Juki DDL-552-2, DDL-553-2, DDL-555-2 Instruction Manual

MODEL

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,

MACHINE

NEEDLE,

MACHINE

WITHANAUTOMATIC

DLN-415-2

WITHANAUTOMATIC

DLU-450-2

WITHANAUTOMATIC

DLD-432-2

WITHANAUTOMATIC

LOCKSTITCH

UNDERTRIMMER

NEEDLE

SEWING

UNDERTRIMMER

TOP

UNDERTRIMMER

DIFFERENTIAL

UNDERTRIMMER

MACHINE

AND

FEED.

BOTTOM

FEED

UKI

Instruction

"Qt

•JUKI

TSK

Book

TOKYO

JOKI

INDUSTRIAL

CO.,LTO

CONTENTS

I.

GENERAL

1.

2. Main

II.

HOW

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

III.

HOW

1.

2.

3.

4.

5.

6. Adjusting

7. Adjusting

8. When low speed sewing is

9. Carefully

10. How

IV.

ADJUSTING

1. Adjusting

2. Adjusting

3.

4.

5. How to sharpen

6. Changing

7. Adjusting

8. Adjusting

9.

10. Adjusting

11. In

V.

DDL-552-2-3

DDL-553-2-3 DDL-553-2-4

DDL-555-2-3 DDL-555-2-4

VI.

DDL-555-2-2B

VII.

MALFUNCTIONS

DESCRIPTION

Outstanding

features

specifications

TO

INSTALL

Table

Installing

the

THE

motor

Limitoflow-speed

Lengthofbelt

Installing Installing

Installing

Construction

Function Howtohandle

Adjusting

TO

the the

the

of

the

OPERATE

control machine

pedal

and

operationofmotor

the

cord

the

clutch

THE

Cautiononoperation Lubrication

Trial

Howtooperate

Threading

Howtoinstall

The

floating rangeofthe

and

runofthe

the

the the

note

to

select

THE

the the

adjusting

machine

the

machine 13

thread needle

the

following

the

presser

MACHINE

timing of positionofthe

the

fixed

the

moving knife 20

the

bobbin

the

slide shaft 22

Howtoinstall

caseofelectrical

and

the

installing angle of

DDL-552-2-4

DDL-555-2-4B

AND

MACHINE

rotationofthe

box

head

and

its

adjustment

control

box

and

machine

lever

cautions

switch

gap 10

MACHINE

the

oiling

amount

pedal

tension 13 stop

position

not

after

thread trimming 14

necessary 15

points

foot,

throat

the

plate, sewing

thread

trimming cam 16

hook

and

feed dog 15

moving knife 17

knife

correctly

second

thread

tension

disc 19

knife blade 20

thread presser 21

remove

the

knife

the

synchronizer

installing

base

malfunctions

CORRECTIVE

MEASURES

VIII. CIRCUIT DIAGRAM, TIME CHART 33

IX.

DIAGRAM

SHOWING

METHOD

OF

ASSEMBLING

TABLE

1

I

1

2

3

3 3

4

5

6 9

11

11 11

11

12

15

16

18

22

23

2^

25

27 28

35

1.

Outstanding

1)

By a

sewing,

controlled,

2)

The

by

electric

features

Simple

operation

simple

operationofone

stopping

Stable

and

all

worriesofoperational

efficiency

thread

trimming

devicetoproduce

I.

GENERAL

pedal,

thread

trimming

tolerances

movementisinterlocked

constant,

with

stable

DESCRIPTION

this

machine

utmost

are

efficiency.

will

perform

ease. Also, as

eliminated.

with

the

rotationofthe

the

high

thread

speed

trimmer

machine

sewing,

is electrically

and

low

speed

controlled

3) All

All

foot,

needle

4)

This machine is

stepped on for high speed sewing until

pedalisstepped

5)

All

attachments

plate,

Dependable

on.

Compact

the

thread

canbeused

which

are

slide plate, etc. can be used on this

safety

device

equipped

construction

used

without

for

alterations

conventional

lockstitch

machine

with

a dependable safety device by which

the

thread trimming is completed after the thread trimming

machines,

without

any

trimming mechanisms are built-in inside the bed in rational

suchasfeed

alterations.

the

machine

ordersothat

dog,

cannot

presser

sewing area is amply wide and all attachments can be used freely.

2.

Main

specifications

Sewing speed DLD-432-2 Up to 4,200 s.p.m.(Cotton) Up to 4,000 s.p.m.(Synthetic Fiber)

Low-speed

the

machine

Threads

Sewing

Needles

hook

Motor

Electric

Safety

control

device

rotation

box

DLU-450-2 Up to

DLN-415-2 Up to

DDL-555-2 Up to

DDL-552-2 Up to

DDL-553-2Upto

of

Cotton

Synthetic

Cotton,

thread

synthetic,

DB type automatic lubricating

DB

x 1

DA

Stop

positioner

needle

positioner)

AMCO

motor

Super

stop

Voltage

IC

Built-in

control

power

control

inside

4,200

5,000

4,300

Maximum

silk

x 1

clutch

motor

DC

46V,

AC 100, 115, 200,

system

the

motor

s.p.m.(Cotton) Up to

s.p.m.(Cotton)

s.p.m.(Cotton) Up to

s.p.m.(Cotton)

s.p.m.

150

s.p.m.

120

s.p.m.

hook

with bobbin thread guide groove attached

motor,

400W (Hitachi

DC 5V

240,

380,

lever

Up to

4,000

clutch

415V

s.p.m.(Synthetic Fiber)

s.p.m.(Synthetic

s.p.m.(Synthetic Fiber)

s.p.m.(Synthetic

motor

with

automatic

(All ±10%)

Fiber)

be

the

- 1 -

II.

HOW

TO

INSTALL

This

machine

machines.

lever,

trimming

machine

All operations are controlled by the pedal and by the

the

control

mechanism

If the adjustment of the pedal is inadequate or if the connections of the cords are wrong,the

will

not

After the

machine.

1.

Table

1)

The

installing

the dimensional diagram which is enclosed within this book.

2)

Fig.l

shows

*

The

installed

purpose of removing the rear cover of the motor easier.

2.

Installing

the

is equipped with different kinds of

box,

with

and the

function

machine

positions

the

position

motor

harmonious

needle

properly.

is properly installed,

of the

rear viewofthe

of the control box is

cooperation

positioner clutch motor, the thread is neatly

table

legs,

set-up.

give

THE

MACHINE

devices

with

the

it a trial run and

than conventional lockstitching

signals

given

needle

positioning

verify

the correctrunning of the

motorandcontrolboxetc. are

rather

far

away

from

the

motor

out from the motor

synchronizer,

trimmed.

clearly

but thisisfor the

thread

illustrated by

1) Stop motor (automatic positioner stoppingclutch motor) is

2) Install the

3)

The

4)

The

counter-clockwise)

*

Before

direction.

motor

installation

of the

motor rotates

installing

the

as shown in the dimensional diagram.

motorissame

toward

machine

the operator. head,besure

asany

conventional

(As

viewed

to rotate the motorand

from

a

used

on this

lockstitching

the

pulley

verify

I I

I !

machine.

side,

(See

Fig.2)

the rotation is

itscorrect rotational

Fig. 1

- 2 -

Fig. 2

50

cycle

3.

Limitoflow-speed

For

trimming

1)

With

determined,

the

sizeofthe

machine:

Outer

the

dia.ofmotor

pulley

High speed

Low

speed

the

For

cotton

For

synthetic

Hitachi,

low-speed

motor

rotation

Hitachi

NATIONAL

rotationofthe

thread,

the

limitoflow-speed

thread

NATIONAL

revolution

pulley

with

the

125.5mm

s.p.m.

5060

s.p.m. 230

machine

motor,

number

high

116.5mm

4630

210

Under

when

is also

and

150

120

low

105mm

4250

rotation

s.p.m.

the

set.

speed

193

shouldbeas

high-speed

Following

rotational

95.5mm

3820

175

follows:

rotation

table

shows

revolution

the

relation

numberofrevolutionofthe

90.5mm

3610

160

81.0mm

3390

155

number

between

76.0mm

is

High speed

_9}

"o

>,

u

'

Low

o .

vo

4.

speed

Lengthofthe

The

lengthofthe

Lengthofbelt

*Note:

Putonthe

wheel.

5. Installing

table

dimentional

shown

'

Install

in Fig. 3.

*Be

sure

the

movementsofall

vibrationofthe

Hitachi NATIONAL

belt

beltisshowninthe

Motor

Outer

belt

control

boxtothe

diagram

to

insertarubber

electrical

running

machine.

pulley

dia.

For

Hitachi

Motors

before

box

and

components

table

mm

125.5

43"

connecting

the

positionasshowninthe

tightenitwith

cushion,

will be

the

otherwise

impaired

5040

228

below:

116.5

42"

cord

whichiscoming

screw

as

the

by

4540

95.5

42"

206

4320

193 173

90.5

42"

out

from

81.0

41"

3790

behind

76.0

41"

the

3520

160

hand

.

"1-

6.

Installing

The

the

table is exactly identical with

the

method

machine

of installing

head

the

machine head, oil reservoir, spool stand and

that

of any conventional lockstitching machine.

- 3 -

the

bobbin winder to

Fig. 3

7. Installing the pedal and its adjustment

In

caseofmotor

1) 1)

positionisadjustedbyloosening

Installing

Fore

and

lever

position

aft

positionofthe

switch

ofthe

type,

pedal

pedalisadjustedbyloosening

the

screw

installationofthe

(Fig.4)

pedal

and

the

its

adjustmentisvery

screw

(T)

and

Fig. 4

left

simple.

a •

and

right

U4-

2) Adjusting the

This

canbeadjustedbyjust

lockstitch machines. j

Loosen

drawing

3) Installing the connecting bar

Loosen

bar comes in straight line. ^

the

the connecting bar. (Fig.5)

the

Also,besuretosecurely

loose.

angle

screw(Dof

motor

lever

Motor

lever

adjusting screw

of the pedal

changing

the

couplingofthe

adjusting

tighten

the

screw

the

nutofthe

lengthofthe

connecting

and

adjustsothat

connecting

bar

barasin

and

adjustbyinserting

the

motor

ball

couplingsothatitwontget

Fig.

5

lever

the

caseofprevious

and

the

connecting

with

Motor

lever

- 4 -

Fig.

6

8.

Construction

(Full

lightly

treated

and

operationofmotor

details are given in

here)

the

Instruction

lever switch

BookofHitachi and National

Stop

Motor, so it is

1)IncaseofHitachi

Safety

Safety solenoid

Main

lever

Basically,

adjustedsoadjust

Even if

completelyupduetothe operation)orwhen

adjusting is

stepped-intothe

or

machine

When

adjusted

for

the

first time, sometimes it is easier to operate if the step-in returning

time

is increased. In

this

theminaccordance

the

screw. Please

stopping

the

step-in

for

easy

step-in

pedalisstepped-intothe

high speed, so

l~3mm(3/64~l/8"). At the sametime, return the thread

so that

adjusting screw and stops.

This lever necessarytoreadjust adjusting

device activates and when the auxiliary lever hits the auxiliary lever

T.SW

Do

will

activate at lmm(3/64") before the auxiliary leverhits the thread trimmingstroke

not

adjust

switch

is so assembled

nut

is screwed in and

mighty

Thread adjusting screw

lever

Auxiliary

lever

switch

insufficient

the

machine

note

operations.

returning

such

a case,

After

the

low speed step-in force adjusting screw or auxiliary lever

the

positionofthe

stop

motor

trimming

/^

lever

stroke

L.SW

Thread

switch

adjusting

needsnoadjustment.

with

torqueofthe

does

not

that

when

this screw is

tighten

amount

return

the

adjustment,

that

even if

the

pressureofthe

Motor

returning

Thread

T.sw spring

trimming

screw

the

following

thread

stop

at the designated position,

lightly as

at

thread

operation.

thread

trimming

Auxiliarv'lever

Auxiliary

stopper

However,asthere

instructions.

trimming

motor

tightened,

longasthere

trimming

However,

trimming

tightly

the

auxiliary lever

tighten

clutch

liningofthe

stopper.

low speed sewing pedal is

lever

spring

lever

force

screw

position,

(whenitstops

the

pedal

is no

abnormalcyinthread

is to be

when

stroke

adjusting

switchadjusting

the

locknut.

When

adjusting

the

stopper

changed,

motorisworn

the

lever also moves to a certain degree with the force of the low speed spring.

Due to this possibilityofthe operator

speed

the

lever

will get used to the machine, so do

sewing.

If

the

clutch

stopperisnot

abrasionofthe

action,

safety

machine can

lining is worn

changed at

clutch

there

is a dangerofthe machine to

device

unabletoperform

not

run at high speed even if the

out.

Exchange the lining with a new lining. If the position of

the

timeofthe

lining. It is

better

not to readjust the auxiliary lever

its role.

not

try

to readjust the step-in force at

new lining, it means the

keeponrunning

After

the machine is used for 1-2 days,

safety

device is

Step-in force

adjusting screw

speed

spring

nut

are

2-3

places

which

can

the

needle

during

tighten

pressure

machineistobeoperated

amount

screw

low speed step-in force

strenthened,

and stops, the main

at high

not

working, it is because

phenomenonisdue

stopper

can

not

thread

trimming

the

step-in force

gets

big

when

trimming

the

machine

at thread trimming

within

the

area

screw

andadjust

stopper

the

spring.

out,

it is

the

speed

and

timeoflow

the

auxiliary

safety

to the

nut.

be

rise

this

is so

of

not

the the

- 5

2) In caseofNational

Pana

Stop

Motor

QoseupofApart

2-3.

Safety device

hook

\

Safety device slanted

adjusting

screw

Safety solenoid height

adjusting screw

Safety

device

stopper

Microswitch

Microswitch B adjusting screw

Microswitch B activating plate

Microswitch A adjusting screw

B

Microswitch

When device

A

>-4 — 5 not

ifety

Si

ictivates

s

Reversestep-in force

adjusting screw

0 - 1 «

m

When the clearanceofthe clutch of the motor is to be adjusted or when the clutch friction

plateand brakefriction plateis to be

safety

device.

the mount up and pedal,

the

hook

becomes

safety

device

even if the pedal is

Adjusting

Loosen

clearance

the installing

down.

Make

between

0~lmm(3/64"), the

completely enters and

stepped

the

reverse step-in force at thread trimming time

the safety

in front.

exchanged,

screw

of the safety

besureto readjust the

device

installing mount and adjustby

adjustment so that with the foot in

device

stopper and upper and

horizontal

(B)

when

direction

the safety

becomes

device

2~3mm(5/64~l/8")

is in action,

height

released

lower

direction of the

machine

of the stopper of the

moving

condition from the

pawl

and

that@ the

will

not rotate

If the thread trimming step-inforce adjustingscrew isscrewedin, 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

machine

and

step-in

becomes

force

at thread trimming time and the

very

difficulttooperate.

reverse

step-in force

collapses

and the

For detailed information on the operation of Hitachi MightyStop Motor and the National Pana

Stop

Motor,

procedures besides the above instructions.

refer to the

respective

Instruction

Book

and

Engineers

Manual

for all operational

of

9.

Functions

The positions of the

functions

(l)

Thisisthe

(D This is the

are

of

same.

the

cord

power

source

cordofmotor

cords,

cord.

for

which are

power

source.

coming

out, depend on the kind of motors but the

(D This is the cord of control box for power source.(3-pole plug)

@ This is the cord which transmits

to the motor. (9-pole plug)

signals

of low speed

- 6 -

sewing

or stopping from the control box

® This is the cord which transmits the signals of machine stopping position to the control box and

alsotoactivate

the

thread

trimming

magnet.

The

plugging

coloriswhite.

(12-pole

plug)

(D This is the cord which transmits the signal of thread trimming by means of pedal operation or

low

speed

sewingtothe

plugging

(2)

This is the cord for the wiper and for automatic reverse

reverse sewing

color

is blue

switch

and

control

this

is plugged in to

activates

box

the

and

alsotoactivate

wiper

(6-pole

the

control

sewing.

plug)

the

safety

deviceofthe

box

front

motor

side. (9-pole plug)

It transmits the signalfrom the

pedal.

The

1) When HITACHI, NATIONAL

JJ

motor

UUK

is used

I

(In

caseofmotor

lever switch system)

i-i][U]c:^a

Fig. 7

- 7

2) Connecting the cords

A. How to connect the cord (D coming

Plug-in

As

Lastly,

Be

the

plug

of cord

showninFig.8,

plug-in

suretopress

the plug into the control box.

down

(§)

into the

hold

the

middleofthis

the

cordsothatitwon't

out

from the sensor

hole

of the

cord

table.

with

touch

the

cord

the

beltorthe

holder

and

cord

bobbin

support.

thread

winder.

B. How to connect the power source cord

a) In case of Hitachi and National motors (Fig.9)

*

The

cord3coming

this

plugtothe

the terminals on the left side of the transformer inside the control box.

*

Connect

cord can be connected either to the

*

With

C. How to

Plug-in

box.

D. How to connect

a) In case of Hitachi and

into

the

white

the

lOOV

connect

Plug-in

black plug hole of the control box.

the

cord,

the

out

from

plug

socketonthe

and

black

stop

motor

for

cord (6) from the

whichiscoming

cord ® for controlling the

National

black

plug

of the

the

cords

single

out

motors

cord,

(3)

rear

of the

motor

sideofthe

to the

terminals

"0"

or 200V terminals. It

phase,

connect

motor

lever

from

the

motor

whichiscoming

\ 1 1 '

transformer

a

2Ry

/ / 1 \ \

control

of "0"

them

lever,tothe

M

isthe

out

AWi

for

att

•!

Fig.

power

box

and

cloesn

to the"0"

from

9

source

and

200V.

and

side

the

connect

t matter)

partofthe

rear

cord.

Plug-in

them

to

(Whiteorblack

lOOV

terminals.

control

of the

motor,

- 8

10.

Howtohandle

1) Wiring to the power source voltage and transformer

® Kinds of transformers and methods of connection

The

side

to the voltage used, four kinds of transformers, A, B, C and D are available.

of the

the

control

transformer

box

on the

and

cautions

power

source

sideiscalled

the

primary

side

and

according

A lOOV, 115V

B

C

D

Be

sure to connect the two electrical source

the terminals® whichareof same

(D Percentage of voltage variance

The limit of voltage variance is ±10%. This control box is so constructed that even if the

voltageisvaried

10%

limit,

However,

and sometimes the sensitive parts may be ruined, so be very careful.

2) Besure to use fuses of 6A, 1A (Small) Amperes.

use

is

wrong

will

repairing will be a tremendous job. -

3) Correct connection of the ground wire (green)

Even

only

In

not be

when

the

case

or if the

There

inserted),

equipment box and needle positioningsynchronizer, correctly.

4) Do

hand

so be

not

When

wheelistouching

mightbetorn

the

same

contingency

If

any

these

parts, so be sure to tie the

5)

When

plug

is so

tipofthe

6)

the

trouble

The

spare6Afuseisattached

fuseisblown

somewhere,

to the limit of

the

timing

the

if the sizeof the

fuses

markedasabove.

the

diode

damaged.Ifover-sized

should

suretoconnect

damage

the 6-core cord coming out from the

and

mightbeshort-circuited

other

cords

pulling

made

to be

terminal

out,

200V,

220V,

380V,

415V

220V,

380V

voltage

10%,itwill

of the

voltage

should

circuit

magnet

gets too

glass

tube is

break

shouldbeshort-circuited,

fuseisused,

be a

ground

terminal

this

the

cords

the

bobbin

might result.

are

contacting

cords

out

the

plug

of the

pulled

out

easily.

might

come

off.

exchange

so inspect

it just

the

sourceofthe

240V

leading

with the power

function

also

changes,

high,

the life of diode, condenser,

same,

the runningcurrent may not be

(in

this

case

the

normally.

causing

current

if the

the

damage

dL

on the

green

thread

anyofthe

firmly

electric

If you

to the

once.

power

sourcesocket(for

ground

with

during

the

wire

to the 4

needle

positioningsynchronizer on the sideof the

the

bobbin

neighboring

moving

to the table or its

equipment

pull

the

cord

control

box

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blowsupagain

trouble.

withared

wires

to the

"0"

source.

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the

malfunctioning

will

runtoany

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willbefelt

by other

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cords

for the motor,the

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parts,

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legs.

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too

after

pull

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there

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safety

device.

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orthe

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covering

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case,

This

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when

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9 -

11. Adjusting

When

bigger

until

becomes

as

follows:

After

which is setting the 2 bolts M6x30 ®.

Then,

adjustsothat

watch the movement of the main shaft of the motor

During

carefultosee

push

the

tighten

the

bolt

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insert

the

bolt

M6x30.

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inviting

adjustedto0.1~lmm

the

clutch gap

the

friction

the

clutchisin

little

difficult.

loosening

turn

lever

the

set

M6x30

power

this

brake

This

the

clearance

adjustment,

that

the

toward

screw

M6xl0®again

® .

friction

source

sound

clearanceisclosed

scorchingofthe

discorbrake

and

the

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the

movement

set

screw

M6xl0®whichissetting

M6x30®toward

becomes

repeat

theinand

brake

friction

the

brake

side

and

diskisslanted,itwill

into

the

motor,

will

disappear,

up,

motororthe

always.

friction

disc

strokeofthe

of the tip of the

right

about

0.5~lmm.

outofthe

disc

does

not

make

the

andatthe

same

andbyrepeating

the

brake

fuse

mightbeblown

beginstowear

treadle

(1mm

per

Judge

(2).

off, the

gets

more

lever

becomes

the

brake,

rotation),

thisbymoving

clutchbymeansofthe

leantoone

bolts

M6x30®contact

time

emanateapeculiar

side.

firmly

set

crying

theinand

mustbeputonwhile

up.Becertain

motion

frequent

15~20mm,

loosen

closeinthe

the

After

the

lock

sound.

outofthe

the

main

that

of the

lever

and

the

operation

adjust

the

lock

nut

clearance,

motor

lever

motor

lever

adjustment,

brake.

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nut

whichissetting

If this

happens,

clutch,

adjust

motorisrotating,

the

clearance

gets

(D

and

be

lightly

firmly

the

it

is

0.5~1mm

setto0.5~1mm

-

10

-

0.5^1mm