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DDL-900B
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Table of contents
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JUKI DDL-900B Instruction Manual

4.6 (20)
DDL-900B
INSTRUCTION MANUAL

CONTENTS

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
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. Setting of thread clamp (NB type only) .........................................................................................29
9. Function setting list ........................................................................................................................ 31
IV. MAINTENANCE ....................................................................................... 49
1. Adjusting the machine head ..........................................................................................................49
2. Error codes ...................................................................................................................................... 50
i

I. SPECIFICATIONS

Supply voltage Single phase 220V/230V/240V
Frequency 50Hz/60Hz
Operating environment
Input 210VA
Temperature : 5 to 35˚C
Humidity 35 - 85 %
DDL-900B-
S : Light- to Medium-weight materials
H : Heavy-weight materials
DDL-900B-S DDL-900B-H
Application
Max. sewing speed 5,000 sti/min 4,000 sti/min
Thread trimming speed 210 sti/min 210 sti/min
Stitch length 4 mm 5 mm
Presser foot lift (by knee lifter) 13 mm 13 mm
Needle
Lubricating oil JUKI CORPORATION GENUINE OIL 7
Noise
*1
Light- to Medium-weight materials Heavy-weight materials
DB × 1 (#14) #9 to 18, 134 (Nm 90) Nm
65 to 110 (for CE)
- 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.
- Equivalent continuous emission
sound pressure level (LpA) at the
workstation :
A-weighted value of 83.0 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 x 1 (#21) #20 to 23
• The sewing speed preset at the time of shipping : 4,000 sti/min
*1 : Needle used depends on the destination.
– 1 –
C
H
G
E
DRAWING OF TABLE
J
D
F
I
A
B
– 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
3xø13 drilled hole
2xø3.5, depth 10
2xø3.5, depth 10
ø40±0.5
ø16 depth 30
ø16 depth 30 (for optional parts)
A
B
C
D
E
F
C1.5 to C2.5 (hinge side only)
G
H
I
J

II. SET-UP

1. Installation

D
1) Carry the sewing machine with two persons as
shown in the gure above.
Do not hold the handwheel D.
C
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 t machine head support stand ❻ in the hole (60 x 141 x ø16, depth 30) (refer to H in
DRAWING OF TABLE p. 2) in the table.
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 cover can break. To prevent such an accident, do not place anything on C section.
3. Be aware that the control box breakage and/or oil leakage can occur if operating the sewing machine with the machine head support rod ❻ removed.
❼
– 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.
1
) 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
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.
• Do not connect the power plug until the connection of cords is completed.
• Fix the cords while taking care not to forcibly bend them or excessively clamp them with staples.
• As for the details of handling respective devices, read carefully the Instruction Manuals supplied with the devices before handling the devices.
❸
❷
❶
❹
Machine head connector
AC power supply
Pedal
Connector connection diagram
Do not insert the power plug into the wall outlet. Check to be sure that the power switch is turned OFF.
1) Connect the connectors listed below to the con-
trol box in the order of ❶ to ❸. ❶ Pedal sensor cable ❷ AC input cable ❸ Machine head connector 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 ❹ to route it to the underside of
the sewing machine table.
Underside of the table
Pedal sensor
❶
❻
Slack
❺
❹
❺
❷
Underside of the table
❺
Pedal sensor
❶
Slack
❺
(For CE)
❹
❺
❷
3) Fix pedal sensor cable ❶ and AC input cable ❷
with a staple ❺.
4) Attach the solenoid cover with two solenoid cover
setscrews ❻ which are supplied with the unit as
accessories.
Take care not to allow the cords to be caught under the cover when attaching the cover.
– 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
❶
❷
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
B
❶
A
❷
❹
C
❻
❼
D
❻
❺
E
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.
❻
❷
❺
❹
A
❸
B
❶
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 ❹ supplied with the sewing machine.
2) Fill the oil tank with the oil until the top end of
oil amount indicating rod ❸ comes between the upper engraved marker line A and the lower engraved marker line B of oil amount indicating window ❷.
If the oil is lled excessively, it will lead from the
junction between the oil shield and bed, or from
the junction between the rubber plug and bed,
or proper lubrication will not be performed. So,
be careful. In addition, when the oil is vigorously
lled, it may overow from the oil hole. So, be
careful.
* When oil is added until MAX. line A is reached,
the oil quantity becomes 600 cc.
* Check the oil quantity while the sewing ma-
chine is at rest.
* Check the quantity of oil in the oil tank by view-
ing the oil surface from the side of oil amount indicating window ❷.
3) When you operate the sewing machine, rell oil if
the top end of oil amount indicating rod ❸ comes down to the lower engraved marker line B of oil amount indicating window ❷.
4) When you operate the machine after lubrication,
you will see splashing oil through oil sight window ❻ if the lubrication is adequate.
* Note that the amount of the splashing oil is
unrelated to the amount of the lubricating oil.
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 7 (Part No. : MML007600CA).
3. Be sure to lubricate clean oil.
4. Be aware oil leakage can occur if the surface of added oil quantity exceeds MAX. line A.
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 ❺.
– 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) Check to be sure that the oil surface in the oil shield rests in the range between the "MAX. line" and the
"MIN. line".
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-
B
A
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) Check to be sure that the oil surface in the oil
shield rests in the range between the "MAX. line"
and the "MIN. line".
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
C
Maximum
❶
Minimum
B
A
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)
S
plashes of oil from the thread take-up lever
1 mm
Appropriate amount of oil (large)
S
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
A
C
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

A
B
C

14. Adjusting the stitch length

A
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

AB
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.
[NB type]
A
(Note) Be sure to pass the thread through the section A.
– 14 –

19. Thread tension

❶
B
❷
A
❸
E
F
(1) Adjusting the needle thread tension
1) The length of thread remaining at the needle tip after thread trimming is shortened by turning ten­sion regulating nut No. 1 ❶ clockwise in direction A.
2) It is lengthened by turning the nut counterclock­wise in direction B.
3) The needle thread tension is increased by turning tension regulating nut No. 2 ❷ clockwise in direc­tion C.
4) It is decreased by turning the nut counterclock­wise in direction D.
C
D

20. Thread take-up spring

❶
❷
A
B
❸
❶
❺
❹
(2) Adjusting the bobbin thread tension
1) The bobbin thread tension is increased by turning tension regulating screw ❸ clockwise in direction E.
2) It is decreased by turning the screw counterclock­wise in direction F.
(1) Changing the stroke of thread take-up
spring ❶
1) Loosen setscrew ❷.
2) As you turn tension post ❸ clockwise (in direc­tion A), the stroke of the thread take-up spring will be increased.
3) As you turn tension post ❸ counterclockwise (in direction B), the stroke will be decreased.
(2) Changing the pressure of thread take-up
spring ❶
1) Loosen setscrew ❷, and remove thread tension asm. ❺.
2) Loosen setscrew ❹.
3) As you turn tension post ❸ clockwise (in direc­tion A), the pressure will be increased.
4) As you turn the tension post ❸ counterclockwise (in direction B), the pressure will be decreased.

21. Adjusting the thread take-up stroke

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.
A
B
❶
C
1) When sewing heavy-weight materials, move thread guide ❶ to the left (in direction A) to increase the length of thread pulled out by the thread take-up.
2) When sewing light-weight materials, move thread guide ❶ to the right (in direction B) to decrease the length of thread pulled out by the thread take­up.
3) Normally, thread guide ❶ is positioned in a way that marker line C is aligned with the center of the screw.
– 15 –
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