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
1
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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).
1
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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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2-
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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
22
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
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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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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 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.
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-5 Looper left
5 Looper left5 Looper left
5 Looper left-
--
-to
toto
to-
--
-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.

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6 Looper/needle front
Looper/needle frontLooper/needle front
Looper/needle front-
--
-to
toto
to-
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-back relationship
back relationshipback relationship
back relationship
Adjust when the needle is at position 3 or 5 (see 5-2).
When the point of the looper is at the center of the
needle, there should be a clearance of 0mm between
the needle and the looper.
Adjustment is made by loosening screw A.
5
55
5-
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-7 Looper setting distance
7 Looper setting distance7 Looper setting distance
7 Looper setting distance
Check the looper setting distance by referring to the table below.
If the looper setting distance is not correct, perform 5-4, 5-5 procedure again.
Needle position Setting distance
(mm)
1，4 4.6
2 3.5~4.0
3，5 5.0~5.5
6 4.0~4.5
5
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-8 Adjusting the looper back spring
8 Adjusting the looper back spring8 Adjusting the looper back spring
8 Adjusting the looper back spring
It is the best that the surface of the spring touches
the looper closely within the range of B.
Check to see if the surface of the spring touches the
looper closely at least on points C within the range
of B. Spun thread #60 should be removed from the
spring at approximately 80~100g of tension.

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【6】ADJUSTING OF NEEDLE GUARD
Align the line (a) on the needle guard
(A) with the center of the needle hole
when the needle is at the bottom of
the stroke. Then, set up the
clearance at 0mm between needle and
needle guard. Adjust the height of
the needle guard with screw (D).
Adjust the front to back of the needle
guard with bush (C) by hand-turning
after loosing of screw (B). The
needle guard is forward to the front
when hand-turning to the clockwise
direction. And it is backward to the
back when hand-turning to the counter-clockwise direction. Fasten the screw (B) after
adjusting. But, do not fasten the screw (B) up so tightly. When the top of the looper has
reached the center of the needle from the right side position, Adjust the clearance at
0~0.05mm between the needle and the top of the looper. At the same time, check and
adjust the position of the line (a) on the needle guard (A), which should be positioned at
the top of the needle.
【7】ADJUSTING THE PRESSER FOOT
7
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7-
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-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 (see the illustration on the
right).
7
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7-
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-2 Position of the presser foot and foot lift
2 Position of the presser foot and foot lift2 Position of the presser foot and foot lift
2 Position of the presser foot and foot lift
The presser foot should not touch the needle.
Adjustment is made by loosening screw A and then
moving the presser foot to the right or left.
■Foot lift
Fit the collar onto the bushing with the presser foot
8.5mm above the top surface of the needle plate.
Then tighten screw B.

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【8】ADJUSTING THE STITCH FORMATION
8
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-1 Adjusting the looper thread eyelets
1 Adjusting the looper thread eyelets1 Adjusting the looper thread eyelets
1 Adjusting the looper thread eyelets
Align the eyes on the looper thread eyelets A with the
center line of the shaft. Adjust looper thread eyelets A
according to sewing conditions such as the fabric or
thread to be used by loosening screws B.
To increase the amount of the thread to be supplied,
move the eyelets backward. To decrease the amount
of the thread to be supplied, move the eyelets
frontward.
Thread guide C should be 6~7mm above the guide
plate.
Adjustment is made by loosening screw D.
8
88
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-2 Position of the looper thread take
2 Position of the looper thread take2 Position of the looper thread take
2 Position of the looper thread take-
--
-up
upup
up
When the bottom of the needle's eye has reached the
top surface of the needle plate while the needle is
descending, the looper thread taken up by looper
thread take-up E should be removed from the looper
thread take-up at point F. Adjustment is made by
screw G.
8
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-3 Adjusting the needle thread guard
3 Adjusting the needle thread guard3 Adjusting the needle thread guard
3 Adjusting the needle thread guard
With the needle bar at the bottom of its stroke, the
centers of eyes on needle bar thread eyelet A should be
level with the top surface of needle thread guard B.
Adjustment is made by screw C.
To tighten the needle thread, move up needle bar
thread eyelet A. To loosen the needle thread, move
down needle bar thread eyelet A.

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【9】ADJUSTING OF FEED MECHANISM
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-1 Position of motor shaft lever
1 Position of motor shaft lever1 Position of motor shaft lever
1 Position of motor shaft lever
Disassemble the motor cover (B) by loosing of 7
pieces of the screw (A). Align the mark (E) on the
motor shaft lever (D) to the mark (G) on the motor
mounting plate (F). Adjust and fasten the bolt (H)
to set the clearance at 1mm with parallel position
between the connecting plate (C) and the motor
mounting plate (F). To make this adjustment
easily, the side surface (N) of the motor shaft lever
(D) shall be aligned to the side surface (L) of motor
shaft.
Refer to below fig.
9
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2 Adjusting of motor spring
Adjusting of motor springAdjusting of motor spring
Adjusting of motor spring
The length of motor spring ( I ) is about 25mm.
Adjust the length by the bolt (J) and nut (K).
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-3
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3 Adjusting of feed dog height
Adjusting of feed dog heightAdjusting of feed dog height
Adjusting of feed dog height
When the motor shaft lever is positioned at 9-1. The feed dog teeth (C) and (D) should be
positioned at 0.5mm lower than the top surface of the needle plate.
Normally, adjust the height by screw (E) and (F). The eccentric pin (H) should be used
when the precise-adjustment is needed. Normally, the driver-groove of the eccentric pin
(H) is horizontal position. After loosing of the nut (G), turning the pin (H) to the
direction of clockwise, then, the height of the feed dog (C) and (D) is downward. And it is
upward when turning to the counter-clockwise. During this adjustment, be careful not
to interfere the looper (L) against the feed dog (R).
< Note >
When adjusting the position of motor shaft
lever, be careful the position of 2 places of
the flat surface on the motor shaft (M) at
the opposite side. One flat surface should
be positioned to the above-direction.
One more flat surface should be positioned
to the lateral-direction such as below fig.
Adjust and fasten the bolt (H).

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4 Adjusting of
Adjusting ofAdjusting of
Adjusting of stitch length
stitch lengthstitch length
stitch length
Loosen bolt A with a 9.5mm T-wrench.
Then turn screw J as required.
To decrease the stitch length, turn it clockwise.
To increase the stitch length, turn it
counterclockwise (see the illustration on the right).
9
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-5
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5 Lubrication
LubricationLubrication
Lubrication
Lubricate the oil in properly to the oil hole (Z)
regularly, after taking the rubber-plug (T) out from
the motor cover (B).
9
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-6
66
6 Position of sensor
Position of sensorPosition of sensor
Position of sensor
1. Initial position sensor (Refer to 9-1.)
Disassemble the motor cover (B). After loosing the screw (E), adjust the position at
1mm between the proximity sensor (H) and the detector (G).
At this adjustment, the mark (E of 9-1) on the motor shaft lever and the mark (G of
9-1) on the motor mounting plate should be aligned.
After loosening the screw (L), adjust the right-left position of the detector (G), in
order to set it to the center of the place (K) of the proximity sensor (H).

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2. Needle position sensor
Disassemble the upper base cover (S) after loosing 4 pcs. of the screw (U).
When the needle is positioned at the end of left side and also at the bottom dead point,
adjust the clearance at 2mm between the looper shaft (W) and the proximity sensor
(V), by adjusting the screw (X). During this adjustment, confirm the turning on the
lamp (Z) of the proximity sensor (V). The up-down position of the proximity sensor
(V) should be aligned to the center of the looper shaft (W), by adjusting the screw (Y).
【10】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.

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【11】OPERATION PANEL AND CONTROL BOX
11
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-1 Mounting and wiring of control box
1 Mounting and wiring of control box1 Mounting and wiring of control box
1 Mounting and wiring of control box
■
Wiring of connectors
Mount the control box (A) under the table in proper place by 4 pcs. of the screw (B).
Connect the following connectors to conformable pairs.
Parts
PartsParts
Parts Description
DescriptionDescription
Description
Proximity sensor C MOLEX 4 PIN
Stepping motor D MOLEX 6 PIN
Proximity sensor E MOLEX 3 PIN
Panel board F OMRON 26 PIN
Position transmitter G MOLEX (AMP) 6 PIN

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■
Wiring of clutch motor and control box
Connect the electric cord (E) of the
clutch motor (B) to the terminal of the
relay socket (C) in the control box.
If the electric cord of the clutch motor is
already connected to the ON-OFF switch
of the table, remove it and re-connect it
to the terminal of the relay socket (C).
Then, connect the electric cord (D) of the
relay socket (C) to the ON-OFF switch.
In case of 3 phase motor, connect to the terminal 1, 2, 4 on the upper row of the relay
socket (C). In case of single phase motor, connect to the terminal 1,2 on the upper row of
the relay socket (C). Make sure to connect the earth cord (green or green / yellow color)
to (F) together with the earth cord of the electric cord (D).
■
Wiring of the electric cord (D)
The following fig. is the wiring method of 3 phase
cord. In case of single phase, connect to only 2
cord.
Make sure to insulate one more cord (black color) by
an insulating tape etc. Also make sure to connect
the earth cord to (J).
< Specifications >
Power source:
Available in the following voltages AC 100~240V
＜Note ＞
When connecting electric cord, make sure to turn
off the switch of main power source.

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-2
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2 Mounting of position transmitter
Mounting of position transmitterMounting of position transmitter
Mounting of position transmitter
1. Mount the position transmitter (A) to the
pulley.
Then, temporary-fasten the screw (B).
2. Set the position-bar (C) to the guide groove of
the position transmitter (A).
Then, fasten the nut (D).
3. Turn on the ON-OFF switch.
4. Confirm whether the lamp of the upper dead
point and the bottom dead point (refer to 11-4.
fig. 11, 12) on the operation panel turns on at
the needle upper dead point and the needle
bottom dead point or not, by hand-turning of the
hand wheel.
■
Adjusting of the needle stopping position
1. Loosen the screw (B) slightly after taking off the
cover (A).
2. Adjusting of the needle upper dead point;
Firstly, move to keep the needle position at the
upper dead point. Then, move to adjust the
detector disc of the upper dead point (C: inner
disc-black color), until turning on the lamp of
the upper dead point (refer to 11-4. fig. 11) on
the operation panel. After that, fasten the
screw (B).
3. Adjusting of the needle bottom dead point;
Move to keep the needle position at the bottom dead point. Then, move to adjust the
detector disc of the bottom dead point (D: outer disc-red color), until turning on the
lamp of the bottom dead point (refer to 11-4. fig. 12) on the operation panel.
In this case, no need to loosen the screw (B).
11
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-3
33
3 Connecting of earth terminal
Connecting of earth terminalConnecting of earth terminal
Connecting of earth terminal
Connect the earth cord (C) of the position
transmitter (B) to the machine head (A) by the bolt
(D).
< Note >
Make sure to connect the earth cord to the machine
head. If not, it may cause to make a miss-operation.

17
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11
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-4
44
4 Operation panel
Operation panelOperation panel
Operation panel
■
Name and function
①LED (PROCESS)
Display the present setting process.
② LED (PATTERN)
Display a certain stitch number from the whole decorative stitches numbers
within process.
③ △▽ (SETTING)
④ △▽ (SETTING)
To be used to set the numerical value of ①and ②.
⑤ AUTOMATIC OPERATION KEY (AUTO)
To be used to start the sewing.
When turning off the lamp, it is impossible to start the sewing.
< Note >
Flower pattern No.4 is not available on MAC-100 yet.