end of sewing Long time Used to change over the one-shot operation between enable / disable ❼...

  • Page 31: Audio Guidance

    4-3. Audio guidance The audio guidance provides the following information when turning ON / OFF the power to the sewing ma- chine, operating the sewing machine and operating the operation panel. The guidance sound is emitted from ① At the time of turning the power ON ...."Hello. (month) (day), (date)" etc. ②...

  • Page 32: Setting The Clock

    4-4. Setting the clock The time displayed on the operation panel can be changed.  in the normal sewing state to display the time change screen. 1) Press ❻ ❼ ❽ 2) The time setting items flash on and off in the order of "year", "month", "day ", "hour", "minute" and "sec- ❼...

  • Page 33: Operating Procedure Of The Sewing Pattern

    4-5. Operating procedure of the sewing pattern 4-5-1. Reverse feed stitching pattern Reverse feed stitching at sewing start and reverse feed stitching at sewing end can be separately pro- grammed. [Setting procedure of the reverse feed Display Display ❼ ❻ section A section B stitching]...

  • Page 34: Overlapped Stitching Pattern

    4-5-2. Overlapped stitching pattern Overlapped stitching pattern can be programmed. A : Number of stitches of normal stitching setting : 1 to 15 stitches B : Number of stitches of reverse stitching setting : 1 to 15 stitches C : Number of stitches of normal stitching setting : 1 to 15 stitches D : Number of times of repetition : 1 to 15 times 1.

  • Page 35: Polygonal-Shape Stitching Pattern

    4-5-3. Polygonal-shape stitching pattern A polygonal-shape stitching pattern can be set. As many as nine different patterns can be set. In addition, nine steps of stitching can be set in one pattern. [How to set a polygonal-shape stitching pattern] ❺ to put the sewing machine to the constant-dimension stitching pattern setting state. In this 1) Press state, one of the processes A, B and C flashes on and off.
  • Page 36 Display After the completion of setting, press section D ❽ to determine the data. When the polygonal-shape stitching is enabled, is displayed in the display section C. The selected pattern number is ❽ displayed in the display section D. Display section C Set number of steps...

  • Page 37: Function Setting

    4-6. Function setting The set value of the function setting can be changed. ❻ ❼ 1) The function setting screen is displayed  held pressed for by keeping three seconds in the normal sewing state. ❽ A indicates the function setting number. B indicates the set value for that func- tion setting number.

  • Page 38: Setting The Function Keys (F1 And F2)

    4-7. Setting the function keys (F1 and F2) The functions you use frequently can be registered to these two function keys. ❾ The set value of the function setting number that is registered can be directly changed by pressing ❻ 1) The function setting screen is displayed ❾...

  • Page 39: Production Support Function

    4-8. Production support function The production support function provides two different functions to allow the operator to know the produc- tion status; one is "to know productivity based on the daily operation rate of the sewing machine" and the other is "to know the progress of sewing work based on the number of times of thread trimming". 4-8-1.

  • Page 40: List Of Production Support Parameters

    4-8-2. List of production support parameters Display Display section C section D Display Display Display section A section B section E < Function setting screen > < Production support screen > Item Setting range Initial value Target number of The target number of pieces to be produced within the work pieces to be pro- hours set with parameters U03 and U04 is set with this 1 to 1999...

  • Page 41: How To Display The Operation Rate Of The Sewing Machine

    4-8-3. How to display the operation rate of the sewing machine 1) Setting the production support parameters Item Setting range Initial value Changeover of the The display of the operation rate (display section E) is display of operation changed over between ON / OFF. 0 - 1 rate between ON / 1: Operation rate is displayed...

  • Page 42: How To Display The Number Of Pieces Produced

    4-8-4. How to display the number of pieces produced Display Display ❼ ❻ section C section D  in the normal sewing 1) Press state. Then, the “number of pieces pro- duced” display screen displayed. Display section E < Number of pieces produced display screen > 2) The number of pieces produced for the data is displayed on the display section C.

  • Page 43: Function Setting List

    4-9. Function setting list Item Description Level Setting range Default Maximum sewing speed The maximum sewing speed reached by fully depressing the 100-[P68] 4000 pedal is set with this function setting item. The maximum sewing (sti/min) speed can be changed within the sewing speed range specified for [P68 Maximum sewing speed].
  • Page 44 Item Description Level Setting range Default Correction of solenoid-on Stitch alignment can be carried out by changing the timing of 0-200 timing for the reverse feed actuating the reverse-feed stitching solenoid at the time of reverse stitching at the end of sew- feed stitching at the end of sewing.
  • Page 45 Item Description Level Setting range Default Machine head selection Machine head type is selected with this function setting item. 2-13 (Initialization of data) 2： DDL-8000ASMS 3： DDL-8000ASSH 4： DDL-8000ABMS 5： DDL-8000ABSH 6： DDL-8000ASSJ 7： DDL-8000ABSJ 8： DDL-8000ASMS(CE) 9： DDL-8000ASSH(CE) 10： DDL-8000ABMS(CE) 11：...
  • Page 46 Item Description Level Setting range Default P131 Condensation stitching The sewing speed for condensation stitching at the beginning of 0-1900 speed at the beginning of sewing is set with this function setting item. (sti/min) sewing ＊ P132 Condensation solenoid ON duty of the condensation solenoid when it starts operation is 1-80(%) operation starting duty set with this function setting item.
  • Page 47 Item Description Level Setting range Default P161 The presser foot lifting The presser foot lifting operation ON/OFF when the thread clamp operation ON/OFF when the works is set with this function setting item. thread clamp works 0: OFF 1: ON P162 The angle at which the The angle at which the presser foot starts going up when the...

  • Page 48: Detailed Explanation Of Selection Of Functions

    4-10. Detailed explanation of selection of functions ① Selection of the soft-start function (Function setting No. P08) The needle thread may fail to interlace with the bobbin thread at the start of sewing when the stitching pitch (stitch length) is small or a thick needle is used. To solve such problem, this function (called “soft-start”) is used to limit the sewing speed, thereby assuring successful formation of the starting stitches.
  • Page 49 Function setting Application Output function No. P139 No. P141 No . P142 It works as normal touch-back switch. ❶ 0 or 1 0 or 1 When operating touch-back switch at the time of depressing front part ❷ of the pedal, reverse feed stitching as many as the number of stitches specified by the function setting No.
  • Page 50 ④ How to balance stitches for [Start Back-Tacking] (Function setting Nos. P18 and P19) Example) Step 1: Setting stitch number for Start Back-Tacking A and B = 3 Step 2: Sewing the pattern in normal speed. Step 3: If unbalanced situation is appeared please correct it as below: Suggestion: Select the balance stitches for Section A before selecting for B.
  • Page 51 ⑤ How to balance stitches for [End Back-Tacking] (Function setting Nos. P25, P26 and P77) Example) Step 1: Setting stitch number for End Back-Tacking C and D = 3 Step 2: Sewing the pattern in normal speed. Step 3: If unbalanced situation is appeared please correct it as below: Suggestion: Select the balance stitches for Section C before selecting for D.
  • Page 52 ⑥ How to balance stitches for [Bar Tacking] (Function setting Nos. P32 and P33) Example) Step 1: Setting stitch number for Bar-Tacking A = B = 4 and turns of Bar-Tacking D = 4 Step 2: Sewing the pattern in normal speed. Step 3: If unbalanced situation is appeared please correct it as below: Start point Case 1 : Longer A and shorter B...
  • Page 53 ⑦ Function of pedal curve selection (Function setting No. P138) This function can perform the selection of the curve of sewing speed of the sewing machine against the depressing amount of the pedal. Change to this function when you feel that inching operation is hard or that pedal response is slow. 0 : Sewing speed in terms of the depressing amount of the pedal increases linearly.

  • Page 54: How To Use The Bobbin Counter

    4-11. How to use the bobbin counter In the case the number of stitches that can be counted on the bobbin counter (Function setting number P113) is set to "x10", the bobbin count complete screen is displayed when the bobbin counter reaches the set value to notify the operator that the bobbin has to be changed.

  • Page 55: Initialization Of Function Setting Data

    4-12. Initialization of function setting data The function setting data that are changed arbitrarily by the customer can be stored in memory. The cur- rent function setting data can be restored to the aforementioned data.  held pressed 1) When you keep for three seconds in the normal sewing state, the function setting screen is displayed.

  • Page 56: Password Lock

    4-13. Password lock  held pressed, with the pass- It is possible to lock the operation for setting the functions by keeping word. ❻ ❼ 1) Call the function setting No. J14 re- ferring to referring to "4-6. Function setting" p. ❽...

  • Page 57: About The Usb

    4-14. About the USB WARNING : The device to be connected to the USB port should have the rated current value or less as shown below. If any device rated current value of which is higher than the rated current value, the main body of the sewing machine or the USB device connected can be damaged or malfunction.

  • Page 58: Upgrading Of The Program By Means Of A Usb

    • Never forcefully insert a USB thumb drive into the USB connector while carefully checking the orientation of the USB thumb drive. Forceful insertion of the USB thumb drive can cause failure. • JUKI does not compensate for loss of data stored on the USB device caused by using it with this sewing machine.

  • Page 59: Adjustment Of The Machine Head (Application)

    5. ADJUSTMENT OF THE MACHINE HEAD (APPLICATION) 5-1. 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. Adjust the timing between the needle and the hook as follows : 1) Adjusting the needle bar height.

  • Page 60: Adjusting The Needle Thread Presser Device

    5-2. Adjusting the needle thread presser device WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. [Feature] The needle thread presser device is able to tuck the needle thread on the wrong side of material as in the case of the conventional wiper device.
  • Page 61 [Adjusting the remaining length of needle thread] Adjust the length of needle thread remaining at the needle to 35 to 45 mm (for the S, H and J types) by turning thread tension No. 1 nut ① . 1) Turn thread tension No. 1 nut ① clockwise (in direction A), to shorten the thread length re- maining on the needle after thread trimming or ①...
  • Page 62 [Response to problems occurring at the beginning of sewing] • In the case needle thread breakage occurs when using a thin thread or fragile thread • In the case needle thread is not tucked on the wrong side of material •...

  • Page 63: Adjusting The Thread Trimmer

    5-3. Adjusting 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. 5-3-1. For checking of the thread trimming ❻ cam timing The purpose of the adjustment of the thread trim- ming is to bring marker line A on electrical box cover ❺...

  • Page 64: Checking Of The Knife Unit

    5-3-3. Checking of the knife unit WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Check to make sure that the power switch is in ❶...

  • Page 65: Adjustment Of The Knife Unit

    5-3-4. Adjustment of the knife unit WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Check to make sure that the power switch is in the OFF state.

  • Page 66: Adjusting The Main Shaft Stop Position

    5-4. Adjusting the main shaft stop position If the position of the marker line (blue) on the handwheel is too far from the position of the marker line (blue) on the cover after thread trimming, machine head angle should be adjusted following the steps of procedure described below.

  • Page 67: Grease Shortage Warning

    5-5. Grease shortage warning 5-5-1. Grease shortage warning When the time of maintenance for adding the grease, "E220 Grease shortage warning" error is displayed for three seconds after turning the power ON. In this state, however, the sewing machine can be used for a certain period time.

  • Page 68: How To Reset The Grease Shortage Error

    5-5-3. How to reset the grease shortage error ❻ 1) Turn ON the power to the sewing  held machine while keeping pressed. Then, the function setting screen is displayed. A shows the function setting number, and B shows the set value for the func- tion setting number.

  • Page 69: Disposal Of Batteries

    5-6. 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) Remove panel ❶...

  • Page 70: Care

    6. CARE Perform the maintenance below every day for longer use of your machine. 6-1. Cleaning the area around the hook WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

  • Page 71: Cleaning The Interior Of The Frame

    6-2. Cleaning the interior of the frame WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Remove face plate ❶ . ❶ 2) Remove dust stuck the parts inside the frame such as needle bar ❷...

  • Page 72: Applying Grease

    3. Be aware that grease can leak from the thread take-up cover and nee- dle bar if the amount of grease is excessive. 4. Be sure to use JUKI GREASE A TUBE ❶ (part number : 40006323). 6-4. Applying grease to the needle bar lower bushing...

  • Page 73: Optional Devices

    Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. JUKI standing-machine pedal unit (PK-70 / -71) can be used with the DDL-8000A Series sewing machine by using the optional standing-work pedal junction unit (JUKI Part No.: 40242689).
  • Page 74 4) Put the rid on the standing-machine pedal junc- tion unit and secure it with four setscrews ❸ you have removed. ❸ ❸ ❸ ❸ 5) Secure the standing-machine pedal junction unit on the undersurface of the sewing machine table with accessory wood screws ❷...

  • Page 75: List Of Error Codes

    7. LIST OF ERROR CODES Error Description How to correct number E001 High-voltage error (320 V or more) Turn the power OFF. Check the supply voltage. E002 Low-voltage error (170 V or less) Turn the power OFF. Check the supply voltage. E003 CPU communication fault Turn the power OFF.
  • Page 76 Error Description How to correct number E220 Grease shortage warning Carry out maintenance for replenishing the grease. Then, "5-5. Grease shortage reset the error (to clear n15). Refer to warning" p. E221 Grease-shortage error Carry out maintenance for replenishing the grease. Then, reset the error (to clear n15).

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Ddl-8000ab

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