JUKI DDL-8000AS User manual

DDL-8000AS, AB
INSTRUCTION MANUAL

CONTENTS
1. SPECIFICATIONS............................................................................................................ 1
1-1. Specications of the sewing machine head ..................................................................... 1
1-2. Specications of the control box....................................................................................... 1
2. SET UP............................................................................................................................. 2
2-1. Drawing of table................................................................................................................... 2
2-2. Cautions when setting up the sewing machine................................................................ 3
2-2-1. How to carry the sewing machine ............................................................................................3
2-2-2. Caution when placing the sewing machine............................................................................. 3
2-3. Installation............................................................................................................................ 3
2-4. Installing the pedal sensor ................................................................................................. 4
2-5. Connecting the connector .................................................................................................. 5
2-6. Installing the reactor box [Only for the EU type models] ................................................ 6
2-7. Installing the power switch................................................................................................. 9
2-7-1. 3-phase 200 to 240V, Single phase 100 to 120V...................................................................... 9
2-8. Installing the thread stand................................................................................................ 11
2-9. Attaching the connecting rod........................................................................................... 11
2-10. Adjustment of the pedal.................................................................................................... 12
2-10-1. Installing the connecting rod................................................................................................ 12
2-10-2. Adjusting the pedal angle ..................................................................................................... 12
2-11. Pedal operation.................................................................................................................. 12
2-12. Power switch...................................................................................................................... 13
2-13. Lubrication ......................................................................................................................... 15
3. PREPARATION BEFORE SEWING .............................................................................. 16
3-1. Attaching the needle ......................................................................................................... 16
3-2. Removing/tting the bobbin case.................................................................................... 16
3-3. Winding the bobbin thread ............................................................................................... 17
3-4. Threading the machine head............................................................................................ 18
3-5. Thread tension................................................................................................................... 18
3-5-1. Adjusting the needle thread tension......................................................................................18
3-5-2. Adjusting the bobbin thread tension ..................................................................................... 18
3-6. Presser foot pressure ....................................................................................................... 19
3-7. Adjusting the stitch length ............................................................................................... 19
3-8. Changing the sewing speed ............................................................................................. 20
3-9. LED hand light ................................................................................................................... 21
3-10. Reverse feed stitching ...................................................................................................... 21
3-11. Adjusting the amount of oil (oil splashes) in the hook .................................................. 22
3-11-1. Adjusting the amount of oil in the hook...............................................................................22
3-11-2. How to conrm the amount of oil (oil splashes)................................................................. 23
3-11-3. Sample showing the appropriate amount of oil.................................................................. 23
3-12. Adjusting the thread take-up spring and the thread take-up stroke............................. 24
4. FOR THE OPERATOR................................................................................................... 25
4-1. How to set the machine head and to initialize data (the factory-set state at the time
of shipment)....................................................................................................................... 25
i

4-2. Operation panel ................................................................................................................. 26
4-3. Audio guidance.................................................................................................................. 28
4-4. Setting the clock................................................................................................................ 29
4-5. Operating procedure of the sewing pattern.................................................................... 30
4-5-1. Reverse feed stitching pattern ...............................................................................................30
4-5-2. Overlapped stitching pattern ..................................................................................................31
4-5-3. Polygonal-shape stitching pattern .........................................................................................32
4-6. Function setting................................................................................................................. 34
4-7. Setting the function keys (F1 and F2).............................................................................. 35
4-8. Production support function ............................................................................................ 36
4-8-1. How to set the production support parameters.................................................................... 36
4-8-2. List of production support parameters.................................................................................. 37
4-8-3. How to display the operation rate of the sewing machine................................................... 38
4-8-4. How to display the number of pieces produced ................................................................... 39
4-9. Function setting list .......................................................................................................... 40
4-10. Detailed explanation of selection of functions ............................................................... 45
4-11. How to use the bobbin counter........................................................................................ 51
4-12. Initialization of function setting data ............................................................................... 52
4-13. Password lock ................................................................................................................... 53
4-14. About the USB ................................................................................................................... 54
4-14-1. Insertion position of the USB thumb drive.......................................................................... 54
4-14-2. Upgrading of the program by means of a USB ................................................................... 55
5. ADJUSTMENT OF THE MACHINE HEAD (APPLICATION) ........................................ 56
5-1. Needle-to-hook relationship ............................................................................................. 56
5-2. Adjusting the needle thread presser device ................................................................... 57
5-3. Adjusting the thread trimmer ........................................................................................... 60
5-3-1. For checking of the thread trimming cam timing ................................................................. 60
5-3-2. Adjustment of the thread trimming cam timing .................................................................... 60
5-3-3. Checking of the knife unit .......................................................................................................61
5-3-4. Adjustment of the knife unit....................................................................................................62
5-4. Adjusting the main shaft stop position ........................................................................... 63
5-5. Grease shortage warning ................................................................................................. 64
5-5-1. Grease shortage warning........................................................................................................ 64
5-5-2. Grease shortage error ............................................................................................................. 64
5-5-3. How to reset the grease shortage error................................................................................. 65
5-6. Disposal of batteries ......................................................................................................... 66
6. CARE ............................................................................................................................. 67
6-1. Cleaning the area around the hook ................................................................................. 67
6-2. Cleaning the interior of the frame .................................................................................... 68
6-3. Applying grease................................................................................................................. 69
6-4. Applying grease to the needle bar lower bushing.......................................................... 69
6-5. Optional devices................................................................................................................ 70
7. LIST OF ERROR CODES .............................................................................................. 72
ii

– 1 –
1. SPECIFICATIONS
• The sewing speed will vary depending on the sewing conditions. The sewing speed preset at the time of
shipping is 4,000 sti/min.
*1 : Needle used depends on the destination.
1-1. Specications of the sewing machine head
1-2. Specications of the control box
Supply
voltage
Single phase
220 to 240V
3-phase 200 to 240V
Single phase 100 to 120V
Single phase
220 to 240V CE
Frequency 50Hz/60Hz 50Hz/60Hz 50Hz/60Hz
Operating environment Temperature : 0 to 35˚C
Humidity : 90% or less
Temperature : 0 to 35˚C
Humidity : 90% or less
Temperature : 0 to 35˚C
Humidity : 90% or less
Input 330VA 330VA 170VA
Classication by voltage of electrical box
E
For the Japanese market and export;
3-phase 200-240 V, single-phase 100 - 120 V
KFor export in general and for China;
single-phase 220 -240 V
NCE; single-phase 220 - 240 V
Classication by auto-lifter
AK Provided with an automatic presser foot lifting
device
Space
Not provided with an automatic presser foot
lifting device
Classication by nipper and touch-back mechanism
OB Provided with an one-touch type reverse-feed switch
NB Provided with a thread nipper device and one-touch type
reverse-feed switch
Classication by model
SSimple type
(standard)
B
Better type
(with shorter-thread
remaining feature)
Classication by lubrication
and sewing specication
MS Semi-dry type for medi-
um-weight materials
SH Minute-quantity lubrication type
for heavy-weight materials
SJ Minute-quantity lubrication type
for jeans
DDL-8000A- ○□□◇◇□□▲
DDL-8000A-*MS DDL-8000A-*SH DDL-8000A-*SJ
Max. sewing speed 5,000 sti/min (P = Less than 4)
4,000 sti/min for "P= 4 or more"
4,500 sti/min (P = Less than 4)
4,000 sti/min for "P= 4 or more"
Stitch length 5 mm
Presser foot lift Hand lifter 5.5 mm
Auto lifter 13 mm or more
Audio guidance Provided
Needle *1 1738 Nm65 to 110 (DB × 1 #9 to 18)
134 Nm65 to 110 (DP × 5 #9 to 18)
1738 Nm125 to 160 (DB × 1 #20 to 23)
134 Nm125 to 160 (DP × 5 #20 to 23)
Lubricating oil JUKI NEW DEFRIX OIL No.1 or JUKI CORPORATION GENUINE OIL 7
Motor AC servo motor
Noise
*MS ;
- Equivalent continuous emission sound pressure level (LpA) at the workstation:
A-weighted value of 78.7 dBA ; (Includes KpA = 2.5 dBA) ; according to ISO 10821-
C.6.2 -ISO 11204 GR2 at 4,000 sti/min.
*SH ;
- Equivalent continuous emission sound pressure level (LpA) at the workstation:
A-weighted value of 82.0 dBA ; (Includes KpA = 2.5 dBA) ; according to ISO 10821-
C.6.2 -ISO 11204 GR2 at 4,000 sti/min.
DDL-8000A- ○□□◇◇□□▲

2×Ｒ10
30
30
60
190
240
297
140
115
50
Ｒ20
Ｒ20
（525.4） 520
154.6
（138.5）
68.5
±0.5
（172.5）
18
Q Q
Z
Z
Ｚ
Ｚ
X X
X X
Ｙ
Ｙ
279 ±1
Ｒ18
Y
Y
T T
U U
WW
R242.5
R242.5
S
S
（15）
390
100
22.5 136
(22.5)
181
0
-1
110
(244)
80
80
80
R20
R22.5
R30
R30
R18
R22.5
29
R10
R10
R10
R10
R20
R22.5
29
50
50
90
1200
R22.5
40
70
535
R30
R30
R30
R30
R6
R6
(591)
141 139
43 86.5
21.5
21.5 84
18
75
52
9
14
17 55
27.5
195
52.5
90
R27.5
R27.5
360
810
R8
R8
R8
R8
R8
R8
40°
27
Ｒ2
Ｃ1
C1
R2
R2
40
R2
R2
（6）
W-W
40°
40°
R2
R2
R2
R2
R2
14
10
U-U
17.5
±0.5
X-X(2ヵ所）
Y-Y（２ヵ所）
23.5
±0.5
Z-Z（２ヵ所）
19.5
±0.5
T-T
1
±0.5
X-X部ｺﾞﾑ取付参考図
1.2
±0.5
1.2
±0.5
Y-Y部ｺﾞﾑ取付参考図
21
+0.5
0
20
+0.5
0
S-S
10
±1
∅16
±0.5
∅26
Q-Q
32 ±1
A
BC
E
F
G
H
I
D
– 2 –
2. SET UP
2-1. Drawing of table
(2 locations) (2 locations) (2 locations)
Y-Y
Rubber cushion
installing drawing for
reference
X-X
Rubber cushion
installing drawing for
reference
A4×ø3.4 on the bottom surface, depth 20 (Drill a hole at the time of set-up.) BInstalling position of drawer stopper (on the reverse side) Cø17 drilled hole D3×ø13 drilled hole E2×ø3.5, depth 10 F2×ø3.5, depth 10 G Through hole H2×ø3.4 on the bottom surface, depth 10 (Drill a hole at the time of set-up.) I C1.5 to C2.5 (hinge side only)

×
❻
❹❼
– 3 –
2-2. Cautions when setting up the sewing machine
2-2-1. How to carry the sewing machine
Carry the sewing machine while holding the machine
arm with two persons as shown in the gure.
1. Never hold the handwheel since it
rotates.
2. Be sure to handle the sewing ma-
chine with two persons or more since
the sewing machine weighs 40 kg or
more.
2-2-2. Caution when placing the sewing ma-
chine
Place the sewing machine on a horizontal and plane
place when placing it and do not place any protrud-
ing thing such as a screwdriver or the like.
Do not hold the handwheel.
2-3. Installation
Thank you very much for the purchase of JUKI Industrial Sewing Machine this time. Make sure of items 2-1
through 2-13 before operating to use this sewing machine with ease.
1) The under cover ❹ should rest on the four cor-
ners of the machine table groove. Mount rubber
hinge seat ❺ on the table and x it on the table
with a nail.
2) Fix two rubber seats ❶on side A(operator’s
side) using nails ❷ as illustrated above. Fix two
cushion seats ❸on side B(hinged side) using a
rubber-based adhesive. Then place under cover
❹ on the xed seats.
3) Fit hinge ❼ into the opening in the machine bed,
and t the machine head to table rubber hinge
seat ❺ before placing the machine head on cush-
ions ❻ on the four corners.
❶
❸
❺
❶
❸
23.5 mm 19.5 mm
❶
❹
❸
AB
❷
1.2 ± 0.5 mm
1.2 ± 0.5 mm
1 ± 0.5 mm

❹
❶
❶❹
❹
❸
❷
❹
❺
Pedal sensor
Slack
Underside of the table
Eu-type
120mm-130mm
– 4 –
Be sure to mount the machine head sup-
port rod
❹
on the machine table so that
its height from the table surface becomes
56 to 60 mm.
4) Securely attach head support rod ❹ to the table
until it goes no further.
2-4. Installing the pedal sensor
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 perpendicular
to the table.
2) After the completion of installation of the pedal
sensor on the table, place the sewing machine
head on the table.
3) Secure pedal sensor cable ❶and AC
input cable ❷with staples ❹.
[EU-type models]
Install ring core ❺.
For one ring core ❺, clamp the pedal
sensor cable ❶ after winding the cable
round the torus of the ring core three
times.
The lateral position of the pedal
sensor should be adjusted so
that the connecting rod is posi-
tioned straight. Then, secure the
pedal sensor at that position.

❸
❶
❷
❶
– 5 –
2-5. 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.
1. Do not insert the power plug into the
wall outlet.
2. Check to be sure that the power
switch is turned OFF.
3. Be sure to fully insert the connectors
into the corresponding ports until
they are locked.
1) Draw out pedal sensor cable ❶and AC input
cable ❷ coming from the electrical box to the
undersurface of the sewing machine table through
cable draw-out hole ❸.
2) Connect pedal sensor cable ❶and the connector
under the table.

– 6 –
2-6. Installing the reactor box [Only for the EU type models]
* For the EU-type models, install the reactor box that is supplied with the sewing machine.
1) Detach reactor cover ❷ from reactor box ❶to
separate from reactor base asm. ❸.
* The reactor cover can be detached with ease
by inserting a tool that has a thin at tip such
as a at-blade screwdriver between the cover
and base.
2) Take out screw bag ❹ from cover ❷.
* The screw bag contains two di󰀨erent kinds of
screws (four pieces each).
3) Slide reactor ❺ in the direction of the arrow to
insert into reactor base asm. ❸.
1. When inserting the reactor, detach
bundled wire clamp ❻ beforehand.
2. Insert reactor ❺ into the reactor base
asm. while facing brown and blue
lead wires side upward.
❺
❸
❷
❷
❻
❸
❹
❶
Blue
Brown

– 7 –
4) Connect the connector ❼ of the power cord that is
xed to reactor base asm. ❸ to the connector of
reactor ❺.
Be sure to insert the former fully into
the latter until the connector is locked.
❸
❼
❺
❸
❺
5) Take out wood screws (ST4.2 x 25) from screw
bag ❹. Secure reactor base asm. ❸and reactor
❺ to the undersurface of sewing machine table
with the wood screws (at four locations).
Refer to the instruction gure shown in
the following step of procedure 11) for
the mounting positions of the reactor
cover and reactor base asm.
7) Connect the connector of power cord asm. ❽to
connector of reactor ❺.
8) Secure earth terminal 󱢳 of power cord asm. ❽to
earth base 󱢴 with a screw.
Secure the earth terminal to the screw
with earth mark 󱢶.
❾
❽
❸
❹
󱢳
󱢴
❽
❺
6) Secure power cord asm. ❽ coming from the elec-
trical box to reactor base asm. ❸ with bundled
wire clamp ❾.
󱢶