Juki DDL-522-2, DLN-415-2, DLU-450-2, DLD-432-2 Instruction Manual

5 (1)
MODEL
From the library of: Superior Sewing Machine & Supply LLC
HIGH
SPEED.
INDUSTRIAL EQUIPPED
MODEL
HIGH
SPEED,
LOCKSTITCH EQUIPPED
MODEL
HIGH
SPEED,
INDUSTRIAL EQUIPPED
MODEL
HIGH
SPEED,
INDUSTRIAL
EQUIPPED
DDL-552-2-553-2-555-2
SINGLE
NEEDLE,
SEWING
SINGLE
INDUSTRIAL
SINGLE
SEWING
SINGLE
SEWING
MACHINE
NEEDLE,
SEWING
NEEDLE,
MACHINE
NEEDLE,
MACHINE
TOP
DIFFERENTIAL
WITHANAUTOMATIC
DLN-415-2
WITHANAUTOMATIC
DLU-450-2
WITHANAUTOMATIC
DLD-432-2
WITHANAUTOMATIC
UNDERTRIMMER
NEEDLE
FEED.
MACHINE
UNDERTRIMMER
AND
BOTTOM
UNDERTRIMMER
UNDERTRIMMER
FEED
FEED
Instruction
lIUKI
i
Book
TOKYO
JOKI
INDUSTRIAL
CO.,LTD.
CONTENTS
From the library of: Superior Sewing Machine & Supply LLC
I. GENERAL DESCRIPTION 1
1.
Outstanding
2.
Main
II. HOW TO
1.
2.
3.
4.
5.
INSTALL
Table Installing
Limit
Lengthofbelt
Installing
6. Installing
7. Installing Construction
8.
9.
Functionofthe
10.
Howtohandle
11.
Adjusting
III.
HOW
TO
OPERATE
1.
Cautiononoperation
2.
Lubrication
3.
Trial
runofthe
4. How to
5.
Threading
6.
Adjusting
7. Adjusting
8. When low
9.
Carefully Howtoselect
10.
IV.
ADJUSTING
1.
Adjusting
2.
Adjusting
3.
Howtoinstall
4.
The
floating
5. Flow
6.
7.
8.
9.
10.
11.
V.
DDL-552-2-3 DDL-553-2-3 DDL-555-2-3 DDL-555-2-4
VI.
DDL-555-2-2B
to Changing Adjusting Adjusting Howtoinstall
Adjusting
In
caseofelectrical
features
specifications
THE
the
motor
of low-speed
the
control
the
machine
the
pedal and
cord
the
the
clutch
THE
and
machine
operate
the
the
the
the
machine
thread
needle
speed
note
the
the
THE
MACHINE
the
timingofthe
the
positionofthe
the
rangeofthe
sharpen
the
the the
the
moving
bobbin
slide
and
the
installing
DDL-552-2-4 DDL-553-2-4
DDL-555-2-4B
MACHINE 2
rotationofthe
machine
box
head
and
its
adjustment
operationofmotor
control
box
and
lever
cautions
switch
gap 10
MACHINE
adjusting
the
oiling
amount
pedal
tension
stop
sewing is
following
presser
fixed
knife
position not
foot,
knife
second
blade
after
thread
trimming
necessary 15
points
throat
plate,
sewing
hook
and
feed
dog
thread
moving
correctly
thread
trimming
knife
tension
cam
disc
knife
thread
presser
shaft
remove
the
angleofthe
malfunctions
knife
installing
synchronizer
base
20 20 21 22 22
23
24
25
27
VII. MALFUNCTIONS AND CORRECTIVE MEASURES , 28
VIII.
IX.
CIRCUIT
DIAGRAM
DIAGRAM,
SHOWING
TIME
METHOD
CHART
OF
ASSEMBLING
TABLE
33
35
1
1
2 2
3
3 3
3 4 5
6
9
11
11
11
11
12
13
13
14
15 15
16
16 17
18
19
1.
From the library of: Superior Sewing Machine & Supply LLC
Outstanding
1)
Simple
By a
simple
sewing, controlled,
by
foot,
2) The
electric
3)
All
needle
4)
This
stopping
all
Stable
thread
devicetoproduce
All
attachments
plate,
Dependable
machineisequipped
steppedonfor
pedalisstepped
5)
Compact
All
the
sewing
areaisamply
features
operation
operation
and
worriesofoperational
efficiency
trimming
attachments
slide
safety
high
speed
on.
construction
thread
trimming
wide
of
thread
trimming
movementisinterlocked
constant,
canbeused
which
are
plate,
etc.
device
sewing
mechanisms
and
all
I.
GENERAL
one
pedal,
this
with
utmost
used
tolerances
stable
without
for
are
efficiency.
alterations
conventional
can be used on
withadependable
until
the
thread
are
attachments
canbeused
DESCRIPTION
machine
will
ease.
eliminated.
with
the
lockstitch
this
machine
safety
perform
Also,asthe
rotationofthe
without
device by
trimmingiscompleted
built-in
inside
freely.
the
high
speed
thread
machines,
suchasfeed
any
which
after
bedinrational
sewing,
trimmeriselectrically
machine
and
dog,
low
speed
controlled
presser
alterations.
the
machine
the
cannot
thread
trimming
ordersothat
be
the
2. Main
Sewing
Low-speed
Threads
Sewing
Needles
Motor
Electric
Safety
the
speed
machine
hook
device
specifications
rotation
control
box
DLD-432-2
DLU-450-2
DLN-415-2 DDL-555-2
DDL-552-2 DDL-553-2
of
Cotton
Synthetic
Cotton,
DB
DB
Stop needle
AMCO
Super
Voltage Voltage IC
Built-in
type
x 1
positioner
positioner)
motor
stop
control
Up to
Up to
Up to Up to
Upto5,000
Upto4,300
thread
thread
synthetic,
automatic
DA
x 1
motor
control power
system
inside
the
4,200
4,200
5,000 5,000
silk
clutch
DC
AC
motor
s.p.m.(Cotton)
s.p.m.(Cotton)
s.p.m.(Cotton) s.p.m.(Cotton)
s.p.m.(Cotton) s.p.m.
Maximum
Maximum
lubricating
motor,
46V,
DC 5V
100,115,
lever
150
120
hook
400W
200,
s.p.m.
s.p.m.
with
(Hitachi
240,
Up to
4,000
Upto4,000
Upto4,000 Upto4,000
Upto4,000
bobbin
clutch
380,
415V
s.p.m.(Synthetic
s.p.m.(Synthetic
s.p.m.(Synthetic s.p.m.(Synthetic
s.p.m.(Synthetic
thread
guide
motor
with
(All
±10%)
groove
automatic
Fiber)
Fiber)
Fiber) Fiber)
Fiber)
attached
- 1 -
This
From the library of: Superior Sewing Machine & Supply LLC
machineisequipped
machines. lever, trimming
machine
machine.
1.
the
control mechanism
If
the
will
After
Table
1)
The
the
2) Fig. 1
All
operations
box,
with
and
adjustmentofthe
not
function
the
machineisproperly
installing positionsofthe
dimensional
shows
the
diagram rear
* The installed positionofthe
purposeofremoving
2.
Installing
1)
2)
Stop
Install
the
motor
motor
(automatic
the
motorasshowninthe
3) The installationofthe
4)
The
motor
rotates
counter-clockwise)
*
Before
installing
direction.
the
II.
HOW
TO
with
different
are
controlled
harmonious
the
needle
pedalisinadequateorif
properly.
by
cooperation
positioner
installed, give it a trial
table
whichisenclosed
viewofthe
set-up.
control
the
rear
coverofthe
positioner stopping
dimensional
motor
is same as any conventional lockstitching machine. (See Fig.2)
toward
machine
the
operator.
head,besure
INSTALL
kindsofdevices
the
pedal
with
clutch
legs,
motor
within
boxisrather
motor
clutch
(As viewed
to rotatethe
THE
MACHINE
than
andbythe
the
motor,
the
and
this
signals given
needle
the
threadisneatly
connectionsofthe
run
and
control
box
book.
far away from the
easier.
motor)
diagram.
is used on this machine.
from
motor
conventional
positioning
verify
the
etc.
are clearly
motor
the
pulley side, the
and
verify
out
from
synchronizer,
trimmed.
cords
are
correct
runningofthe
illustrated
but
this is for the
its
correct
lockstitching
the
motor
thread
wrong,
the
by
rotation
rotationjal
is
I I
Fig.
1
- 2 -
Fig.
3.
From the library of: Superior Sewing Machine & Supply LLC
Limitoflow-speed
For
trimming
rotationofthe
the
thread,
For
cotton
For
synthetic
the
limitoflow-speed
thread
thread
machine
Under
Under
150
120
rotation
s.p.m.
s.p.m.
should
be as follows:
1) With
determined,
the
sizeofthe
machine:
Outer
High
.H
o
Low
o
lO
High
•3
u
Low speed
0
ve
4.
Lengthofthe
The
Lengthofbelt
Hitachi,
the
low-speed
motor
dia.ofmotor
pulley
speed
rotation
speed
Hitachi NATIONAL
speed
Hitachi
NATIONAL
belt
lengthofthe
Motor
Outer
NATIONAL
revolution
pulley
with
125.5mm
5060
s.p.m.
s.p.m.
230
motor,
number
the
116.5mm
beltisshowninthe
pulley
dia.
For
Hitachi
Motors
high
4630
210
and
table
125.5
43"
when
the
high-speed
is also
set.
Following
low
speed
105mm
4250
193
5040
228
below:
mm
116.5
42" 42" 42"
rotational
95.5mm
3820
175
4540
206
95.5
rotation
table
shows
revolution
the
relation
number
numberofrevolutionofthe
90.5mm
3610
160
4320
193
90.5
81.0mm
81.0
41"
3390
155
3790
173
76.0
41"
is
between
76.0mm
3520
160
*Note:
5.
Installing
Install
table
dimentional
shown
*Be
movementsofall
vibrationofthe
6.
Installing
Putonthe
wheel.
the
the
control
belt
control
boxtothe
diagram
in Fig. 3.
suretoinsertarubber
electrical
running
the
machine.
machine
before
box
and
tightenitwith
components
head
connecting
the
cord
whichiscoming
positionasshowninthe
the
screw
cushion,
will be
otherwise
impaired
the
by
out
from
behind
as
The method of installing the machine head, oil reservoir, spool stand and the bobbin winder to
the table is exactly identical with that of any conventional lockstitching machine.
- 3 -
the
hand
Fig. 3
7. Installing
From the library of: Superior Sewing Machine & Supply LLC
the
pedal
and
Its
adjustment
In case of motor lever switch type, installation of the pedal and its adjustment is very simple.
1) 1)
Installing
positionofthe
pedal
Fore and aft position of the pedal is adjusted by loosening the screw (I) and left and right
position is adjusted by loosening the screw
2) Adjusting the angleofthe pedal
(2).
(Fig.4)
Fig. 4
This can be adjusted by just changingthe length of the connecting bar as in the caseof previous
lockstitch
drawing the connecting bar. (Fig.5)
machines.
Loosen the screw
(3)
of the coupling of the connecting bar and adjust by inserting and with
ss
Fig. 5
3) Installing
Loosen the motor lever adjusting screw and adjust so that the motor lever and the connecting
bar
comesinstraight
Also, be sure to securely tighten the nut of the connecting ball coupling so that it won't get
loose.
the
connecting
line.
Motor
adjusting screw
lever
bar
- 4 -
Motor
lever
Fig. 6
8.
From the library of: Superior Sewing Machine & Supply LLC
Construction
(Full
lightly
treated
and
operationofmotor
details are given in
here)
the
Instruction
lever switch
BookofHitachi
and
National
Stop
Motor,
so it is
1) In caseofHitachi
Safety
Safety
solenoid
Main
lever
Basically,
adjustedsoadjust
Even if
completely
operation)orwhen
adjusting screw. Please
is
stepped-intothe
or
machine
When
adjusted
for
the
first time, sometimes it is easier to operate if the step-in returning amount at thread trimming
time
is increased. In
this
theminaccordance
the
pedal is stepped-in to
up
duetothe
high
stopping
the
step-in
for easy step-in
l~3mm(3/64~l/8"). At the sametime,return the thread
T.SW
will
so that
adjusting
screw
activate at lmm(3/64") before the auxiliary
and
mighty
Thread
trimming
adjusting screw
lever
Auxiliary
lever
switch
insufficient
the
machine
note
that
speed,sotighten
operations.
returning
returning
such
a case,
stops.
After
stop
motor
stroke
Thread trimming
tsw
L.SW
/^Thread
lever
switch
adjusting
needsnoadjustment.
with
torqueofthe
does
not
when
this screw is
amount
amount
return
the
the
adjustment,
spring
trimming
screw
the
following
the
thread
stopatthe
lightlyaslongasthere
at
thread
operation.
thread
tightly
Motor
lever
returning
Auxiliary
Auxiliary
stopper
However,asthere
instructions.
trimming
motor
designated
tightened,
trimmingistobechanged,
However, when
trimming
trimming
tighten
spring
lever
r
lever
force
screw
position,
(whenitstops
position,
the
pedal pressure gets big
is no
abnormalcyinthread
stroke
adjusting
switchadjusting
lever
hits the thread trimming stroke
the
locknut.
adjusting
the
Step-in force adjusting screw
speed
spring
nut
are 2-3
places
the needle can
during
thread
tighten
machine istobe
screw
the
the
within
screw
which
not
trimming
step-in
when
trimming
machine
operated
the
and adjust
can be
rise
force
this
is so
area
Do not adjust the low speed step-in force adjusting screw or auxiliary lever stopper spring.
This lever
switch
is so assembled
that
even if the
clutch
liningofthe
motorisworn
out,
it is
not
necessary to readjust the position of the auxiliary lever stopper. When the low speed step-in force
adjusting
device activates and when the auxiliary lever hits the auxiliary lever
lever also moves to a certain degree
nut
is screwed in
and
the
pressureofthe low speed sewing pedal is
with
the
forceofthe low speed spring.
stopper
strenthened,
the
and stops, the main
safety
Due to this action, there is a danger of the machine to keep on running at high speed and the
possibilityofthe
operator
speed
will get used to
sewing.
safety
device unable to
the
machine,
perform
so do
not
its role.
try
to readjust
After
the machine is used for 1-2 days,
the
step-in force at
the
timeoflow
the
If the machine can not run at high speed even if the safety device is not working, it is because
the
clutch
lining is
worn
out.
Exchange
the
lining
with
a new lining. If the positionofthe auxiliary
lever stopper is not changed at the time of the new lining, it means the phenomenon is due to the
abrasion of the clutch lining. It is
better
not
to readjust the auxiliary lever
stopper
nut.
of
- 5 -
2)IncaseofNational
From the library of: Superior Sewing Machine & Supply LLC
Pana
Stop
Motor
GoseupofApart
Safety
device
hook
\
Safety device slanted
adjusting
When
screw
Safety
adjusting
the
clearanceofthe
Safety
device
stopper
Microswitch
Microswitch B adjusting screw
Microswitch B activating
solenoid
height
screw
MicroswitchAadjusting
clutchofthe
When
device
B
Microswitch
plate
motoristobeadjustedorwhen
A
screw
5
safety
activates
Reverse step-in force,
adjusting screw y
the
clutch
friction
plate and brake friction plate is to be exchanged, be sure to readjust the heightof the stopper of the
safety device. Loosen the installing screw of the safety deviceinstalling mount and adjust by moving
the mount up and down. Make adjustment so that with the foot in released condition from the
pedal,
the
hook
safety
even if
clearance
becomes
device
the
pedalisstepped
Adjusting
between the safety
0~lmm(3/64"),the
device
horizontal
stopper and upper and lowerdirectionof the
direction
completely enters and ® when the safety
in front.
the
reverse step-in force at thread trimming time
becomes
device
pawl
2~3mm(5/64~l/8")andthat@ the
is in action,
machine
will not rotate
of
If the thread trimming step-in force adjusting screw is screwed in, this force gets stronger and if
returned, it becomes weaker. After adjustment, tighten the locknut securely. The reverse step-in
amount at the time of thread trimming is meaningless unless the installing position of the thread
trimming switch must also be changed, so do
not
make adjustment.
Do not adjust the step-in pressure or the step-in amount of the low speed sewing.
This is because unless the adjustment is correctly made, the balance of force of low speed
sewing and step-in force at thread trimming time and the reverse step-in force collapses and the
machine
becomes
very difficult to
operate.
For detailed information on the operation of Hitachi Mighty Stop Motor and the National Pana
Stop Motor, refer to the respective Instruction Book and Engineers
procedures
besides
the
above
instructions.
Manual
for all operational
9.
Functions
of
the
cord
The positions of the cords, which are coming out, depend on the kjnd of motors but the
functions
(3)
d) (3) This is
are
same.
Thisisthe
power
This is the cord of
the
cord of control box for power source. (3-pole plug)
source
motor
cord.
for power source.
® This is the cord which transmits signals of low speed sewing or stopping from the control box
to
the
motor.
(9-pole
plug)
- 6 -
(D This is the cord which transmits the signalsofmachine stopping position to the control box and
From the library of: Superior Sewing Machine & Supply LLC
alsotoactivate
the
thread
trimming
magnet.
The
plugging
coloriswhite.
(I2-pole
plug)
(D This is the cord which transmits the signal of thread trimming by means of pedal operation or
low
speed
sewingtothe
plugging
color
is blue and this is plugged in to
(?) This is the cord for the wiper and for automatic reverse
reverse sewing
switch
and
control
activates
box
the
and
alsotoactivate
wiper
(6-pole plug)
the
control
sewing.
the
safety
deviceofthe
box
front
motor
side. (9-pole plug)
It transmits the signalfrom the
pedal.
The
1) When HITACHI, NATIONAL
motor
•JUKI
is used
(In
caseofmotor
lever switch system)
[-flCLOKD
Fig.
7
- 7
2)
From the library of: Superior Sewing Machine & Supply LLC
Connecting
A.
Howtoconnect
* Plug-in
* As
showninFig.8,
the
the
plugofcord
* Lastly, plug-in * Be suretopress
cords
the
cord(Dcoming
hold
the
plug
down
(§)
into
the
the
middleofthis
into
the
control
the
cordsothatitwon't
out
from
holeofthe
cord
box.
the
table.
with
touch
sensor
the
the
cord
holder
beltorthe
bobbin
Fig. 8
and
cord
thread
support.
winder.
B. How to
connect
a) In caseofHitachi
*
The
cord 3
this plug
the
terminals
*
Connect
cord
canbeconnected
*
With
the
C.
Howtoconnect
Plug-in
the
box.
D.
Howtoconnect
a) In
caseofHitachi
Plug-in
into
the
black
plug
to
the
lOOV
cord,
the
the
power
and
coming
the
on
white
the
stop
the
out
plug
left
and
motor
cord
whichiscoming
the
cord0for
and
National
black
plugofthe
holeofthe
source
cord (J)
National
socket
black
eithertothe
(6)
motors
from
the
on
sideofthe
cordstothe
for
single
from
the
controlling
motors
control
(Fig.9)
rearofthe
the
sideofthe
transformer
"0"or200V
phase,
motor
out
from
the
cord,
whichiscoming
box.
TRAKSFORMER
a
*»r
/ / 1 V \
motoristhe
control
inside
terminalsof"0"
terminals.Itdoesn't
connect
lever
the
motor
motor
themtothe
lever, to
»•
the
out
m
xai
f^OR
ATr
Fig.
power
box and
control
and
"0"
the
side partofthe
from
9
source
box.
200V.
and
the
rearofthe
connect
matter)
cord.
Plug-in
them
(Whiteorblack
lOOV
terminals.
control
motor,
to
- 8
10.
From the library of: Superior Sewing Machine & Supply LLC
Howtohandle
the
control
box
and
cautions
1) Wiring to
the
power
(D Kindsoftransformers
The
sideofthe
to
the
voltage
A lOOV, B
C
D
Be
suretoconnect
the
terminals®which
used,
transformer
four
kindsoftransformers,
the
areofsame
(D Percentage of voltage variance
The
limitofvoltage
voltage is varied to
10%
limit,
the
However, when
and
sometimes
2) Be
use
is will
repairing
sure
Evenifthe
only
the
In
case
wrongorif
notbedamaged.
will
the
limitof10%, it will
timingofthe
the
voltage gets
the
sensitive
to use fusesof6A,1A(Small)
sizeofthe
fuses
markedasabove.
the
diode
should
the
circuit
If over-sized
be a
tremendous
source voltage
and
and
transformer
methodsofconnection
on
the
power
source A, B, C
115V
200V,
220V,
240V
380V,
415V
220V,
380V
two
electrical
voltage
varianceis±10%.
source
with
the
This
leading
power
control
function
magnet
parts
also changes, causing
too
high,
the
mayberuined,
life of diode, condenser, I.C. etc. will be
so be
Amperes.
glass
tubeissame,
break
(in
this
case
the
the
running
current
shouldbeshort-circuited,ifthe
fuseisused,
job.
the
damage
Ht
sideiscalled
andDare
wires to
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6)
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This
the
11.
From the library of: Superior Sewing Machine & Supply LLC
Adjusting
When
bigger
until
becomes
as
follows:
After
which is
Then,
adjustsothat
watch
the
During this
carefultosee
push
the
tighten
the
bolt
If
insert
the
bolt
M6x30.
the
the
the
little
difficult.
loosening
setting
turn
the
movement
that
lever toward
the
set
screw
M6x30
the
brake
power
This
clutch
friction
clutch
discorbrake
is in When
the
the2bolts
the
the
clearance
of
the
adjustment,
the
brake
the
M6xl0
0 .
friction
source
into
sound
will
Also, if the clearance is closed up,
inviting scorching of the
adjustedto0.l~lmm
always.
gap
friction
and
the
strokeofthe
the
movementofthe
set screw
M6x30
M6xl0
0.
M6x300toward
becomes
main
repeat
friction
about
shaftofthe
theinand
disc
disc
beginstowear
(D which is
right
(1mm
0.5~lmm.
motor
outofthe
does
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gets
tipofthe
setting
per
rotation),
Judge
clutchbymeansofthe
leantoone
brake side and make the bolts M6x30 0
® again
disk is
the
disappear.
motor
and
slanted,
motor,
at the same
it will
and
by
the
brake must be
time
firmly
emanateapeculiar
repeating
theinand
put
or the fuse might be blown up. Be certain
off,
the
motionofthe
more
frequent
lever
becomes
the
brake,
loosen
close in
thisbymoving
side.
After
the
contact
set
the brake. Next, firmly
the
lock
crying
sound.Ifthis
outofthe
on while
the
and
the
15~20mm,
the
the
clearance,
the
motor
motor
adjustment,
nut
whichissetting
clutch,
main
motorisrotating,
that
the
lever
gets
operation
adjust
lock
nut
and
lever
and
lever
and
lightly
happens,
adjust
the
clearance is
it
(3)
be
0.5~1mm
setto0.5~1mm
-
10
-
0.5^1mm
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