KANSAI SPECIAL DX Series User manual

INSTRUCTION
DX/UTCMANUAL
Industrial Sewing Machines
DX9902-3U
DX9900-4U
First published : November 1997
Second edition : January 1999
No. 980101

INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Thank you for your purchasing Kansai Special's DX/UTC Series.
Read and study this instruction manual carefully before beginning any of
the procedures and save it for later use.
This instruction manual describes adjustments and maintenance
procedures for the thread trimmer.
Refer to the DX Series instruction manual for other information.

CONTENTS
CONTENTSCONTENTS
CONTENTS
1. HOW TO USE THE THREAD TRIMMER
････････････････････ 1
2. INSTALLING THE POSITION DETECTOR
･････････････････ 1
3. ADJUSTING THE THREAD TRIMMER AIR CYLINDER
3-1 Air cylinder stroke ･････････････････････････････････････････････ 2
4. ADJUSTING THE THREAD TRIMMER
4-1 Home position of the knives
(at the extreme right end of their stroke) ･････････････････････････ 2
4-2 Upper knife at the extreme left end of its stroke ･･････････････････ 2
4-3 Position of each lower knife ･････････････････････････････････････ 2
4-4 Position of the points of the lower knives ･････････････････････････ 2
4-5 Relationship between the lower knives and the needles ･･･････････ 3
4-6 Relationship between the upper and lower knives ････････････････ 3
4-7 Overlap of the upper and lower knives ･･･････････････････････････ 3
4-8 Adjusting the leaf springs ･･･････････････････････････････････････ 4
4-9 Relationship between lower knives, needle threads and looper threads ･4
5. ADJUSTING THE THREAD RELEASER
5-1 Thread releaser lever ･･･････････････････････････････････････････ 5
5-2 Thread releaser plate ･･･････････････････････････････････････････ 5
5-3 Thread releaser hook ･･･････････････････････････････････････････ 5
6. SAFETY DETECTOR
･･････････････････････････････････････････ 5
7. ADJUSTING THE SPEED CONTROLLER AND AIR PRESSURE
･･ 6
8. ADJUSTING THE PRESSER FOOT LIFT
･･･････････････････ 6
9. ADJUSTING THE AIR BLOWER
･････････････････････････････ 7
10. CONNECTING AIR LINES AND CORDS FOR PNEUMATIC
DEVICES
10-1 DX004U ･･･････････････････････････････････････････････････････ 8
10-2 DX2-3U ･･･････････････････････････････････････････････････････ 8
10-3 DX2-3U/LK ････････････････････････････････････････････････････ 9

1
【1】HOW TO USE THE THREAD TRIMMER
■
Pressing the pedal with toe (position A) starts the
machine.
Releasing the pedal (position B) stops the needle at the
top/bottom of its stroke (adjustable with the motor).
■
If the needle stops at the bottom of its stroke as adjusted,
pressing the pedal with heel (position C) raises the needle.
As soon as the needle stops at the top of its stroke by
pressing the pedal with heel, the thread trimmer gets
actuated (if the needle stops at the top of its stroke as
adjusted, the thread trimmer gets actuated by pressing
the pedal with heel).
■
Returning the pedal to position B lowers the presser foot.
■
The presser foot can be raised or lowered freely by releasing the pedal (position B) or
pressing the pedal with heel (position C) until the pedal is placed at position A for the
next sewing operation after the threads are cut.
【2】INSTALLING THE POSITION DETECTOR
■
Install position detector A and tighten screw B
temporarily.
■
Fit positioner bar C onto the guide groove of the position
detector. Then tighten screw D.
■
Turn on the motor.
■
Press the pedal with heel after two to three stitches are
formed by pressing the pedal with toe.
Then the needle stops.
■
Loosen screws B for the position detector.
Turn the machine pulley while checking that the position
of screws B is not shifted. Align mark P on handwheel E
with the alignment mark on the arm.
Then the needle bar is at the top of its stroke.
Tighten screws B to secure the position detector.
■
Check to see if the needle bar stops at the top of its stroke
by pressing and then releasing the pedal.
< Note >
Remove the connector for the thread trimmer cylinder.
Make sure the knife is retracted all the way.
< Note >
Do not use this thread trimmer with no fabric under the presser foot.

2
【3】ADJUSTING THE THREAD TRIMMER AIR CYLINDER
3
33
3-
--
-1 Air cylinder stroke
1 Air cylinder stroke1 Air cylinder stroke
1 Air cylinder stroke
The stroke of the air cylinder varies according to the gauge. Refer to the table below.
Adjustment is made by loosening adjusting collars A and B.
Gauge Stroke
4.8-10-10-10 39.2mm
5.0-13-13-13 41.6mm
9.5-9.5-9.5 37.1mm
8.5-8.5-8.5 37.1mm
6.4-6.4-6.4 37.1mm
【4】ADJUSTING THE THREAD TRIMMER
4
44
4-
--
-1
11
1 Home position of the knives (at the extreme right end of their stroke)
Home position of the knives (at the extreme right end of their stroke)Home position of the knives (at the extreme right end of their stroke)
Home position of the knives (at the extreme right end of their stroke)
The home position of each knife varies according
to the gauge.
Adjust distance A by referring to the illustration
and the table below.
Then fasten collar B (see 3-1).
Gauge Distance A
4.8-10-10-10 46.6mm
5.0-13-13-13 45.6mm
9.5-9.5-9.5 47.1mm
8.5-8.5-8.5 46.1mm
6.4-6.4-6.4 43.9mm
4
44
4-
--
-2 Upper knife at the extreme left end of its stroke
2 Upper knife at the extreme left end of its stroke2 Upper knife at the extreme left end of its stroke
2 Upper knife at the extreme left end of its stroke
Lower knife carrier A and upper knife carrier B
move to the left simultaneously.
Upper knife carrier B stops when reaching
positioning stopper C.
4
44
4-
--
-3 Position of each lower knife
3 Position of each lower knife3 Position of each lower knife
3 Position of each lower knife
The lower knives should be parallel with each
other. Adjustment is made by loosening screws
D. Each distance between the points of the
lower knives should be 6.5mm (see 4-6).
4
44
4-
--
-4 Position of the points of the lower knives
4 Position of the points of the lower knives4 Position of the points of the lower knives
4 Position of the points of the lower knives
When the loopers are at the extreme left end of their travel, move lower knives E to the
left and then make sure the points of lower knives E are 0.7mm above the blades of the
loopers.
< Note >
When operating the thread trimmer by hand, bring the needle to the top of its stroke.

3
4
44
4-
--
-5 Relationship between the lower knives and the needles
5 Relationship between the lower knives and the needles5 Relationship between the lower knives and the needles
5 Relationship between the lower knives and the needles
■
On DX9902-3U/UTC
When lower knife E is at the extreme left end of its travel,
adjust distance (a) from needle thread cutting edge F to
the center of the left needle by referring to the table
below.
Adjust distance (a) by moving lower knife drive lever L to
the left or right and then fasten collar A.
■
On DX9900-4U/UTC
Adjust distance (b) from the thread cutting edge to the
center of the needle by following the procedure stated
above.
Distance
Gauge a b
4.8-10-10-10 4.0mm
5.0-13-13-13 3.8mm
9.5-9.5-9.5 6mm
8.5-8.5-8.5 6mm
6.4-6.4-6.4 6mm
4
44
4-
--
-6 Relationship between the upper and lower knives
6 Relationship between the upper and lower knives6 Relationship between the upper and lower knives
6 Relationship between the upper and lower knives
Check to make sure positions G on lower knives E are
aligned with positions I on upper knife H.
Each distance between the points of the lower knives
should be 6.5mm.
4
44
4-
--
-7 Overlap of the upper and lower knives
7 Overlap of the upper and lower knives7 Overlap of the upper and lower knives
7 Overlap of the upper and lower knives
Loosen screws J. Then adjust each looper thread cutting
edge Y by referring to the cutting edge of upper knife H as
shown in the illustration below (see 4-6).

4
4
44
4-
--
-8 Adjusting the leaf springs
8 Adjusting the leaf springs8 Adjusting the leaf springs
8 Adjusting the leaf springs
Loosen screws D and remove lower knives E.
The left-to-right position of leaf springs K varies
according the gauge. Adjust this position by
referring to the illustration and the table below.
Align positions L on leaf springs K with positions I
on upper knife H. Tighten screws M.
After this adjustment has been made, replace lower
knives E (see 4-7).
Gauge Distance A
4.8-10-10-10 3.4mm
5.0-13-13-13 4.1mm
9.5-9.5-9.5 3.3mm
8.5-8.5-8.5 3.0mm
6.4-6.4-6.4 3.0mm
4
44
4-
--
-9 Relationship between lower knives, needle threads and looper threads
9 Relationship between lower knives, needle threads and looper threads9 Relationship between lower knives, needle threads and looper threads
9 Relationship between lower knives, needle threads and looper threads
After all the adjustments have been completed, confirm the following to thread and start
the machine.
■
Lower knife E should enter the needle thread loop(s).
Looper thread cutting edge Y should travel in front of the loop thread.
■
When lower knife E returns home, the needle and looper threads are hooked by their
cutting edges F and Y and pulled to the right. Then they are trimmed by the upper
knife.

5
【5】ADJUSTING THE THREAD RELEASER
5
55
5-
--
-1 Thread releaser lever
1 Thread releaser lever1 Thread releaser lever
1 Thread releaser lever
When thread releaser cylinder H gets activated, the
thread tension disks should open as soon as possible.
Adjustment is made by positioning thread releaser
lever I. After the adjustment tighten screw J (located
behind the arm) for the thread releaser lever.
5
55
5-
--
-2 Thread releaser plate
2 Thread releaser plate2 Thread releaser plate
2 Thread releaser plate
Adjust the position of thread releaser plate G so that
the tension disks will open as soon as possible.
To make this adjustment, install thread releaser bar A
to thread releaser bar connection plate F with screw E.
The top end of thread releaser bar A should protrude
50mm from the top surface of thread releaser bar guide
B. There should be a clearance of 4mm between E
ring K and thread releaser bar guide B.
5
55
5-
--
-3 Thread releaser hook
3 Thread releaser hook3 Thread releaser hook
3 Thread releaser hook
The needle threads should not protrude long from the
back side of the fabric at the start of sewing.
Loosen screw C and adjust the position of thread
releaser hook D. To decrease the amount of the
threads to be supplied, raise the thread releaser hook.
To increase the amount of the threads to be supplied, lower the thread releaser hook.
Note that the stitches are not formed at the start of sewing if the amount is too little.
【6】SAFETY DETECTOR
■
The safety detector is included so that the machine will
not start running until the thread trimmer cuts the
threads and returns home safely.
Switch A must be kept pressed (ON) during sewing
(with the thread trimmer completely returned home).
Adjustment is made by loosening screws B and E and
moving brackets C and D.

6
【7】ADJUSTING THE SPEED CONTROLLER AND AIR PRESSURE
■
Speed controller F controls the speed when the thread
trimming knife carriers protrude.
Speed controller G controls the speed when the thread
trimming knife carriers retract. If the screw for F is too
loosened, the carriers will protrude too fast and then the
position of the lower knives will become unstable, causing
cutting error. If the screw for G is too loosened, the
carriers will retract too fast and then the looper threads
may not be held properly. The speed controllers are
factory-set (see the illustration in [6] ).
【8】ADJUSTING THE PRESSER FOOT LIFT
■
The foot lift should be 7mm above the top surface of the
needle plate. To make this adjustment, loosen screw D
for crank lever C and then set the clearance between slot
A on the presser bar clamp connection plate and screw B
at 0.5~1mm.
■
When the air cylinder on the pneumatic presser foot lift
gets actuated, the presser foot lift should be 7mm above
the top surface of the needle plate.
To make this adjustment, position stopper E so that lever
G cannot be lowered. After stopper E has been
positioned, secure stopper E with nut F.
< Note >
Set the regulator at 4~5kgs/cm2. To decrease the pressure,
turn the adjusting knob clockwise. Too fast speed will give a
shock to the knife carriers. Then the threads will be cut
before they are cut by the knives or the threads will not be
held properly. It may cause trouble.

8
【9】ADJUSTING THE AIR BLOWER
■
When the needles are at the top of their stroke, set air
blower C so that air blower outlet A is 1~2mm below
the center of the left needle's eye.
Adjustment is made by loosening screws B.
Adjust the amount of air with speed controller D.
The amount should be as little as possible.
Turning the adjusting screw clockwise decreases the
amount. Turning the adjusting screw
counterclockwise increases the amount. The air must
blow through behind the needles. If the air blows
through in front of the needles, it may cause the needle
threads to be removed from the needles.
< Note >
The air blowing time is factory-set at 1.5 sec's.
Therefore remove the fabric from the machine as soon as
the threads are cut and the presser foot is raised.