KANSAI SPECIAL DLR-1501SPF User manual

INSTRUCTION
Industrial Sewing Machines
First published : August 2005
No. 050072

INTRODUCTION
Thank you for your purchasing Kansai Special's DLR Series.
Read and study this instruction manual carefully before beginning any of
the procedures and save it for later use.
1. This instruction manual describes adjustments and maintenance procedures
on this machine.
2. Before starting the machine, check to make sure the pulley cover, safety cover,
etc. are secured.
3. Before adjusting, cleaning, threading the machine or replacing the needle, be
sure to turn off the power.
4. Never start the machine with no oil in the reservoir.
5. Refer to the parts list as well as this instruction manual before performing
preventive maintenance.
6. The contents described in this instruction manual are subject to change
without notice.
Indication of serial number
Model
0 5 0 0 0 0 1
Serial number
The date of manufacture
Zip code

CONTENTS
1. SPECIFICATIONS
1-1 Stitch type ···············································1
1-2 Model ·····················································1
2. NEEDLES & THREADING THE MACHINE
2-1 Needles ···················································1
2-2 Replacing the needle ·································1
2-3 To thread the machine ······························2
3. MACHINE SPEED
3-1 Machine speed & direction in which the machine
pulley runs ·············································4
3-2 Motor & belt ············································4
4. LUBRICATION
4-1 Oil ·························································5
4-2 To fill the machine with oil ························5
4-3 Replacing the oil and the filter element ·······5
5. SEWING MACHINE INSTALLATION
5-1 Cutting the machine table ·························6
5-2 To install the machine ·······························7
6. TIMING OF THE LOOPER TO THE NEEDLE
6-1 To install the looper ··································7
6-2 Looper left-to-right movement ····················8
6-3 Looper setting distance ·····························8
6-4 Needle height ··········································8
6-5 Needle/looper front-to-back relationship ······9
6-6 Length of the looper connecting bar ············9
7. ADJUSTING THE NEEDLE GUARD
7-1 Position of the needle guard (rear) ··············9
8. ADJUSTINGTHEFEEDDOG&STITCHLENGTH
8-1 Feed dog height & tilt ····························· 10
8-2 Left and right feed dog height ·················· 10
8-3 Stitch length ·········································· 10
9. ADJUSTING THE PRESSER FOOT
9-1 Presser foot pressure ······························ 11
9-2 Position of the presser foot and foot lift ····· 11
10. ADJUSTING THE REAR PULLER DEVICE
10-1 Upper puller angle adjustment ················12
10-2 Lower puller angle adjustment ················12
10-3 Guide plate adjustment ··························13
10-4 Manual lever ········································13
10-5 To adjust the puller pressure ··················13
10-6 Adjusting the feeding amount of the rear
puller ··················································13
10-7 The minor adjustment of the rear puller
feeding amount ·····································14
11. ADJUSTING THE STITCH FORMATION
11-1 Thread tension adjustment ·····················14
11-2 Position of the needle thread eyelet ··········15
11-3 Adjusting the needle thread guard ···········15
11-4 Adjusting the looper thread eyelets ··········15
11-5 Position of the looper thread take-up ········16
12. CLEANING THE MACHINE ···················16

【1】SPECIFICATIONS
1-1 Stitch type
JIS401 double chainstitch machines
1-2 Model
Model 1501 1502，1507 1503 1504 1508
No. of needles 12 3 4 4
No. of threads 2 4 6 8 8
No. of loopers 1 2 3 4 4
Needle count UY×128GAS
#14~#18 TV×5 #21 UY×128GAS
#14~#18 TV×5 #21
Needle space 3/16~1 1/2 1/4，9/32 1''，1 1/8 1/4-1-1/4
Needle bar stroke 31mm 34mm
【2】NEEDLES & THREADING THE MACHINE
2-1 Needles
UY×128GAS，TV×5 of Schmetz or Organ
Select the proper needle for the fabric and thread.
< Needle count comparison table >
Schmetz Nm90 Nm95 Nm100 Nm105 Nm110 Nm120 Nm125 Nm130
Organ # 14 # 15 # 16 # 17 # 18 # 19 # 20 # 21
2-2 Replacing the needle
When replacing the needle, check the needle carefully to
see that the scarf is turned to the rear of the machine (see
the illustration).
< Note >
When replacing the needle, be sure to turn off the
machine. A clutch motor continues running for a while
after the machine is turned off. Therefore keep on
pressing the pedal until the machine stops.
1

2-3 To thread the machine
Thread the machine correctly by referring to the next page.
Incorrect threading may cause skip stitching, thread breakage and/or uneven stitch
formation. When threading the looper, tilt the looper holder toward the front of the
machine by means of the looper drawing bar.
■To tilt the looper toward the front
1. Bring the needle bar to the top of its stroke.
2. Tilt looper holder B toward the front of the machine by pressing pushbutton flat
spring A (see below).
3. After the machine is threaded, replace the looper holder.
2

■A，B，C，D …Needlethreads E，F，G，H …Looper threads
3

【3】MACHINE SPEED
3-1 Machine speed & direction in which the machine pulley runs
Maximum speed : 4,500 rpm
Standard speed : 4,000 rpm
To extend machine life, run the machine
approximately 15-20% below the maximum speed for
the first 200 hours of operation (approx. 1 month).
Then run the machine at the standard speed. The
machine pulley turns counterclockwise as seen from
the end of the machine pulley (see the illustration).
3-2 Motor & belt
Motor : 3-phase，2-pole，400W clutch motor
Belt : M type V belt
Select the proper motor pulley according to the
machine speed (refer to the motor pulley outer
diameter on the table below). Adjust the position of
the motor by pressing the finger onto the middle of
the belt so that 1~2cm deflection can be achieved (see the illustration).
< Motor pulley selection table >
Machine speed (SPM)
Motor pulley outer
diameter (mm) 50Hz 60Hz
70 2900 3450
80 3300 3900
90 3700 4400
100 4100 (4900)
110 4500 (5400)
4

【4】LUBRICATION
4-1 Oil
Use Kansai Special’s genuine oil.
(Part No. 28-611)
4-2 To fill the machine with oil
Remove oil plug A.
Fill the machine with oil until the oil level is at the
top line (see H in the illustration) on oil gauge C.
After the first lubrication, add oil so that the oil
level will be between H and L.
After filling the machine with oil, tighten plug A and
run the machine to check the oil is splashing onto oil
pot A.
4-3 Replacing the oil and the filter element
To extend machine life, be sure to replace the oil
after the first 250 hours of operation.
To replace the oil, follow the procedures below.
1. Remove the V belt from the motor pulley and
then remove the machine from the table.
2. Remove screw D and then drain the oil.
Be careful not to stain V belt with the oil.
3. After draining the oil, be sure to tighten screw
D.
4. Fill the machine with oil by referring to 4-2
shown above.
If filter element E is contaminated, proper oiling
may not be performed. Clean the filter element
every six months. If just a little or no oil flows out from the nozzle with the proper
amount of oil in the machine, check the filter element.
To clean the filter element, remove oil reservoir.
5

【5】SEWING MACHINE INSTALLATION
5-1 Cutting the machine able
6

5-2 To install the machine
Install the brackets on the underside of the table board (see the illustration below).
Fit the rubber cushions onto the brackets.
Mount the machine head on the rubber cushions.
【6】TIMING OF THE LOOPER TO THE NEEDLE
6-1 To install the looper
Insert the looper to the proper depth and tighten
screw A.
7

6-2 Looper left-to-right movement
When the point of the looper, moving to the left or
right, has reached the center of the needle, the point
of the looper should be 2mm above the top of the
needle's eye. Adjustment is made by removing the
cover and loosening three screws A.
After this adjustment, tighten three screws A with
the same torque.
6-3 Looper setting distance
When the needle is at the bottom of its stroke and
the looper is at the extreme right end of its travel,
adjust distance A from the point of the looper to the
center of the needle (see the table below).
Model Looper setting
Distance A
1508 3mm
■Adjustment is made by loosening screw C on lever
B.
6-4 Needle height
When the point of the looper has reached the center
of the back side of the needle with the machine
pulley turning in the operating direction, the point
of the looper should be 2mm above the top of the
needle's eye (see 6-2).
When the needle bar is at the top of its stroke,
remove plug A on the side cover plate, loosen screw
C on needle bar clamp B with a 3mm hexagonal
wrench and then move the needle bar up or down as
required.
< Note >
After the above adjustment is made, check to make
sure each needle drops correctly into the center of
each needle drop hole.
8

6-5 Needle/looper front-to-back relationship
When the point of the looper has reached the center
of the needle, the point of the looper should be 2mm
above the top of the needle's eye.
With the looper and the needle in this position,
there should be a clearance of 0~0.1mm between the
needle and the point of the looper.
Adjustment is made by loosening screw A on the
looper avoid lever and moving looper holder B front
or back.
6-6 Length of the looper connecting bar
The distance between the centers of both connecting
rods should be 87mm.
【7】ADJUSTING THE NEEDLE GUARD
7-1 Position of the needle guard (rear)
When the point of the looper has reached the center
of the back side of the needle from the extreme right
end of its travel, align the point of the needle with
bottom surface C of the needle guard (rear).
With the needle and the needle guard (rear) in this
position, set clearance D between the needle and the
needle guard (rear) at 0.
Adjust the needle guard (rear) front to back by
loosening screw A. Adjust the needle guard (rear)
up and down by loosening screw B.
< Note >
When moving the looper holder front or back, check
to make sure the looper setting distance is not
changed.
9

【8】ADJUSTING THE FEED DOG & STITCH LENGTH
8-1 Feed dog height & tilt
When the feed dog is at the top of its stroke,
the feed dog teeth should be 1.0~1.2mm
above the top surface of the needle plate.
Adjustment is made with screw A.
The fine tilt adjustment is made by
loosening nut C and turning screw B.
8-2 Left and right feed dog height
Feed dog divides between left and right side.
( See the illustration ), left side feed dog D
and right side feed dog E can be adjusted
independently.
When the bottom of left feed dog D bring
down to the pin F, both left and right feed dog height would be same. In case of the
adjustment, loosen screw A and make the left feed dog higher than the right side how
much the angle of the curved waist band is.
Original both feed dog position at the beginning are set to the same height.
8-3 Stitch length
The stitch length can be adjusted from 2 to 5mm
with no step. The following table shows the stitch
length with the number of stitches within 1 inch
(25.4mm) and 30mm.
No. of stitchesStitch
length(mm
)within 1" within 30mm
2 13 15
3 8.5 10
5 5 6
< To change the stitch length >
1. Loosen bolt A while checking the direction in
which the bolt is loosened.
2. Insert a screwdriver from hole C.
To decrease the stitch length, turn screw B clockwise. To increase the stitch length,
turn screw B counterclockwise.
3. After this adjustment is made by turning screw B, be sure to tighten screw A.
< Note >
Be sure turn off the motor when changing the stitch length.
10

【9】ADJUSTING THE PRESSER FOOT
9-1 Presser foot pressure
The presser foot pressure should be as light as
possible, yet be sufficient to feed the fabric and
produce uniform stitches.
To increase the presser foot pressure, turn the
adjusting knob clockwise (see the illustration).
9-2 Position of the presser foot and foot lift
Fit the presser foot properly onto the presser bar.
Make sure the needle drops correctly to the center of
the needle drop hole on the presser foot.
Adjustment is made by loosening screw A.
■Foot lift
The presser foot should be 7~9mm above the top
surface of the needle plate.
■Set stopper B at the required position.
Fasten the presser foot lift lever with nut C so that
the lever cannot be lowered.
11

【10】ADJUSTING THE REAR PULLER DEVICE
10-1 Upper puller angle adjustment
Loosen both screw E of the upper puller bracket G
and screw F of the bracket R, and change the angle
of the upper puller bracket.
And adjust scale plate H to scale mark D on the
cloth cover how much the angle of the curved waist
band is. After the angle adjustment, tighten screw
E & F. At this moment, check the bracket J ( See the
illustration above), is located to straight position
and tighten screw E & F.
10-2 Lower puller angle adjustment
Loosen two screws A of the lower puller bracket P,
and turn adjusting screw B counter-clockwise as the
drawing shows. Therefore, the angle of the lower
puller bracket can be adjusted horizontally.
And, match the scale plate H of the puller bracket
on the point K of the lower puller guide plate.
Then, the both angle of the upper and lower puller
would be same.
< Note >
The point K of the lower puller guide plate is matched
with the third mark L of the cloth plate on the factory
adjustment. This adjustment is set for the curved
waistband radius of apporoximately 600 to 700mm.
12

10-3 Guide plate adjustment
Adjust guide plate M & T according to the width of
waist band. Loosen screw N & S for the adjustment.
10-4 Manual lever
To position or remove the fabric, raise manual lever
A.
10-5 To adjust the puller pressure
The puller pressure should be as light as possible,
yet be sufficient to feed the fabric smoothly.
To increase the pressure, turn adjusting knob D
clockwise. To decrease the pressure, turn adjusting
knob D counterclockwise.
10-6 Adjusting the feeding amount of the rear puller
Adjust the feeding amount of the rear puller
according to that of the feed dog.
To increase the amount, loosen nut G and move it to
the left. To decrease the amount, move it to the
right.
< Note >
The adjustment of the factory set is as the drawing
shows.
13

10-7 The minor adjustment of the rear puller feeding amount
The feeding amount will be bigger by loosening nut B of lever A, and moving the
connecting rod C to the left. And the feeding amount will be smaller by loosening nut B
of lever A, and moving the connecting rod C to the right.
【11】ADJUSTING THE STITCH FORMATION
11-1 Thread tension adjustment
Thread tension varies according to sewing
conditions such as the fabric, thread and stitch
length to be used. Tension on the needle thread
can be adjusted with nuts A.
Tension on the looper thread can be adjusted with
nuts B. To increase the tension, turn the nuts
clockwise.
< Note >
The tension should be as light as possible, yet be
sufficient to produce uniform stitches.
14

11-2 Position of the needle thread eyelet
Secure needle thread eyelet C at the bottom end of
the slot.
< Note >
Adjust the needle thread eyelet according to the
thread to be used. To tighten the needle thread,
raise the needle thread eyelet.
11-3 Adjusting the needle thread guard
With the needle bar at the bottom of its stroke, the
top surface of needle thread guard A should be level
and parallel with the centers of the eyes on needle
bar eyelet B.
11-4 Adjusting the looper thread eyelets
Align the eyes on looper thread eyelets A with the
center of the lower shaft.
To increase the amount of the looper thread to be
supplied, loosen screws B and move looper thread
eyelets A to the rear of the machine.
To decrease the amount of the looper thread to be
supplied, loosen screws B and move looper thread
eyelets A to the front of the machine.
In case of model 1508SPF, move looper thread
eyelets A fully toward the front of the machine and
secure them with screws B.
Adjust the looper thread eyelets according to the
thread and stitch length to be used.
< Note >
Raising needle thread guard A increases the size of
the needle thread loop. Lowering needle thread
guard A decreases the size of the needle thread
loop.
15

11-5 Position of the looper thread take-up
Adjust thread guide E so that the clearance between
thread guide E and the top surface of the guide plate
is 6~7mm. Adjustment is made by loosening screw
D. When the point of the needle has reached
bottom surface B of the looper blade while the looper
is moving to the right from the extreme left end of
its travel, the looper thread should be removed from
point A on the looper thread take-up.
Adjustment is made by loosening screw C.
【12】CLEANING THE MACHINE
At the end of each day, remove the presser
foot and the needle plate and then clean the
slots of the needle plate and the area
around the feed dogs.
16