JUKI DDL-900A Instruction Manual

DDL-900A

INSTRUCTION MANUAL

COVERI

I. SPECIFICATIONS ........................................................................................ 1

II. SET-UP ........................................................................................................ 3

1. Installation ......................................................................................................................................... 3

2. Installing the pedal sensor ...............................................................................................................4

3. Installing the power switch (for CE) ................................................................................................ 4

4. Connecting the connector ...............................................................................................................5

5. How to install the power plug .......................................................................................................... 6

6. Attaching the connecting rod ..........................................................................................................6

7. Winding the bobbin thread ..............................................................................................................7

8. Adjusting the height of the knee lifter ............................................................................................. 8

9. Installing the thread stand ...............................................................................................................8

10. Lubrication ........................................................................................................................................9

11. Adjusting the amount of oil (oil splashes) .................................................................................... 10

12. Attaching the needle .......................................................................................................................12

13. Setting the bobbin into the bobbin case ......................................................................................13

14. Adjusting the stitch length .............................................................................................................13

15. Presser foot pressure ..................................................................................................................... 13

16. Hand lifter ........................................................................................................................................13

17. Adjusting the height of the presser bar ........................................................................................ 14

18. Threading the machine head .........................................................................................................14

19. Thread tension ................................................................................................................................15

20. Thread take-up spring ....................................................................................................................15

21. Adjusting the thread take-up stroke .............................................................................................15

22. Needle-to-hook relationship ..........................................................................................................16

23. Height of the feed dog .................................................................................................................... 16

24. Tilt of the feed dog .......................................................................................................................... 17

25. Adjusting the feed timing ...............................................................................................................17

26. Counter knife ................................................................................................................................... 18

27. Pedal pressure and pedal stroke ...................................................................................................18

28. Adjustment of the pedal .................................................................................................................19

29. Marker dots on the handwheel ......................................................................................................19

III. FOR THE OPERATOR ............................................................................. 20

1. Operating procedure of the sewing machine ............................................................................... 20

2. Setting procedure of the machine head .......................................................................................21

3. Operation panel built in the machine head ..................................................................................22

4. Operating procedure of the sewing pattern .................................................................................23

5. One-touch setting ...........................................................................................................................25

6. Setting of functions ........................................................................................................................26

7. Production support function .........................................................................................................27

8. Function setting list ........................................................................................................................ 29

9. Detailed explanation of selection of functions ............................................................................33

10. Automatic compensation of neutral point of the pedal sensor .................................................. 43

11. Selection of the pedal specications ............................................................................................44

12. Setting of the auto lifter function ..................................................................................................44

13. Selecting procedure of the key-lock function .............................................................................. 45

14. Initialization of the setting data .....................................................................................................45

15. LED hand light .................................................................................................................................46

16. Height adjustable one-touch type reverse stitching switch ....................................................... 46

IV. MAINTENANCE ....................................................................................... 47

1. Adjusting the machine head ..........................................................................................................47

2. Error codes ...................................................................................................................................... 48

I. SPECIFICATIONS

Supply voltage Single phase 220 to 240V

Frequency 50Hz/60Hz

Operating environment

Input 210VA

Temperature : 5 to 35˚C

Humidity 35 - 85 % or less

DDL-900A-

S : Light- to Medium-weight materials

DDL-900A-S

Application

Max. sewing speed 5,000 sti/min

Thread trimming speed 300 sti/min

Stitch length 4 mm

Presser foot lift (by knee lifter) 13 mm

Needle

Lubricating oil JUKI CORPORATION GENUINE OIL 1 or JUKI MACHINE OIL #7

Noise

- Equivalent continuous emission sound pressure level (LpA) at the workstation :

A-weighted value of 81.0 dB; (Includes KpA = 2.5 dB); according to ISO 10821-

C.6.2 -ISO 11204 GR2 at 4,000 sti/min.

A-weighted value of 80.0 dB; (Includes KpA = 2.5 dB); according to ISO 10821-

C.6.2 -ISO 11204 GR2 at 3,500 sti/min.

DB × 1 (#14) #9 to 18, 134 (Nm 90) Nm 65 to 110 (for CE)

Light- to Medium-weight materials

• The sewing speed preset at the time of shipping : 4,000 sti/min

*1 : Needle used depends on the destination.

– 1 –

DRAWING OF TABLE

– 2 –

drilled hole

4xø3.4 on the bottom surface, depth 20 (Drill a hole at the time of set-up.)

Installing position of drawer stopper (on the reverse side)

ø18 drilled hole D 3xø13 drilled hole

2xø3.5, depth 10

ø40±0.5

ø16 depth 30

C1.5 to C2.5 (hinge side only)

II. SET-UP

1. Installation

1) Carry the sewing machine with two persons as

shown in the gure above.

Do not hold the handwheel D.

❸

❶

❷

❽

❶

A B

❹

❾

❸

❶

19.5 mm23.5 mm

❸

2) Do not put protruding articles such as the screw-

driver and the like at the location where the

sewing machine is placed.

3) Adjust so that the underside cover is supported at

the four corners of the table. Mount rubber hinge seat ❽ on the table and x it on the table with a

nail.

4) Two rubber seats ❶ for supporting the head por-

tion on the operator side A are xed on the extended portion of the table by hitting the nail ❷ , and the other two rubber cushion seats ❸ on the

hinge side B are xed by using a rubber-based adhesive. Then, underside cover ❹ is placed.

❼

5) Fit hinge ❼ into the opening in the machine bed,

and t the machine head to table rubber hinge ❽ before placing the machine head on cushions ❾

on the four corners.

6) Securely attach machine head support rod ❻ to

the table until it goes no further.

❽

❻

1. Be sure to install the machine head support rod ❻ supplied with the unit.

2. If a pair of scissors or the like is caught between the control box and the table, the control box

3. Be aware that the control box breakage and/or oil leakage can occur if operating the sewing

❼

cover can break. To prevent such an accident, do not place anything on C section.

machine with the machine head support rod ❻ removed.

– 3 –

2. Installing the pedal sensor

❶

3. Installing the power switch (for CE)

WARNING :

1. Be sure to attach the ground wire (green/yellow) to the specied 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.

1) Install the pedal sensor to the table with mounting

screws ❶ supplied with the unit.

It is necessary to install the pedal sensor at such

a position that the connecting rod is perpendicu-

lar to the table.

2) After the completion of installation of the pedal

sensor on the table, place the sewing machine

head on the table.

❷

1ø 220V-240V

❹

Blue Blue

❶

Do not insert the power plug into the plug

receptacle.

) Remove screw ❶ on the side face of the power

switch cover to open the power switch cover.

2) Pass AC input cord ❷(40145128), ❸(M6102461DAA) through the rear face of the

power switch. Bundle the cord with cable clip band ❹ to secure it.

3) Securely x the terminals of the AC input cord

❷(40145128), ❸(M6102461DAA) by tightening

the screws at the specied locations.

4) Close the power switch cover. Tighten screw ❶

on the side face of the power switch cover.

❷

Green/ Yellow

❸

Brown Brown

– 4 –

4. 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 ve minutes or more before installing the pedal

sensor.

• To prevent damage of device caused by maloperation and wrong specications, be sure to connect all the corresponding connectors to the specied places. (If any of the connectors is inserted into a

wrong connector, not only the device corresponding to the connector can break but also it can start abruptly, inviting the risk of personal injury.)

• To prevent personal injury caused by maloperation, be sure to lock the connector with lock.

• As for the details of handling respective devices, read carefully the Instruction Manuals supplied with the devices before handling the devices.

Do not insert the power plug into the wall outlet. Check to be sure that the power switch is turned OFF.

❶

❸

Machine head connector

AC power supply

Pedal

Connector connection diagram

Underside of the table

Pedal sensor

❶

Slack

❹

❸

❹

❷

1) Connect pedal sensor cable ❶ and AC input cable ❷ supplied with the machine to the control

box. For the connection ports of the cables, refer

to the connector layout drawing.

Be sure to fully insert the connectors into

the corresponding ports until they are

locked.

2) Draw out cable of the control box through cable draw-out hole ❸ to route it to the underside of

the sewing machine table.

Underside of the table

❹

Pedal sensor

❶

Slack

❹

(For CE)

❸

❹

❷

3) Fix pedal sensor cable ❶ and AC input cable ❷ with a staple ❹.

– 5 –

5. How to install the power plug

WARNING :

1. Be sure to attach the ground wire (green/yellow) to the specied location (on the ground side).

2. Take care not to allow terminals to come in contact with each other.

1ø 220-240V

Blue

Brown

Green / Yellow (ground wire)

AC 220-240V

❶

1) Connect the power cord to power plug ❶. Con-

nect the blue and brown wires (1ø) to the power

supply side and the green/yellow wire to the

earth side as illustrated in the gure.

1. Be sure to prepare the power plug ❶

which conforms to the safety standard.

2. Be sure to connect the ground lead

(green/yellow) to the grounding side.

2) Check that the power switch is in the OFF state. Then, insert the power plug ❶ coming from the

power switch into the plug receptacle.

In prior to the connection of the power plug ❶, re-check the supply voltage spec-

ication indicated on the control box.

* The power plug ❶ is different in shape ac-

cording to the destination of the sewing

machine.

6. 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.

❸

❷

❶

❸

Fix connecting rod ❶ to installing hole of pedal lever ❷ with nut ❸.

– 6 –

7. Winding the bobbin thread

1) Insert the bobbin deep into the bobbin winder

❽

❸

❶

❷

❹

❻

❼

❻

❺

❻

6) In case that the bobbin thread is not wound evenly on the bobbin, loosen screw ❺ and adjust the height of bobbin thread tension ❽.

• It is the standard that the center of the bobbin is as high as the center of thread tension disk ❻.

• Adjust the position of thread tension disk ❻ to the direction of D when the winding amount of the bobbin

thread on the lower part of the bobbin is excessive and to the direction E when the winding amount of

the bobbin thread on the upper part of the bobbin is excessive.

After the adjustment, tighten screw ❺.

7) To adjust the tension of the bobbin winder, turn the thread tension nut ❼.

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

following the order as shown in the gure on the

left. Then, wind clockwise the end of the bobbin

thread on the bobbin several times.

(In case of the aluminum bobbin, after winding

clockwise the end of the bobbin thread, wind

counterclockwise the thread coming from the

bobbin thread tension several times to wind the

bobbin thread with ease.)

3) Press the bobbin winder trip latch ❷ in the direc-

tion of A and start the sewing machine. The bob-

bin rotates in the direction of C and the bobbin thread is wound up. The bobbin winder spindle ❶

automatically as soon as the winding is nished.

4) Remove the bobbin and cut the bobbin thread

with the thread cut retainer ❸.

5) When adjusting the winding amount of the bobbin

thread, loosen setscrew ❹ and move bobbin winding lever ❷ to the direction of A or B. Then tighten setscrew ❹.

To the direction of A : Decrease

To the direction of B : Increase

1. When winding the bobbin thread, start the winding in the state that the thread between the

bobbin and thread tension disk ❻ is tense.

2. When winding the bobbin thread in the state that sewing is not performed, remove the needle

thread from the thread path of thread take-up and remove the bobbin from the hook.

3. There is the possibility that the thread pulled out from the thread stand is loosened due to

the inuence (direction) of the wind and may be entangled in the handwheel. Be careful of the

direction of the wind.

– 7 –

8. Adjusting the height of the knee lifter

WARNING :

Be sure to turn the power OFF before the following work in order to prevent personal injury due to unintentional starting of the sewing machine.

❶

1) The standard height of the presser foot lifted

using the knee lifter is 10 mm.

2) You can adjust the presser foot lift up to 13 mm

using knee lifter adjust screw ❶.

3) When you have adjusted the presser foot lift

to over 10 mm, be sure that the bottom end of needle bar ❷ in its lowest position does not hit presser foot ❸.

❸

9. Installing the thread stand

❷

1) Assemble the thread stand unit, and insert it in

the hole in the machine table.

2) Tighten nut ❶.

❶

– 8 –

10. Lubrication

WARNING :

1. Do not connect the power plug until the lubrication has been completed so as to prevent accidents due to abrupt start of the sewing machine,

2. To prevent the occurrence of an inammation or rash, immediately wash the related portions if oil

adheres to your eyes or other parts of your body.

3. If oil is mistakenly swallowed, diarrhea or vomitting may occur. Put oil in a place where children cannot reach.

Shortage

①

(MIN. line C or lower)

B B

C C

When red line E appears, replenishment of oil is necessary.

Upper limit

③

(On MAX. line B)

B B

C C

When blue line D aligns with MAX. line B, the upper limit is reached.

Red line E disappears once the added oil quantity reaches MIN. line C.

(MAX. line B is exceeded)

If oil is added after the oil quantity exceeds MAX. line B, neither blue line D nor red line E is shown.

❹

❶

❷

❸

Lower limit

②

(On MIN. line C)

Excessive

④

1) Before running the sewing machine, remove

rubber plug ❶ from the top of the machine arm,

and add oil through the oil inlet using accessory funnel ❸ supplied with the sewing machine.

2) Visually check the oil quantity through oil sight

window A on the top surface of the bed.

Oil sight window A has two lines.

• Upper line : MAX. line B

• Lower line : MIN. line C

While visually observing the oil quantity through

oil sight window A, add oil until the blue line D meets MAX. line B (state ③).

* When oil is added until MAX. line B is reached,

the oil quantity becomes 450 cc.

* Check the oil quantity while the sewing machine

is at rest.

3) When you operate the machine after lubrication,

you will see splashing oil through oil sight window ❷ if the lubrication is adequate.

* Note that the amount of the splashing oil is

unrelated to the amount of the lubricating oil.

4) When the remaining oil quantity reaches MIN.

line C or lower, red line E appears to warn the oil shortage (state ①).

If red line E appears on oil sight window A after

nishing sewing machine operation, add oil until

state ③ is restored.

1. When you use a new sewing machine or a sewing machine after an extended period of disuse, use the sewing machine after performing break-in at 2,000 sti/min or less.

2. For the oil lubrication, purchase JUKI CORPORATION GENUINE OIL 1 (Part No. : 40157520) or JUKI MACHINE OIL #7 (Part No. : 40102087 or 40148329).

3. Be sure to lubricate clean oil.

4. Be aware oil leakage can occur if the surface of added oil quantity exceeds MAX. line B.

5. Transporting the sewing machine with

the sewing machine lled with oil can

give rise to the risk of oil leakage. Be sure to discharge oil from the sewing machine through drain cock ❹.

– 9 –

11. Adjusting the amount of oil (oil splashes)

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.

(1) Conrmation of the amount of oil in the hook

Amount of oil (oil splashes) conrmation paper

①

25 mm

70 mm

Oil splashes conrmation paper

Position to conrm the amount of oil (oil splashes)

②

3 - 10 mm

Closely t the paper against the wall

surface of the bed.

* When carrying out the procedure described below in 2), remove the slide plate and take extreme caution

not to allow your ngers to come in contact with the hook.

1) If the machine has not been sufciently warmed up for operation, make the machine run idle for approxi-

mately three minutes. (Moderate intermittent operation)

2) Place the amount of oil (oil spots) conrmation paper under the hook immediately after the machine stops

running.

3) Conrm the height of the oil surface in the oil reservoir is within the range between “HIGH” and “LOW”.

4) Conrmation of the amount of oil should be completed in ve seconds. (Check the period of time with a

watch.)

(2) Adjusting the amount of oil (oil spots) in the hook

1) Tilt the sewing machine. Turn oil amount adjust-

ment screw ❶, which is mounted on the front

bushing of lower shaft, in the "+" direction (direc-

❶

tion A) to increase the oil amount (oil spots), or in the "-" direction (direction B) to decrease it.

* The oil-amount +/- indication mark is shown on

2) After the amount of oil in the hook has been

properly adjusted with the oil amount adjustment screw ❶, make the sewing machine run idle for

approximately 30 seconds to check the amount

of oil in the hook.

the underside cover.

– 10 –

(3) Sample showing the appropriate amount of oil in the hook

Appropriate amount of oil (small)

Splashes of oil from the hook

1 mm

Appropriate amount of oil (large)

Splashes of oil from the hook

2 mm

1) The amount of oil shown in the samples on the

left should be nely adjusted in accordance with

sewing processes. Be careful not to excessively

increase/decrease the amount of oil in the hook.

(If the amount of oil is too small, the hook will be

seized (the hook will be hot). If the amount of oil

is too much, the sewing product may be stained

with oil.)

2) Check the oil amount (oil splashes) three times

(with three sheets of paper).

(4) Conrmation of the amount of oil supplied to the face plate parts

Amount of oil (oil splashes) conrmation paper

①

25 mm

70 mm

Position to conrm the amount of oil

②

(oil splashes)

Oil splashes

conrmation paper

* When carrying out the work described below in

2), remove the face plate and take extreme cau-

tion not to allow your ngers to come in contact

with the thread take-up lever.

1) If the machine has not been sufciently warmed

up for operation, make the machine run idle for

approximately three minutes. (Moderate intermit-

tent operation)

2) Place the amount of oil (oil spots) conrmation

paper under the hook immediately after the ma-

chine stops running.

3) Conrm the height of the oil surface in the oil

reservoir is within the range between “HIGH” and

“LOW”.

4) The time required for the conrmation of the

amount of oil (oil splashes) should be completed

in ten seconds. (Measure the period of time with

a watch.)

(5) Adjusting the amount of oil supplied to the face plate parts

1) Adjust the amount of oil supplied to the thread

take-up and needle bar crank ❷ by turning adjust

Maximum

❶

Minimum

❷

❶

– 11 –

pin ❶.

2) The minimum amount of oil is reached when

marker dot A is brought close to needle bar crank ❷ by turning the adjust pin in direction B.

3) The maximum amount of oil is reached when

marker dot A is brought to the position just

opposite from the needle bar crank by turning the adjust pin in direction C.

(6) Sample showing the appropriate amount of oil supplied to the face plate parts

Appropriate amount of oil (small)

plashes of oil from the thread take-up lever

1 mm

Appropriate amount of oil (large)

plashes of oil from the thread take-up lever

2 mm

1) The state given in the gure shows the appropri-

ate amount of oil (oil splashes). It is necessary to

nely adjust the amount of oil in accordance with

the sewing processes. However, do not exces-

sively increase/decrease the amount of oil in the

hook. (If the amount of oil is too small, the face

plate parts will be hot or seize. If the amount of oil

is too much, the sewing product may be stained

with oil.)

2) Check the oil amount (oil splashes) three times

(with three sheets of paper).

12. Attaching the needle

WARNING :

Be sure to turn the power OFF before the following work in order to prevent personal injury due to unintentional starting of the sewing machine.

Use the specied needle for the machine. Use the

proper needle in accordance with the thickness of

❶

D B

❷

thread used and the kinds of the materials.

1) Turn the handwheel until the needle bar reaches

the highest point of its stroke.

2) Loosen screw ❷, and hold needle ❶ with its indented part A facing exactly to the right in direction B.

3) Insert the needle fully into the hole in the needle

bar in the direction of the arrow until the end of

hole is reached.

4) Securely tighten screw ❷.

5) Check that long groove C of the needle is facing exactly to the left in direction D.

When polyester lament thread is used,

if the indented part of the needle is tilted

toward operator's side, the loop of thread

becomes unstable. As a result, hangnail

of thread or thread breakage may occur.

For the thread that such phenomenon

is likely to occur, it is effective to attach

the needle with its indented part slightly

slanting on the rear side.

– 12 –

13. Setting the bobbin into the bobbin case

14. Adjusting the stitch length

1) Pass the thread through thread slit A, and pull the thread in direction C. By so doing, the thread

will pass under the tension spring and come out from notch B.

2) Check that the bobbin rotates in the direction of

the arrow when thread is pulled.

* The dial calibration is in millimeters (reference

value).

1) Turn stitch length dial ❶ in the direction of the

arrow, and align the desired number to marker dot A on the machine arm.

❶

15. Presser foot pressure

29 to 32 mm

❷

16. Hand lifter

❶

1) Loosen nut ❷. As you turn presser spring regulator ❶ clockwise (in direction A), the presser foot

pressure will be increased.

2) As you turn the presser spring regulator ❶ counter-clockwise (in direction B), the pressure will be

decreased.

3) After adjustment, tighten nut ❷.

The standard value of the pressure regulating thumb

screw is 29 to 32 mm.

1) The presser foot is lifted by moving the lever

upward.

2) The presser foot is lowered by moving the lever

downward.

– 13 –

17. Adjusting the height of the presser bar

WARNING :

Be sure to turn the power OFF before the following work in order to prevent personal injury due to unintentional starting of the sewing machine.

❶

18. Threading the machine head

WARNING :

Be sure to turn the power OFF before the following work in order to prevent personal injury due to unintentional starting of the sewing machine.

1) Loosen setscrew ❶, and adjust the presser bar

height or the angle of the presser foot.

2) After adjustment, securely tighten the setscrew ❶.

– 14 –

+ 36 hidden pages

JUKI DDL-900A Instruction Manual

CONTENTS

I. SPECIFICATIONS

II. SET-UP

1. Installation

2. Installing the pedal sensor

3. Installing the power switch (for CE)

4. Connecting the connector

5. How to install the power plug

6. Attaching the connecting rod

7. Winding the bobbin thread

8. Adjusting the height of the knee lifter

9. Installing the thread stand

10. Lubrication

11. Adjusting the amount of oil (oil splashes)

12. Attaching the needle

13. Setting the bobbin into the bobbin case

14. Adjusting the stitch length

15. Presser foot pressure

16. Hand lifter

17. Adjusting the height of the presser bar

18. Threading the machine head