JUKI DDL-9000B-SH, DDL-9000B-MA, DDL-9000B-SS, DDL-9000B-MS, DDL-9000B-DS Engineering Manual

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40089335

No.E392-01

ENGINEER’S MANUAL

Direct-drive, High-speed, 1-needle, Lockstitch Machine with Automatic Thread Trimmer

DDL-9000B

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 these machines intended for the maintenance personnel and operators at an apparel factory contains operating instructions in detail. It is advisable to use the Instruction Manual and Parts List for SC-920 together with this Engineer's Manual when carrying out the maintenance of these machines. This manual gives the "Standard Adjustment" on the former section under which the most basic adjustment value is described and on the latter section the "Results of Improper Adjustment" under which stitching errors and troubles arising from mechanical failures and "How To Adjust" are described.

CONTENTS

1. Specifications ............................................................................................... 1

2. Name of each component ............................................................................ 2

3. Standard adjustment .................................................................................... 4

(1) Feed dog height and gradient ...................................................................................4

(2) Timing for the needle and the inner hook ................................................................6

(3) Needle and feed timing ..............................................................................................8

(4) Feed locus and phase ..............................................................................................10

(5) Bobbin insertion .......................................................................................................12

1) Bobbin case with idling prevention spring ..................................................................................12

(6) Adjustment of inner hook presser position ...........................................................14

(7) Lubrication ................................................................................................................16

1) Method of lubrication .....................................................................................................................16

2) Method of lubrication to the oil tank.............................................................................................18

3) Method of oil drainage from the oil tank ......................................................................................18

4) Cleaning of the oil filter..................................................................................................................20

5) Oil in the gear box ..........................................................................................................................22

6) Placement/displacement of the gear box cover ..........................................................................22

7) Cautions for gear box cover oil during transportation ...............................................................22

8) Adjustment of hook oil quantity....................................................................................................24

9) Hook oil adjustment procedures...................................................................................................24

10)Essentials for hook oil adjustments .............................................................................................24

11) Replacement of the hook shaft oil wick .......................................................................................24

(8) Adjustment of the amount of feeding .....................................................................26

1) Adjustment of forward feed stitch length.....................................................................................26

2) Adjustment of reverse feed stitch length (manual) .....................................................................26

3) Adjustment of reverse feed stitch length (motor-power)............................................................26

4) Optional switch ...............................................................................................................................28

5) Adjustment of normal/reverse stitching.......................................................................................30

6) Adjustment of Feed 0 .....................................................................................................................30

1. Method by removing the gear box cover (standard adjustment) .................................................30

7) Adjustment of the feed dial section ..............................................................................................32

8) Installation of the reverse feed arm and the reverse feed solenoid ..........................................34

9) Stop position of the feed control spring rack ..............................................................................34

(9) Adjustment of the presser lifter ..............................................................................36

1) Adjustment of the presser pressure .............................................................................................36

2) Adjustment of thread release changeover ...................................................................................36

3) Adjustment of the micro-lifter .......................................................................................................38

4) Adjustment of the micro-lifter unit (available separately) ..........................................................38

(10) Adjustment of needle stop position........................................................................40

1) Adjustment of upper stop position (Stop position after thread trimming)................................40

2) Adjustment of lower stop position ................................................................................................40

(11) Thread trimming unit ................................................................................................42

1) Adjustment of the thread trimming cam position........................................................................42

2) Adjustment of the thread trimming link stopper screw ..............................................................42

3) Standard timing for the thread trimming cam..............................................................................44

1. Method of confirmation ................................................................................................................45

2. Method of adjustment ..................................................................................................................45

4) Correct position of the moving knife ............................................................................................46

1. Extreme backward position .........................................................................................................47

2. Initial position ...............................................................................................................................47

5) Correct position of the counter knife............................................................................................48

6) Adjustment of rise of the second thread tension disc................................................................50

1. How to check the amount of rise of the second thread tension disc ...........................................51

2. How to adjust the amount of rise of the second thread tension disc ...........................................51

7) Adjustment of the fixed knife blade tip.........................................................................................52

8) Replacement of the moving knife .................................................................................................54

9) Replacement of the knife thread guide.........................................................................................56

10)Adjustment of the picker................................................................................................................58

1. Method of confirmation ................................................................................................................59

2. Method of standard adjustments (Adjustment of clearance) .......................................................59

3. Method of standard adjustments (Adjustment of tip position)......................................................59

11) Adjustment of the drive part stopper............................................................................................60

12)Replacement of the knife unit........................................................................................................62

13)Installed length of the thread trimmer connector bar (asm.)......................................................62

14)Protrusion of the thread trimming shaft and stopper position ..................................................64

(12) Adjustment of the wiper (DDL-9000B-   -WB) ...................................................66

(13)

Adjustment of the thrust values for the upper shaft and the upper/lower feed shafts .........

(14) Adjustment of external parts ...................................................................................70

1) Adjustment of the pulley cover .....................................................................................................70

2) Clearance of the hand wheel .........................................................................................................70

3) Adjustment of the bobbin winder unit ..........................................................................................72

1. Replacement of the bobbin friction wheel....................................................................................73

2. Adjustment of the bobbin winder driver wheel position ...............................................................73

4. Maintenance ................................................................................................ 74

(1) Oil quantity check.....................................................................................................74

(2) Cleaning.....................................................................................................................74

(3) Application of appropriate grease ..........................................................................74

1) Needle bar lower bushing (DDL-9000B-M , B-DS Specification) .............................................74

2) Feed bar mechanisms ....................................................................................................................76

3) Face plate mechanism ...................................................................................................................78

(4) Lubrication mechanism configuration and adjustments

(DDL-9000B-SS, SH, MA, MS) ..................................................................................80

(5) Thread take-up lever mechanism............................................................................82

(6) Replacement of the motor .......................................................................................84

(7) Replacement of the timing belt ...............................................................................84

5. Screws for attachment and positions of external parts.......................... 86

6. Dry hook....................................................................................................... 87

(1) Cautions when a dry hook is used..........................................................................87

(2) Replacement of the dry hook ..................................................................................87

7. Head section and control circuit connection diagram............................ 88

8. Air blow type hook cooling unit (available separately) ........................... 89

9. Troubles and corrective measures ........................................................... 90

(1) Mechanical parts.......................................................................................................90

(2) Sewing conditions ....................................................................................................96

10. Drawing of the table................................................................................ 107

– 1 –

DDL-9000B-SS DDL-9000B-SH DDL-9000B-MA DDL-9000B-MS DDL-9000B-DS

Minute-quantity lubrication Minute-quantity lubrication

Semi-dry *4 Semi-dry Dry

For standard materials

For heavy-weight materials For light-weight materials

For standard materials For standard materials

1 Max. sewing speed 5000sti/min *1 4500sti/min *1 5000sti/min *1, *4 4000sti/min

2 Max. stitch length Difference of stitch length 5 mm Difference of stitch length 5 mm

3 Needle bar stroke 30.7mm 35mm 29mm 30.7mm 30.7mm 4

Take-up lever stroke (standard value)

110mm 108mm 110mm 110mm 110mm 5 Thread trimming method Horizontal type 6 Lower bobbin winder unit Built-in, top surface of machine head (with bobbin thread holding plate) 7 Wiper (only for WB specification) Electromagnetic side wiper 8 Automatic reverse feeding unit Built-in electromagnetic type

Plate (needle bar) Oil wick lubrication Grease lubrication

9 Hook Plunger pump type No lubrication

Gearbox Sealed type Plate (needle bar) With oil tank (capacity: 200 ml) No lubrication Hook With oil tank (capacity: 200 ml) No lubrication

JUKI New Defrix Oil No. 1 or Exclusive grease

Plate (needle bar) JUKI Machine Oil 7 JUKI Grease A (product No.: 40006323) 20g contained

(equivalent to ISO VG7) *2

JUKI New Defrix Oil No. 1 or JUKI Machine Oil 7

(equivalent to ISO VG7) *2

Gearbox JUKI New Defrix Oil No.2 (equivalent to ISO VG32) *3

12 Lifting amount of presser Presser lifter lever: 5.5 mm/By knee: 15 mm/AK: 8.5 mm

DB x 1 (#11) DB x 1 (#21) DB x 1 (SF#9) DB x 1 (#11) DB x 1 (#11)

#9 to 18 #20 to 23 #8 to 11 #9 to 18 #9 to 18

DP x 5 (#75) DP x 5 (#130) DP x 5 (#65) DP x 5 (#75) DP x 5 (#75)

#65 to 110 #125 to 160 #60 to 75 #65 to 110 #65 to 110

134 (Nm75) 134 (Nm130) 134 (Nm65) 134 (Nm75) 134 (Nm75)

Nm65 to 110 Nm125 to 160 Nm60 to 75 Nm65 to 110 Nm65 to 110

Sewing space width

303mm

14 Dimensions

Sewing space height

139mm

Bed size 178mmX517mm 15 Machine head weight 38kg, 40kg (with AK) 16 Power consumption SC-920 : 320VA 17

Working temperature and humidity

Temperature: 5 °C to 35°C, humidity: 35% to 85% (No dew condensation permissible)

18 Supply voltage and frequency Rated voltage ±10%, 50/60Hz

1. Specifications

Model

Item

10 Oil supply

No.

Hook

*1: The machine shall be used at maximum of 4,000 rpm for the stitch of 4 mm. *2: JUKI New Defrix Oil No. 1 or JUKI Machine Oil 7 (equivalent to ISO VG7) *3: JUKI New Defrix Oil No.2 (equivalent to ISO VG32) *4: When a version of the DDL-9000B-MA specification is used over a speed of 4,000sti/min, the presser pressure adjusting spring

should be replaced for the standard type.

*5: The needle can change according to the destination.

No lubrication

Oil to be used (grease)

Lubrication system

Difference of stitch

length 4 mm

13 Needle *5

– 2 –

2. Name of each component

Power switch Knee lifter Operation panel (CP-18, 180 or IP-110) Oil filler port (except for DDL-9000B-DS) Pulley cover Feed lever Thread stand Minute adjustable presser lifting screw Control box (SC-920) Hand wheel Operation pedal Take-up lever cover One-touch type reverse feed button Finger guard Wiper Under cover Bobbin winder unit 1st thread tension Stitch dial 2nd thread tension

– 3 –

Power switch This switch turns on and off the power to the head unit motor, electric components, and operation panel.

Operation panel (CP-18, 180 or IP-110) This panel allows users to conduct the settings of automatic reverse stitching, head sewing, sewing speed, and more.

Pulley cover This cover protects the machine head motor.

Thread stand Control box (SC-920)

The box contains the circuit that controls the head unit and motor, the output circuit that operates each output (the thread trimming solenoid, back solenoid, wiper solenoid, etc.), the pedal sensor that detects the pedal operation, and the power circuit that performs each function.

Operation pedal This pedal allows users to conduct machine speed control, thread trimming, presser lifting motion (only for AK-

138), and more by depressing the front or back part of the pedal. One-touch type reverse feed button

This button allows users to conduct reverse stitching. Wiper

The wiper moves the needle from the sewing material after thread trimming under control of the wiper signal from the control box.

Bobbin winder unit This unit is integrated into the head unit.

Stitch dial This dial adjusts the front feeding amount.

Knee lifter Oil filler port (except for DDL-9000B-DS)

This port is used for lubrication to the hook. Feed lever

This lever allows users to conduct reverse stitching. Minute adjustable presser lifting screw Hand wheel Take-up lever cover

This cover prevents users from touching the take-up lever. Finger guard

This guard prevents users (mainly thumb and fingers) from touching the needle. Under cover 1st thread tension 2nd thread tension

– 4 –

3. Standard adjustment

(1)Feed dog height and gradient

Standard feed dog height (Feed dial graduation 0)

0.8mm : DDL-9000B- S, DDL-9000B-MA

1.2mm : DDL-9000B-SH Standard feed dog gradient The engraved marker dot on the feed bar shaft is adjusted by a feed dog of relevant standard.

Shipped feed dog

•B1613012I00 • 23614506 (B- S, B-MA) (B- S)

• D1613155W00 • 11403003, 11062601 (B-MA) (B-SH)

Engraved marker dot position on the horizontal feed bar shaft

9000B- S, 9000B-MA : 0.8mm 9000B-SH : 1.2mm

Standard Adjustment

– 5 –

1. Set the amount of feeding (feed dial graduation) at 0.

2. Loosen the setscrew of the vertical feed bracket shaft and the setscrew of the horizontal feed bracket shaft .

3. The feed dog height and gradient are changed when both shafts of the vertical feed bracket shaft and the horizontal feed bracket shaft are turned by means of a screwdriver.

4. After adjustments, firmly tighten the screws that have been loosened. (Screw tightening should be done under the condition that the setscrews and are pushed against the vertical feed bracket shaft and the horizontal feed bracket shaft .)

(Cautions) 1. In regard to the locus of standard feeding, the throat

plate and the feed dog rise almost horizontally when the throat plate rises.

2. The direction of the engraved marker dots for the vertical feed bracket shaft and the horizontal feed bracket shaft should be adjusted on the right side (operator side).

3. If there is rattle in the vertical feed bracket shaft and the horizontal feed bracket shaft , this can be a cause of unusual sound and improper linearity.

o If the gradient of the feed dog is

adjusted for either shaft only, the feed dog height may be changed. Adjustments are needed for both shafts in all cases.

o According to the shaft adjusting

position, the position of feed dog motion may be shifted. In such a case, loosen the tightening screw of the X feed arm to adjust the position of motion.

o According to the result of feed dog

height or gradient adjustments, there is possibility of interference with the thread trimmer unit.

o When the feed dog height is set

above the standard level, the feeding power is improved. Instead, there can be problems of presser jumping at high speed and flaws in light materials.

o If the feed dog height is too much,

a return will be given to the front side (Section C) of the feed dog. As a result, the behavior of material feeding may be affected. If the height has to be increased for an unavoidable reason, the amount of return can be reduced by adjusting the gradient of the feed dog to raise its tip.

0.8mm DDL-9000B- S, MA

1.2mm DDL-9000B-SH

Adjustment Procedure Results of Improper Adjustment

– 6 –

(2)Timing for the needle and the inner hook

0.04 to 0.1mm

Standard Adjustment

Lubricated hook K Part No. : 23621303

– 7 –

1. Turn the flywheel until the needle bar comes to its lowest position, and loosen the needle bar connecting setscrew .

2. Determine the needle bar height. Adjust the engraved marker line (marker line A for the DB needle and marker line C for the DA needle) of the needle bar to the lower end of the needle bar lower metal and tighten the needle bar connecting setscrew . (Be careful not to tighten the needle bar connecting setscrew too much.)

3. Determine the mounting position of the hook . Turn the three hook setscrews in the direction of flywheel forward revolutions to raise the needle bar. In this direction, adjust the engraved marker line (marker line B for the DB needle and marker line D for the DA needle) to the lower end of the needle bar lower metal .

4. In this state, adjust the blade point of the inner hook to the center of the needle so that a clearance of 0.04 to 0.1mm (goal value) is secured between the needle and the hook . Since then, firmly tighten the three hook setscrews.

(Cautions) 1. Since the needle bar of the DDL-9000B-MS, -DS is

black, the engraved marker line may be hard to see. Work should be carried out under bright circumstances by giving a light to the spot, for example.

<Information about the dry hook> A dry hook (RP hook) is employed for the DDL-9000B-DS type. For replacement, use the part numbers specified below. The hook part numbers come in two types according to the specifications. 22890206 (without the needle guard) 22890404 (with the needle guard) 22890305 (22890206 with special surface treatment)

(Cautions) The dry hook (RP hook) tends to collect thread chips

and material dust. This can cause malfunction or defective stitches. Periodic cleaning is required.

<Lubricated hook K: Available separately> This is a hard blade point hook with a needle holder applicable to needle size #9 (#65). Where a thin needle has to be used for reasons of sewing processes, this type of hook is applicable to the prevention of stitch skipping and needle breakage.

Adjustment Procedure Results of Improper Adjustment

About the needle bar

Specifications Part No. Needle shank

DDL-9000B-SS 22886904 1.8mm ø1.64 DDL-9000B-SS 22887004 1.8mm ø2.02 DDL-9000B-M , DS 40086602 1.8mm ø1.64 DDL-9000B-M , DS 40086604 1.8mm ø2.02 DDL-9000B-SH 40061767 2.3mm ø2.04

Amount of

looper return

o If this clearance is too small, the

blade point of the hook may be damaged.

o Too much clearance may give rise

to stitch skipping.

– 8 –

(3) Needle and feed timing

Vertical feed cam phase

(engraved marker line position)

1mm

Standard Adjustment

Models Other than DDL-9000B-SH DDL-9000B-SH

Vertical feed cam engraved marker line 0° +20°

Feed dial graduations 3 4

In a moment when the feed dog is positioned below the upper surface of the throat plate, the upper end (lower end of the throat plate for B-SH) of the needle hole shall be 0±1mm from the upper plane of the throat plate.

Needle and feed timing

B-SHOther than B-SH

Needle and feed timing

Standard Adjustment

– 9 –

1. Adjust the feed dial graduations. o DDL-9000B-SH: Feed dial graduation 4 o Other than DDL-9000B-SH: Feed dial graduation 3

2. Let the sewing machine fall down and check the engraved marker line position of the vertical feed cam . o DDL-9000B-SH: +20° ( ) oOther than DDL-9000B-SH: 0° ( )

For adjustments, loosen two vertical feed cam setscrews and adjust the cam to the engraved marker line .

(Cautions) The angle of the engraved marker line graduation 1

denotes 10°.

3. Loosen two lower sprocket screws .

4. At the feed dog lowering timing (position where the upper end of the feed dog coincides with the upper plane of the throat plate), fix the vertical feed cam and slowly turn the flywheel in forward direction until the upper end of the needle hole coincides with the upper plane of the throat plate. *In cases other than the DDL-9000B-SH, coincidence of the

engraved marker dot of the pulley cover with the engraved marker dot of the flywheel can be regarded as the standard for needle hole upper end lowering. When coincidence is confirmed, tighten two lower sprocket screws

(Tightening torque for reference: 4.5N•m)

5. Adjust the thread trimmer cam timing. Refer to [3.–(11) Thread trimmer unit -3) Thread trimmer cam standard timing].

6. Adjust the hook timing. Refer to [3.-(2) Needle and hook timing].

(Cautions) When the above-mentioned adjustments are finished,

operate the sewing machine and examine whether any unusual sound or torque is generated or the thread trimmer unit works normally.

o When tightening the two vertical

feed cam setscrews , this work should be done while a good cen- tering is secured. Otherwise, there will be adverse torque or unusual sound generation, or abnormal wear may be caused.

Adjustment Procedure Results of Improper Adjustment

– 10 –

(4) Feed locus and phase

1. Timing standard

2. Timing fast

3. Timing slow

Standard Adjustment

– 11 –

[Feed locus change] By adjusting the phase of the vertical feed cam , it is possible to change the up/down timing for the feed locus and needle. Adjustments can be carried out with two setscrews .

1. Timing standard The vertical feed shaft engraved marker line coincides with the vertical feed cam engraved marker line at 0°. Refer to [3.-(3) Needle and feed timing].

2. Timing fast If you adjust the vertical feed shaft engraved marker line to the vertical feed cam engraved marker line and the minus side, the vertical feed timing is hastened against horizontal feed. (Also hastened against the needle)

(Cautions) Adjustments should be done within –20° (2

graduations).

3. Timing slow If you adjust the vertical feed shaft engraved marker line to the vertical feed cam engraved marker line and the plus side, the vertical feed timing is delayed against horizontal feed. (Also delayed against the needle)

(Cautions) Adjustments should be done within +20° (2

graduations).

(Cautions) 1. When timing of the vertical feed cam is changed,

the feed timing is also changed against the needle. When the timing is adjusted, re-adjustment is required in accordance with [(3) Needle and feed timing].

2. The angle of the engraved marker line graduation 1

denotes 10°.

o When tightening the two setscrews

of the vertical feed cam , this work should be done while a good centering is secured. Otherwise, there will be adverse torque or unusual sound generation, or abnormal wear may be caused.

oSince the motion in horizontal

direction is reduced at the beginning of feeding, the material cloth is fed assuredly by the effect of creep reduction.

o Feeding force is reduced around

the end of feeding because the feed dog lowers faster.

o The motion becomes moderate at

the beginning of feeding, thus making the material cloth biting worse.

o Light materials tend to be less

damaged.

o The material cloth is fed assuredly

at the end of feeding. Thanks to the leading effect, puckering tends to be improved.

Adjustment Procedure Results of Improper Adjustment

– 12 –

(5) Bobbin insertion

1) Bobbin case with idling prevention spring

(Drawing is for 40000264.)

o For the bobbin case with idling prevention spring

(1)

(2)

(3)

(4)

Ear

Change the height.

0.3

0.2mm

Bobbin revolution

Standard Adjustment

– 13 –

1. Hold the bobbin so that it turns to the right and insert it in the bobbin case. (See Drawing.)

2. Pass the thread through the threading port

of the bobbin case.

When the thread is pulled in the direction of

, it can be pulled toward the threading port B passing beneath the thread tension spring.

3. Examine if the bobbin turns in the direction of the arrow when the bobbin thread is pulled.

Part name MS, SS DS SH MA

Bobbin case 22896252 40000264 40000264

11038700

Bobbin

D1837555

BAAA

D1837555

BOBA

40091141

(Made of aluminum)

B9117012000 (Made of iron)

About the standard part numbers (DDL-9000B- )

1) Bobbin case with idling prevention spring The DDL-9000B Series employs the bobbin case with an idling prevention spring. Adjustments of idling prevention spring tension can be carried out in the procedures below. If bobbin idling occurs, increase the idling prevention spring tension

When the bobbin runs idle Increase the tension of the idle-prevention spring.

When the thread is not well tightened Decrease the tension of the idle-prevention spring.

* Adjustment of idling prevention spring tension (1) Insert an old needle as illustrated and remove the spring by lifting it up.

(Suggestion: Use the thumb to prevent the spring from popping out.)

(2) The spring tension can be changed by changing the height of the arch-shaped section of the spring.

(Make sure not to permit the free end of the spring to come out of the bobbin case.)

(3) Firstly, set the ear and insert the needle. Then, settle the ear is the state that the center part of the

spring is lifted.

(4) When a bobbin case with an idling prevention spring is used, it should be inserted in the winding direction

as illustrated.

(Unevenness in sewing at high or low speed)

When sewing seems to be too tight Adjust the bobbin thread tension and the idling at low speed: prevention spring tension to be strengthened.

When sewing seems to be too weak Adjust the bobbin thread tension and the idling prevention at low speed: spring tension to be weakened.

* If there is a problem of bobbin idling or uneven sewing at high or low speed, use of a bobbin case with an

idling prevention spring is effective.

o If the direction of clockwise wind-

ing is adopted, variation is less- ened possibly caused by a change in the amount of bobbin thread.

Adjustment Procedure Results of Improper Adjustment

Bobbin case with idling

prevention spring

40091141

(Made of aluminum)

– 14 –

(6)Adjustment of inner hook presser position

Other than DDL-9000B-SH DDL-9000B-SH

Inner hook presser 40089607 40089610

Needle entry

About the standard part numbers

Standard Adjustment

Inner hook

* As seen from above, after removing

the throat plate

– 15 –

1. The front and rear positions of the inner hook presser can be adjusted by means of the setscrew . [Standard adjusting value] Fasten the needle entry section by means of the setscrew so that it is located closer to the shoulder section toward the front side from the center of the embossed part in the inner hook presser .

o If the embossed part of the inner

hook presser has any flaw, this can be a cause of thread break- age or uneven sewing. In such a case, the damaged part shall be replaced with a new one.

o If the inner hook presser is

positioned inadequately, an extra tension is exerted when the thread comes out of the embossed part. This can be a cause of shrinkage errors.

Adjustment Procedure Results of Improper Adjustment

– 16 –

(7)Lubrication

1) Method of lubrication

Float

Standard Adjustment

DDL-9000B-S  (Specification for minute-quantity lubrication)

DDL-9000B-M  (Specification for semi-dry items)

DDL-9000B-DS (Specification for dry items)

– 17 –

1. DDL-9000B-S  (Specification for minute-quantity lubrication) Face plate needle bar lubrication : Minute-quantity lubrication by the oil wick Hook : Forced lubrication by the plunger pump

Quantity of oil can be adjusted by the hook oil adjusting screw . Lubricant can be fed to the oil tank through the arm lubrication hole .

2. DDL-9000B-M  (Specification for semi-dry items) Face plate needle bar lubrication : Lubrication by grease sealed in the needle bar lower

metal

Hook : Forced lubrication by the plunger pump

Quantity of oil can be adjusted by the hook oil adjusting screw . Lubricant can be fed to the oil tank through the arm lubrication hole .

3. DDL-9000B-DS (Specification for dry items) Face plate needle bar lubrication : Lubrication by grease sealed in the needle bar lower

metal

Hook :Dry hook (RP hook)

Adjustment Procedure Results of Improper Adjustment

– 18 –

(7)Lubrication

2) Method of lubrication to the oil tank (DDL-9000B-S  and DDL-9000B-M  only)

3) Method of oil drainage from the oil tank (DDL-9000B-S  and DDL-9000B-M  only)

Engraved marker line MAX

Engraved marker line MIN

Standard Adjustment

– 19 –

2) Method of lubrication to the oil tank

(DDL-9000B-S  and DDL-9000B-M  only)

1. Remove the lubrication hole cap

and replenish the JUKI New Defrex Oil No. 1 (Part No.: MDFRX160000) or the JUKI Machine Oil 7 (Part No.: MML007600CA) with the use of an accessory oilcan.

2. Feed the oil until the tip of the oil level indicator bar

stays between the upper and lower engraved marker lines A and B of the oil gauge window . Be careful at that time that no dust and others enter the interior.

3. Lubrication is needed if the tip of the oil level indicator bar comes below the lower engraved marker line B of the oil gauge window while the sewing machine is used.

(Cautions) 1. When using a new sewing machine or the one that

has not be used for a long time, trial running is required at the speed of 2000sti/min or below.

2. The hook oil shall be the one recommended by Juki.

3. Clean oil shall be replenished at all times.

4. Never operate the sewing machine while the lubrication hole cap is removed. Carefully manage this cap not to loose it.

(For reference) Even after making the sewing machine fall down, it is

possible to check the quantity of oil in the oil tank.

The quantity of oil is adequate if the oil level stays

between the MAX and MIN lines.

3) Method of oil drainage from the oil tank

(DDL-9000B-S  and DDL-9000B-M  only) When carrying the sewing machine or during maintenance servicing, it is possible to remove the lubricant from the oil tank.

1. Let the sewing machine fall down.

2. Insert the oil pan in the undercover.

3. Turn the oil drain screw of the oil tank to drain oil.

4. A maximum of 200ml of oil (to the MAX line) is contained in the oil tank .

(Cautions) 1. Be careful not to forget to tighten the oil drain screw

Otherwise, this can be a cause of oil leakage.

2. Do not tighten the oil drain screw too much. Otherwise, this can be a cause of oil leakage as a result of breakage.

o If too much oil is replenished, there

will be oil leakage from the air re- lief hole of the oil tank . In addi- tion, there can be possibility of fail- ure in adequate lubrication.

oViolent lubrication can result in

overflow from the lubrication hole.

o Lubricant shall be removed,

without fail, when transporting the sewing machine. Due to vibration during transportation, oil leakage may be caused through the air relief hole located on top of the oil tank .

Adjustment Procedure Results of Improper Adjustment

– 20 –

(7)Lubrication

4) Cleaning of the oil filter (DDL-9000B-S  and DDL-9000B-M  only)

Standard Adjustment

– 21 –

(DDL-9000B-S  and DDL-9000B-M  only) Clean the oil filter periodically (approximately once every three

months).

1. Let the sewing machine fall down.

2. Remove the lubrication pipe stop ring .

3. Remove the lubrication pipe from the float case .

4. Remove thread chips and material dust accumulated in the oil filter .

Refer to [4. Maintenance – (4) Lubrication mechanism configuration and adjustments (DDL-9000B-SS, SH, MA, MS)].

o If there is clogging in the oil filter

, smooth lubrication cannot be maintained from the lubrication hole.

Adjustment Procedure Results of Improper Adjustment

– 22 –

(7)Lubrication

5) Oil in the gear box

6) Placement/displacement of the gear box cover

7) Cautions for gear box cover oil during transportation

Adequate oil level line (top)

Adequate oil level line (bottom)

Oil level

Standard Adjustment

– 23 –

5) Oil in the gear box

1. The condition is normal (within the range between the upper and lower lines for the oil quantity) if the oil level in the gear box can be seen through the oil peep window when the sewing machine is made to fall down. (Same as for the AK unit installed)

(Cautions) 1. The gear box oil and the internal mechanism are

maintenance-free. The oil type is different from that of the hook oil. Except for unavoidable problems, never open the gear box cover .

2. The quantity of oil is normal if the oil level can be seen through the oil peep window .

6) Placement/displacement of the gear box cover

Never open the gear box unless any problem occurs. In the case of placement/displacement for unavoidable reasons, pay attention to the cautions specified below.

[Displacement procedures]

1. Let the sewing machine fall down.

2. Insert the oil pan in the undercover.

3. Remove the oil drain screw to drain oil.

4. Remove the setscrew of the thread tension releasing wire holder and remove the thread tension releasing wire.

5. Loosen the thread trimmer SOL cable setscrew and remove the thread trimmer SOL cable.

6. Loosen nine setscrews of the gear box cover and remove the gear box cover and the gasket.

[Placement procedures]

1. Provide for a new gasket. Gear box cover gasket Part No.: 40037166

2. The gear box cover and the bed mounting face shall be kept clean. Wipe off waste oil from these parts.

3. Tighten nine setscrews of the gear box cover. (2-turn tightening)

4. Remove the lubrication stop plug from the bed side and replenish 140cc of the JUKI New Defrex Oil No. 2. (JUKI New Defrex Oil No. 2 Part No.: MDFRX2700C0)

* After replenishment, confirm the oil level through the oil peep window . * Apply a sealant when mounting the lubrication stop plug again.

7) Cautions for gear box cover oil during transportation

When the sewing machine is transported, there may be oil leakage from the air relief hole of the bed side due to vibration. During transportation, mount the air relief cap , without fail.

(Cautions) Never operate the sewing machine while the air relief

cap is mounted. Air relief cap : 23601305

oToo less quantity of oil can result

in mechanical wear or heat gen- eration.

oToo much quantity of oil can raise

inner pressure in the gear box. As a result, there will be oil leakage from the air relief hole or the oil seal of each shaft.

o According to the position of the

head support bar on the sewing table, the oil level may change. Use, without fail, the table exclusively specified by JUKI.

oOil leakage may occur unless the

coupling face is kept clean.

o Change in the oil quantity can be

a cause of problem.

o Inner pressure is raised and oil

leakage occurs.

Adjustment Procedure Results of Improper Adjustment

– 24 –

(7)Lubrication

8) Adjustment of hook oil quantity

9) Hook oil adjustment procedures

10) Essentials for hook oil adjustments

11) Replacement of the hook shaft oil wick

Less

Much

Oil quantity (trace) checking paper

Approx. 25mm

Lower shaft front metal

Bed

Hook

3 to 10mm

To be applied to the bed wall.

Oil trace checking paper

Approx. 70mm

* Unnecessary to worry about the quality of paper.

* Apply the oil quantity (trace) checking paper to hook’s

lower side and check it from a distance of 3 to 10mm.

Oil quantity (small)

Oil quantity (large)

Oil sprinkles from the hook

• DDL-9000B-SS, B-M  : 0.5 to 1mm

• DDL-9000B-SH : 1 to 3mm

• DDL-9000B-SS, B-M  : 1 to 1.5mm

• DDL-9000B-SH : 2 to 4mm

Standard Adjustment

– 25 –

8) Adjustment of hook oil quantity

When the hook oil quantity adjusting screw is tightened (turned to the right), the amount of hook oil is increased. When it is loosened (turned to the left), the amount of hook oil is decreased.

9) Hook oil adjustment procedures

1. Tighten the hook oil quantity adjusting screw to obtain the maximum oil rate and operate the machine for about 30 seconds.

2. Loosen the oil adjusting screw by two turns and check the quantity of oil. In this case, give 30 seconds of idling to the sewing machine and measure the quantity of oil at the intervals of 5 seconds (about 35 seconds in total).

3. According to the quantity of oil secured at that time, determine the amount of turning for the hook oil quantity adjusting screw . Give 30 seconds of idling to the sewing machine after re-adjustment and measure the quantity of oil at the intervals of 5 seconds.

4. Adjust the screw position in the procedures of 2. to 3. above until an adequate quantity of oil has been attained.

(Cautions) When the hook is replaced or in the case of the head

(including the heads in a new state) not used for a long time, it takes about 10 to 20 seconds (4,000sti/min) until the oil begins to appear from the hook. he machine stays in the state of causing seizure. Therefore, use the machine after running-in operation at 2,000rpm or below.

10) Essentials for hook oil adjustments

1. When the quantity of hook oil is adjusted from excessive oiling condition to reducing condition (loosening the screw), it is possible to carry out stable adjustments.

2. Check the oil quantity about three times to confirm the stability.

3. If the quantity of oil is too much before adjustments, operate the machine continuously for about one minute so that the oil attached to the hook and remaining in the oil path can be flung off completely .

11) Replacement of the hook shaft oil wick

The hook shaft filter is a consumable item. Periodic replacement is recommended for the stabilization of hook oil quantity.

1. Remove the hook.

2. Remove the hook shaft filter screw .

(Cautions) Make sure not to hurt the tip hole of the hook shaft

filter screw .

3. Enter a new hook shaft filter to the inner part of the hook shaft filter screw and then get it around the hook shaft.

o By feeding very much oil, let the

oil prevalent around the hook and through the lubrication route as a whole so that the oil path can be stabilized.

<When the quantity of hook oil is too much> oToo much oil can stain the

materials to be sewn.

o Oil consumption in the oil tank is

increased.

<When the quantity of hook oil is too

less>

o The lubrication route tends to be

affected easily by factors such as dust. It is, therefore, necessary to check the condition of oil quantity periodically.

o Under rigorous conditions (operation

at high speed or continuous operation), pay attention to the possible occurrence of problems such as hook seizure and thread breakage by heat.

o If a contaminated oil is used, filter

clogging occurs earlier and this can be a cause of unstable oil quantity.

Adjustment Procedure Results of Improper Adjustment

Part name Part No.

Hook shaft filter asm. 22916555

Hook shaft filter screw 22916506

Hook shaft filter 11015906

– 26 –

(8)Adjustment of the amount of feeding

1) Adjustment of forward feed stitch length

2) Reverse feed stitch length check (manual)

3) Reverse feed stitch length check (motor-power)

Standard Adjustment

+ 83 hidden pages

JUKI DDL-9000B-SH, DDL-9000B-MA, DDL-9000B-SS, DDL-9000B-MS, DDL-9000B-DS Engineering Manual

Specifications and Main Features

Frequently Asked Questions

User Manual