JUKI DDL-8000A Quick start guide
40218604
No. E440-00
ENGINEER’S MANUAL
DDL-8000A
Direct-drive, High-speed, Automatic Thread Trimmer
PREFACE
This Engineer’s Manual is written for the technical personnel who are responsible for the service and mainte-
nance of the machine.
The Instruction Manual for these machines intended for the maintenance personnel and operators at an
apparel factory contains operating instruction in detail. And this manual describes “Standard Adjustment”,
“Adjustment Procedures”, “Results of Improper Adjustment”, and other important information which are not
covered in the Instruction Manual.
When carrying out the maintenance work on the sewing machine, be sure to refer also to the Instruction
Manual and the Parts List. Further, refer to Engineer’s Manual.
In addition, for the motor for the sewing machine with thread trimmer, refer to the separate Instruction Manual
or This manual gives the “Standard Adjustment” on the former page under which the most basic adjustment
value is described, and on the latter page “Results of Improper Adjustment” under which stitching errors and
troubles arising from mechanical failures and “How to adjust” are described.
i
For the sewing machine, automatic machine and ancillary devices (hereinafter collectively referred to as
"machine"), it is inevitable to conduct sewing work near moving parts of the machine. This means that there
is always a possibility of unintentionally coming in contact with the moving parts. Operators who actually
operate the machine and maintenance personnel who are involved in maintenance and repair of the
machine are strongly recommended to carefully read to fully understand the following Safety precautions
before using/maintaining the machine. The content of the Safety precautions includes items which are not
contained in the specications of your product.
The risk indications are classied into the following to help understand the meaning of the labels described
in this service manual and the product. Be sure to fully understand the following description and strictly
observe the instructions.
(I) Explanation of risk levels
(II)
Explanation of pictorial warning indications and warning labels
Warning label
❶
❷
❸
❶
• There is the possibility that slight to serious injury or death may be caused.
• There is the possibility that injury may be caused by touching moving part.
❷• To perform sewing work with safety guard.
• To perform sewing work with safety cover.
• To perform sewing work with safety protection device.
❸
• Be sure to turn the power OFF before carrying out "machine-head threading,"
"needle changing," "bobbin changing" or "oiling and cleaning".
Electrical-shock
danger label
DANGER :
This indication is given where there is an immediate danger of death or serous injury if the person in charge or any third
party mishandles the machine or does not avoid the dangerous situation when operating or maintaining the machine.
WARNING :
This indication is given where there is a potentiality for death or serious injury if the person in charge or any third party
mishandles the machine or does not avoid the dangerous situation when operating or maintaining the machine.
CAUTION :
This indication is given where there is a danger of medium to minor injury if the person in charge or any third party
mishandles the machine or does not avoid the dangerous situation when operating or maintaining the machine.
Items requiring special attention
Pictorial warning indication
There is a risk of injury if contact-
ing a moving section.
Pictorial warning
indication
Be aware that holding the sewing
machine during operation can
hurt your hands.
There is a risk of electrical shock if
contacting a high-voltage section.
There is a risk of entanglement
in the belt resulting in injury.
There is a risk of a burn if contact-
ing a high-temperature section.
There is a risk of injury if you
touch the button carrier.
Be aware that eye deciency can
be caused by looking directly at
the laser beam.
Indication label
The correct direction is indicat-
ed.
There is a risk of contact between
your head and the sewing ma-
chine.
Connection of a earth cable is
indicated.
TO ENSURE SAFE USE OF YOUR SEWING MACHINE
ii
Basic precaution
1. Be sure to read the engineer's manual and other explanatory documents supplied with accessories of
the machine before using the machine. Carefully keep the engineer's manual at hand for quick reference.
2. The content of this section includes items which are not contained in the specications of your product.
3. Be sure to wear safety goggles to protect against accident caused by needle breakage.
4. Those who use a heart pacer have to use the machine after consultation with a medical specialist.
Safety devices and warning labels
1. Be sure to operate the machine after verifying that safety device(s) is correctly installed in place and
works normally in order to prevent accident caused by lack of the device(s).
2. If any of the safety devices is removed, be sure to replace it and verify that it works normally in order to
prevent accident that can result in personal injury or death.
3. Be sure to keep the warning labels adhered on the machine clearly visible in order to prevent accident
that can result in personal injury or death. If any of the labels has stained or come unstuck, be sure to
change it with a new one.
Application and modication
1.
Never use the machine for any application other than its intended one and in any manner other than that
prescribed in the engineer's manual in order to prevent accident that can result in personal injury or death.
JUKI assumes no responsibility for damages or personal injury or death resulting from the use of the ma-
chine for any application other than the intended one.
2.
Never modify and alter the machine in order to prevent accident that can result in personal injury or death.
JUKI assumes no responsibility for damages or personal injury or death resulting from the machine which
has been modied or altered.
Education and training
1. In order to prevent accident resulting from unfamiliarity with the machine, the machine has to be used
only by the operator who has been trained/educated by the employer with respect to the machine oper-
ation and how to operate the machine with safety to acquire adequate knowledge and operation skill. To
ensure the above, the employer has to establish an education/training plan for the operators and edu-
cate/ train them beforehand.
Items for which the power to the machine has to be turned off
Turning the power off: Turning the power switch off, then removing the power plug from the outlet.
This applies to the following.
1. Be sure to immediately turn the power off if any abnormality or failure is found or in the case of power
failure in order to protect against accident that can result in personal injury or death.
2. To protect against accident resulting from abrupt start of the machine, be sure to carry out the follow-
ing operations after turning the power off. For the machine incorporating a clutch motor, in particular,
be sure to carry out the following operations after turning the power off and verifying that the machine
stops completely.
2-1. For example, threading the parts such as the needle, looper, spreader etc. which have to be thread-
ed, or changing the bobbin.
2-2. For example, changing or adjusting all component parts of the machine.
2-3. For example, when inspecting, repairing or cleaning the machine or leaving the machine.
3. Be sure to remove the power plug by holding the plug section instead of the cord section in order to pre-
vent electrical-shock, earth-leakage or re accident.
4. Be sure to turn the power off whenever the machine is left unattended between works.
5. Be sure to turn the power off in the case of power failure in order to prevent accident resulting of break-
age of electrical components.
PRECAUTIONS TO BE TAKEN IN VARIOUS OPERATION STAGES
Accident means "to cause
personal injury or death or
damage to property."
CAUTION
DANGER
SAFETY PRECAUTIONS
1.
When it is necessary to open the control box containing electrical parts, be sure to turn the power off and
wait for ve minutes or more before opening the cover in order to prevent accident leading to electrical
shock.
iii
Transportation
1. Be sure to lift and move the machine in a safe manner taking the machine weight in consideration. Refer
to the text of the engineer's manual for the mass of the machine.
2. Be sure to take sufcient safety measures to prevent falling or dropping before lifting or moving the
machine in order to protect against accident that can result in personal injury or death.
3. Once the machine has been unpacked, never re-pack it for transportation to protect the machine against
breakage resulting from unexpected accident or dropping.
Unpacking
1. Be sure to unpack the machine in the prescribed order in order to prevent accident that can result in
personal injury or death. In the case the machine is crated, in particular, be sure to carefully check nails.
The nails have to be removed.
2. Be sure to check the machine for the position of its center of gravity and take it out from the package
carefully in order to prevent accident that can result in personal injury or death.
Installation
(I) Table and table stand
1.
Be sure to use JUKI genuine table and table stand in order to prevent accident that can result in personal
injury or death. If it is inevitable to use a table and table stand which are not JUKI genuine ones, select the
table and table stand which are able to support the machine weight and reaction force during operation.
2. If casters are tted to the table stand, be sure to use the casters with a locking mechanism and lock
them to secure the machine during the operation, maintenance, inspection and repair in order to prevent
accident that can result in personal injury or death.
(II) Cable and wiring
1.
Be sure to prevent an extra force from being applied to the cable during the use in order to prevent electri-
cal-shock, earth-leakage or re accident. In addition, if it is necessary to cable near the operating section
such as the V-belt, be sure to provide a space of 30 mm or more between the operating section and the cable.
2. Be sure to avoid starburst connection in order to prevent electrical-shock, earth-leakage or re accident.
3. Be sure to securely connect the connectors in order to prevent electrical-shock, earth-leakage or re
accident. In addition, be sure to remove the connector while holding its connector section.
(III) Grounding
1. Be sure to have an electrical expert install an appropriate power plug in order to prevent accident caused
by earth-leakage or dielectric strength voltage fault. In addition, be sure to connect the power plug to the
grounded outlet without exceptions.
2. Be sure to ground the earth cable in order to prevent accident caused by earth leakage.
(IV) Motor
1. Be sure to use the specied rated motor (JUKI genuine product) in order to prevent accident caused by
burnout.
2. If a commercially available clutch motor is used with the machine, be sure to select one with an entan-
glement preventive pulley cover in order to protect against being entangled by the V-belt.
Before operation
1. Be sure to make sure that the connectors and cables are free from damage, dropout and looseness be-
fore turning the power on in order to prevent accident resulting in personal injury or death.
2. Never put your hand into the moving sections of the machine in order to prevent accident that can result
in personal injury or death.
In addition, check to be sure that the direction of rotation of the pulley agrees with the arrow shown on
pulley.
3. If the table stand with casters is used, be sure to secure the table stand by locking the casters or with
adjusters, if provided, in order to protect against accident caused by abrupt start of the machine.
During operation
1. Be sure not to put your ngers, hair or clothing close to the moving sections such as the handwheel,
hand pulley and motor or place something near those sections while the machine is in operation in order
to prevent accident caused by entanglement that can result in personal injury or death.
2. Be sure not to place your ngers near the surround area of the needle or inside the thread take-up lever
cover when turning the power on or while the machine is in operation in order to prevent accident that
can result in personal injury or death.
3. The machine runs at a high speed. Never bring your hands near the moving sections such as looper,
spreader, needle bar, hook and cloth trimming knife during operation in order to protect your hands
against injury. In addition, be sure to turn the power off and check to be sure that the machine complete-
ly stops before changing the thread.
4. Be careful not to allow your ngers or any other parts of your body to be caught between the machine
and table when removing the machine from or replacing it on the table in order to prevent accident that
can result in personal injury or death.
5.
Be sure to turn the power off and check to be sure that the machine and motor completely stop before re-
moving the belt cover and V-belt in order to prevent accident caused by abrupt start of the machine or motor.
iv
6.
If a servomotor is used with the machine, the motor does not produce noise while the machine is at rest.
Be sure not to forget to turn the power off in order to prevent accident caused by abrupt start of the motor.
7. Never use the machine with the cooling opening of the motor power box shielded in order to prevent re
accident by overheat.
Lubrication
1. Be sure to use JUKI genuine oil and JUKI genuine grease to the parts to be lubricated.
2. If the oil adheres on your eye or body, be sure to immediately wash it off in order to prevent inamma-
tion or irritation.
3. If the oil is swallowed unintentionally, be sure to immediately consult a medical doctor in order to pre-
vent diarrhea or vomiting.
Maintenance
1. In prevention of accident caused by unfamiliarity with the machine, repair and adjustment has to be car-
ried out by a service technician who is thoroughly familiar with the machine within the scope dened in
the engineer's manual. Be sure to use JUKI genuine parts when replacing any of the machine parts. JUKI
assumes no responsibility for any accident caused by improper repair or adjustment or the use of any
part other than JUKI genuine one.
2. In prevention of accident caused by unfamiliarity with the machine or electrical-shock accident, be sure
to ask an electrical technician of your company or JUKI or distributor in your area for repair and mainte-
nance (including wiring) of electrical components.
3. When carrying out repair or maintenance of the machine which uses air-driven parts such as an air cyl-
inder, be sure to remove the air supply pipe to expel air remaining in the machine beforehand, in order to
prevent accident caused by abrupt start of the air-driven parts.
4. Be sure to check that screws and nuts are free from looseness after completion of repair, adjustment
and part replacement.
5. Be sure to periodically clean up the machine during its duration of use. Be sure to turn the power off
and verify that the machine and motor stop completely before cleaning the machine in order to prevent
accident caused by abrupt start of the machine or motor.
6. Be sure to turn the power off and verify that the machine and motor stop completely before carrying out
maintenance, inspection or repair of the machine. (For the machine with a clutch motor, the motor will
keep running for a while by inertia even after turning the power off. So, be careful.)
7. If the machine cannot be normally operated after repair or adjustment, immediately stop operation and
contact JUKI or the distributor in your area for repair in order to prevent accident that can result in per-
sonal injury or death.
8. If the fuse has blown, be sure to turn the power off and eliminate the cause of blowing of the fuse and
replace the blown fuse with a new one in order to prevent accident that can result in personal injury or
death.
9. Be sure to periodically clean up the air vent of the fan and inspect the area around the wiring in order to
prevent re accident of the motor.
Operating environment
1. Be sure to use the machine under the environment which is not affected by strong noise source (electro-
magnetic waves) such as a high-frequency welder in order to prevent accident caused by malfunction of
the machine.
2. Never operate the machine in any place where the voltage uctuates by more than "rated voltage ±10 %"
in order to prevent accident caused by malfunction of the machine.
3. Be sure to verify that the air-driven device such as an air cylinder operates at the specied air pressure
before using it in order to prevent accident caused by malfunction of the machine.
4. To use the machine with safety, be sure to use it under the environment which satises the following
conditions:
Ambient temperature during operation 5°C to 35°C
Relative humidity during operation 35 % to 85 %
5. Dew condensation can occur if bringing the machine suddenly from a cold environment to a warm one.
So, be sure to turn the power on after having waited for a sufcient period of time until there is no sign
of water droplet in order to prevent accident caused by breakage or malfunction of the electrical compo-
nents.
6. Be sure to stop operation when lightning ashes for the sake of safety and remove the power plug in
order to prevent accident caused by breakage or malfunction of the electrical components.
7. Depending on the radio wave signal condition, the machine may generate noise in the TV or radio. If this
occurs, use the TV or radio with kept well away from the machine.
8. In order to ensure the work environment, local laws and regulations in the country where the sewing
machine is installed shall be followed.
In the case the noise control is necessary, an ear protector or other protective gear should be worn ac-
cording to the applicable laws and regulations.
9. Disposal of products and packages and treatment of used lubricating oil should be carried out properly
according to the relevant laws of the country in which the sewing machine is used.
v
Transportation
1. Be sure to lift this machine with four or more workers and use a carriage for moving it in order to pre-
vent personal injury.
2. Be sure to take sufcient safety measures to prevent falling or dropping before lifting or moving the
machine in order to protect against accident that can result in personal injury or death.
3. Installation is described in the Instruction Manual. Be sure to fully understand the description before
putting the machine into operation.
Replacement of parts
1. In prevention of accident caused by unfamiliarity with the machine or electrical-shock accident, be sure
to ask an electrical technician of your company or JUKI or distributor in your area for replacement of
electrical components.
2. When it is necessary to open the control box containing electrical parts, be sure to turn the power off
and wait for ve minutes or more before opening the cover in order to prevent accident caused by un-
familiarity with the machine or electrical-shock accident. In addition, do not carry out replacement work
with wet hands in order to prevent electrical-shock accident.
3. Be sure to replace parts according to the instructions given in this Engineer's Manual and in the Instruc-
tion Manual in order to protect against accident that can result in personal injury.
4. Be sure to carry out replacement work after having installed the machine in a stable state in order to
protect against accident that can result in personal injury.
In addition, be sure to select appropriate tools.
5. Make sure, after the completion of replacement work, that there is no loose soldering, no contact with
other parts, inadequate contact between connectors and receptacles, and loose screws/nuts in order to
protect against accident that can result in personal injury.
6. Make sure, after the completion of replacement work, that neither connectors nor cables are damaged,
slipped off or loosened in order to protect against accident that can result in personal injury.
It should be remembered that some parts have been factory-insulated with tubes or tapes, or oated
above the PWB for safety's sake. In addition, internal wiring has been factory-routed or -clamped in such
a way that it does not come close to high-voltage parts. Be sure to re-place those parts as they are at the
time of delivery.
7. Be sure to use JUKI genuine parts when replacing any of the machine parts.
JUKI assumes no responsibility for any accident caused by any part other than JUKI genuine one.
In addition, in the event you cannot replace parts within the specied range, immediately stop the re-
placement work and ask JUKI or distributor in your area for replacement of the parts.
8. If the fuse has blown, be sure to turn the power off and eliminate the cause of blowing of the fuse and
replace the blown fuse with a new one in order to prevent accident that can result in personal injury or
death.
Adjustment
1. In prevention of accident caused by unfamiliarity with the machine or electrical-shock accident, be sure
to ask an electrical technician of your company or JUKI or distributor in your area for adjustment of
electrical components.
2. When it is necessary to open the control box containing electrical parts, be sure to turn the power off
and wait for ve minutes or more before opening the cover in order to prevent accident caused by un-
familiarity with the machine or electrical-shock accident. In addition, do not carry out adjustment work
with wet hands in order to prevent electrical-shock accident.
3. In prevention of accident that can result in personal injury, adjust adjustment variable resistor or the like
installed on PWB within the specied range given in this Engineer's Manual and in the Instruction Manu-
al.
4. Be sure to carry out replacement work after having installed the machine in a stable state in order to
protect against accident that can result in personal injury.
In addition, be sure to select appropriate tools.
5. In prevention of accident that can result in personal injury, make sure, after the completion of adjust-
ment work, that neither screws nor nuts are loosened or come in contact with other parts.
PRECAUTIONS TO BE TAKEN IN VARIOUS OPERATION STAGES
ELECTRICAL COMPONENTS
CAUTION
vi
6. Make sure, after the completion of replacement work, that neither connectors nor cables are damaged,
slipped off or loosened in order to protect against accident that can result in personal injury.
7. In prevention of accident that can result in personal injury or entanglement accident, be sure to ensure
safety at the time of test run. In addition, be sure to take care not to allow hair or cloths to come in con-
tact with the machine belt.
Disassembly/assembly
1. In prevention of accident that can result in personal injury, be sure to carry out disassembly/assembly
work within the specied range given in this Engineer's Manual and in the Instruction Manual.
2. In prevention of accident caused by unfamiliarity with the machine or electrical-shock accident, be sure
to ask an electrical technician of your company or JUKI or distributor in your area for disassembly/as-
sembly of electrical components.
3. When it is necessary to open the control box containing electrical parts, be sure to turn the power off
and wait for ve minutes or more before opening the cover in order to prevent accident caused by unfa-
miliarity with the machine or electrical-shock accident. In addition, do not carry out disassembly/assem-
bly work with wet hands in order to prevent electrical-shock accident.
4. Be sure to carry out replacement work after having installed the machine in a stable state in order to
protect against accident that can result in personal injury.
In addition, be sure to select appropriate tools.
5. In prevention of accident that can result in personal injury, be sure to tighten screws and nuts in assem-
bly work with a specied torque, if specied, or with an appropriate torque, if not specied.
After the completion of assembly work, be sure to check that screws and nuts are not loosened before
starting test run.
6. In prevention of accident that can result in personal injury, make sure, after the completion of adjust-
ment work, that neither screws nor nuts are loosened or come in contact with other parts.
7. Make sure, after the completion of replacement work, that neither connectors nor cables are damaged,
slipped off or loosened in order to protect against accident that can result in personal injury.
It should be remembered that some parts have been factory-insulated with tubes or tapes, or oated
above the PWB for safety's sake. In addition, internal wiring has been factory-routed or -clamped in such
a way that it does not come close to high-voltage parts. Be sure to re-place those parts as they are at the
time of delivery.
8. In prevention of accident that can result in personal injury, be sure to check whether the direction of
rotation is correct at the time of test run.
9. In prevention of accident that can result in personal injury or entanglement accident, be sure to ensure
safety at the time of test run. In addition, be sure to take care not to allow hair or cloths to come in con-
tact with the machine belt.
vii
PRECAUTIONS TO BE TAKEN SO AS TO USE THE DDL-8000A
SERIES MORE SAFELY
1. Neither open the pulley cover nor touch the parts inside the pulley cover with the power
remained on in order to prevent accidents due to electrical shock.
2.Toavoidpersonalinjury,neverputyourngersundertheneedlewhenyouturnONthe
powerswitchoroperatethesewingmachine.
3.Toavoidpersonalinjury,neverputyourngersintothethreadtake-upcoverwhilethesew-
ingmachineisinoperation.
4. To avoid personal injury, turn OFF the power switch when you tilt the machine head.
5.Toavoidpersonalinjury,becarefulnottoallowyourngersinthemachinewhentiltingthe
machine head.
6.Besuretomountthemachineheadsupportbaronthemachinetablesothatitsheight
from the table surface becomes 55 to 60 mm.
1.Donotoperatethesewingmachinewiththepulleycoverandthengerguardremovedin
ordertoprotectagainstpersonalinjury.
2.Neitherplacengers,hairand/orclothesnorputanythingintheareanearthethreadtake-
upleverwhilethesewingmachineisinoperationinordertoprotectagainstpersonalinjury
duetoentanglement.
3.Keepngersawayfromthethreadtake-upcoverandtheneedlewhenturningthepoweron
inordertoprotectngersandhandsagainstinjury.
4. To avoid personal injury, turn OFF the power switch when you tilt the machine head.
5.Thehookrotatesatahighspeedwhilethemachineisinoperation.Topreventpossible
injurytohands,besuretokeepyourhandsawayfromthevicinityofthehookduringoper-
ation.Inaddition,besuretoturnOFFthepowertothemachinewhenreplacingthebobbin.
6. So as to avoid personal injuries caused by abrupt start of the machine, turn OFF the power
switchandascertainthatthesewingmachinedoesnotrunevenifthestartingpedalisde-
pressedwhenperformingsuchworksasinspectionoradjustmentofthesewingmachine,
cleaning,threading,replacingtheneedle,etc.
7. So as to avoid electrical shock hazards, do not operate the machine with the power supply
earth wire removed.
8.Soastoavoidelectricalshockhazardsandaccidentscausedbydamagedelectricalcom-
ponents,besuretoturnOFFthepowerswitchbeforeinserting/detachingthepowerplug.
9. So as to avoid personal injuries caused by abrupt start of the machine, turn OFF the power
switchwhenleavingthesewingmachinetable.
10. So as to avoid personal injuries caused by abrupt start of the machine, turn OFF the power
switch when the electricity fails.
11.Topreventres,periodicallydrawoutthepowerplugfromtheplugsocketandcleanthe
root of the pins and the space between pins.
12. The motor does not produce noise while the machine is at rest. To avoid possible accidents
due to abrupt start of the machine, be sure to turn OFF the power to the machine.
13.Becarefulofhandlingthisproductsoasnottopourwateroroil,shockbydropping,and
the like since this product is a precision instrument.
14. In a domestic environment this product may cause radio interference, in which case the
user may be required to make corrective actions.
viii
CAUTION :
To avoid malfunction and damage of the machine, conrm the
following.
• Clean the sewing machine thoroughly before using it for the rst time.
• Remove all dust collected on the sewing machine during the transportation.
• Conrm that the voltage and phase are correct.
• Conrm that the power plug is properly connected.
•
Never use the sewing machine in the state where the voltage type is different from the designated one.
• The direction of rotation of the sewing machine is counterclockwise as observed from the hand-
wheel side. Be careful not to rotate it in reverse direction.
SAFETY DEVICES AND WARNING LABELS
CAUTION BEFORE OPERATION
*
The mounting location
and shape of the power
switch differs with the
place of destination.
Pulley cover
This is a cover for
preventing entangle-
ment of hands, hair
and clothes by the
hand pulley.
Power switch
This is a switch for disconnecting the
power unit of the sewing machine from
the power supply.
Selection of the power switch (EU type)
Be sure to use the IEC60204-1-compli-
ant power switch with rated current of
20A or more and short-circuit breaking
capacity of 120 A or more.
Warning label
against pinching
This label warns
thar fingers or other
parts of human body
can be pinched in
the thread take-up
lever.
Thread take-up lever
cover
This is a cover for pre-
venting contact between
the human body and the
thread take-up lever.
Power switch
This is a switch for
disconnecting the power
unit of the sewing ma-
chine from the power
supply. (Sewing machine
for export in general and
for China type)
Warning label
against pinching
This is the caution
label to protect fin
gers, etc. from being
caught between the
bed and table during
maintenance.
Warning label
(Refer
to the
warning
label on
page i.)
The label gives
the minimum
precautions to
be taken when
operating the
sewing machine.
High-voltage
caution label
This label warns
that there is a
high-voltage part
inside cover.
Finger guard
This is a cover for
preventing contact
between fingers
and the needle.
ix
CONTENTS
1. Specications ................................................................................................................. 1
2. Name of each component.............................................................................................. 3
3. Standard adjustment...................................................................................................... 5
(1) Feed dog height and gradient............................................................................................... 5
(2) Adjusting the needle and the hook....................................................................................... 7
(3) Setting of feed timing ............................................................................................................ 9
1) Standaed adjustment.......................................................................................................................9
2) Feed trace and phase adjustment ...............................................................................................11
(4) Adjustment of inner hook presser position....................................................................... 13
(5) Bobbin insertion................................................................................................................... 15
1) Bobbin case with idling prevention spring .................................................................................15
(6) Adjustment of inner hook presser position....................................................................... 17
(7) Lubrication............................................................................................................................ 19
1) Method of lubrication ....................................................................................................................19
2) Method of lubrication to the oil tank ...........................................................................................21
3) Method of oil drainage from the oil tank......................................................................................21
4) Cleaning of the oil lter ................................................................................................................23
5) Adjusting the amount of oil in the hook ......................................................................................25
6) Hook oil adjustment procedures ..................................................................................................25
7) Essentials for hook oil adjustments ............................................................................................25
8) Replacement of the hook shaft oil wick.......................................................................................25
(8) Adjustment of the origin of a presser lifter motor ........................................................... 27
(9) Adjustment of the amount of feeding................................................................................. 31
1) Adjustment of foeward feed stitch length ...................................................................................31
2) Reverse feed stitch length check (manual) .................................................................................31
3) Reverse feed stitch length check (electrically-operated)...........................................................31
4) Adjustment of normal/reverse stitching ......................................................................................33
5) Adjustment of feed 0......................................................................................................................33
6) Adjustment of ffeed dial section...................................................................................................35
7) Installation of the reverse feed arm and the reverse feed solenoid..........................................37
(10) Adjusting the needle thread presser device.................................................................... 39
1) Needle thread presser device .......................................................................................................39
2) Adjusting the remaining length of needle thread .......................................................................41
3) Length of needle thread remaining at the needle .......................................................................41
4) Response to problems occurring at the beginning of sewing ..................................................43
(11) Adjusting the thread trimming unit................................................................................... 45
1) Adjustment of the thread trimming cam position .......................................................................45
2) Adjustment of the thread trimming link stopper screw..............................................................45
3) Thread trimming cam timing.........................................................................................................47
4) Adjusting the knife unit .................................................................................................................51
5) Adjustment of thread trimming speed .........................................................................................51
6) Adjustment of rise of the second thread tension disc ...............................................................53
7) Adjustment of the driver part stopper..........................................................................................55
8) Replacement of the knife unit.......................................................................................................57
9) Installed of thread tspreading plate .............................................................................................59
10) Installed length of the thread trimmer connector bar (asm.) ..................................................61
11) Installation position of the thread trimming shaft ....................................................................61
x
(12) Adjustment of external parts............................................................................................. 63
1) How to remove the control box ....................................................................................................63
2) Clearance of the hand wheel ........................................................................................................65
3) Adjustment of the bobbin winder unit ........................................................................................67
(13) Replacement of the main motor ....................................................................................... 69
(14) Replacement of the timing belt......................................................................................... 69
(15) Lubrication mechanism conguration and adjustments ............................................... 71
1) Conguration .................................................................................................................................71
2) Procedure of ataaching and detaching........................................................................................73
(16) How to remove a panel ...................................................................................................... 75
(17) Adjustment of thrust values of an upper shaft................................................................ 79
4. Operation panel ............................................................................................................ 81
(1) Function of panel key .......................................................................................................... 81
(2) Function setting ................................................................................................................... 83
(3) Head selection (memory switch No. P70) .......................................................................... 84
(4) Adjusting the main shaft stop position(Memory switch No. P72) ................................... 84
(5) Passworf lock (Memory switch No. 14).............................................................................. 85
(6) Monitor function................................................................................................................... 86
(7) List key input functions at power-on ................................................................................. 88
5. Function setting list...................................................................................................... 89
(1) Function setting list ............................................................................................................. 89
(2) Further information aboout memory switch...................................................................... 95
(3) List of error code................................................................................................................ 103
6.Electrical component and the like ............................................................................ 105
(1) Control Box......................................................................................................................... 105
(2) Panel.................................................................................................................................... 106
7. Maintenance................................................................................................................ 107
(1) Oil quantity check .............................................................................................................. 107
(2) Cleaning .............................................................................................................................. 107
(3) Application of appropriate grease.................................................................................... 109
1) Grease-up warning and grease-up error ...................................................................................109
2) Needle bar lower bushing and presser bar bushing ................................................................109
3) Feed bar mechanism .................................................................................................................. 111
4) Face plate mechanism.................................................................................................................113
5) Inside a gear box..........................................................................................................................115
(4) Thread take-up lever mechanism ..................................................................................... 117
(5) Initialize ............................................................................................................................... 119
(6) Memory switch data reset ................................................................................................. 119
8. Optional....................................................................................................................... 120
(1) Option list ........................................................................................................................... 120
(2) Optional part number......................................................................................................... 120
(3) Optional mounting ............................................................................................................. 122
1) Ultrashort remain kit....................................................................................................................122
2) Condensation sewing device......................................................................................................127
9. Dry hook...................................................................................................................... 133
(1) Cautions when a dry hook is used ................................................................................... 133
(2) Replacement of the dry hook............................................................................................ 133
xi
10. Screws for attachment and positions of external parts........................................ 134
11. Troubles and corrective measures ......................................................................... 135
(1) Mechanical components ................................................................................................... 135
(2) Sewing performance.......................................................................................................... 149
12. Block diagram........................................................................................................... 158
13. Drawing of table........................................................................................................ 159
– 1 –
1. Specications
No.
Model DDL-8000AB-MS DDL-8000AB-SH DDL-8000AB-SJ
Item
Semi-dry for standard materi-
als (Short tail)
Minute-quantity lubrication for
heavy-weight materials (Short tail)
Minute-quantity lubrication for
heavy-weight materials (Short tail)
1 Max. sewing speed 5000sti/min
*1
4500sti/min
*2
4500sti/min
*2
2 Max. stitch length Difference of stitch length 5 mm
3 Needle bar stroke 30.7mm 35mm 35mm
4 Take-up lever stroke 110mm 113mm 113mm
5
Thread trimming method
Double-edged rotary type
6
Shorter-thread remaining
function
With *7
7
Lower bobbin winder unit
Built-in the machine head (with bobbin thread holding plate)
8
Needle thread nipper
unit（NB type）
Electromagnetic
9
Needle thread tension
Spring type
10 Presser foot pressure
Spring type
11 Number of patterns Sewing pattern : 99 patterns
(For the polygonal shape sewing, as many as 10 patterns can be registered.)
Cycle sewing pattern : 9 patterns
Custom-pitch pattern 20 patterns
Condensation custom pattern 9 patterns
12
Data com-
munication
USB
With
LAN
Without
13
Lubrication
system
Plate (needle bar) Grease lubrication Oil wick lubrication Oil wick lubrication
Hook Plunger pump type
Gearbox
Grease lubrication+Special surface processing
14
Oil sup-
ply
Plate (needle bar) Grease lubrication +
Special surface processing
Oil wick lubrication Oil wick lubrication
Hook With oil tank (capacity: 160 ml)
15
Oil to be
used
Plate (needle bar)
JUKI Grease A
(Part No.: 40006323)
No.1
or
7
*3
No.1
or
7
*3
Hook
No.1 or 7 *3
Gearbox
JUKI Grease A (product No.: 40006323)
16 Lifting amount of presser
By hand：5.5mm
Auto : 1st step 5.0mm
: 2nd step 8.5mm
17 Needle
DB×1(#11)#9 to 18
1738 (Nm75) Nm65 to 110
DB×1(#21)#20
to
23
1738
（Nm130）Nm125 to 160
DB×1(#21)#20
to
23
1738
（Nm130）Nm125 to 160
DP×5(#11)#9 to 18
134（Nm75）
Nm65 to 110
DP×5(#21)#20
to
23
134（Nm130）
Nm125 to 160
DP×5(#21)#20
to
23
134（Nm130）Nm125 to 160
18
Dimensions
From needle to ma-
chine arm (width)
303mm
From needle to ma-
chine arm (high)
137mm
Bed size 178mm × 517mm
19
Machine head drive Compact AC servomotor：550W that is directly connected to the main shaft（direct-drive system）
20 Machine head weight 40.2kg
21 Power consumption 330VA
22 Working temperature and
humidity
Temperature: 5 °C to 35°C, humidity: 35% to 85% (No dew condensation permissible)
23
Supply voltage and frequency
Rated voltage ±10%, 50/60Hz
24
Noise SMS ;- Equivalent continuous emission sound pressure level (LpA) at the workstation:
A-weighted value of 78.7 dBA ; (Includes KpA = 2.5 dB) ; according to ISO 10821- C.6.2 -ISO 11204
GR2 at 4,000 sti/min.
PSH ;- Equivalent continuous emission sound pressure level (LpA) at the workstation:
A-weighted value of 77.5 dBA ; (Includes KpA = 2.5 dB) ; according to ISO 10821- C.6.2 -ISO 11204
GR2 at 4,000 sti/min.
*1：
Stitch length
0.00 to 4.00：5,000sti/min,
stitch length
4.05 to 5.00：4,000sti/min
*2：
Stitch length
0.00 to 4.00：4,500sti/min,
stitch length
4.05 to 5.00：4,000sti/min
*3：JUKI New Defrix Oil No. 1 or JUKI CORPORATION GENUINE OIL.7 (equivalent to ISO VG7)
*5：Steady operation denotes the noise level produced when the machine is operated for 300 mm at a constant speed in the state
that straight sewing is performed and no other units are actuated.
*6：Attachment device operation denotes the noise level produced while sewing a standard pattern for 300 mm operating
automatic auto-back, thread trimmer, and needle thread clamp.
*7：The presence or absence of the shorter-thread remaining function denotes the presence or absence of the condensation
device.
When the shorter-thread remaining function is present, the condensation device is a standard item.
When the shorter-thread remaining function is absent, on the other hand, the condensation device is not a standard item.
The condensation device can be installed afterward.
– 2 –
No.
Model DDL-8000AS-MS DDL-8000AS-SH DDL-8000AS-SJ
Item
Semi-dry for standard materi-
als
Minute-quantity lubrication for
heavy-weight materials
Minute-quantity lubrication for
heavy-weight materials
1 Max. sewing speed 5000sti/min
*1
4500sti/min
*2
4500sti/min
*2
2 Max. stitch length Difference of stitch length 5 mm
3 Needle bar stroke 30.7mm 35mm 35mm
4 Take-up lever stroke 110mm 113mm 113mm
5
Thread trimming method
Double-edged rotary type
6
Shorter-thread remaining
function
With *7
7
Lower bobbin winder unit
Built-in the machine head (with bobbin thread holding plate)
8
Needle thread nipper
unit（NB type）
Electromagnetic
9
Needle thread tension
Spring type
10 Presser foot pressure
Spring type
11 Number of patterns Sewing pattern : 99 patterns
(For the polygonal shape sewing, as many as 10 patterns can be registered.)
Cycle sewing pattern : 9 patterns
Custom-pitch pattern 20 patterns
Condensation custom pattern 9 patterns
12
Data com-
munication
USB
With
LAN
Without
13
Lubrication
system
Plate (needle bar) Grease lubrication Oil wick lubrication Oil wick lubrication
Hook Plunger pump type
Gearbox
Grease lubrication+Special surface processing
14
Oil sup-
ply
Plate (needle bar) Grease lubrication +
Special surface processing
Oil wick lubrication Oil wick lubrication
Hook With oil tank (capacity: 160 ml)
15
Oil to be
used
Plate (needle bar)
JUKI Grease A
(Part No.: 40006323)
No.1
or
7
*3
No.1
or
7
*3
Hook
No.1 or 7 *3
Gearbox
JUKI Grease A (product No.: 40006323)
16 Lifting amount of presser
By hand：5.5mm
Auto : 1st step 5.0mm
: 2nd step 8.5mm
17 Needle
DB×1(#11)#9 to 18
1738 (Nm75) Nm65 to 110
DB×1(#21)#20
to
23
1738
（Nm130）Nm125 to 160
DB×1(#21)#20
to
23
1738
（Nm130）Nm125 to 160
DP×5(#11)#9 to 18
134（Nm75）
Nm65 to 110
DP×5(#21)#20
to
23
134（Nm130）
Nm125 to 160
DP×5(#21)#20
to
23
134（Nm130）Nm125 to 160
18
Dimensions
From needle to ma-
chine arm (width)
303mm
From needle to ma-
chine arm (high)
137mm
Bed size 178mm × 517mm
19
Machine head drive Compact AC servomotor：550W that is directly connected to the main shaft（direct-drive system）
20 Machine head weight 40.2kg
21 Power consumption 330VA
22 Working temperature and
humidity
Temperature: 5 °C to 35°C, humidity: 35% to 85% (No dew condensation permissible)
23
Supply voltage and frequency
Rated voltage ±10%, 50/60Hz
24
Noise SMS ;- Equivalent continuous emission sound pressure level (LpA) at the workstation:
A-weighted value of 78.7 dBA ; (Includes KpA = 2.5 dB) ; according to ISO 10821- C.6.2 -ISO 11204
GR2 at 4,000 sti/min.
PSH ;- Equivalent continuous emission sound pressure level (LpA) at the workstation:
A-weighted value of 77.5 dBA ; (Includes KpA = 2.5 dB) ; according to ISO 10821- C.6.2 -ISO 11204
GR2 at 4,000 sti/min.
*1：
Stitch length
0.00 to 4.00：5,000sti/min,
stitch length
4.05 to 5.00：4,000sti/min
*2：
Stitch length
0.00 to 4.00：4,500sti/min,
stitch length
4.05 to 5.00：4,000sti/min
*3：JUKI New Defrix Oil No. 1 or JUKI CORPORATION GENUINE OIL.7 (equivalent to ISO VG7)
*5：Steady operation denotes the noise level produced when the machine is operated for 300 mm at a constant speed in the state
that straight sewing is performed and no other units are actuated.
*6：Attachment device operation denotes the noise level produced while sewing a standard pattern for 300 mm operating
automatic auto-back, thread trimmer, and needle thread clamp.
*7：The presence or absence of the shorter-thread remaining function denotes the presence or absence of the condensation
device.
When the shorter-thread remaining function is present, the condensation device is a standard item.
When the shorter-thread remaining function is absent, on the other hand, the condensation device is not a standard item.
The condensation device can be installed afterward.
– 3 –
❶
❸
⓴
❹
❾
❷
⓫
⓬
⓲
⓭
⓱
⓰
⓳
❿
❺
⓮
❼
⓯
❽
❻
2. Name of each component
❶Control box Reverse feed lever
❷Operation Panel Hand wheel
❸Power switch Take-up lever cover
❹Thread stand Finger guard
❺Operation pedal Under cover
❻LED hand light 2nd thread tension
❼One-touch type reverse feed button Power switch (For CE)
❽Needle thread presser device ⓳Pedal sensor
❾Bobbin winder unit ⓴USB terminal
1st thread tension USB terminal
Oil ller port
– 4 –
❶Control box
The box contains the circuit that controls the head unit and motor, the output circuit that operates each
output (the reverse feed solenoid, etc.), the pedal sensor that detects the pedal operation, and the pow-
er circuit that performs each function.
❷Operation panel
It allows you to adjust the automatic reverse feed stitching speed and a head sewing speed and set a
feed pitch and so on.
❸Power switch
This switch turns on and off the power to the head unit motor, electric components, and operation panel.
❹Thread stand
❺Operation pedal
This pedal allows users to conduct machine speed control, thread trimming, presser lifting motion (only
for AK-154), and more by depressing the front or back part of the pedal.
❻LED hand light
This is the LED hand light installed on the bottom of the arm jaw. The light illuminates the area sur-
rounding the needle entry. Its brightness can be adjusted with the hand switch. It should be adjusted to
match the sewing item and/or to your preference.
❼One-touch type reverse feed button
This button allows users to conduct reverse stitching.
❽Needle thread presser device
This device is able to tuck the needle thread on the wrong side of material under control of the signal
from the control box.
❾Bobbin winder unit
This unit is integrated into the head unit.
1st thread tension
Oil ller port
This port is used for lubrication to the hook.
Reverse feed lever
This lever allows users to conduct reverse stitching.
Hand wheel
Take-up lever cover
This cover prevents users from touching the take-up lever.
Finger guard
This guard prevents users (mainly thumb and ngers) from touching the needle.
Under cover
2nd thread tension
Power switch (for CE)
⓳Pedal sensor
⓴USB terminal
It can be used a power supply. (The sewing machine cannot be updated from this USB terminal.)
USB terminal
Insert a USB ash drive on which the software is copied. The sewing machine can be updated from this
USB terminal.
– 5 –
3. Standard adjustment
(1) Feed dog height and gradient
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.
Standard adjustment
Shipped feed dog • 40133950
(MS)
• 11403003
(SH-AA/BB)
• 11062601
(SH-GG)
Engraved marker dot
position on the horizontal
feed bar shaft
ab
A
B
a
b
a
b
A
B
❶
❷
❹
❻
❸
❺
DDL-8000A*-MS : 0.8mm
DDL-8000A*-SH (DDL-8000*-SJ) : 1.2mm
Standard feed dog height (Feed dial graduation 0)
0.8mm : DDL-8000A*-MS
1.2mm : DDL-8000A*-SH (DDL-8000A*-SJ)
Standard feed dog gradient
The engraved marker dot on the feed bar shaft is adjusted by a feed dog of relevant standard.
❼
ab
– 6 –
Adjustment Procedure
Results of Improper Adjustment
1. Set the amount of feeding (feed dial graduation) at 0.
2. Loosen the setscrew of the vertical feed bracket shaft and
the setscrew of the horizontal feed bracket shaft .
3. The feed dog height and gradient are changed when both
shafts of the vertical feed bracket shaft and the horizontal
feed bracket shaft are turned by means of a atblade screw-
driver.
4. After adjustments, firmly tighten the screws that have been
loosened.
(Screw tightening should be done under the condition that the
setscrews and are pushed against the vertical feed brack-
et shaft and the horizontal feed bracket shaft .)
(Caution)1. In regard to the locus of standard feeding, the
throat plate and the feed dog rise almost horizon-
tally when the throat plate rises.
2. The position of the engraved marker dots for the
vertical feed bracket shaft ❶and the horizontal
feed bracket shaft ❸should be adjusted on the
near side (operator side). (Refer to Fig. D.)
３. Assemble the feeder bar ❼perpendicular to the
vertical feed bracket shaft ❶and horizontal feed
bracket shaft ❸without load.
○ If the gradient of the feed dog
is adjusted for either shaft only,
the feed dog height may be
changed. Adjustments are need-
ed for both shafts in all cases.
○ According to the shaft adjusting
position, the position of feed dog
motion may be shifted.
In such a case, loosen the tighten-
ing screw of the horizontal feed
arm to adjust the position of
motion.
○ According to the result of feed
dog height or gradient adjust-
ments, there is possibility of
interference with the thread
trimmer unit.
○ When the feed dog height is
set above the standard level,
the feeding power is improved.
Instead, there can be problems
of presser jumping at high speed
and aws in light materials.
○ If the feed dog height is too
much, a return will be given to
the front side (Section C) of the
feed dog. As a result, the behav-
ior of material feeding may be
affected.
If the height has to be increased
for an unavoidable reason, the
amount of return can be reduced
by adjusting the gradient of the
feed dog to raise its tip.
0.8mm DDL-8000A*-MS
1.2mm DDL-8000A*-SH
(DDL-8000A*-SJ)
❶
❷
❶
❷
Rear sideNear side
Right
Marking point
Wrong
Fig. D
C
– 7 –
(2) Adjusting the needle and the hook
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.
Standard adjustment
❶
❹
❻
C
D
A
B
❷
❸
B
❺
0.04 to 0.1mm
A
Lubricated hook K
Part No. : 23621303
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