KANSAI SPECIAL V Series User manual

INSTRUCTION 


Industrial Sewing Machines
Third edition : March 2001
No. 010012
V7100/D,DE,F,ML
W8100/D,DE,F,C
W8042
W8042-1
V7002-1S
W8103-1S

INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Thank you for your purchasing Kansai Special's V.W 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.

CONTENTS
CONTENTSCONTENTS
CONTENTS
1. NEEDLES & THREADING THE MACHINE
1-1 Needles ･･････････････････････････････････････････････････････ 1
1-2 Replacing the needle ･･････････････････････････････････････････ 1
1-3 Threading the machine ････････････････････････････････････････ 1
2. MACHINE SPEED
2-1 Machine speed & direction in which the machine pulley runs ･････ 3
2-2 Motor & belt ･･････････････････････････････････････････････････ 3
3. LUBRICATION
3-1 Oil ･･･････････････････････････････････････････････････････････ 4
3-2 Oiling ････････････････････････････････････････････････････････ 4
3-3 Replacing the oil and the filter element ･････････････････････････ 4
4. SEWING MACHINE INSTALLATION
4-1 Cutting the machine table ･････････････････････････････････････ 5
4-2 Installing the machine ･････････････････････････････････････････ 6
5. TIMING OF THE LOOPER TO THE NEEDLES
5-1 Angle and height for installing the looper ･･･････････････････････ 6
5-2 Looper left-to-right movement ･･････････････････････････････････ 7
5-3 Needle height ･････････････････････････････････････････････････ 7
5-4 Length of the looper connecting bar ･････････････････････････････ 7
5-5 Looper setting distance ････････････････････････････････････････ 8
5-6 Needle/looper front-to-back relationship ････････････････････････ 8
6. FRONT AND REAR NEEDLE GUARDS
6-1 Position of the needle guard (rear) ･･････････････････････････････ 9
6-2 Position of the needle guard (front) ･････････････････････････････ 9
7. ADJUSTING THE FEED DOGS & STITCH LENGTH
7-1 Feed dog height ･･････････････････････････････････････････････10
7-2 Stitch length ･････････････････････････････････････････････････10
7-3 Differential feed ratio ････････････････････････････････････････10
8. ADJUSTING THE SPREADER
8-1 Position of the spreader ･･･････････････････････････････････････11
8-2 Position of the spreader thread eyelet ･･････････････････････････11
9. ADJUSTING THE PRESSER FOOT
9-1 Presser foot pressure ･････････････････････････････････････････12
9-2 Position of the presser foot & foot lift ･･････････････････････････12
10. ADJUSTING THE STITCH FORMATION
10-1 Position of the needle thread eyelet ････････････････････････････13
10-2 Position of the thread support ･････････････････････････････････13
10-3 Position of the spreader thread eyelet ･･････････････････････････13
10-4 Position of the thread eyelet of the looper thread take-up ････････14
10-5 Position of the looper thread take-up ･･････････････････････････14
11. CLEANING THE MACHINE
･･･････････････････････････････14

1
< Note >
Before 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】NEEDLES & THREADING THE MACHINE
1
11
1-
--
-1 Needles
1 Needles1 Needles
1 Needles
UY128GAS of Schmetz or Organ
Select the proper needle for the fabric and thread.
< Needles and needle size >
Schmetz UY128GAS Nm65 Nm70 Nm75 Nm80 Nm90
Organ
UY128GAS # 09 # 10 # 11 # 12 # 14
< Right needle of model-1S series >
Schmetz TV7 Nm75
Organ TV7 # 11
1
11
1-
--
-2 Replacing the needle
2 Replacing the needle2 Replacing the needle
2 Replacing the needle
When replace the needle, check the needle carefully to see
that the scarf is turned to the rear of the machine (see the illustration). Then install the
needle correctly.
1
11
1-
--
-3 Threading the machine
3 Threading the machine3 Threading the machine
3 Threading the machine
Thread the machine correctly by referring to the illustration below.
Threading the machine incorrectly may cause skip stitching, thread breakage and/or
uneven stitch formation.
A，B，C ... Needle threads
D .............. Top cover thread
E .............. Looper thread

2
A，B，C ... Needle threads
D ...............Top cover thread
E，F，G ... Looper thread
A，B，C，D ... Needle threads
E ..................... Top cover thread
F，G ...............Looper thread

3
【2】MACHINE SPEED
2
22
2-
--
-1 Machine speed & direction in which the machine pulley runs
1 Machine speed & direction in which the machine pulley runs1 Machine speed & direction in which the machine pulley runs
1 Machine speed & direction in which the machine pulley runs
Refer to the table below for maximum and standard
speeds of the Series. 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.
2
22
2-
--
-2 Motor & belt
2 Motor & belt2 Motor & belt
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 where to
position the motor by pressing the finger onto the
middle of the belt so that 1~2cm deflection can be
obtained (see the illustration on the right).
< Machine speed >
Type Maximum speed Standard speed
V7100 6000SPM 5500SPM
W8100 5500SPM 5000SPM
W8042-1 4500SPM 4000SPM
W8103-1S 3000SPM 2500SPM
< Motor pulley selection table >
Machine speed
(SPM)
Motor pulley
outer diameter
(mm) 50Hz 60Hz
60 2500 2950
70 2900 3450
80 3300 3900
90 3700 4400
100 4100 4900
110 4500 5400
120 5000 5900
130 5300 (6400)
140 5800 (6900)

4
【3】LUBRICATION
3
33
3-
--
-1 Oil
1 Oil1 Oil
1 Oil
Use Kansai Special’s genuine oil.
(Part No. 28-611)
3
33
3-
--
-2 Oiling
2 Oiling2 Oiling
2 Oiling
■
To fill the machine with oil
Remove rubber plug A from the oil hole.
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.
■
To check for proper oil flow
After filling the machine with oil, run the machine
to check the oil is splashing from oil pipe outlet B.
3
33
3-
--
-3 Replacing the oil
3 Replacing the oil3 Replacing the oil
3 Replacing the oil and the filter element
and the filter elementand the filter element
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 3-2
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
【4】SEWING MACHINE INSTALLATION
4
44
4-
--
-1 Cutting the machine table
1 Cutting the machine table1 Cutting the machine table
1 Cutting the machine table

6
4
44
4-
--
-2 Installing the machine
2 Installing the machine2 Installing the machine
2 Installing 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.
【5】TIMING OF THE LOOPER TO THE NEEDLES
5
55
5-
--
-1 Angle and height for installing the looper
1 Angle and height for installing the looper1 Angle and height for installing the looper
1 Angle and height for installing the looper
To obtain the proper angle and height, insert the
looper fully into looper holder A and then tighten
screw B.
The proper angle for the looper on V7100 and W8100
is 3°. Distance at 25mm from the point of the looper
between the bottom of the looper blade and the
extension line from the point of the looper :
Approximately 1.3mm

7
5
55
5-
--
-2 Looper left
2 Looper left2 Looper left
2 Looper left-
--
-to
toto
to-
--
-right movement
right movementright movement
right movement
When the point of the looper, moving to the left or
right, has reached the left side of the left needle,
distances As from the top of the left needle's eye to the
point of the looper should be the same.(see the
illustration on the right). To adjust the timing of the
looper to the needles, remove the machine cover, loosen
three screws C on eccentric B and then shift the
eccentric by turning the machine pulley while holding
the eccentric.
5
55
5-
--
-3 Needle height
3 Needle height3 Needle height
3 Needle height
When the needle bar is at the top of its stroke, adjust
distance A from the top surface of the needle plate to
the point of the left needle according to the gauge size
in the table below. To make this adjustment, loosen
nut B and move the needle bar up or down.
On W8042 and W8042-1, use the front needle for
reference.
Gauge size A (mm)
1/8
5/32 8.8
3/16 8.2
7/32 7.8
2-Needle
1/4 7.4
7/32 7.8
3-Needle 1/4 7.4
W8042 8.7
W8042-1 9.5
V7002-1S 9
W8103-1S 7.8
5
55
5-
--
-4 Length of the looper connecting bar
4 Length of the looper connecting bar4 Length of the looper connecting bar
4 Length of the looper connecting bar
Adjust distance A between two connecting rods
according to pitch A in the table below (see the
illustration on the right).
Adjustment is made by loosening nuts B and turning
connecting bar C as required.
Model Pitch A (mm)
V7100 100
W8100 100
W8042 102
W8042-1 105

8
5
55
5-
--
-5 Looper setting distance
5 Looper setting distance5 Looper setting distance
5 Looper setting distance
Adjust setting distance A from the point of the
looper to the center of the right needle when the
looper is at the farthest position to the right. The
point of the looper should be 1.2~1.5mm above the
top of the left needle's eye when the point of the
looper, moving to the right on the back side of the
needles, has reached the left side of the left needle.
Adjust distance A according to the needle space in
the table below.
Adjustment is made by loosening screw D (see the
illustration in 5-4).
Needle space
(inch) Looper setting distance A
3.2mm (1/8) 5.0mm
4.0mm (5/32) 4.6mm
4.8mm (3/16) 4.2mm
5.6mm (7/32) 3.7mm
6.4mm (1/4) 3.5mm
W8042 4.0mm
W8042-1 4.5mm
5
55
5-
--
-6 Needle/looper front
6 Needle/looper front6 Needle/looper front
6 Needle/looper front-
--
-to
toto
to-
--
-back relationship
back relationshipback relationship
back relationship
The clearance between the right needle and the
looper should be 0~0.05mm when the looper is
moving on the back side of the needles.
Adjustment is made by loosening screw A.
The clearance between the left needle and the
looper should be 0.2mm when the looper is moving
on the back side of the needles.
Adjustment is made by loosening screws B on the
eccentric. To increase the clearance, turn the
eccentric backward. To decrease the clearance,
turn the eccentric frontward.
< Note >
On W8042 and W8042-1, use the front needle for
reference.

9
【6】FRONT AND REAR NEEDLE GUARDS
6
66
6-
--
-1 Position of the needle guard (rear)
1 Position of the needle guard (rear)1 Position of the needle guard (rear)
1 Position of the needle guard (rear)
■Height adjustment
With needles down at bottom dead center
adjust line a of needle guard A even with the
center of the eye of the right needle.
Adjustment is made by loosening screw D,
raise or lower the guard as needed then
tighten D.
■Clearance adjustment
Clearance between the needles and rear
needle guard should be 0.0mm to 0.05mm.
Adjust by loosening screw B and turning bushing C. Turn C clockwise to move the guard
forward or counterclockwise to move the guard rearward. At this time tighten screw B
slightly.
■On -1S
When the point of the looper has reached the center of
the back side of the right needle, the distance from the
point of the right needle to line A on the needle guard
should be 0.8mm. At this time, there should be a
0mm clearance between the needle and the needle
guard.
Adjustment is made by loosening screw B.
■
On W8042 (fixed type)
When the needle bar is at the bottom of its stroke, the
distance from line A to the point of the needle should
be 3mm. Adjustment is made by loosening screw D.
■
On W8042-1
When the point of the looper has reached the right side
of the needle, the distance from line A to the point of
the needle should be 1mm and the clearance between
the needle and the needle guard should be 0mm.
Adjustment is made by loosening screw E. The height adjustment is made with
adjusting screw F.
6
66
6-
--
-2 Position of the needle guard (front)
2 Position of the needle guard (front)2 Position of the needle guard (front)
2 Position of the needle guard (front)
When the point of the looper has reached the center of
the right needle, align the center of the right needle's
eye with line A on the needle guard (front).
Adjustment is made by loosening screw B.
The clearance between the needles and the needle
guard (front) should be 0.2~0.5mm.
Adjustment is made by loosening screw C.

10
【7】ADJUSTING THE FEED DOGS & STITCH LENGTH
7
77
7-
--
-1 Feed dog height
1 Feed dog height1 Feed dog height
1 Feed dog height
When the feed dogs are at the top of their stroke, the
feed dog teeth should be 0.8~1.2mm above the top
surface of the needle plate.
Adjustment is made by loosening screws A and B.
7
77
7-
--
-2 Stitch length
2 Stitch length2 Stitch length
2 Stitch length
Loosen bolt A with a 9.5mm T wrench and turn screw
B as required. To increase the stitch length, turn
screw B counterclockwise.
To decrease the stitch length, turn screw B clockwise.
7
77
7-
--
-3 Differential feed ratio
3 Differential feed ratio3 Differential feed ratio
3 Differential feed ratio
Remove rubber plug C. Loosen nut D.
To increase the differential feed ratio, move nut D
up.
To decrease the differential feed ratio, move nut D
down.

11
【
【【
【8】ADJUSTING THE SPREADER
8
88
8-
--
-1 Position of the spreader
1 Position of the spreader1 Position of the spreader
1 Position of the spreader
The distance from the top surface of the needle
plate to the bottom surface of the spreader should
be 7~8mm. When the point of the thread carrying
notch passes the left needle, the clearance between
the point of the carrying notch and the left needle
should be 0.5~1mm. With the spreader at the
extreme left end of its travel, the distance from the
center of the left needle to the point of the thread
carrying notch should be 5~6.5mm.
Adjustments are made by loosening screws A and
B.
■
On W8042 and W8042-1
On these types of machines the needles are shifted
front to back, so the threads are pushed backward
by the auxiliary guide.
With the spreader at the extreme left end of its
travel, install the spreader correctly as shown in
the illustration. Adjustment is made by loosening
screws C.
8
88
8-
--
-2 Position of the spreader thread eyelet
2 Position of the spreader thread eyelet2 Position of the spreader thread eyelet
2 Position of the spreader thread eyelet
Set the clearance between spreader thread eyelet B
and spreader A at 0.5~0.8mm.
With the spreader at the extreme right end of its
travel, align point (a) of the spreader thread
carrying notch with the center of the slot on the
spreader thread eyelet. With the needle bar at the
bottom of its stroke, set the clearance between
spreader thread eyelet B and spreader thread
eyelet C at 1mm and align the eye of spreader
thread eyelet C with the center line of the slot on
spreader thread eyelet B.
Adjustments are made by loosening four screws D
and screw E and moving each spreader thread
eyelet up or down, or left or right.

12
【9】ADJUSTING THE PRESSER FOOT
9
99
9-
--
-1 Presser foot pressure
1 Presser foot pressure1 Presser foot pressure
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.
9
99
9-
--
-2 Position of the presser foot & foot lift
2 Position of the presser foot & foot lift2 Position of the presser foot & foot lift
2 Position of the presser foot & foot lift
Fit the presser foot onto the presser bar so that the
needle can drop correctly to the center of the
presser foot needle drop hole.
■Position of the presser foot
Loosen screw A.
Adjust by moving the presser foot left or right while
checking to make sure the needle drops correctly to
the center of the presser foot needle drop hole.
■Foot lift
For machines with the spreader, the presser foot
should be 5mm above the top surface of the needle
plate. Check to make sure presser foot does not
touch the spreader with the presser foot in the
above position. For machines without the
spreader, the presser foot should be 6mm above the
top surface of the needle plate.
After the proper foot lift is achieved, fit collar B
onto the presser bar bushing and tighten screw C.

13
【10】ADJUSTING THE STITCH FORMATION
10
1010
10-
--
-1 Position of the needle thread eyelet
1 Position of the needle thread eyelet1 Position of the needle thread eyelet
1 Position of the needle thread eyelet
The distance from the center of the eyelet of the
needle thread eyelet to that of set screw A should be
approximately 16mm (see the illustration).
Adjustment is made by loosening screw A and
moving the thread eyelet up or down.
■To tighten the needle thread, move the thread
guide up.
■To loosen the needle thread, move the thread guide
down.
10
1010
10-
--
-2 Position of the thread support
2 Position of the thread support2 Position of the thread support
2 Position of the thread support
With the needle bar at the bottom of its stroke, the
centers of the eyes on thread eyelet A should be
level with the top surface of thread support B and
thread eyelet A should be parallel with thread
support B.
Adjust the height of thread support B by loosening
screw C and moving thread support B up or down.
■To tighten the needle thread, move it up.
■To loosen the needle thread, move it down.
10
1010
10-
--
-3 Position of the spreader thread eyelet
3 Position of the spreader thread eyelet3 Position of the spreader thread eyelet
3 Position of the spreader thread eyelet
With the needle bar at the top of its stroke, there
should be a distance of approximately 13mm from
the center of the eye of thread eyelet A to part (a) on
thread eyelet B. Adjustment is made by loosening
screw C and moving thread eyelet A up or down.

14
10
1010
10-
--
-4 Position of the thread eyelet of the looper thread take
4 Position of the thread eyelet of the looper thread take4 Position of the thread eyelet of the looper thread take
4 Position of the thread eyelet of the looper thread take-
--
-up
upup
up
Align the eyes on thread eyelets B and C with mark
(a) on guide plate A. To increase the amount of
looper thread to be supplied, move thread eyelets B
and C to the back. To decrease the amount of
looper thread to be supplied, move thread eyelets B
and C to the front. Adjustment is made by
loosening screws D. Set the distance from the top
surface of guide plate A to the bottom surface of
thread guide E at 6~7mm. Adjustment is made by
loosening screw F.
Adjust the thread eyelets of the thread take-up
according to the thread and stitch length to be used.
10
1010
10-
--
-5 Position of the looper thread take
5 Position of the looper thread take5 Position of the looper thread take
5 Position of the looper thread take-
--
-up
upup
up
When the point of the left needle has reached the
bottom surface of the looper blade while the looper
is moving from the extreme left end of its travel, the
looper thread should be removed properly from
highest position B on thread take-up A.
Adjustment is made by loosening screw C.
【11】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.