KANSAI SPECIAL SX Series User manual

INSTRUCTION
Industrial Sewing Machines
SX6803PD
(Differential feed)
SX6803P
(Plain feed)
Second edition : January 2005
No. 040111

INTRODUCTION
Thank you for your purchasing Kansai Special's SX6800 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
Zip code
Model
0 4 0 0 0 0 1
Serial number
The date of manufacture

CONTENTS
1. SPECIFICATIONS
1-1 Description ···············································1
1-2 Stitch type ················································1
2. NEEDLES & THREADING THE MACHINE
2-1 Needles ····················································1
2-2 Replacing the needle ··································1
2-3 Threading ················································2
3. MACHINE SPEED
3-1 Machine speed & direction in which the
machine pulley runs ·································2
3-2 Motor & belt ·············································3
4. LUBRICATION
4-1 Oil ··························································3
4-2 To fill the machine with oil ·························3
4-3 To check for proper oil flow ·························3
4-4 Putting a small amount of oil ······················4
4-5 Replacing the oil ·······································4
4-6 Cleaning the filter element ·························4
< Note >
All of adjustment categories for SX6803PD
and SX6803P are same, expecting feed dog
& stitch length adjustment, category No.8.
5. SEWING MACHINE INSTALLATION
5-1 Cutting the machine table ··························5
5-2 Installing the mount base ···························9
5-3 Installing the machine ·······························9
5-4 Installing the pulley cover ··························9
6. TIMING OF THE LOOPERS TO THE NEEDLES
6-1 To adjust the timing ································ 10
6-2 Angle and height for installing the loopers ·· 11
6-3 Looper setting distance ···························· 11
6-4 Needle height ········································· 11
6-5 Installing the needle holder ······················ 12
6-6 Relationship between the needles and
needle plate ··········································· 12
6-7 Needles/loopers front-to-back relationship ··· 12
6-8 Adjusting the amount of looper front-to-back
movement ············································· 13
7. ADJUSTING THE NEEDLE GUARD ····· 13
8. ADJUSTINGTHEFEEDDOGS&STITCHLENGTH
SX6803PD (Differential feed)
8-1 To install and adjust the feed dogs ············· 14
8-2 Stitch length ··········································· 15
8-3 Adjusting the differential feed ··················· 15
SX6803P (Plain feed)
8-4 Feed dog height ······································· 16
8-5 Feed dog front-to-back ····························· 16
8-6 Stitch length ··········································· 16
9. ADJUSTING THE PRESSER FOOT
9-1 Presser foot pressure ································17
9-2 Disassembling and reassembling the
presser foot ············································17
9-3 Presser foot lift ········································17
9-4 Adjusting the thread releaser shaft ············18
10. ADJUSTING THE FEED ROLLER
10-1 Adjusting the movement amount of the
feed roller ·············································18
10-2 Feed roller pressure ·······························18
10-3 Disassembling, reassembling and adjusting
the feed roller ·······································19
11. ADJUSTING THE STITCH FORMATION
11-1 Needle thread tension ·····························19
11-2 Looper thread tension ·····························20
12. CLEANING THE MACHINE ···················20

【1】SPECIFICATIONS
< 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.
1-1 Description
High speed feed-off-the-arm machines with
differential feed
1-2 Stitch type
JIS401 double chainstitch machines
【2】NEEDLES & THREADING THE MACHINE
2-1 Needles
TV×3 of Schmetz or Organ
Select the proper needle for the fabric and thread.
< Needles and needle size >
Schmetz TV×3 Nm90 Nm100 Nm110 Nm125 Nm130 Nm140
Organ TV×3 # 14 # 16 # 18 # 20 # 21 # 22
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).
1

2-3 Threading2-3 Threading
Thread the machine correctly by referring to the illustration below.Thread the machine correctly by referring to the illustration below.
To thread the loopers, lay the looper holder down using the looper drawing device.To thread the loopers, lay the looper holder down using the looper drawing device.
■To lay the looper holder down■To lay the looper holder down
When the needle bar is at the bottom of its stroke, press push button G.When the needle bar is at the bottom of its stroke, press push button G.
Threading is easy.Threading is easy.
< Note >
Run the machine at 3,500 spm for the first 200 hours
(approximately 1 month) for durability.
The handwheel turns counterclockwise as shown in
the illustration.
【3】MACHINE SPEED【3】MACHINE SPEED
3-1 Machine speed & direction in which the machine pulley runs
Maximum speed : 4,500 spm (4,000 spm for normal use)
A，B，C .. Needle threads
D，E，F .. Looper thread
2

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 in the table below.) Position the motor by pressing the finger onto the
mid-point of the belt so that 1~2cm deflection can be achieved (see the illustration).
Machine speed
Motor pulley outer
diameter 50Hz 60Hz
75 ㎜3500SPM
85 ㎜4000SPM
90 ㎜3500SPM
95 ㎜4500SPM
100 ㎜4000SPM
110 ㎜4500SPM
【4】LUBRICATION
4-1 Oil
Use Kansai Special's genuine oil. (Part No.28-617)
4-2 To fill the machine with oil
Remove screw A and B from the oil hole.
Fill the machine with oil until the oil level reaches the top
line on oil gauge E and D. Maintain the oil level between
the lines of the gauges. After filling the machine with oil,
run the machine to check the oil is splashing to oil flow
sight window C and F.
4-3 To check for proper oil flow
When starting a new machine after filling the reservoirs,
or when beginning to operate a machine that has been idle
for some time, it may be necessary to prime the pump.
To do this, remove the two plug screw G.
Apply oil from an oil can to these holes and operate
machine until bubbling can be observed at the windows.
3

4-4 Putting a small amount of oil
Put a small amount of oil onto the positions shown in the illustration.
4-5 Replacing the oil
To extend machine life, replace the entire oil after the first 200 hours of operation.
Thereafter replace the oil every 6 months. To drain the oil, remove screw I and J.
< Note >
Contaminated oil may shorten machine life. Replace the oil as early as possible.
4-6 Cleaning the filter element
Before replacing the oil, remove reservoir K and
clean the cylinder, inside of the reservoir and filter
element. Also remove the oil pump and clean the
filter element L. If these parts are contaminated,
proper oiling may not be performed.
4

【5】SEWING MACHINE INSTALLATION
5-1 Cutting the machine table
■Type A (clutch motor)
5

■Type B (clutch motor)
6

■Type C (servo motor)
7

8

5-2 Installing the mount base
Refer to the Parts list page 25~30,60~65.
■Install the mount base correctly by referring to the
illustration right.
5-3 Installing the machine
■Install the machine correctly by referring to the
illustration right.
5-4 Installing the pulley cover
■Install the pulley cover correctly by referring to the
illustration right.
9

【6】TIMING OF THE LOOPERS TO THE NEEDLES
■Timing of the looper to the needle is factory-set properly.
However, when disassembling the needle bar mechanism, looper mechanism or using a
new part, this timing should be readjusted. Refer to the following procedures.
6-1 To adjust the timing
1. Remove the needle, needle plate, presser foot, feed
dog and auxiliary feed dog and feeding roller.
2. Remove the front looper. Then install test bar A
(diameter : 3.97). Tighten screw B.
3. With the looper holder at the extreme right end of
its travel, position test bar A so that it is normal to
the throat plate. Adjustment is made by
loosening screw C and positioning the looper
holder again.
4. Bring test bar A to the extreme left end of its
travel. Then install the needle plate.
5. Turn the machine pulley counterclockwise slowly
until the test bar touches slightly the needle plate.
6. Fit timing gauge D onto the underside of the
machine head. Then secure it on the needle bar.
7. Turn the machine pulley clockwise slowly until
timing gauge D touches the machine head or test
bar A touches the needle plate.
Clearance between timing gauge D and the
machine head or test bar A and the needle plate
should be within 0.1mm. If it is, the timing will
be correctly achieved. If it is more than 0.1mm,
follow the procedures below.
8. Remove the cover of the crank chamber and
packing. Loosen screws F of joint collar E.
If timing gauge D touches the machine head before
test bar A touches the needle plate while the
machine pulley is turned slowly clockwise, the
looper timing is fast. Therefore fix the crankshaft
and turn main shaft G clockwise.
If test bar A touches the needle plate and there is a
clearance between timing gauge D and the
machine head, the looper timing is slow.
Turn main shaft G counterclockwise.
■Every time joint collar E is readjusted, perform 6, 7 and
8 procedures repeatedly.
To do so, tighten any one of screws F temporarily.
After the adjustment has been achieved, tighten screws
F securely. Then make sure the correct timing is
obtained by referring to the above procedures.
10

6-2 Angle and height for installing the loopers
Insert loopers A, B and C fully into looper holders D, E
and F. Tighten screws G.
Height and an angle of 3°are achieved.
6-3 Looper setting distance
With the loopers at the extreme left end of their travel,
there should be a distance of approximately 3.6mm
from each center of the needles to each point of the
loopers. Adjustment is made by loosening screws H.
6-4 Needle height
When each point of the loopers passing behind the
needles has reached each center of the needles, there
should be a distance of 1.5~2.0mm from each point of
the loopers to each top of the needles' eyes.
Adjustment is made by loosening screw J of the needle
bar clamp and moving the needle bar up or down as
required.
11

6-5 Installing the needle holder
Torque the needle holder into the needle bar to 20kgf･cm.
6-6 Relationship between the needles and needle plate
When the height of the needle bar is adjusted, check to see
if each needle is centered in its needle drop hole.
6-7 Needles/loopers front-to-back relationship
The looper passes behind the needle when it moves from
the extreme left end of its travel to the right.
When the point of the looper has reached the center of the
needle, the looper should be as close to the needle as
possible with no contact between the looper and the
needle. Adjustment is made by loosening screw K on the
looper holder. When the looper moves to the left from the
extreme right end of its travel while the needle is
descending to the back of the looper blade, check to see if
the needle touches slightly the back side of the looper.
If the needle is bent by the looper or there is a clearance
between the needle and the looper, adjust the amount of
looper front-to-back movement by referring to the below.
12

6-8 Adjusting the amount of looper front-to-back movement
Remove the side cover of the cylinder. Loosen screw L (see the illustration) on the looper
avoiding rod. Move the looper avoiding rod up or down as required.
Raising the rod decreases the amount. Lowering the rod increases the amount.
< SX6803PD > < SX6803P >
【7】ADJUSTING THE NEEDLE GUARD
When the looper moves to the right from the extreme left
end of its travel, the looper passes behind the needle.
When the point of the looper has reached the centerline of
the needle, the needle should be 0~0.5mm deflected by
needle guard M. Adjustment is made by loosening screw
N. The needle guard should be installed as low as
possible. In addition, the needle must touch the needle
guard surface until the point of the looper passing behind
the needle reaches the right side of the needle.
Adjustment is made by loosening screw O.
< Note >
Since the needle guard is installed on the feed dog bracket,
the relationship between the needle and the needle guard
varies according to the stitch length. Therefore readjust the
needle guard if the stitch length is changed.
13

【8】ADJUSTING THE FEED DOGS & STITCH LENGTH
SX6803PD (Differential feed)
8-1 To install and adjust the feed dogs
■Position of the feed rocker arm eccentric pin
Eccentric pin A which is located at the middle of the
cylinder is used for a fine height adjustment on the
main and differential feed dogs.
Before installing the main and differential feed dogs,
set the groove on the eccentric pin in a vertical
position and then fasten the eccentric pin with screw
B. The above adjustment should be made in order
to raise the main and differential feed dogs
simultaneously (the extreme rear ends of these feed
dogs must be 2.5mm raised).
Assemble eccentric pin A so that the feed dogs can
be raised by turning eccentric pin A clockwise.
■To assemble the feed dogs
1. Install feed dog C with screw D.
2. Fit feed dog support E onto feed dog C and
tighten screw F.
3. Fit differential feed dog G slightly onto feed dog
C and tighten screw H.
4. Check to see if the machine pulley turns easily
with differential feed effective.
■Feed dog height
When the main feed dog is in its highest position,
the first tooth from the front should be 1.5mm above
the needle plate. Adjustment is made by loosening
screws D, F and H.
■Position of the feed rocker arm
If the feed dogs touch the slots of the needle plate at the front or back, adjust the position
of the feed rocker arm. Adjustment is made by loosening screw I, turning eccentric pin J
and moving feed rocker arm K front or back as required.
To turn eccentric pin J, tap the V groove on the brim of the pin with a tapered tool.
After this adjustment, secure feed rocker arm K and feed link L with screw I while
checking there is no play on these parts.
14

8-2 Stitch length
Adjustable from 2.1mm to 4.2mm with no steps.
The number of stitches per inch (25.4mm) is as follows.
Stitch
length Number of stitches per inch
4.2mm 6
3.6mm 7
3.2mm 8
2.8mm 9
2.5mm 10
2.3mm 11
2.1mm 12
< Note >
Screws B are used to fix the lever or to regulate an adjustable range of differential
feed ratio.
■To change the stitch length
1. Loosen screw A on the needle guard.
Move needle guard B to the extreme rear end of
the machine.
Then tighten screw A temporarily.
2. Remove rubber plug C.
3. Loosen screw D. To increase the stitch length,
move screw D upward. To decrease the stitch length, move screw D downward.
4. When the required stitch length is achieved, tighten screw D securely and then
replace rubber plug C.
5. Adjust needle guard B and tighten screw A (refer to "Adjusting the needle guard" on
page 11).
8-3 Adjusting the differential feed
To adjust the differential feed, turn differential feed
adjusting outside lever A clockwise or
counterclockwise. If lever A is aligned with the
mid-point between readings "4" and "5", the
movement amount of the main feed dog will be equal
to that of the differential feed dog.
Then the differential feed will not become effective.
■Normal differential feed (for gathering effect)
Move lever A toward reading "＋".
The maximum differential feed ratio is 1:1.3 with
lever A at reading "9".
■Reverse differential feed (for stretching effect)
Move lever A toward reading "−".
The maximum reverse differential feed ratio is 1:0.7 with lever A at reading "1".
If the top ply is left at the end of sewing, move lever A toward reading "＋".
If the bottom ply is left at the end of sewing, move lever A toward reading "−".
15

SX6803P (Plain feed)
8-4 Feed dog height
1. The top of the screw B should be 2.7mm above the top
of feed dog bracket A, and setting the feed dog.
2. Install those parts on the feed bar C with screw D and
E.
3. When the main feed dog is in its highest position, the
first tooth from the front should be 2mm above the
needle plate. Then tighten screw D and E.
4. Stopper pin F is touched under the feed dog and
tighten screw G.
8-5 Feed dog front-to-back
The feed dog should be centered front to back.
The feed dog should not touch the needle plate.
Fine adjustment is made by tightening screw C, D and
turning front to back adjusting eccentric pin A.
8-6 Stitch length
Adjustable from 2.1mm to 4.2mm with no steps.
The number of stitches per inch (25.4mm) is as follows.
Stitch
length Number of stitches per inch
4.2mm 6
3.6mm 7
3.2mm 8
2.8mm 9
2.5mm 10
2.3mm 11
2.1mm 12
■To change the stitch length
1. Loosen screw A on the needle guard.
Move needle guard B to the extreme rear end of the machine.
Then tighten screw A temporarily.
2. Remove rubber plug C.
3. Loosen screw D. To increase the stitch length, move screw D upward.
To decrease the stitch length, move screw D downward.
4. When the required stitch length is achieved, tighten screw D securely and then
replace rubber plug C.
5. Adjust needle guard B and tighten screw A (refer to "Adjusting the needle guard" on
page 13).
16

【9】ADJUSTING THE PRESSER FOOT
9-1 Presser foot pressure
The presser foot pressure should be as light as
possible, yet be sufficient to produce uniform
stitches and feed the fabric properly.
If the pressure is too light, the fabric may not be fed
evenly or skip stitching and/or uneven stitching may
occur. Adjustment is made by loosening screw A
and turning adjusting screw B.
To increase the pressure, turn adjusting screw B
clockwise. To decrease the pressure, turn adjusting
screw B counterclockwise.
9-2 Disassembling and reassembling the presser foot
■To disassemble the presser foot
Move the presser bar all the way to the up position
by pressing the presser foot lift pedal.
Loosen screw A.
■To reassemble the presser foot
Move the presser bar all the way to the up position
by pressing the presser foot lift pedal.
Install the presser foot with screw A.
Make sure the presser foot is replaced onto the flat
spot of the presser bar. The needles should drop
into the centers of the needle drop holes on the
presser foot. To make this adjustment, loosen
screw B of the presser bar clamp and turn the
presser bar.
■To adjust the presser bar clamp
Loosen screw B of the presser bar clamp with the
presser foot tightly rested on the top surface of the
needle plate. Clearance between presser foot link C
and screw D should be approximately 0.5mm.
9-3 Presser foot lift
With the presser foot tightly rested on the top
surface of the needle plate (the presser foot lift pedal
is not pressed), there should be a clearance of
approximately 0.5mm between presser foot link C
and screw D of the presser bar clamp.
To make this adjustment, adjust screw J on the
presser foot lift lever or screws L.
17