MODEL DDL-552-2 • 553-2 • 555-2

HIGH SPEED, SINGLE NEEDLE, LOCKSTITCH

INDUSTRIAL SEWING MACHINE
EQUIPPED WITH AN AUTOMATIC UNDERTRIMMER

MODEL DLN-415-2
HIGH SPEED, SINGLE NEEDLE, NEEDLE FEED.
LOCKSTITCH INDUSTRIAL SEWING MACHINE
EQUIPPED WITH AN AUTOMATIC UNDERTRIMMER

MODEL DLU-450-2
HIGH SPEED, SINGLE NEEDLE, TOP AND BOTTOM FEED
INDUSTRIAL SEWING MACHINE
EQUIPPED WITH AN AUTOMATIC UNDERTRIMMER

MODEL DLD-432-2
HIGH SPEED, SINGLE NEEDLE, DIFFERENTIAL FEED
INDUSTRIAL SEWING MACHINE
EQUIPPED WITH AN AUTOMATIC UNDERTRIMMER

Instruction Book

UKI

"Qt
•JUKI

TSK

TOKYO of:
From the library JOKI INDUSTRIAL
Superior CO.,LTO & Supply LLC
Sewing Machine
 CONTENTS

I. GENERAL DESCRIPTION 1
1. Outstanding features I
2. Main specifications 1
II. HOW TO INSTALL THE MACHINE 2
1. Table 2
2. Installing the motor 2
3. Limit of low-speed rotation of the machine 3
4. Length of belt 3
5. Installing the control box 3
6. Installing the machine head 3
7. Installing the pedal and its adjustment 4
8. Construction and operation of motor lever switch 5
9. Function of the cord 6
10. How to handle the control box and cautions 9
11. Adjusting the clutch gap 10
III. HOW TO OPERATE THE MACHINE 11
1. Caution on operation 11
2. Lubrication and adjusting the oiling amount 11
3. Trial run of the machine 11
4. How to operate the pedal 12
5. Threading the machine 13
6. Adjusting the thread tension 13
7. Adjusting the needle stop position after thread trimming 14
8. When low speed sewing is not necessary 15
9. Carefully note the following points 15
10. How to select the presser foot, throat plate, sewing hook and feed dog 15
IV. ADJUSTING THE MACHINE 16
1. Adjusting the timing of the thread trimming cam 16
2. Adjusting the position of the moving knife 17
3. How to install the fixed knife correctly 18
4. The floating range of the second thread tension disc 19
5. How to sharpen the knife blade 20
6. Changing the moving knife 20
7. Adjusting the bobbin thread presser 21
8. Adjusting the slide shaft 22
9. How to install and remove the knife installing base 22
10. Adjusting the installing angle of the synchronizer 23
11. In case of electrical malfunctions 2^
V. DDL-552-2-3 DDL-552-2-4
DDL-553-2-3 DDL-553-2-4
DDL-555-2-3 DDL-555-2-4 25
VI. DDL-555-2-2B DDL-555-2-4B 27
VII. MALFUNCTIONS AND CORRECTIVE MEASURES 28

VIII. CIRCUIT DIAGRAM, TIME CHART 33

IX. DIAGRAM SHOWING METHOD OF ASSEMBLING TABLE 35

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 I. GENERAL DESCRIPTION

1. Outstanding features

1) Simple operation
By a simple operation of one pedal, this machine will perform high speed sewing, low speed
sewing, stopping and thread trimming with utmost ease. Also, as the thread trimmer is electrically
controlled, all worries of operational tolerances are eliminated.

2) Stable efficiency
The thread trimming movement is interlocked with the rotation of the machine and controlled
by electric device to produce constant, stable efficiency.

3) All attachments can be used without alterations

All attachments which are used for conventional lockstitch machines, such as feed dog, presser
foot, needle plate, slide plate, etc. can be used on this machine without any alterations.

4) Dependable safety device

This machine is equipped with a dependable safety device by which the machine cannot be
stepped on for high speed sewing until the thread trimming is completed after the thread trimming
pedal is stepped on.

5) Compact construction
All the thread trimming mechanisms are built-in inside the bed in rational order so that the
sewing area is amply wide and all attachments can be used freely.

2. Main specifications
Sewing speed DLD-432-2 Up to 4,200 s.p.m.(Cotton) Up to 4,000 s.p.m.(Synthetic Fiber)
DLU-450-2 Up to 4,200 s.p.m.(Cotton) Up to 4,000 s.p.m.(Synthetic Fiber)
DLN-415-2 Up to 5,000 s.p.m.(Cotton) Up to 4,000 s.p.m.(Synthetic Fiber)
DDL-555-2 Up to 5,000 s.p.m.(Cotton) Up to 4,000 s.p.m.(Synthetic Fiber)
DDL-552-2 Up to 5,000 s.p.m.(Cotton) Up to 4,000 s.p.m.(Synthetic Fiber)
DDL-553-2 Up to 4,300 s.p.m.
Low-speed rotation of
the machine Cotton thread Maximum 150 s.p.m.
Synthetic thread Maximum 120 s.p.m.
Threads Cotton, synthetic, silk
Sewing hook DB type automatic lubricating hook with bobbin thread guide groove attached
Needles DB x 1 DA x 1
Motor Stop positioner clutch motor, 400W (Hitachi clutch motor with automatic
needle positioner)
AMCO motor
Super stop motor
Electric control box Voltage control DC 46V, DC 5V
Voltage power AC 100, 115, 200, 240, 380, 415V (All ±10%)
IC control system
Safety device Built-in inside the motor lever

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 II. HOW TO INSTALL THE MACHINE

This machine is equipped with different kinds of devices than conventional lockstitching
machines. All operations are controlled by the pedal and by the signals given out from the motor
lever, the control box, with harmonious cooperation with the needle positioning synchronizer, thread
trimming mechanism and the needle positioner clutch motor, the thread is neatly trimmed.
If the adjustment of the pedal is inadequate or if the connections of the cords are wrong, the
machine will not function properly.
After the machine is properly installed, give it a trial run and verify the correct running of the
machine.

1. Table

1) The installing positions of the table legs, motor and control box etc. are clearly illustrated by
the dimensional diagram which is enclosed within this book.
2) Fig.l shows the rear view of the set-up.
* The installed position of the control box is rather far away from the motor but this isfor the
purpose of removing the rear cover of the motor easier.

2. Installing the motor

1) Stop motor (automatic positioner stopping clutch motor) is used on this machine.
2) Install the motor as shown in the dimensional diagram.
3) The installation of the motor is same as any conventional lockstitching machine. (See Fig.2)
4) The motor rotates toward the operator. (As viewed from the pulley side, the rotation is
counter-clockwise)
* Before installing the machine head, be sure to rotate the motor and verify its correct rotational
direction.

I I

a I !

Fig. 1 Fig. 2

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 c50ycle
3. Limit of low-speed rotation of the machine

For trimming the thread, the limit of low-speed rotation should be as follows:
For cotton thread Under 150 s.p.m.
For synthetic thread Under 120 s.p.m.

1) With Hitachi, NATIONAL motor, when the high-speed rotation revolution number is
determined, the low-speed revolution number is also set. Following table shows the relation between
the size of the motor pulley with the high and low speed rotational number of revolution of the
machine:

Outer dia. of motor

125.5mm 116.5mm 105mm 95.5mm 90.5mm 81.0mm 76.0mm
pulley

s.p.m.
High speed rotation 5060 4630 4250 3820 3610 3390

Low speed
s.p.m.
Hitachi
230 210 193 175 160 155
NATIONAL

_9}
High speed 5040 4540 4320 3790 3520
"o
>,
u
' Low speed
o .
vo Hitachi
228 206 193 173 160
NATIONAL

4. Length of the belt

The length of the belt is shown in the table below:

mm
Motor pulley
125.5 116.5 95.5 90.5 81.0 76.0
Outer dia.

For Hitachi
Length of belt 43" 42" 42" 42" 41" 41"
Motors

*Note: Put on the belt before connecting the cord which is coming out from behind the hand
wheel.

5. Installing the control box

Install the control box to the position as shown in the
table dimentional diagram and tighten it with the screw as
shown in Fig. 3.
' *Be sure to insert a rubber cushion, otherwise the
movements of all electrical components will be impaired by
vibration of the running machine.

. "1-
Fig. 3

6. Installing the machine head

The method of installing the machine head, oil reservoir, spool stand and the bobbin winder to
the table is exactly identical with that of any conventional lockstitching machine.

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7. Installing the pedal and its adjustment
In case of motor lever switch type, installation of the pedal and its adjustment is very simple.
1) 1) Installing position of the pedal a • U4-
Fore and aft position of the pedal is adjusted by loosening the screw (T) and left and right
position is adjusted by loosening the screw (Fig.4)

Fig. 4

2) Adjusting the angle of the pedal

This can be adjusted by just changing the length of the connecting bar as in the case of previous
lockstitch machines. j
Loosen the screw (D of the coupling of the connecting bar and adjust by inserting and with
drawing the connecting bar. (Fig.5)

Fig. 5

3) Installing the connecting bar

Loosen the motor lever adjusting screw and adjust so that the motor lever and the connecting
bar comes in straight line. ^
Also, be sure to securely tighten the nut of the connecting ball coupling so that it won t get
loose.

Motor lever
adjusting screw

Motor lever
Fig. 6

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 8. Construction and operation of motor lever switch
(Full details are given in the Instruction Book of Hitachi and National Stop Motor, so it is
lightly treated here)

1) In case of Hitachi mighty stop motor

Thread trimming stroke Motor lever

adjusting screw returning spring

Safety lever Thread trimming

T.sw spring
Safety solenoid L.SW

Step-in force
adjusting screw

speed spring
Main lever / ^ Thread trimming Auxiliarv'lever
Auxiliary lever switch Auxiliary lever force adjusting nut
adjusting screw stopper screw
Basically, this lever switch needs no adjustment. However, as there are 2-3 places which can be
adjusted so adjust them in accordance with the following instructions.
Even if the pedal is stepped-in to the thread trimming position, the needle can not rise
completely up due to the insufficient torque of the motor (when it stops during thread trimming
operation) or when the machine does not stop at the designated position, tighten the step-in force
adjusting screw. Please note that when this screw is tightened, the pedal pressure gets big when this
is stepped-in to the high speed, so tighten lightly as long as there is no abnormalcy in thread trimming
or machine stopping operations.
When the step-in returning amount at thread trimming is to be changed, the machine is so
adjusted for easy step-in returning amount operation. However, when the machine is to be operated
for the first time, sometimes it is easier to operate if the step-in returning amount at thread trimming
time is increased. In such a case, return the thread trimming stroke adjusting screw within the area of
l~3mm(3/64~l/8"). At the sametime, return the thread trimming switchadjusting screw and adjust
so that T.SW will activate at lmm(3/64") before the auxiliary lever hits the thread trimmingstroke
adjusting screw and stops. After the adjustment, tightly tighten the locknut.
Do not adjust the low speed step-in force adjusting screw or auxiliary lever stopper spring.
This lever switch is so assembled that even if the clutch lining of the motor is worn out, it is not
necessary to readjust the position of the auxiliary lever stopper. When the low speed step-in force
adjusting nut is screwed in and the pressure of the low speed sewing pedal is strenthened, the safety
device activates and when the auxiliary lever hits the auxiliary lever stopper and stops, the main
lever also moves to a certain degree with the force of the low speed spring.
Due to this action, there is a danger of the machine to keep on running at high speed and the
possibility of the safety device unable to perform its role. After the machine is used for 1-2 days, the
operator will get used to the machine, so do not try to readjust the step-in force at the time of low
speed sewing.
If the machine can not run at high speed even if the safety device is not working, it is because
the clutch lining is worn out. Exchange the lining with a new lining. If the position of the auxiliary
lever stopper is not changed at the time of the new lining, it means the phenomenon is due to the
abrasion of the clutch lining. It is better not to readjust the auxiliary lever stopper nut.

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 2) In case of National Pana Stop Motor
Qose up of A part
2-3.

>-4 — 5 not
Safety device hook Safety device stopper
When Siifety 0 - 1 «m
\ device sictivates

Microswitch B
Microswitch A

Microswitch A adjusting screw

Safety device slanted Microswitch B adjusting screw
adjusting screw Microswitch B activating plate Reverse step-in force
Safety solenoid height adjusting screw
adjusting screw

When the clearance of the clutch of the motor is to be adjusted or when the clutch friction
plate and brake friction plate is to be exchanged, be sure to readjust the height of the stopper of the
safety device. Loosen the installing screw of the safety device installing mount and adjust by moving
the mount up and down. Make adjustment so that with the foot in released condition from the
pedal, the clearance between the safety device stopper and upper and lower direction of the pawl of
hook becomes 0~lmm(3/64"), the horizontal direction becomes 2~3mm(5/64~l/8") and that@ the
safety device completely enters and (B) when the safety device is in action, machine will not rotate
even if the pedal is stepped in front.
Adjusting the reverse step-in force at thread trimming time
If the thread trimming step-in force adjusting screw is screwed in, this force gets stronger and if
returned, it becomes weaker. After adjustment, tighten the locknut securely. The reverse step-in
amount at the time of thread trimming is meaningless unless the installing position of the thread
trimming switch must also be changed, so do not make adjustment.
Do not adjust the step-in pressure or the step-in amount of the low speed sewing.
This is because unless the adjustment is correctly made, the balance of force of low speed
sewing and step-in force at thread trimming time and the reverse step-in force collapses and the
machine becomes very difficult to operate.
For detailed information on the operation of Hitachi Mighty Stop Motor and the National Pana
Stop Motor, refer to the respective Instruction Book and Engineers Manual for all operational
procedures besides the above instructions.

9. Functions of the cord

The positions of the cords, which are coming out, depend on the kind of motors but the
functions are same.
(l) This is the power source cord.
(D This is the cord of motor for power source.
(D This is the cord of control box for power source.(3-pole plug)
@ This is the cord which transmits signals of low speed sewing or stopping from the control box
to the motor. (9-pole plug)

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 ® This is the cord which transmits the signals of machine stopping position to the control box and
also to activate the thread trimming magnet. The plugging color is white. (12-pole plug)
(D This is the cord which transmits the signal of thread trimming by means of pedal operation or
low speed sewing to the control box and also to activate the safety device of the pedal. The
plugging color is blue and this is plugged in to the control box front motor side. (9-pole plug)
(2) This is the cord for the wiper and for automatic reverse sewing. It transmits the signal from the
reverse sewing switch and activates the wiper (6-pole plug)

1) When HITACHI, NATIONAL motor is used (In case of motor lever switch system)

UUK I

JJ

i-i][U]c:^a

Fig. 7

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 2) Connecting the cords
A. How to connect the cord (D coming out from the sensor
Plug-in the plug of cord (§) into the hole of the table.
As shown in Fig.8, hold the middle of this cord with the cord holder and cord support.
Lastly, plug-in the plug into the control box.
Be sure to press down the cord so that it won't touch the belt or the bobbin thread winder.

B. How to connect the power source cord (3)

\ 1 1 '
AWi
transformer for att
a
2Ry M •!
/ / 1 \ \

Fig. 9

a) In case of Hitachi and National motors (Fig.9)

* The cord 3 coming out from the rear of the motor is the power source cord. Plug-in
this plug to the plug socket on the side of the control box and connect them to
the terminals on the left side of the transformer inside the control box.
* Connect the white and black cords to the terminals of "0" and 200V. (White or black
cord can be connected either to the "0" or 200V terminals. It cloesn t matter)
* With the lOOV stop motor for single phase, connect them to the "0" and lOOV terminals.

C. How to connect the cord (6) from the motor lever

Plug-in the cord, which is coming out from the motor lever, to the side part of the control
box.

D. How to connect the cord ® for controlling the motor

a) In case of Hitachi and National motors
Plug-in the black plug of the cord, which is coming out from the rear of the motor,
into the black plug hole of the control box.

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 10. How to handle the control box and cautions

1) Wiring to the power source voltage and transformer

® Kinds of transformers and methods of connection
The side of the transformer on the power source side is called the primary side and according
to the voltage used, four kinds of transformers, A, B, C and D are available.

A lOOV, 115V AOK AOJJAOOJ AO AMI

B 200V, 220V, 240V TRANSFOHUER FOR ATT
9 OCCkCI usuu c» iini
C 380V, 415V 2RY. S Siv 9v

D 220V, 380V

Be sure to connect the two electrical source leading wires to the "0" V of primary sideand to
the terminals ® which are of same voltage with the power source.
(D Percentage of voltage variance
The limit of voltage variance is ±10%. This control box is so constructed that even if the
voltage is varied to the limit of 10%, it will function normally. When the voltage goes below the
10% limit, the timing of the magnet also changes, causing malfunctioning of the safety device.
However, when the voltage gets too high, the life of diode, condenser, I.C. etc. will be shortened
and sometimes the sensitive parts may be ruined, so be very careful.
2) Be sure to use fuses of 6A, 1A (Small) Amperes.
Even if the size of the glass tube is same, the running current may not be same. So be sure to
use only the fuses marked as above.
In case the diode should break (in this case the current will run to any direction), or the wiring
is wrong or if the circuit should be short-circuited, if the fuse of 6A is used, other electrical parts
will not be damaged. If over-sized fuse is used, the damage will be felt by other parts also and the
repairing will be a tremendous job. -
dL dl
3) Correct connection of the ground wire (green)
There should be a ground terminal on the power source socket (for 3-phase, 4 plugs can be
inserted), so be sure to connect this green ground wire to the 4 cords for the motor, the electrical
equipment box and needle positioning synchronizer, correctly.
4) Do not damage the cords
When the 6-core cord coming out from the needle positioning synchronizer on the side of the
hand wheel is touching the bobbin thread during the bobbin thread winding, the vinyl covering
might be torn and might be short-circuited with the neighboring electric wire. It it touches the belt,
the same contingency might result.
If any other cords are contacting any of the moving parts, there is always the danger of tearing
these parts, so be sure to tie the cords firmly to the table or its legs.
5) When pulling out the plug of the electric equipment box, do not pull the cord strongly. This
plug is so made to be pulled out easily. If you pull the cord too strongly, the copper wire and the
tip of the pin terminal might come off.
6) The spare 6A fuse is attached to the control box with a red vinyl tape. In either case, when
the fuse is blown out, exchange it just once. If it blows up again after replacing, there may be some
trouble somewhere, so inspect the source of the trouble.

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11. Adjusting the clutch gap

When the friction disc or brake friction disc begins to wear off, the motion of the lever gets
bigger until the clutch is in and the stroke of the treadle gets more frequent and the operation
becomes little difficult. When the movement of the tip of the lever becomes 15~20mm, adjust it
as follows:

After loosening the set screw M6xl0 ® which is setting the brake, loosen the lock nut (D
which is setting the 2 bolts M6x30 ®.
Then, turn the the M6x30 ® toward right (1mm per rotation), close in the clearance, and
adjust so that the clearance becomes about 0.5~lmm. Judge this by moving the motor lever and
watch the movement of the main shaft of the motor (2).
During this adjustment, repeat the in and out ofthe clutch by means ofthe motor lever and be
careful to see that the brake friction disc does not lean to one side. After the adjustment, lightly
push the lever toward the brake side and make the bolts M6x30 ® contact the brake. Next, firmly
tighten the set screw M6xl0 ® again and at the same time firmly set the lock nut which is setting
the bolt M6x30 ® .
If the brake friction disk is slanted, it will emanate a peculiar crying sound. If this happens,
insert the power source into the motor, and by repeating the in and out of the clutch, adjust the
bolt M6x30. This sound will disappear,
Also, if the clearance is closed up, the brake must be put on while the main motor is rotating,
inviting scorching of the motor or the fuse might be blown up. Be certain that the clearance is
adjusted to 0.1~lmm always.

0.5 ~ 1mm
0.5 ^ 1mm

set to 0.5 ~ 1mm

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 III. HOW TO OPERATE THE MACHINE

1. Cautions on operation
Turn the switch on once and after turning it off, step on the pedal and observe the rotational
direction of the machine.
* Unpack the machine and after setting it up, clean it well.
* Before operating this machine, please read and digest every paragraph of the INSTRUCTION
BOOK on DDL-552, 553 and 555 or DLN-4I5, DLU-450, DLD-432 thoroughly.
* Do not run the machine without filling up the oil reservoir.
* The machine should rotate toward the operator. (As viewed from the pulley side, the direction is
counter-clockwise). Do not run the machine in the reverse direction.
* For the first month, drop the speed to 4,500 s.p.m. for DDL-552-3 and DDL-555-3 and 4,300
s.p.m. for DLN-415-3 and 3,800 s.p.m. for DDL-553-3, DLU-450-3 and DLD-432-3. After that,
increase the speed depending on the nature of work and the capability of the operator.
* When the power switch is turned on, do not put your hands around and under the needle parts.
* When the power switch is turned on, do not touch the hand wheel.
* When the machine head has to be tilted for oiling or cleaning, be sure to turn the switch off.
* If the needle does not stop at the top position even when the pedal is stepped on toward the rear,
turn the switch off.
* When transporting the machine, do not touch the cover on the rear part of the hand wheel.
* Sometimes when the power switch is turned on and the thread is trimmed but if you step on the
pedal to the rear immediately after these actions, the needle will not come down and trimming
cannot be done. In such a case, just step on the pedal toward front once and the needle will come
down and normal trimming can be resumed.

2. Lubrication and adjusting the oiling amount

Before running the machine, fill up the oil reservoir with the designated JUKI industrial
machine oil to the "HIGH" mark. Please refer to the chapter on "Lubrication and drainage" on the
separate instruction volume.

3. Trial run of the machine

* At first, verify the correct movement of the machine without passing the thread.
1) When the power switch is turned on, the needle always stops at the raised position. In case
the needle does not stop at the raised position, refer to the chapter on "Malfunctions and corrective
mea.sures" and make proper adjustment.
2) Step on the pedal lightly toward front and verify the correct low speed sewing operation.
If the machine does not function even after these re-adjustments, refer to the chapter on "Mal
functions and corrective measures".
3) After the pedal is stepped on front (away from the operator) and the foot is released, be sure
to ascertain that the machine stops with the needle at lower position.

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 4) Step on the pedal toward rear and verify the tlircad trimming operation.
5) Re-adjusting the low-speed switch and verifying the correct working of the safety device.
Step on the pedal toward rear (the thread trimming switch will start) and if you hear the sound
of the magnet working from under the bed, immediately step on the pedal tov/ard front.
If these movements are repeated over and over again, invariably there will be a position where
the pedal will not move toward front any more. At this position, the machine will be stopping but
if the machine should move for low-speed sewing, re-adjust the low-speed sewing switch to stop the
machine at this position.
6) Insert the needle and start sewing.
Note: *"Front" means away from the operator
*"Rear" means toward the operator

4. How to operate the pedal

As shown in Fig. 10, the pedal of this machine functions in 4 stages as follows:
CD The machine is stopping by just resting your foot lightly on the pedal.
(D When the pedal is stepped on lightly to front, it becomes low-speed sewing.
(D When the pedal is stepped on further strongly to front, it becomes high speed sewing.
@ When the pedal is stepped on fully toward rear, the machine will perform thread trimming.
* Normal thread trimming can be performed even if the pedal is stepped on abruptly to the rear
either from high speed or low speed sewing.
* After the machine hasstarted the trimming, the trimming can be done even if the pedal is returned
to the neutral position. It is not necessary to keep on stepping on the pedal to therear until the
needle goes up and stops.

HIGH SPEED

LOW SPEED

High speed
Low speed STOPPED
Stopped position POSITION

" Thread trimming

THREAD
TRIMMING

Fig. 10

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 * When the machine is stopped, the needle always comes down and stops.
* If the lowered needle is to be raised up again, step on the pedal toward rear fully. Needle goes up
and stops after the trimming action.

(Caution)
After completing the trimming (stepping the pedal to rear), if you try to step on the pedal to
front suddenly, sometimes the pedal will not move. This is because the safety deviceinside the pedal
is acting to prevent any undue damage to the machine. In such a case, return the pedal to the rear
once and then step on the pedal toward front once more and the machine will start its normal
running.

5. Threading the machine

*The needle always stops at the raised position. But if it is at the lowered position when thread
ing the machine, step on the pedal toward rear once and do the trimming action once. Then the
needle will go up and stops there.
*Pass the needle thread in the order of (D ~ ©as shown in Fig,27.

6. Adjusting the thread tension (Fig.28)

Adjusting the thread tension of this machine is exactly like a conventional lockstitching
machine. Please follow the procedures as outlined in the INSTRUCTION BOOK on DDL-552, 553
and 555, DLN-4I5, DLU-450 or DLD-432. However, please note that due to the thread trimmer
attached to this machine, the adjustment is little different than other lockstitch machines.

First tension disc

Weak I Strong
(Adjusts thelength ofi
thread remaining at
the needle eye after
trimming >
(D
(4)
Strong
w
Second tension disc
Weak
(adjusts the thread
tention)

Fig. 11 Fig. 12

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 1) Thread take-up.^ring
When fine cotton thread or synthetic threads (tetoron, nylon eic.) arc used, the tension of the
take-up spring may become too strong or the range of movement of the spring may become too wide,
causing skip-stitching just before the machine stops and sometimes the machine does not trim the
thread.
Be extremely careful.
2) Adjusting the first thread tension disc
*When the tension of the first thread tension is made stronger, the thread remaining at the tip of
the needle eye becomes shorter after trimming and when it is made weaker, the remaining thread
becomes longer.
*For fine threads (synthetic fiber), weaken the tension and for thick thread, make it stronger.
3) Adjusting the second thread tension
* Normally, the adjustment of this disc is same as any other lockstitching machines.
* However, please note that when synthetic thread isused, if the tension isadjusted too weak,
the thread might break at the start of sewing.
4) Adjusting the bobbin thread tension.
The adjustment of the bobbin thread tension is practically same asany conventional lockstitch
ing machine. However, if the tension istoo weak, the bobbin might spin idly at the trimming instant,
causing the needle thread to "float" up at the start of sewing, and for synthetic threads, thread
breakage or slipping out of the needle thread at the start of sewing might occur. Be very careful.
* As a rule, this machine is used with a bobbin case in which a magnet is built-in to prevent
idle spinning of the bobbin. (Part number is D 1837555 BAO and sold separately)

7. Adjusting the needle stop position after thread trimming (Fig.13)

After the thread is trimmed, this machine can change the needle stop position. To adjust to
the standard needle stop position, rotate the needle position adjusting knob (I) (on the side of the
control box) to right and left so that, after the thread is trimmed and the needle has stopped, the
red mark on the arm and the white mark on the hand wheel are matched with each other.
If the adjusting knob is rotated toward the "FAST" direction, the needle will stop above the
standard stopping position (in case of A) and if it's rotated toward the "SLOW direction, the needle
will stop below the standard stopping position (in case of B).
* If the thread should slip out even if the length of needle thread is adjusted after the thread
is trimmed, rotate the adjusting knob toward the "SLOW" direction, (toward [B] direction).
* If the needle should hit the wiper, rotate the knob toward the "FAST" direction, (toward
[A] direction).
(Caution)
If the adjusting knob is rotated too much toward the "SLOW" direction (toward B direction),
sometimes the machine does not stop. In such a case rotate the knob toward the "FAST" direction.
IB) [A]

^^"FAST"
"SLOW" Adjusting knob
Adjusting knob

Standard needle
stop position
)iiiii)ii)i i/mmn Fig. 13
Throat plate

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 8. When low speed cewing is not necessary (Fig.14)
* Be sure to cut off the power and make adjustment. When low speed sewing is not necessary
at the start of sewing;
(T) Cut off the power source.
(D open the cover of the control box.
(3) Pull out the inserted ® of the figure from the pin fg) and insert it into the pin (0.
Thus, the low speed sewing function can be eliminated without affecting the thread trimming
function.

Fig. 14

9. Carefully note the following points

* Be certain that the needle thread comes out smoothly from the thread spindle. (Otherwi.se,
the remaining thread at the needle eye after trimming will become short and thread slipping out
might result.)
* When skip-stitching occurs, the bobbin thread may break but the needle thread docs not
break. In such a case, re-adjust the timing of the needle with the sewing hook.

10. How to select the presser foot, throat plate, sewing hook and feed dog
1) Presser foot Select small a and b parts (Fig. 15)
2) Throat plate Select small needle eye and A part.
3) Needle Finer needle for less thread slippage
4) Sewing hook Automatic lubricating hook with a groove
5) Feed dog If a feed dog which is commonly used is adopted, there is no problem,
but if an extremely thick feed dog is used, the backside of the dog teeth might be scratched when
the moving knife moves fully.

1) Presser foot

2) Throat plate
} Na
Fig. 15

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 IV. ADJUSTING THE MACHINE

This machine consists of lockstitching part and the thread trimming part. The lockstitching
function is same as all other previous models, so this text will cover the thread trimming part only.

1. Adjusting the timing of the thread trimming cam

1) How to judge the correct timing of the trimming cam
In order to change the length of the thread remaining at the needle eye after trimming, adjust
the timing of the thread trimming cam. This can be done easily by matching the arm with the
indicated line on the hand wheel, according to the kind of thread used-cotton or synthetic thread.
Tilt the machine, turn the hand wheel with your hand until the thread take-up comes just
before the upper dead point and if the sewing hook presser (Fig. 16 (D) is pushed deeply to right, the
cam roller (Fig. 17) will enter the cam groove of the cam (Fig. 17) and will be interlocked there. In
that condition, rotate the hand wheel in the reverse direction than the conventional way, and the
hand wheel will come to a point where it will not rotate any more. At this point if cam timing is
matched so that the indicated line of the arm (Fig. 18 (D) and the indicated line of the hand wheel
(Fig. 18 (D) are matched together as shown in Fig. 18, it becomes a cotton thread timing. But if the
indicating line (Fig.l8 (D) is matched with the indicating line (Fig.l8 (D), it becomes a timing for
synthetic thread.

Rotational direction

Thread trimming
cam
Mil

Cam roller Thrust collar

Set screw No.2

Cam roller shaft

Rotate cam in this
arm set screw
direction with hand
DLD-4322

Fig. 17
Fig. 16

2) How to match the timing of the thread trimming cam

First, loosen the 2 set screws of the trimming cam (Fig. 17) in order from set screw No.l and
No.2, and match the indicating line of the arm with the indicating line of the hand wheel. (For
cotton thread, match red color (i) with the red color (D and for synthetic thread, red color (I) with
the green color (D), (Fig. 18)
Then, by pushing the sewing hook presser (Fig. 16 (D) to right, interlock the cam and the cam
roller, and without rotating the hook shaft, rotate the cam only toward the reverse direction than the
normal hook shaft rotational direction with your finger tips. At the position where the cam does
not rotate any more, push the cam against the thread trimming cam thrust collar (Fig. 17) and
finally tighten the cam set screws (Fig. 17) in the order of No.2 and No.l.

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 2. Adjusting the position of the moving knife
1) The correct position of the moving knife when it has moved to its maximum range is, as
shown in Fig.l9, when the tip of the moving knife hasretreated to 2~2.5mm(l/6"~3/32") from the
center of the needle. When the retreated range is less than this position, it cannot scoop up the
needle or bobbin thread at the trimming instant, while if it's too much, the feed dog and the moving
knife might hit each other. Therefore, it is very important to match the position of the moving
knife correctly.

Green

2 ~2.5mm

Needle Moving knife

Fig. 19

Fig. 18

2) How to match the position of the moving knife

This is adjusted by changing the right or left position of the moving knife shaft (Fig.20 ®)
when the machine stops. By this adjustment, the interlocking of the cam and the cam roller also
changes, so match the position of the thread trimming cam toward the shaft direction, also.
a. First, loosen the magnet set screw (Fig.20 (D and pull out the magnet link pin (Fig.20 (D).
b. Move the magnet link (Fig.20 (£)) downwards and adjust the .screwed-in amount of the knife
moving shaft adjusting nut (Fig.20 (D). If this nut is screwed in deep, the retreating range of
th the knife becomes greater and if it's loosened, the range gets less.
c. Loosen both set screws of trimming cam (7) and the thrust collar (6).
d. Match the indicating line of the hand wheel with the indicating line of the arm.
(In case of cotton thread, match (D with (2) of Fig.18 and for synthetic thread, match (D with (3))
e. Rotate the set screw No.2 (Fig.20 ®) (indicated point) of the trimming cam so that it comes to
front and when it comes to front, push the sewing hook presser to right.
f. Move the cam to right and left and interlock the cam and the cam roller.
g. With this condition, as you pull the cam to right, move it toward teh arrow direction until the
cam cannot rotate anymore.
h. Temporarily tighten the set screw No.2 (D of the cam.
i. Tighten the lock nut. (Fig.20 (D)
j. At this point, verify the following:
(D Is the indicating line of the pulley matched?
(2) Is the roller inserted smoothly into the cam groove?
(D Is the retreated range of the moving knife 2~2.5mm?
k. Tighten the two set screws of the cam securely.
1. Push the thrust collar against the cam and tighten the two set screws,
m. Attach the magnet link pin in its original position.

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 The simple method to judge the correct position of the moving knife would be to verify if the
step part of the bed and the forked base of the knife are paralled to each other. If they are
parallel, the position is correct.
(Note)
1) No matter how slight the right or left position adjustment may be, it has a big bearing on
the retreating range of the moving knife.
2) Verify if the moving knife disposes the thread properly as shown in Fig.21.

s
0

wism 0

®(2)(3)®(4 Fig. 20

Fig. 21

3. How to Install the fixed knife correctly

The correct method of installing the fixed knife is shown in Fig.22. The standard distance from
the center of the needle to the tip of the fixed knife is 4.2mm(5/32"). The tip of the fixed knife
should be 0.6mm above the installing surface. (Fig.23).
When the angle of the installing fixed knife's tip is changed, the cutting power changes. When
the cutting part of the fixed knife and the moving knife is precisely matched, then and only then
the cutting power becomes most powerful. When the fixed knife is to be adjusted or when it is to
be changed, be sure to verify the sharpness of the blade and at the same time, adjust the angle of
installation (Fig.22A).

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 Lower part
of throat plate
Moving knife

(Note): DLN-415-2
Set the feed adjusting dial to "0".
Needle
a i.5bb

Graded part
of bed
Fixed knife

0.6mm

Shorter Longer
Length of remaining thread
after trimming
Fig. 22 Fig. 23

The fixed knife can be installed by moving it to the right of the standard installation position.
In that case, the length of the remaining thread of needle thread and the bobbin thread not
only gets longer by the distance the fixed knife has moved, but because the timing of the
trimming also is delayed which makes the length of the thread at the tip of the needle eye
much longer (Fig.25)
In the case of synthetic thread, move the fixed knife to right to delay the timing of the thread
trimming. However, to make the adjustment complete, it is also necessary to adjust the timing
of the thread trimmer. (Chapt. IV-1).

4. The floating range of the second thread tension disc

1) How to verify the floating range

At the position where the take-up has come just before the upper dead point, lower the presser
foot and when the hook thread presser (Fig. 16 (D) is pushed hard to right, verify that the floating
range of the second thread tension disc is 0.5~lmm.
2) Adjusting the floating range of the second thread tension disc (Fig.26)
(DTo increase the floating range, loosen nut (B) and tighten nut ©.
©To decrease the floating range, loosen nut (g) and tighten nut ©.
After the adjustment is completed, tighten both ® and (B> nuts.

Wlien fixed knife

is moved to right
Bring to Standard
center

Moving knife Moving knife

Fixed knife

Bobbin thread
® (D ® d) ©
l(M Sewing
presser

Fig. 24 Fig. 25 Fig. 26

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5. How to sharpen the knife blade
The shape of the blade tip of the fixed knife greatly affects the cutting power of the knife. In
most cases, just sharpen the blade of the fixed knife and the cutting becomes sharper.
1) It is very important that the blade surface of the moving knife should contact the blade of
fixed knife.
© Just sharpen the "A" surface (Fig.27) and cutting becomes better. (Note the angle shown by
X in Fig.27)
® The cutting power becomes weak when the B surface tip is sagging and blunted. So, do not
change the angle of x when sharpening.
® When cutting power is not so good even though the blade tips are sharpened, it is because the
blade surface of the moving knife and the fixed knife is not contacting to right and left at the
same time. Correct the inclination angle of the fixed knife.
♦ To improve the contacting of the moving and fixed knife, change the angle of the arrow
mark of Fig.29. When the D side of Fig.28 does not cut well, shorten the angle and when the C side
does not cut well, make the angle larger.

Moving knife Fixed knife

Shave off corners
and sharpen well
Sharpen this surface
A surface

Blade tip
B surface

Fixed knife

C& D parts of moving knife and fixed knife

should contact each other at the same time

Fig. 27 Fig. 28

Changing the moving knife

To change the moving knife, do as follows:
1) Loosen the knife forked base pin set screw (Fig.32 ®) and pull out the knife forked base
pin (Fig.32 (D). . . • /-n
2) Remove the moving knife hinge screw (Fig.30 ®), move the knife forked base (Fig.30 (D)
and the moving knife (Fig.30 (D) to the position shown in Fig.31 Aand remove the pin ol
the moving knife from the knife forked base.
3) Move the knife forked base to the position shown in Fig.31B and remove the knife hinged
screw (Fig.3IB). For this purpose, use the special spanner in the accessories box.

Fig. 29

Fig. 30
Fixed knife

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 For installing back, reverse the above procedure. After the knife hinged screw is tightened,
move the moving knife with your hand and see if it moves smoothly without any rattling. Match the
knife forked base to the position shown in Fig.31C and firmly insert the knife forked base pin into
the forked base. (If the knife moving shaft is moved to right or left, the pin will go in deep into
the base). When the shaft is moved to right, be sure to see that the knife moves to right, also.

N (
Knife forked Knife forked
base Knife forked base
base

Knife hinged
screw

Moving knife
Moving knife
Moving knife

Fig. 31A
/
Fig. 31B Fig. 31C

7. Adjusting the bobbin thread presser

If the bobbin thread presser (Fig.32 (3)) is penetrating too deep toward the bobbin case at the
trimming time, the bobbin will not rotate and the bobbin thread will be trimmed too short, causing
thread slippage at the start of sewing.
On the contrary, if it is not inserted deep enough, the needle thread will slip out from the tip
of the bobbin thread presser at the trimming time, shortening the thread remaining amount at the
tip of the needle eye after the trimming and invites thread slipping out.
1) The correct position of the bobbin thread presser
When the thread trimming lever is pressed hard against the stopper side, the bobbin thread
should be pulled out easily. At this position, the clearance between the tip (Bobbin presser) of the
bobbin thread presser and the upper carved part of the bobbin should be 1.5~2mm as shown in Fig.47.

1.5 ~2mm

DLD-432'2 V

Fig. 32 Fig. 33

2) How to adjust the bobbin thread presser

Loosen the screws (Fig.32 ®), and adjust by moving the bobbin thread presser in and out or up
ond down. At this instant, adjust the fore and aft position of the bobbin thread presser and adjusting
the position of the thread trimming stopper arm (Fig.26 (D). As shown in figure.
After adjusting, tighten the set screw of the stopper. Be sure to verify that the tip of the roller
shaft is not contacting the bottom of the cam groove when the stopper is deeply inserted. If it's
contacting, refer to the chapter on "Adjusting the slide shaft" and re-adjust the positionof the slide
shaft collar.

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8. Adjusting the slide shaft
The moving range of the slide shaft (Fig.34 ®) is 5.4mm(7/32"). This is adjusted by moving
the slide collar (Fig.34 (D) toward the shaft direction. Also, the position of the cam roller shaft arm
(Fig.34 (D) should be 13.5mm(33/64") as shown in Fig.34.
* The adjusting procedure is as follows:
(D Determine the position of the thread trimming arm stopper depending upon the position of
the hook thread presser.
(D Adjust the position of the slide collar so that the moving range of the slide shaft comes to
5.5mm(7/32").
(D Adjust the position of the thread trimmer magnet (DC solenoid).
When the thread trimming arm has moved to the position were it is almost touching the stopper,
adjust the position of the thread trimming magnet so that the snap ring which is attached to the
thread trimming magnet plunger hits the rubber ring and stops and also when the magnet is pulling,
there should be no clearance between the two ends of the rubber ring.

20mm
E

13.5mm

Fig. 34
Fig. 35

9. How to install and remove the knife installing base

To remove the knife installing base (Fig.35 ®), do as follows in order:
®Take out the sewing hook.
(D Loosen the knife forked base (Fig.35 (D), and pull out the knife forked base pin (Fig.35 (D).
(D After removing the hook thread presser link hinged screw (Fig.35 (D), and if the hook presser
hinged screw (Fig.35 ®) knife installing base set screw (Fig.35 (D) is pulled out, the knife installing
base will come off. To install back, reverse this order.

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 10. Adjusting the position of the synchronizer (Fig.36)
This synchronizer has adopted semi-leading element, non-contacting type called hole IC, so it
is impossible to verify the position of the synchronizer by the tester by pulling out the 12P plug.
Therefore, the position of the synchronizer should be adjusted in the following order:
® Remove the belt.
(D Remove the cover ® of the synchronizer and loosen the screw ®.
(DTurn the power source switch to "ON".
® Match the black indicating lineof the pulley with the red indicating lineof the machine head.
(D If the synchronizer is moved gently by the hand without moving the pulley, the auxiliary
motor will either rotate or stop. So, at the position where the auxiliary motor has started to stop,
tighten the screw ®.
(D Replace the cover of the synchronizer to the original position.

(Note) When the above adjustments are made, do not loosen the screw (© (+ screw), absolutely. If
this part is either loosened or released, sometimes the synchronizer does not function. So,
use extreme caution.

0 0

Fig. 36

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 11. In case of electrical malfunctions, be sure to investigate the following
discrepancies: (Refer to malfunctions and corrective
measures for complete details)

No. Malfunctions Causes Corrective measures

1 Does not run at low 1. Defective L.SW switch. * Exchange the L.SW switch.
speed * Plug-in correctly.
2. Motor cord is pulled out (does not
stop at upper stop position).
3. Inadequate plug-in of bi-directional- * Plug-in correctly.
triode thyristor printed board.
4. Wire of auxiliary motor is dis * Connector inside the motor (end cover)
connected. is disconnected.

5. Inadequate returning of MB clutch * Repair the clutch part with oil stone.
part..

6. Low speed function changing pin is * Replug-in the pin to the "on" side.
connected to the low speed (ofO side.
(Inside the control box).

2 Main motor is 1. No clearance at clutch part. * Adjust the clearance of clutch part.
over-heated
2. One phase of 3 phases is disconnected * Inspect the plug-in condition of the
(single phase running). power source cord.
(Verify the fuse of the power source of
the plant)

3 Auxiliary motor is 1. Inadequate returning of the MB part. * Repair the clutch part with oil stone.
over-heated
2. Inadequate lead relay (contact point) * Exchange the lead relay.
3. One phase of 3 phases is disconnected. * Connector inside the motor (end cover)
is disconnected.

4 Enters into low 1. Inadequate position of L.SW switch. * Adjust the position of L.SW switch.
speed running with * Exchange the L.SW switch.
2. Defective L.SW switch.
the power source
"ON". 3. 12P connector of head is pulled out * Re-plug-in the connector.
4. Inadequate adjustment of the adjust * Rotate the knob toward the "FAST"
ing knob of stopping position. direction.

5. Pedal cord is pulled out (make it to * Re-plug-in the connector.

upper stopping position).

5 Machine does not 1. Defective L.SW switch. * Exchange the L.SW switch.
stop (keeps on * Re-adjust the clearance.
2. Too much clearance of magnet brake.
running at low
speed) 3. 6A fuse is blown out. * Exchange the 6A fuse.
4. Pressure of returning spring of motor * Tighten the adjusting screw.
lever is too weak.

5. 12P connector of head is pulled out. * Re-plug-in correctly.

6 Does not rotate at 1. lA fuse is blown out. * Exchange the lA fuse.

low speed. Thread
trimming not
performed and
stops at any
position.

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 V. HIGH SPEED, SINGLE NEEDLE, LOCKSTITCH, AUTOMATIC
UNDERTRIMMER EQUIPPED WITH A WIPER

Model DDL-552-2-3 DDL-552-2-4

DDL-553-2-3 DDL-553-2-4
DDL-555-2-3 DDL-555-2-4

1. Adjusting the position of the wiper

The position of the wiper is adjusted according to the thickness of the sewing cloth. Normally,
adjust it as follows:

1) Rotate the hand wheel toward the regular direction and as shown in Fig.37, bring the white
point (D of the hand wheel so that it will match with the red point (D of the frame.

z 2inin

1mm

Fig. 37 Fig. 38

2) Then, as shown in Fig.38, insert the wiper ® into the driving shaft (D and bring the tip
of the wiper so that it will come to 2mm (approx. 1/16") under the point of the needle. Make sure
that the space between the flat surface of the wiper and the center of the needle comes to 1mm
(approx. 5/128").

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2. Adjusting the position of the wiper magnet
1) Pull in the plunger entirely into the coil, loosen the wiper magnet set screw 0 and by
moving the wiper magnet up and down and as shown in Fig.3, adjust so that the edge of the wiper
comes to the position where it will be away from the needle center by 2mm (approx. 1/16"). After
this adjustment, securely tighten the wiper magnet set screw.

2min Fig. 39

With the exception of above, all operating instructions and adjustments are same as DDL-555-2.

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 VI. HIGH SPEED, SINGLE NEEDLE, LOCKSTITCH INDUSTRIAL
SEWING MACHINES WITH AUTOMATIC THREAD TRIMMER
AND AUTOMATIC REVERSE SEWING UNIT

Model DDL-555-2-2B DDL-555-2-4B

1. How to sew automatically

(D If the push button (i) is pushed, the machine will become
in reverse sewing state and reverse sewing can be performed.
(D As long as this button is kept pressed, the machine will
do reverse sewing.
(D If the button is released, the machine will return to normal
sewing condition.
@ When half-stitching process is to be performed, use the
normal back lever. Fig. 40

2. Adjusting the switch lever of reverse sewing

CD The height of the push button (D is not specially set, so
adjust it to an appropriate position.
(D Loosen screw (2), move the push button up and down
and adjust to the proper height. After adjustment, securely
tighten the screws.

Fig. 41
3. Adjusting the pitch of reverse sewing
Due to the adoption of push button system, until the operator gets used to the system, some
times the length of the reverse sewing might become longer than necessary.
In case when the pitch of the reverse sewing may be lessened than the normal sewing, do as
follows and the pitch of the reverse sewing will become smaller and accordingly the length of the
reverse sewing will become shorter.
Loosen the screw (D from the bottom of the bed and raise up the stopper (2) and the pitch
of reverse sewing will become less. If this is lowered fully to bottom, the pitches of the normal
feed and the reverse sewing will become same.

Fig. 42

With the exception of above, all operating instructions and adjustments are same as DDL-555-2,
Please refer to INSTRUCTION BOOK on DDL-552, 553, 555.

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VII. MALFUNCTIONS AND CORRECTIVE MEASURES

Malfunctions Causes Order of Inspection and Corrective Measures

A. l-scvcral stitches skip at 1. Thread remaining at the * Needle eye passing is defective. Tension of needle thread 'D Inspect the needle thread route, correct idle spinning of thread from thread guide
start of sewing needle eye after thread at trimming time may be too strong. rod and position of thread guide of the thread stand.
trimming is too short ' Tension of first tension disc too strong ® Rotate the thread adjusting nut of the first tension disc to left and weaken
* Floating of second tension disc at trimming time inadequate the tension.
* Timing of cam too fast (D Check and see if the floating range of the second tension disc is 0.5mm~l mm
* Position of hook presser wrong, causing needle thread to (l/64"~3/64") when the bobbin presser is pushed in to right and adjust by the
slip off at trimming time adjusting nut under the bed (Refer iV-4).
* Fixed knife placed too close to needle. Blade point is Also see if the disc is loosened evenly, horizontally, and if not, cither rotate
sticking out too far the tension spring 180° or change the slant of the spring.
* Knife thread guide, moving knife and sewing hook are (4) Follow IV-1 and adjust cam timing.
bruised (D Inspect the loose condition of bobbin thread presser set screw (IV 7).
(6) Remove the needle plate, inspect the position of the fixed knife and adjust any
bruise of moving knife (lV-3, lV-6).
(T) Inspect the bruised condition of the sewing hook and knife thread guide hole.
If any bruises are found, thoroughly polish with buff, etc. If the bruises are
serious, change the parts.

2. The needle, needle plate * The "a" dimension is too large (T) Inspect the shaping of "a" and "b" part of presser foot and "A" part of needle
and presser foot used The "b" groove is too large plate.
are inadequate or the So the sewn needle thread cannot be pressed down a. When using synthetic thread on tricot material.
pressing power is * Needle is too large a < 0.8mm b & A part r < 0.3mm
too weak * Needle hole of needle plate too large b. When synthetic thread is used, a 1.2mm, b & A part without grooves.
* Groove of "A" part of needle hole of needle plate too long c. For cotton thread too, as long as no defective thread tightening, a, b, A parts
* Pressing power too weak should have small grooves.
d. The finer the cloth, more mesh the cloth, the more slippery the thread, the
smaller the stitch pitch, the grooves of a, b, A parts should be small.
® As long as the thread tightening is not defective, use a finer needle.
Use #7 #9 needles especially for tricot material
(3) If pressing power is too weak, adjust by the presser foot adjusting screw.

3. Hook point does not scoop ' Bad timing of needle with sewing hook - too much clearance (f) Run the machine at low speed and if skip-stitch is verified, correct the angle of
up the needle thread ' Blade point of hook is abraded the needle and its curvature.
(skip-stitching) * Inadequate installation of needle ® Try decreasing the spring power of the take-up spring and its range of movement
to 5~7mm(3/16~l/4").
<D Make the timing of hook faster than normal lockstitching machine.
Make clearance less than 0.0Smm(l/S12").

4. The bobbin thread is too ' The bobbin thread tip is pulled in inside the bobbin case (D After the thread is trimmed, take out the bobbin case and if the idle spinningof the
short at the start of sewing by the idle spinning of bobbin. bobbin is too much:
a. Inadequate pressingpressure of bobbin presser. a. Make the pressure of the bobbin presser stronger. (Refer to IV 7).
b. Bobbin thread tension is too weak b. Check the tension of the bobbin thread.
* Fither the bobbin thread tension is too strong or the hook Conduct the above inspection and make the length of the bobbin thread to 35^
is bruised and the bobbin thread is cut short 50mm(l-3/8~l-31/32").
(D After the thread is trimmed, if there is no idlespinning of the bobbinand the thread
is trimmed short, make the pressure of the bobbin presser weaker. (Refer to IV 7).
® Polisli the sewinghook or exchangeit.
B. Needle thread slips out from 5. The length of needle * The timing of the cam is too slow, thus first thread (D Stop the motor and at the position where the needle is lowered, insert the hook
the needle at the start of thread after trimming is tension disc becomes too strong and the thread is cut presser into the bobbin case. Rotate the hand wheel with your hand, trim the
sewing scattered before the blades of the moving knife and the fixed knife thread and stop the machine at the upper dead point. At this instant if the needle
interlock each other. thread remaining at the tip of the needle eye is more than 10mm(3/8") shorter
(So-called intermediate cutting) than when trimmed by pedal action, this means a "intermediate" cutting.
• Penetration of hook presser into the bobbin case is too a. So, quicken the cam timing and weaken the first thread tension.
shallow, thus the needle thread slips off from the hook b. Sharpen the fixed knife again correctly. (IV-5).
presser c. Polish the knife thread guide, moving knife and the sewing hook thoroughly.

From the library of: Superior Sewing Machine & Supply LLC 28
 Malfunctions Causes Order of Inspection and Corrective Measures

* Hie fixed knife is too sharp (too pointed at top) cutting

the thread only with the fixed knife
* Knife thread guide, moving knife and hook are bruised
Needle thread slips out from * C^m timing is too fast so even the needle thread on the ® When the length is less than 20mm(25/32"), adjust the position of the bobbin
the needle immediately side of the needle is trimmed also presser (IV—7).
after trimmin;* ' Needle is too thick ® When the needle thread breaks just after trimming, this is because the needle
thread remaining at the side of the needle is being cut due to the inadequate
disposition of the thread by the moving knife. When the needle plate is removed,
about 20mm(25/32") of the needle thread is remaining. In such a case,delay the
timing of the cam (IV-1).

C. At the start of sewing, 1. The needle thread remain * The first tension disc tension is too weak ® Try strengthen the first tension disc (lV-2).
the tip of needle tluead ing at the needle eye after * Cam timing is too late (D Try bring the fixed knife closer to the needle (lV-3).
sticks out atop the cloth thread trimming is too long * The fixed knife is retreated too far (D Try quickening the cam timing(IV-1).

D. The back side of the cloth 1. Tlie needle thread remain (Please refer to previous chapters) 0 Refer to previous chapter.
is dirty at the start ing at needle eye after (D Refer to 1-2 chapter on "Malfunctions and corrective measures" and make proper
of sewing trimming is too long adjustments.
(Long needle thread is 2. Needle, needle plate and
remaining under the presser foot inadequate
cloth) and after trimming, can
not shorten the remain
ing needle thread at
needle tip

I-;. Thread tension is bad at 1. The needle tluead tension • Inadequate installation of bobbin presser. CO Adjustthe installedposition of bobbin presser.
start of sewing at start of sewing too • Due to idle spinning of the bobbin, the tension of the bobbin (2) Inspect the presser foot and the needle plate closely and refer to 1-2 para for
weak thread is weakened. adjustment.
a. Tlic tension of the bobbin thread loo weak ® Take out the bobbin case after (rimming and as you push the bobbin, try pulling
• Both needle thread and bobbin thread tensions arc too weak out the bobbin thread. If the tension is weak, strengthen the bobbin thread tension.
• The prc.vwr fool and the needle plate arc not suitable. ® Make the needle thread tensionstronger.
(D Increase the pressure of presser foot.
(D Use a bobbincasewith a spring.
F. Needle thread cannot 1. Skip stitching at the end • Defective needle insertion 0 Correct the installed angle of the needle and change the curved needle.
be cut (bobbin tlircad of sewing cycle • Stroke of take-up spring too big ® Make the stroke of the take-up spring smaller (5~7mm).
is cut) • Timing of sewing hook bad 0 Inspect the skip-stitching at low speed and correct the timing of the sewing hook
(Make the timing of the sewing hook a little quicker than normal lockstitching
machine).

2. One part of blade of • The trimming parts of moving knife and fixed knife arc Remove the needle plate, and move the knife with your hand and try cutting the
trimming knife docs not not sticking together at trimming time. #50 cotton thread (3 strands at the same time). If the 3 threads are cut evenly,
cut well (The angle of the fixed knife, its position and the slant it's adequate but if not:
of the cutting point are not matched with the cutting part (V Sharpen the fixed knife blade (IV-5).
of moving knife. 0 Correct the inclined angle of the tip of the fixed knife (IV-5).
@ Re-adjust the installed position of the fixed knife (IV-3).

29
From the library of: Superior Sewing Machine & Supply LLC
 Malfunctions Causes Order of Inspection and Corrective Measures

G. Only bobbin (hrcad is 3. Retreating range of * Inadequate adjustment of the moving knife (left-right CO Verify the retreating amount of the moving knife and adjust the left-right position
not cut (needle thread moving knife insufficient position of the knife shaft and thread trimming cam of the trimming cam so that the retreating amount comes to 2. 2.Smm
is cut) inadequate). (5/64" ~3/32").

4. Tiic bobbin thread position * Due to using undesignated sewing hook CO Inspect and see if the sewing hook is equipped with a bobbin thread guide
at trimming time is not groove and if not, change the sewing hook.
steady
If. Both needle thread 1. Defective thread trimming * Incorrect installed position of trimming switch
and bobbin thread are switch components * Inadequate contact and functioning of thread trimming (0 Step on the pedal to the rear and verify the working sound of the thread trimming
magnet. If the sound can not be heard;
not cut (Stops at components
lowered position) ' Inadequate connection of the cords to (he trimming CO In the case of HITACHI motor, screw-in the thread trimming adjusting screw, and
verify the moving sound of the switch.
components
In the case of NATIONAL motor, exchange the switch.
1) Iwen when the pedal
® Inspect the continuity of all parts by a tester and measure the resistance value,
is stepped on to the rear,
a. Inspect the thread trimming switch.
sound of thread
Inspect the conductivity between the No.4(red) and No.6(blue) pin terminals of
trimming magnet is
12P plug and if at the pedal stopping position there is no conductivity but there is
no) heard
conductivity when the pedal is stepped to rear (thread trimming action), it is
normal. When the resistance value al conductivity time is 5n, exchange it.

2. Thread trimming magnet (1) Inspect the thread trimming magnet.

is either disconnected or Measure the resistance value between No.2(black) and No.5(brown) pin terminals of
shorted. the I2P plug coming out from the machine head,
a. If the resistance is 11 n ... it is normal.
* If the resistance is oo ... inspect the wiring and if the magnet is di.sconncctcd,
exchange it.
* When the resistance is On ... inspect and sec if the circuit is shorted. If its
.shorted inside the magnet, exchange the magnet. After that if the magnet is "ON"
condition, exchange the Tr23. At this point, inspect the 033.

2) Needle stops midway before 1. Belt is too loose UJ) Tighten the belt somewhat.
reaching the upper stop
position 2. Inadequate torque at low ' Voltage is too low. (.0 Inspect the voltage of the power source.
speed sewing * Faulty condition of the clutch plate of the auxiliary motor (2) Tighten the hinge nut at lever returning spring gradually, little at a time.
' Motor lever returning spring is too weak

3) The .sound of magnet is I. Insuffieient retreating Remove the needle plate and inspect and if the thread is not trimmed when
heard but the thread is range of the knife or the thread trimming operation is performed by the pedal, it is because of insufficient
not trimmed moving knife forked base retreating range of the moving knife or insufficient trimming power (IV-5, 6).
is broken or insufficient
trimming power

2 The thread trimming cam * The right and left position of the thread trimming cam is (D Inspect the knife driving shaft adjusting nut, slide shaft collar and the cam roller
and the roller do not inadequate arm not screws for loosened condition and correct them to the right positions.
interlock ' Faulty timing of the thread trimming cam @ Inspect and see if the trimming arm moves smoothly until it hits the stopper
* The screws of the slide shaft collar or the cam roller arm within the 60° zone of the main shaftrotating angle when the needle tip slips out
are loose from the needle hole of the needle plate. If it does not move smoothly, verify first
* Installation of parts which are moved by the trimming if the retreating range of the moving knife is adequate and then adjust the right
magnet is faulty and left position of the cam (IV-1).
* The knife moving shaft adjusting nut screw is loose (D Adjust the timing of the thread trimming cam with the indicating point of the
hand wheel (IV-1).

From the library of: Superior Sewing Machine & Supply LLC - 30 -
 Malfunctions Causes Order of Inspection and Corrective Measures

I. Machine does not stop 1. Auxiliary driving device Insufficient voltage of electrical source for the brake and (D Inspect the6A and 1Afuses andif blown out, replace them with new ones.
at the uppei or lower fixed of the motor or the special auxiliary motor device or wrong connection of the dis (D Check the voltage of the switch part and if it is normal, measure the voltage
position function of the brake is connecting cord of alternate current of the transformer inside the control box. If the voltage
(The stopping position of not working right a) When connecting the electrical cord of HITACHI motor between 0 and 3IV is 25~37V, it is normal. If not, the connecting method
the needle is not definite) to the transformer of the control box, the method of of the input cord to the transformer is wrong, so correct it.
connection is wrong (D Put out all the input cords, once, and correct the insertions.
b) The fuse of the control box Is blown out

The magnet brake of the motor is defective (D Inspect the clearance of the magnet brake.
Remove the cover of the magnet brake and adjust so that the clearance between
the brake plate and the brake friction plate becomes O.Smm. (For full dctail.<i.
refer to Instruction Book of Hitachi and National motors).
® Inspect the disconnection or shorting of the magnet brake. Pull out tlie black
plugging cord inside the control box, measure the resistance between the No.3
(red lead wire) and No.4(yellow lead wire) and if it's "0" or they are dis
connected or shorted and if the connection of the cords is nonnal, exchange the
magnet brake.

Auxiliary motor is defective (D Remove the black cap of the tip of the cord coming outfrom the motor, remove
the end cover of the motor, also, and by removing the vinyl cover of the pin
terminal (3 ea. of 3 phase, 2 ea. of single phase) of the cord which is connected
to the auxiliary motor and measure the conductivity of respective pin terminals
by a tester. If the resistance is "0" or <», it means disconnection of the motor
coil or shorting. (Be sure to measure the resistance within the range of R x 1.
Also, the tester should measure so that when 2 test pins are contacted that tl>cy
are matched to show the resistance indicator points to "0".)
® Verify that the low speed function changing pin on top of mother printed board is
connected to the ON ' side. Flip up the black cap at thetipof thecord coming out
from the motor, input the current (pedal Is neutral and machine isstopping) and
measure the voltage between the pin terminals No.l(whitc) and No.2(black) by
means of tester AC250V range. If the voltage is over 40V, it is ok but if it's OV, the
bi-directional-triode thyristoris defective. With the 3 phase motor,measure between
No.8(grey) and No.9(orange) terminals in the same manner andif not over 40V, the
bi-directional-triode thyristor is defective, so in cither case exchange the defective
thyristor.

Defective bi-directional-triode thyristor (D When the auxiliary motor is abnormally heated, it means defective bi-directional-
triode thyristor or running with defective phases (of 3 wires, 1 wire is disconnected
or defective connection)
® Step on the pedal to low speed sewing and measure the voltage between No.2(b!ack)
and No.l(white) and if it's "0", it's ok and similarily if the voltage between No.8
(grey) and No.9(orange) is "0", it's ok and if any terminals showvoltage of over40V,
it means defective bi-directional-triode thyristor. In such a case, exchange the
thyristor.
(Note) The inspection of ® will be conducted with the powersourcein turned-on
condition, so be extremely careful not to receiveelectric shock. Also, do not
forget to set the range of the tester to AC250V.

- 31
From the library of: Superior Sewing Machine & Supply LLC
 Malfunctions Causes Order of Inspection and Corrective Measures

• Motor lever returning spring too weak or too much i) Rotate the machine at high speed, release your foot from the pedal and at the
clearance between the worm gear of low speed rotation same time lift up the motor lever and if the machine stops at this time, the
or brake lining of (he hand wheel gear and the clutch above-stated spring is too weak.
plate a. In the case of HITACHI motor, tighten the motor lever returning lever
adjusting screw and make the spring stronger.
(D In the case of HITACHI motor and NATIONAL motor, screw in the adjusting
screw of the gear head part to lessen the moving range of the motor lever.

2. Malfunction of sensor ' Malfunction of needle positioning sensor (1) Inspect the wire connection of power source to the control box.
components a. Inadequate contact of the cord connecting the sensor to (2) Inspect and see if the fuse is disconnected or not.
the control box or wrong connection. (D Remove the belt of the machine from the pulley, turn overthe grey capof the 12P
b. Defective connection of the electrical wiring from the connector, turn the power switch on and while measuring the DC voltage between
control box to the transformer or inadequate plug-in of the No. l(white) and No.6(blue) terminals with the direct wire lOV range (black
3P connector. lead rod to No.6), rotate the pulley with the hand and if the voltage is OV between
c. 6A and lA fu-ses of the control box blown out. the synchronizing zone and shows 5V at other areas, it's normal and if it's .same
condition between No.4(yellow) and No.6(blue), it's normal. But in either case, if
the needle of the tester should remain showing OV or SV even once, verify the wiring
connections and they are not in error, exchange them.

J. Kvcn when (he pedal is 1. Inadequate adjustment of 'D When the pedal is lightly stepped on and if the moving sound of the motor lever
set at stopping position, low speed sewing switch part can not be heard, adjust the position of L.SW.
the machine runs at Release the plugged-in cord of the motor lever and while lowering or separating the
low speed motor lever lightly, inspect the continuity between the cords V3(red) and Y7(grey)
which come out from the motor lever.
If they do not become "ON" or "OFF", exchange the switches.

2. Connector is pulled out (X) Verify the plugged-in condition of the 12P connector and 9P connector (blue).

3. Defective brake of the X) Readjust the clearance of the magnet brake.

motor magnet (D Inspect the wiring to magnet brake between X3- X4 tcrininal.s.
(D Inspect the conductivity of the magnet brake of motor and if resistance is about
90n (Hitachi), 60f2 (National) its ok if not,
® Exchange the magnet brake.

4. Inadequate adjustment of D Try to rotate the adjusting knob toward the "FAST" direction and see.
stop position adjusting ® Inspect the cord of the adjusting knob inside the control box.
knob

K. Needle breaks at (he I. Malfunction of the * Safety magnet cord is disconnected. Remove the needle, step on the pedal to rear and when the pedal is stepped on to
start of sewing movement of the safety the front quickly, verify to see if the pedalcannot be stepped on before the stopping
Unusual sound is heard device position, (National) or becomes idle stepping (Hitachi).
from the bed part If it can be stepped on, adjust the safety device stopper.
® Verify and see if the moving sound of the safety magnet can be heard at the
trimming time. If it cannot be heard, re-adjust the installed position of the safety
lever so that the movement of the safety lever will become smooth.
® Re-adjust the installed position of the pedal connecting rod.
® Measure the resistance of the safety magnet. When the resistance between the
terminals Y2~Y5 of the 9P plug is 0 or the connection is bad or the safety
magnet is defective, (change the magnet)

From the library of: Superior Sewing Machine & Supply LLC - 32
 CIRCUIT DIAGRAM FOR DDL-555-2-2, 2B
DDL-555-2-4, 4B

®—I ®-j|^ 1
JICll
No. 1Spmltesiiei^
|£N7«0Tt J
fICIJ 7mfMi (wndoil* |sN74on»
R94
[lC»3M4 [sN7477ni
W ^Vcc A Un.. 1??_. R113 C91 [iClB Fpwti i«iiuiaiM TAIOKU
^Itosuiaa i
OAZ ficic •kytoldtC
V06ET
i ...... -- ♦ - - i
fDMM troToiim 2NS3BSnCA
UiJUS :2SC»Mmc ^
TNIAC *rri>f '*
VR2 -iHITACMI.. ,

jVni jCMiillxvilVBrMiNtMBn iTMIOkfPVl.j

WlMl „.C63 Ivn? 1V«noW» mNlOf ^70UtAV24V ^
R)15 V06E
H
fwM [e* \
M.B [-@- 1" , |lA '1
® @OPEN |«TI n«iiiw« ^MSCi ^
RIOI V06E
•sTa ^M«C6
H
f.

M.S
NwiwHierA SSXDOSOO ^
7r2t ,«.r. ^Not* nipp»M*e< 0 ! Wf-2a«0
034
Q65 A7e Rt04 V06E
w
jCVDC
R66 IT7
'wio
; HITMMI
vm
Tr24 _VM
»221*ICP4
D33
RU)3 V03E 'yw
VW M
C67 R72 VR1
o?&<r40oiw

@ D32
Vee R<OZ V03e
R67 tTH

^aoi»r35«w

ST. 2 M4C-5 Plug fockot connection}

UJ U2,3
45V OC PkiiMctoteP t MvyfockM V ! Mub
4C31V

® 114.15
6K0

^Vec <3VDC)
tt 11 l i
•jL^PtT
recii C59 cse
TTTT
crS-vCTB
06ND

NOTE THE FIGURES IN THE CIRCLES SHOW THE TIME CHART INDICATING COOES

- 33 -
From the library of: Superior Sewing Machine & Supply LLC
 TIME CHART FOR DDL-555-2-2,-2B, DDL-555-2-4,-4B

UPPER DEAD POINT

LOW SPEED
FUNCTION

LOWER DEAD POINT U

LOW SPEED FUNCTION L

nm
n nn n r n r m n

nnrmmn

(NOTEI
• FIGURES (N THECIRCLES ARESHOWN IN THECIRCUIT DIAGRAM.
• CPSHOWS ONESHOTPULSE. CP-1 SHOV/S 2 20 MSEC. CP-2SHOWS 14-15.4MSEC.
• CP-3 SHOWS APPROXIMATELY 34 MSEC. CP-4 SHOWS APPROXIMATELY 72 MSEC.

From the library of: Superior Sewing Machine & Supply LLC
- 34
 DDL-552-2
DDL-553-2
Diagram Showing Method of Assembling Table for DDL-555-2
DLN-415-2
DLU-450-2
JZ-D31 DLD-432-2

88212-125-000x2
88216-012-0A0
88213-125-AA0X2
88207-012-000x2

88209-125-000 x2

D820 -555-COO

88204-012-000 x2

SK-1211000-SC x4

88102-552-000

D8203-555-B00

88104-552-000 x2
D7114-555-8A8

SK-3514000-SDX4
88101-552-000

SM-9082023-SE x4 88126-552-OAE
88105-552-000
WP-0871602-SE x4 SM-9082023-SE
WP-0871602-SE
WS-0861410-KR x4
WS-086f410-KR
D8112-555-B0E
NM-6080721-SE
SM-9061203-SE x3
WP-0671016-SE x3
SD-1204215-SE x4'| WS-062I210-KRX3

WP-12522I0-SC x4

WS-1253010-KN x4 88111 -552-000

88110-552-000

NM-6120003-SE

88107-552-000 —88108-552-000
88103-552-000
08113-555-8002x2 D8110-555-B0E 88109-552-000

88112-552-000 x2
D8II4-555-B0E D8115-555-B00

WP-0871602-SE x2 SM-9082023-SE
WS-0861410-KR x2 WP-087I602-SE
SM-9082023-SE x2 WS-0861410-KR
NM-6080721-SE

From the library of: Superior Sewing Machine & Supply LLC
- 35 -
 MOTOR A 8 C

HITACHI 105 159 66.5

DIMENTIONAL DIAGRAM OF THE TABLE {TOP SURFACE) FOR DDL-555-2 NATIONAL 57 159 eas

QUICK 80 120 70
1200

CONTROL BOX 3-^8.5 (holes)

INSTALLING
POSITION 100 018 (holes)
016
depth 30

035±O.5
(holes
80

DRAWER
INSTALLING LEG
POSITION INSTALLING
LEG POSITION
INSTALLING
339.7 ± I
POSITION

STOPPER
INSTALLING
POSITION

POWER SOURCE
SWITCH INSTALLING
POSITION
70 80

From the library of: Superior Sewing Machine & Supply LLC
 MEMO

From the library of: Superior Sewing

- 37 -
Machine & Supply LLC
 iys&riSR

TOKYO JUKI INDUSTRIAL CO..LTO.

Head Office & Plant, 2-1, 8-chome, Kokuryo-cho, Chofu-shi, Tokyo, Japan
From the library of: Superior Sewing Machine & Supply LLC
Business Office: 23, Kabuki-cho, Shinjuku-ku. Tokyo, Japan
Cable Address: JUKI TOKYO Telex: 22967 JUKITK