kansai MAC100 User manual

INSTRUCTION
INSTRUCTIONINSTRUCTION
INSTRUCTION
Industrial
IndustrialIndustrial
Industrial Sewing
SewingSewing
Sewing Machines
MachinesMachines
Machines
First published : March 2003
No. 030043

M
MA AC C1 10 00 0
INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Thank you for your purchasing Kansai Special's MAC100.
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.

M
MA AC C1 10 00 0
CONTENTS
CONTENTSCONTENTS
CONTENTS
1. NEEDLES & THREADING THE MACHINE
1-1 Needles ････････････････････････････ 1
1-2 Replacing the needle ････････････････ 1
1-3 To thread the machine ･･･････････････ 1
2. MACHINE SPEED
2-1 Machine speed & direction in which the
machine pulley runs ･････････････････ 2
2-2 Motor & belt ････････････････････････ 2
3. LUBRICATION
3-1 Oil ･････････････････････････････････ 3
3-2 To fill the machine with oil ･･･････････ 3
3-3 Replacing the oiland the filter element ･･ 3
4. SEWING MACHINE INSTALLATION
4-1 Cutting the machine table ･･･････････ 4
4-2 To install the machine ･･･････････････ 5
5. TIMING OF THE LOOPER TO THE NEEDLE
5-1 Needle height ･･･････････････････････ 5
5-2 Needle drop and needle side stroke ･･･ 6
5-3 To install the looper ･････････････････ 6
5-4 Position of the looper rocker ･･････････ 7
5-5 Looper left-to-right movement ････････ 7
5-6 Looper/needle front-to-back relationship ･8
5-7 Looper setting distance ･･････････････ 8
5-8 Adjusting the looper back spring ･･････ 8
6. ADJUSTING OF NEEDLE GUARD ･････ 9
7. ADJUSTING THE PRESSER FOOT
7-1 Presser foot pressure ･････････････････9
7-2 Position of the presser footand foot lift ･･･9
8. ADJUSTING THE STITCH FORMATION
8-1 Adjusting the looper thread eyelets ･･･10
8-2 Position of the looper thread take-up ･･･10
8-3 Adjusting the needle thread guard ･･･10
9. ADJUSTING OF FEED MECHANISM
9-1 Position of motor shaft lever ･････････11
9-2 Adjusting of motor spring ･･･････････11
9-3 Adjusting of feed dog height ･････････11
9-4 Adjusting of stitch length ････････････12
9-5 Lubrication ････････････････････････12
9-6 Position of sensor ･･･････････････････12
10. CLEANING THE MACHINE ･･････････13
11. OPERATION PANEL AND CONTROL
BOX
11-1 Mounting and wiring of control box ･･･14
＊In case of single phase, three phase･･･15
11-2 Mounting of position transmitter ･････16
11-3 Connecting of earth terminal ････････16
11-4 Operation panel ････････････････････17
11-5 Other function ･････････････････････22

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【1】NEEDLES & THREADING THE MACHINE
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-1 Needles
1 Needles1 Needles
1 Needles
UO163 of Schmetz or Organ
Select the proper needle for the fabric and thread.
< Comparison table of needle sizes >
Schmetz UY163GAS Nm65 Nm70 Nm75 Nm80 Nm90
Organ UO163 # 9 #10 #11 #12 #14
1
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1-
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-2 Replacing the needle
2 Replacing the needle2 Replacing the needle
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).
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1-
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-3 To thread the machine
3 To thread the machine3 To thread the machine
3 To thread the machine
Thread the machine correctly by referring to the illustration below. Incorrect threading
may cause skip stitching, thread breakage and/or uneven stitch formation.
Furthermore, set the thread eyelet D, screw C, screw E (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.
A ... Needle threads
B ... Looper threads

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【2】MACHINE SPEED
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-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
Maximum speed : 2,500 rpm
Standard speed : 2,000 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).
2
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-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 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
40 1650 1950
50 2050 2450
60 2500 2950
70 2900 3450

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【3】LUBRICATION
3
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3-
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-1 Oil
1 Oil1 Oil
1 Oil
Use Kansai Special’s genuine oil
(Part No. 28-611)
3
33
3-
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-2 To fill the machine with oil
2 To fill the machine with oil2 To fill the machine with oil
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
from oil pipe outlet B.
3
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3-
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-3 Replacing the oil and the filter element
3 Replacing the oil and the filter element3 Replacing the oil and the filter element
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 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.

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【4】SEWING MACHINE INSTALLATION
4
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-1 Cutting the machine table
1 Cutting the machine table1 Cutting the machine table
1 Cutting the machine table

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2 To instal
To instalTo instal
To install the machine
l the machinel the machine
l 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 correctly.
【5】TIMING OF THE LOOPER TO THE NEEDLE
5
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-1
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1 Nee
NeeNee
Needle height
dle heightdle height
dle height
When the needle bar is at the top of its stroke
(needle position 2~3), there should be a distance of
approximately 9~9.5mm from the top surface of the
needle plate to the point of the needle.
Adjustment is made by loosening screws A.
< Note >
After the above adjustment is made, check to make
sure each needle drops correctly into the center of
each needle drop hole.

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2 Needle drop and needle side stroke
Needle drop and needle side strokeNeedle drop and needle side stroke
Needle drop and needle side stroke
The needle side stroke on this machine is 5.55mm. To increase the stroke, loosen screw
B and move it up in the slot. To decrease the stroke, loosen screw B and move it down in
the slot. The point of the needle should be centered left to right between fingers of the
needle plate when the needle drops to the needle plate. Adjustment is made by
loosening screw C. The needle side stroke movement should start when the point of the
needle moves up from the top surface of the needle plate. The needle side stroke
movement should stop when the point of the needle reaches the top surface of the needle
plate.
This timing adjustment is made by worm gear D. To adjust the position of the needle
drop, loosen screws A and turn the needle bar as required.
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-3
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3 To install the looper
To install the looperTo install the looper
To install the looper
To set the angle and height of the looper, insert the
looper fully into looper holder A and tighten screw
B.
< Note >
Position of the needle drop 1, 2, 3, 4 from the left side, 4 is the extreme right end.
4, 5, 6, 1 from the right side

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-4 Position of the looper rocker
4 Position of the looper rocker4 Position of the looper rocker
4 Position of the looper rocker
The setting distances of the looper with the needle
at position 4 and position 1 should be equal (see
5-2).
To achieve this adjustment, loosen screw A to loosen
the collar. Loosen screws B and C.
Then adjust looper rocker D and lever E.
■Example
If the setting distance with the needle at position 4
is 4mm and the setting distance with the needle at
position 1 is 5mm, move looper rocker D
approximately 1mm to right. After the adjustment
is made, tighten screws B and C securely.
Then tighten screw A with the collar fitted onto
looper
rocker D.
5
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-5 Looper left
5 Looper left5 Looper left
5 Looper left-
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-to
toto
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-right movement
right movementright movement
right movement
This adjustment should be made when the needle is
at position 1 (see 5-2). When the point of the looper,
moving to left or right position, has reached the left
side of the needle, it should be 0.5~1mm above the
top of the needle's eye. It means the timing of the
looper should be the same. (See the illustration on
the right.)
■Adjustment is made by loosening three screws F.
After the adjustment, tighten these three screws
equally.