JUKI DDL-555-4 User manual

BE5554S0B0A
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MODEL DDL-555-4
High Speed, Single Needle. Lockstitch
Industrial Sewing Machine Equipped with
Automatic Thread Trimmer
Instruction Book
nJ U Kl
TOKYO JUKI INDUSTRIAL CO..LTO
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INSTRUCTION BOOK
JUKI DDL-SSS-4 model is designed to sew white shirt, blouse and similar articles using general
shirtings and many other materials.
Especially, the components of this model such as thread take-up, sewing hook, feed mechanism
and others are designed for high-speed operations, so that the machine is satisfactorily operated at
ahigh speed without vibration or noise.
Carefully read through this Instruction Book and operate your machine in the optimum sewing
condition at all times.
SPECIFICATIONS
DDL-555-4
General materials
DDL-555A-4
Light-weight materials
DDL-555H-4
Heavy-weight materials
Stitch
formation
1-needle, lockstitch
Applications General, light-weight
and
medium-weight materials
General and light
weight materials
Medium and heavy
weight materials
Sewing speed
S,000 s.p.m.
4,000 s.p.m.
3,500 s.p.m.
Thread
take-up
Link-type thread take-up
Sewing hpok Automatic lubricating rotary hook (07.94)
Needle
DBxI,#ll~#I8 DAxl,#9~#Il
DBxl, #20'-#23
Stitch length
0 to 4 mm
(0 to 5/32")
0 to 4 mm
(0 to 5/32")
0 to 4.5 mm
(0 to 11/64")
Stitch length
control
Stitch dial
Lubrication
system
Fully automatic lubrication
Lubricating
oil
NEW DEFRIX OIL No. 1
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CONTENTS
I. INSTALLATION I
1. Attaching the thread stand to the table I
2. Installing the oil reservoir 1
3. Motor pulley and belt 2
4. Installing and adjusting the pedal 3
5. Installing the synchronizer 4
6. Connecting the cords 5
7. Confirming the operating voltage 6
8. Mounting the belt cover and bobbin winder on the table 7
II. HOW TO OPERATE THE MACHINE 8
1.
General instruction 8
2.
Lubrication and amount of oil 9
3. Checking the pedalaction 10
4. How to operate the pedal 11
5. Adjusting the pedalpressureand stroke 12
6. Automatic count-back stitching 13
7. Passing the needlethread 14
8. Bobbin thread 15
9. Adjusting the threadtension 16
10. Attaching the needle 17
11. Presser foot 18
12. Stitchlengthadjustment 19
13.
Reverse stitchingby using the reverse feedcontrol lever 19
HI. ADJUSTMENT 20
1. Feed mechanism 20
2. Replacingthe sewinghook 22
3. Sewinghook position related to the needle 23
4. Heightof the presserbar 24
5. Thread take-upaction 25
6. Returningpressureof the reverse feedcontrol lever 25
7. Adjusting the needle stop position after thread trimming 26
8. Sharpening the counterknife 27
IV. HOWTO ADJUST THE WIPER 28
1. Adjusting the positionof the wiper 28
2. Adjust the position of the wiper magnet 28
V. HOW TO USE AND ADJUST THE SWITCH-BACK BUTTON 29
1. Formingthe switch-back stitches 29
2. Adjustingthe position of the switch-backlever 29
3. Adjustingthe reversestitch length 30
VI. AUTOMATIC PRESSER FOOT LIFTER (AK-2) 30
1. How to operate AK-2 30
2. Adjusting the presserlifter stroke 30
VII. TROUBLES AND CORRECTIVE MEASURE 31
VIII. DIAGRAM SHOWING METHOD OF ASSEMBLING TABLE 35
IX. DIMENSIONAL DIAGRAM OF THE TABLE (TOP SURFACE) 36
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I. INSTALLATION
1. Attaching the thread stand to the table
Assemble the thread stand and set it up on the machine table by using the installation holes in the
table as illustrated.
Do not tighten the clamping nut too much. When power source issupplied by the overhead wires,
pass the power supply cord through the spool rest rod.
2. Installing the oil reservoir
oi Rubber cushion
j-vf-r
reservoir
Operator side
Hinge side
Install the oil reservoir in such a manner that it
is supported by the 4 corners of an opening in
the table.
1. Nail in the 2 felt pads of 4 mm (5/32")
thick to the 2 corners near the operator.
2. Nail in the 2 felt pads of 6 mm (15/64")
thick to the remaining 2 corners (hinged
side).
3. Place the oil reservoir on the felt pads.
4. Insert the rubber cushions into 4 corners by
your finger.
5. Put the round felt pads to 4 rubber cush
ions.
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3. Motor pulley and belt
You must use the M-typc V-belt.
The under mentioned table indicate tlie maximum sewing speeds related to tlie motor pulley and
the length of belts. The elTective diameter of the motor pulley is obtained by deducting 5 mm
(13/64") from the outer diameter.
Ou ler dia
meter of
motor pulley
Motor pulley
Sewing speed
Belt Belt
Part No.
50Hz
60Hz
length
Part No.
125 mm MTS-P01200AO
5,060 s.p.m.
44"
MTJ-VM004400
115
MTS-POl 100 AO 4,630
105 MTS-POIOOOAO
4,250
5,040 s.p.m.
100
MTS-P00950AO
4,000
4,780
43" MTJ-VM004300
95
MTS-P00900A0 3,820
4,540
90 MTS-P00850A0 3,610
4,320
85
MTS-P00800A0
3,390
4,000
80
MTS-P00750A0 3,160
3,790
42"
MTJ-VM004200
75 MTS-P00700A0
2,950
3,520
70
MTS-P00650A0
2,740
3,260
(Note) The center hole on the motor pulley is tapered, and the normal pulleys commercially avail
able in the market can not be used for these machines.
If the belt is too long, the connecting rod may not work smoothly.
(How to install the pulley)
Remove pulley cover 0 and put the pulley
into the motor shaft by aligning the key way
with the key of the shaft. Tighten pulley nut
(D and fix it in position by set screw (3).
To remove the motor pulley, take out the
pulley cover and reverse the above mentioned
procedure for installation.
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4. Installing and adjusting the pedal
Motor regulating lever
1. How to attach the connecting bar
After the motor regulating lever and the pedal
were connected by means of the connecting
bar, adjust the vertical position of the connect
ing bar by sliding the connecting bar positioner.
Connecting
bar posi
tioner
2. How to adjust the pedal angle
You can adjust the pedal angle by changing the
effective length of the connecting bar.
Loosen the clamp screw and change the effec
tive length
of the connecting bar.
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5. Installing the synchronizer
The necessary instruction for installation is indicated on the packing case on both of
"MATSUSHITA" and "HITACHI" motors.
(CAUTIONS)
Support
rod
Nylon clamper
Cord \\\ \\ \
Stater
Magnet
Rotor
Printed circuit board
"MATSUSHITA" motors
Screw the support rod into the threaded hole
located on the right looking from the hand-
wheel side and fix it with a lock nut. Fix the
cord onto the support rod by means of the
nylon clamper so that it does not contact with
the V-belt.
"HITACHI" motors
Be careful not to allow the rotor and the stater
to contact with each other.
The clearance between the printed circuit
board cover and the rotor magnet is 0.S to 1.5
mm. Pass the cord through the inside of the
synchronizer cover and fix it with the cord
clamp so that it does not contact with the V-
belt.
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1/
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6. Connecting the cords
Before starting to connect the cords, make sure that the power source is cutout. Connect each cord
with care not to let it touch the motor pulley, V-belt or any other moving parts.
While you are connecting each plug, make sure that the plug is firmly secured in the receptacle by
trying to pull it lightly.
(1) is the power supply cord.
(2) is the cord for the magnetic clutch brake which is pre-connccted with 4-pole connector (HITA
CHI) or 3-pole connector (MATSUSHITA).
(3) is the cord for controlling the knee lifter (2-pole connector). Only for AK-2.
(4) is the cord to the selector switch for controlling the count-back stitching (with 3-pole con
nector for HITACHI, 6-pole connector for MATSUSHITA).
(5) is the cord to the wiperand the control leverfor switch-backstitching (with 6-pole connector).
Pass the cord through the opposite side of the motor pulley via the hook beneath the table and
plug in.
(6) is the cord for driving the thread trimmer solenoid and the automatic reverse feed solenoid,
(with 4-pole connector).
(7)is the cord to drive the solenoid for the automatic lifter (with 4-pole connector). Only for
AK-2.
(8)is the cord to the synchronizer, (with 12-poIc connector for HITACHI and 8-poleconnector for
MATSUSHITA).
(9) is the pre-connected cord to the controller. (3-pole connector).
(HITACH Motor)
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MATSUSHITA Motor
7. Confirming the operating voltage
(HITACHI)
(MATSUSHITA)
HlOchi.Ud. Totx j.Mi
PANA STORE
TYPE ENAM RATING CONT.
FORM TSAI ROTOR C
LAWP6V20WSER NO.
jnn 0 V A rptnlcoocO
4UUw/P0US0 200 17 2e8C H
• n-i034 60 200 Ij6 34S0 G
imsusTO Eiicwic rcusTittL cajjo
•JUKI
>JUKB
I®®
Clieck your operating voltage with the rated
voltage, Hz., and phase specified by the
machine plate of each motor.
If the motor is operated with a different
voltage, not only the motor itself but also the
control circuits may be broken, please note.
- 6 -
V
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8. Mounting the belt cover and bobin winder on the table
Mount the belt cover and bobbin winder on the machine table according to the drawing and
procedure detailed below :
(Procedure)
1. Make guide holes ® ® , O and for wood screws in the table top.
2. Insert belt coverframestud (T) into the tapped hole in the machinearm.
3. Attach belt coverframe (A) (D to the arm. One of the tappedholesisjointly usedfor attach
ing a cord holder.
4. Attach bobbin winder thread tension post assembly ® to belt cover frame (B) (D and insert
them intb belt cover frame (A) (D.
5. Put bobbin winder (D into belt cover frame (A).
6. Attach belt cover panel (6) to belt cover frame (A).
7. Fix belt cover frame (B) to the table top by screwing2 wood screwsinto guide holes ® and
(8) .Similarly, fix the bobbinwinderby using guideholes (Q and .
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II. HOW TO OPERATE THE MACHINE
1. General instruction
After the machine has been set up, bring down the needle by rotating the handwheel with your
hand, switch on the machine on trial and check that the motor rotates in the correct direction by
watching the rotation of the handwheel. The handwheel must rotate counterclockwise watching
from the open side of the handwheel.
If you fail to judge it, you can repeat to switch on and off the machine until the direction is found,
o Clean up the installed machine.
o Before starting to operate the machine, read through the separate INSTRUCTION BOOK,
o Do not drive the machine before the oil reservoir is filled with the lubricating oil.
o Do not replace the motor pulley with alarger one within first 1 month.
You may operate the machine at a higher speed depending on the necessity of sewing works
and operator's ability after the first 1 montli has passed,
o Keep away from the needle dropping place when you switch the machine on.
o Do not fail to switch off the machine before you tilt the machine head backwards for lubrica
tion or cleaning or removing the V-belt.
(If you mistakenly tread on the pedal, the motor puUeywill be stopped immediately by means
of the built-in safety device in the case of "HITACHI" motor assembly.)
o Whan
you move the machine to other places, do not hold it with the cover located on the rear
of the handwheel.
o Even if you tread on the pedal backwards (heel-down) immediately after the machine is switch
ed on or the thread is trimmed, the needle would not come down or the thread trimmer would
not work. Such thread trimming motion is performed only after the pedal has been trod once
forwards (toc-down).
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Oil sight window
As long as the oil reservoir is properly filled up
with the lubricating oil, you will see the oil
splashing on the internal surface of the oU sight
window while the machine is running. Since the
oil sight window is used only to check if the
lubricating oil is flowing or not, you do not
have to worry about the amount of oil appear
ing in it.
(Notes)
1. As soon as lubricating oil has become dirty, renew the oil.
It can be drained by removing the oil drain cap screw.
2. In order to thoroughly lubricate the machine, provide it with an idle run for about 10 minutes
at asewing speed of 3,000 to 3,500 s.p.m. before using a newly installed machine or a machine
which has not been operated for along period of time.
2. Lubrication and amount of oil
HIGH mark
Oil reservoir
LOW mark
Before driving the machine, fill the oil reservoir
with JUKI New Defrix Oil No. 1 up to "HIGH"
level. Take care not to allow the oil level to
come down below the "LOW" mark during
operation.
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Oil adjusting
pin
Mark
r\
Oil amount
gets less
Crank
Mark
Crank
amount gets more
I I II
Adjustment of oil amount fed to the face
plate components-
When adjusting the amount of lubricating oil
flowing into the face plate components such as
the thread take-up and needle bar crank,
remove the face plate and the arm oil shield and
rotate the oil adjusting pin which is located on
the top end of the main shaft.
To minimize the oil flow, bring the dot mark
on the adjusting pin close to the crank.
To ma.\imize it, bring the dot mark to the far
side of the crank.
(Note)
After this adjustment, let the machine run and confirm the result of adjustment.
Oil regulating valve
Adjustment of oil amount fed to the
sewing hook:
Adjust it by means of the oil adjusting screw
which is located on the hook driving shaft from
bushing. Amount of flowing oil is increased by
turning clockwise and decreased by turning
counterclockwise.
More
3. Checking the pedal action
Firstly, check your machine without passing the threads.
Switch on the machine,and the needle will be held at it's highest position without fail.
Even the needle staying at a lower position will be brought upand held at the highest position
by switching on the machine.
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4. How to operate the pedal
As the following illustration shows, the pedal of this model is operated in 4 stages.
® Place your feet gentlyon the pedalat the stop position.
(The needle is held at the lowest position).
(D Tread on the pedal lightly forwards (toe-down), and the machine starts to rotate at a low
speed.
(D Tread on the pedal further forwards (toe-down), and the machine will increase it's speed
gradually and attain the maximum speed when it has been trod down fully. However, when the
switch for the counter-back stitching is turned on, the machine will attain it's maximum sewing
speed only after the count-back stitch has been formed, even though you tread on the pedal
fully.
High speed
Low speed
Stop (needle down)
Thread trimming
o You can obtain the normal performance of thread trimming by treading on the pedal back
wards (heel-down) directly from the high or low speed position,
o You can tread back the pedal to the neutral position immediately after the machine has started
to perform the thread trimming action.
The thread trimming action is automatically completed and youdo not needto keepthe pedal
at the thread trimming position any longer,
o When the machinestops, the needle will be held at the lower position,
o When you want to bringup the needle, threadon the pedalfully backwards (heel-down) once.
Then, the machine will perform a thread trimmingaction and willbringup the needleand hold
at it's highest position.
(Note)
Insome cases, the machine with "MATSUSHITA" motor,doesnot start to run immediately after a
thread trimming action was made even thoughthe pedal istrod forwards (toe-down). Thisis simply
because the machine is locked by the safety device built in the motor assembly, in sucha case,
tread on the pedal back to the neutral position once and tread on it again forward to drive the
machine.
In the case of the machine with "HITACHI" motor,suchsafety device is automatically released
after thread trimming action has been completed.
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5. Adjusting the pedal pressure and stroke
(MATSUSHITA)
Adjustment grooves
Adjustment
nut of the
backward
pressure
spring.
C?
(MATSUSHITA)
Motor regulating lever
(HITACHI)
I Pedalpressure
^spring
(HITACHI)
Connecting rod
(u
Adjustment of the forward pressure
Adjust the forward pressure by changing the
position of the spring.
"HITACHI" motor:
The pressure is reduced by moving tiie spring to
the left and is increased to the right.
"MATSUSHITA" motor:
The pressure is reduced by moving the spring
to the right and is increased to the left.
Adjustment of the backward pressure
"HITACHI" motor;
The backward pressure can be adjusted by
means of the adjustment nut of the backward
pressure spring. The pressure is increased by
tightening the springand reduced by loosening.
Adjustment of the pedal stroke
The pedal stroke can be adjusted by changing
the connection of the upper connecting rod
with the motor regulating lever.
"HITACHI" motor:
The stroke is reduced by connecting the rod
with the left hand side of the lever and in
creased by the right hand side.
"MATSUSHITA" motor:
The stroke is reduced by connecting the rod
with the right hand .side of the lever and is
increased by the left hand side.
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6. Automatic count-back stitching
You can form the count-back stitches at the start and/or the end of a seam line automatically
without operation of the feed control lever or switch-back lever.
Count-back stitch
at the start.
Count-back stitch
at the end.
BACK TAG SW.
START
0FF|^^l6iA
END(»*') )
OFF^^-SiT
•JUKI
Selector switch for
forming a count-
back stitch at the
start of a seam line.
Selector switch for
forming a count-
back stitch at the
end of a seam line.
J
13
(T) You can preset the machine to form the
count-back stitches at the start and/or the
end of the seam line by means of the se
lector switches.
(D If the number of count-back stitch is not
enough for your sewing purpose, turn off
the selector switch and produce the neces
sary length of reverse stitches manually by
making us of the reverse feed control lever
or the switch-back lever.
(3) When the selector switch for "Start" is
turned on, you can let the machine to
automatically trim off the thread immedi
ately by treading on the pedal backwards
before or after forming the count-back
stitch at the start of a seam line. Even
tiiough you tread on the pedal for thread
trimming while the count-back stitch is
being formed, the thread trimming action
will not be performed prior to the forma
tion of the said count-back stitch.
® When the selector switch for "End" is
turned on, the thread trimming action will
be performed after the count-back stitch has
been formed at the end of a seam line. If
you tread on the pedal for thread trimming
while the machine is forming a count-back
stitch at the end of a .seam line, the machine
will trim off the thread after completing the
said count-back stitch.
(Note)
When the selector switch for the automatic count-back stitching is not used (with a HITACHI
motor): Disconnect the swjtch from the motor control box.
When it is used, insert a connector which is wired as illustrated below intothe position of 3-p plug
( 4 , Fig. paragraph 5)on the motorcontrolbox. (Option. PartNo. D6010555DA0)
A
O
o
o
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7. Passing the needle thread
o ir the machine stops leaving the needle at a lower position, tread on the pedal backwards for
performing an idle thread trimming before passing the needle thread.
Then, the needle will go up and stay at the highest position,
o Pass the needle thread in the order from ® to ® as shown in the illustration.
I
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8. Bobbin thread
Bobbin case
Adjustment screw
Tension
screw
Hook
Thread tension
post bracket
—Thread hole
Thread
passing hole
- 15
Inserting and removing the bobbin case:
1. Bring up the needle to its highest position
by manually rotating the handwheel.
2. Tilt the machine head back and allow it to
rest on the rubber pads attached to the
table.
3. Lift up the bobbin case latch and take out
the bobbin case.
Bobbin will not fall down as long as the
latch is lifted.
4. To insert the bobbin case, fully insert it
into tiic hook shaft so that the nose of the
bobbin case rests in tlic hook groove and
close the latch.
Winding the bobbin:
1. Thread the bobbin winder in the order as
illustrated and wind the thread end several
times round the bobbin.
2. Push down the bobbin trip latch to let the
bobbin winder pulley touch the belt.
3. Adjust the winding adjustment screw so that
the thread is wound round the bobbin for
about 80 per cent of its capacity.
4. When the bobbin is wound unevenly,
correct it by moving the thread tension post
bracket.
Tighten the screw for increasing the thread
length to be wound and loosen for reduce.
5. As soon as the bobbin in filled, the bobbin
winder will automatically stop.
(Note)
In order not to wound the bobbin too tight
with a synthetic thread, adjust the tension
screw so that the thread is lightly drawn from
thr thread tension post socket,
inserting the bobbin into the bobbin case:
1. Take the bobbin in your hand so that
the thread is directed clockwise and place it
into the bobbin case.
2. Take the thread in your fingers and pull up
toward the slot in the bobbin case.
3. Pull the thread, and it will pass through the
thread tension spring.
""Make sure that the bobbin spins in the
bobbin case in the direction indicated with
the arrow when the thread is drawn.
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9. Adjusting the thread tension
Decreased
Decreased
Moving range
V\S—Increased
Thread tension
No. 1
Thread tension
bar
Increased
Thread tension
No. 2
thread take-up
spring
Tension bracket
set screw
Thread tension bar
set screw
Thread
tension
socket
Thread take-up spring
(Note)
When using a thin cotton or synthetic thread,
excessive tension or stroke.
Otherwise, stitch may be skipped at the end of
Needle thread tension:
Needle thread tension is adjusted by the thread
tension nuts No. 1 and No, 2 thread tension is
increased by a clockwise turn and reduced by a
counter-clockwise turn,
o Thread tension No. 1.
The length of needle thread remaining in the
needle after thread trimming becomes short
when the thread tension nut No. 1 is tight
ened, and vice versa. Tighten the tension nut
when a thin thread like synthetic thread is
used and loosen it when a thick thread is
used.
o Thread tension No. 2
Adjust the thread tension nut No. 2 so that
the needle and bobbin threads are inter-
looped in the middle of the material. Do not
excessively reduce the thread tension when
sewing with a synthetic thread, or the
thread may be broken at the start of sewing.
Thread take-up spring
Adjust the thread take-up spring for the follow
ing standard:
Thread Thread No.
Stroke
Tension
Cotton
#40 or less
7 to 10 mm
(9/32" to 25/64") 20 to 35g
Cotton
#50 or more
6 to 9 mm
(15/64" to 23/64") 15 to 30g
Synthetic
6 to 9 mm
(15/64" to 23/64") 7 to 20g
o To change the stroke of the thread take-up
spring, loosen the screw of the thread
tension post socket and turn the thread
tension post in either direction,
o To change the tension of the thread
tate-up
spring, loosen the screw of the thread
tension post socket, remove the thread
tension post and adjust the tension after
loosening the set screw.
Tension is increased by turning the thread
tension post in the clockwise direction, and
vice versa.
take care not to provide the take-up spring with an
sewing and the threads will not be trimmed.
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Howto adjust the thread length remaining in the needleafter thread trimming:
o In order to prevent the needle thread from slipping off and produce neat stitch on the bottom
. face of the materialat the start of sewing, a proper lengthof needlethread must beleft in the
needle eye after thread trimming.
o The thread length is adjusted by the thread tension No. 1.
o It is possible to provide the thread trimmer with different timing of action to trim a synthetic
thread from that of cotton thread. Consult withour distributorsor agentsin your area for this
modification.
Increased
Adjusting screw
Reduced
10. Attaching the needle
Bobbin thread tension:
Bobbin thread tension can be adjusted by
tightening or loosening the tension screw of the
bobbin case. Turn the screw clockwise for
increasing and counterclockwise for reducing
the bobbin thread tension.
Use a proper size of DB,\1 or DAxl needle according to the
material as listed below; thickness and
type of thread and
Needle
Thread
Material
Cotlon
Synthetic
DB X 1
#9 #80
#80
Fine
Georgette, nylon, tetron
broadcloth
11
80-60
80-60
Light-weight Broadcloth, light-weight knits
14
60-50
60-50
General cloth
Cotton gabardine, drill
16
0
1
o
50-30
Medium-weight Coatings
18
30-20
30-20
Heavy-weight
Denim
21
30- 8
Extra-heavy
Cantton, canvas
22.23
8
Extra-heavy
Cantton, canvas
DA xl
8-9
80
80 Fine
Georgette, nylon, tetron
broadcloth
11
60 60
Light-weight
Broadcloth, fine knits
14
50
50
General cloth
Cotton gabardine, drill
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