kansai wx-8800 series Owner's manual

Industrial Sewing Machines
WX-8800 SERIES
TECHNICAL
INSTRUCTION MANUAL
fj) MORIMOTO MFG. CO., LTD.
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Tables of Contents
1. Looper Needle Timing
Page 1
1-1 The looper and the looper carrier
1-2 Looper-Needle synchronization
1-3 Looper-Needle distance
1-4 Needle height
1-5 Looper-Needle clearance
1-6 Adjustment of the looper avoid angle
1.7 Needle deflection
2. The Needle Guards
2-1 Position of the rear needle guard
2-2 Position of the front needle guard
3. The Top Cover Looper
8
3-1 Position of the top cover looper
3-2 Position of the top cover thread guide
3-3 Top cover looper timing
4. Feed Dogs and Stitch Length
12
4-1 Feed dog height and level
4-2 Adjustment of the stitch length
4-3 Adjustment of the differential feeding
5. Presser Foot Adjustments
15
5-1 Position of the foot
5-2 Presser foot lift height
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6. Stitching Adjustments
6-1 Position of the silicone tank eyelet
6-2 Adjustment of the needle thread take up 16
6-3 Needle thread take up control 17
6-4 Needle thread take up wire
6-5 Thread nipper location 18
6-6 Cover thread take up and take up eyelet 19
6-7 Position of the looper thread take up eyelets
6-8 Looper thread take up cam 21
6-9 Height of the guide plate
7. The Timing Belt
22
7-1 Timing belt markings
7-2 Changing the timing belt
8. Lubrication System
25
8-1 Placing the oil in the machine
8-2 Oil flow rate
9. The Tabletop
26
9-1 Tabletop cutout design specification 26
9-2 Mounting the machine
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Thank you for purchasing a KANSAI SPECIAL WX SERIES MACHINE.
This instruction manual is a technical service manual featuring specific information regarding the
adjustments and settings of the machine.
1. LooperfNeedle Timing
he Looper And The Looper Carrier
The shaft of the looper is set into the top of the looper carrier ("A", Fig 1) and fastened in place
with the set screw ("B", Fig 1). The height and the position of the looper are automatically set as
long as the looper is set fully into the looper carrier and the set screw is tightened squarely onto
the flat on the looper shaft.
By design, the inner surface of the looper is offset three degrees away from the horizontal plane
(see Fig 2).
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Looper-Needle Synchronization
The timing (synchronization) of the looper and
needles are equal for the leftwards movement as for
the return movement. As the looper moves to the left,
behind the needles: As the tip of the looper reaches
the center of left needle, the dimension from the tip of
the looper to the top of the eye of the left needle must
be 1 to 1.5mm (see Fig 3A). As the looper returns to
the right, in front of the needles: As the tip of the
looper reaches the center of the left needle, the
dimension from the tip of the looper to the top of the
eye of the left needle must be 1 to 1.5mm (Fig 3B).
Adjustment of the looper-needle timing is done by
removing the top housing cover, loosening the set
screwsCA") on the top timing pulley, and moving the
position of the timing pulley on the top shaft
accordingly (see Fig 4).
Looper-Needle Distance
At the time the needles are in their lowest position,
the looper is in its rightmost position. At this time,
the distance from the tip of the looper to the center of
the middle needle (needle bar center) must be 6.5mm
(Fig 5). This dimension is standard for all gauge sizes.
Because it is common practice to measure the looper-
needle distance from the tip of the looper to the
center of the right needle (Fig 6), corresponding
looper-needle distances for various gauge sizes are
shown on chart 1.
Fig 3A
Fig 3B
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Chart 1
Gauge width
"A"
1/8" (3.2mm)
4.9mm
5/32"(4.0mm)
4.5mm
3/16"(4.8mm) 4.1mm
7/32"(5.6mm)
3.7mm
1/4" (6.4mm)
3.3mm
Needle Height
As the looper moves to the left, behind the needles,
the tip of the looper reaches the center of the left
needle. At this time, the distance from the tip of
the looper to the top of the eye of the needle must
be 1 to 1.5mm (Fig 7). If the needle height needs
adjusting, remove the face plate to gain access to
the clamp screw ("A", Fig 8). Loosen the clamp
screw by using A 3mm hex key wrench. Adjust the
height up or down as needed. Retighten the clamp
screw.
Note
1. Do not overtighten the screw more than 3 to 4 ft.
lbs. (30 to 35 kgcm) torque.
2. When tightening the clamp screw, be sure the
needles are in alignment with the needle holes in
the needle plate (Fig 9).
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(^^^^Looper-Needle Clearance
As the looper moves to the left, behind the needles,
the tip of the looper will lightly brush against the
right needle (zero clearance). As it continues
across and passes behind the left needle, the
clearance will be 0.1 to 0.15mm. The same
conditions apply to both two and three needle
models (see Fig 10 and 11).
To make an adjustment, first check to see that the
needles are in proper alignment with the needle
holes in the needle plate (Fig 9). Next, check to be
sure the looper is set so that the set screw is
positioned squarely on the flat of the looper shaft
(see Fig 1). Next, check to be sure that the looper
avoid angle is appropriate (see section 1-6).
Three Needle Gauge
Two Needle Gauge
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Adjustment Of Looper Avoid Angle
The looper avoid motion, or path, has a
standard offset angle such that the tip of the
looper just brushes the back surface of the right
needle and has a clearance of 0.1 to 0.15mm as
it passes behind the left needle, (see Fig 12).
In the WX series of machines, the looper avoid
angle is adjustable for obtaining improved
results under various sewing conditions.
To adjust, loosen the set screw ("B", Fig 13) on
the avoid eccentric ("A", Fig 13), and move the
eccentric forward or backward on the shaft as
needed. Moving the timing mark forward (in
the "X" direction. Fig 14) decreases the avoid
angle. Moving the timing mark backward (in
the "Y" direction. Fig 14) increases the avoid
angle. Standard looper avoid angle is achieved
when the timing marks are aligned.
Caution
The adjustment of the looper avoid angle is
intended for slight variations only. Large
variations in looper avoid angles in either
direction may result in skip stitching.
©
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Needle Deflection
As the needles move downward and the looper
moves to the right, the left needle must contact
the back of the looper 3 to S.Snim behind the eye
of the needle (see Fig 15). The left needle must
deflect off the back 1/3 of the looper, appro
ximately 0.3 to 0.6mm (see Fig 16).
If heavier needles are used, the looper position
may need to be adjusted. Loosen the nut on the
stop pin for the looper avoid rod (Fig 17).
Reposition
the looper by turning the screw ("A",
Fig 17). By turning the screw clockwise, the
assembly will move in the "X" direction (see
Fig 18). This will decrease the looper avoid
motion. By turning the screw counterclockwise,
the assembly will move in the "Y" direction.
This will increase the looper avoid motion. The
standard amount of looper avoid motion should
be 2.3 to 3.1mm.
By decreasing the looper avoid motion, needle
breakage may occur because of too much
contact between the looper and needles and
increased friction. By increasing the looper
avoid motion, skip stitching may occur.
3~3.5mm
0.3'^0.6mm
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2. The Niedle Guards
Imposition Of The Rear Needle Guard
At the time the needles are in the lowest
position, the height of the rear needle guard
must be arranged so that the contacting edge
("a", Fig 19) lines up with the eye of the right
needle (see Fig 19). Also at that time, the
clearance and orientation to the needles must
be such that there is a 0.3 to 0.4mm clearance to
the right needle and a 0.6 to 0.7mm clearance to
the left needle (see Fig 19). Adjust by loosening
screws "B" and "C" (Fig 22) and position as
needed. Retighten all screws.
As the looper moves to the left and the tip of the
looper reaches the center of the right needle (see
Fig 20), the needle guard must be contacting the
right needle to make a "zero clearance" (0 to 0.
05mm) between the looper tip and the scarf of
the right needle (see Fig 20).
As the looper continues across and the tip of the
looper reaches the center of the left needle,
there should be a clearance of 0.15 to 0.2mm
between the left needle and the rear needle
guard (see Fig 21).
At this time, the rear needle guard does not
contact the needles.
All adjustments to height and position orien
tation are done with screws "B" and "C" shown
in figure 22.
Fig 20
Fig 22
0—0.05mm
0.1~0.15mm
0.15—02mm
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Position Of The Front Needle Guard
As the looper moves to the left behind the
needles, and the tip of the looper reaches the
center of the left needle, the clearance between
the front of the needles and the front needle
guard must be 0 to 0.5mm (see fig 23). Adjust by
loosening screw "B" and repositioning the front
needle guard appropriately. Retighten the
screw "B".
3. The Tdp Coyer Looper
Position Of The Top Cover Looper
The height of the top cover looper should be
9.0 to 11.0mm above the top surface of the
needle plate (see Fig 24).
Recommended height for the top cover looper
for gauge sizes 1/8", 5/32", and 3/16" is 9.0mm,
Recommended height for gauge sizes 7/32" and
1/4" is 11.0mm (see chart 2). To adjust the
height of the top cover looper, loosen the clamp
screw ("B". Fig 25) and position up or down as
needed. Retighten the screw securely.
Chart 2
Gauge Looper Height Gauge Looper Height
11.0mm
11.0mm
11.0mm
9.0mm
9.0mm
Fig 24
SMImm
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Top Cover Looper Cont'd
As the top cover looper moves across the front
of the needles, the clearance between the front
of the left needle and the tip of the thread hook
must be 0.3 to 0.8mm (see Fig 26). To adjust,
loosen the set screw ("B", Fig 25), reposition as
necessary, and retighten the set screw securely.
As the top cover looper is in its leftmost
position, the tip of the thread hook should be
4.5 to 5.5mm to the left of the center of the left
needle (see Fig 27). To adjust the leftmost
position, loosen the set screw ("C", Fig 25),
move left or right appropriately, and retighten
the set screw securely.
To adjust the stroke of the top cover looper,
loosen the nut ("D", Fig 28) and move the
connecting pin up or down the slot of the lever.
Moving the pin in the "b"direction increases the
stroke. Moving the pin in the "a" direction
decreases the stroke (see Fig 28). Retighten the
nut.
4.5~5.5mm
Fig 28
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Position Of The Top Cover Thread Guide
The distance from the top of the top cover
looper ("A", Fig 29) to the bottom of the top
cover thread guide ("D", Fig 29) should be 0.5 to
0.8mm. Also, at the time the top cover looper is
in its rightmost position, the tip of the thread
hook should be visible in the center of the slot of
the top cover thread guide (see Fig 30). To
adjust the position of the top cover thread
guide, loosen the screws CA" & "B", Fig 31) and
position the thread guide as needed. Screws "A"
are used to adjust up or down and screws "B"
are used to adjust right or left. Retighten the
screws.
At the time the needle bar is in its lowest
position, the distance from the top of the top
cover thread guide("D", Fig 29) to the bottom of
the top cover thread eyelet ("B", Fig 29) should
be 1.0mm (see Fig 29). Also, at that time, the
center of the hole in the top cover thread eyelet
("B", Fig 32) and the tip of the slot in the top
cover thread guide ("D", Fig 32) must be in
alignment (as in Fig 32). To adjust the height
and the alignment of the top cover thread
eyelet, loosen the set screw ("G", Fig 32) and
position accordingly. Retighten the screw.
Fig 29
Fig 30
Fig 32
O.Smm
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Top Cover Looper Timing
The timing of the top cover looper may be
adjusted to accommodate various sewing
conditions according to the type of thread used.
To adjust, remove the top cover of the machine,
loosen the set screws ("A", Fig 33) on the top
cover eccentric, and move forward or backward
as nesessary. Moving the timing mark in the
direction of "E" (see Fig 34) will increase the
speed of the timing. Moving the timing mark in
the direction of "F" will decrease the speed of
the timing of the top cover looper. Retighten the
set screws.
Fig 33
Fig 34
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4. Front And Rear Feed Dogs And Stich Length Adjustments
^ Feed Dog Height And Level
At the time the needle bar is in its highest
position, the feed dogs should be in their
highest position. At this time, the distance from
the top of the needle plate surface to the tip of
the feed dog tooth must be 1.0 to 1.2mm (see Fig
35).
The front ("A") and the rear ("B") feeder
heights must be the same, but because they are
moved by different mechanisms, they are
adjusted separately. To adjust the height of the
front and rear feeders, loosen the screw at the
base of each feeder (see Fig 36) and move up or
down to the proper height. Retighten the
screws.
The feeders must also be level to the surface of
the needle plate.
To adjust the level of the feeders, remove the
back cover on the bed of the machine. Loosen
the set screw ("D", Fig 37) with a 2.5mm hex key
wrench (access to the screw is through hole "C"
in the bed as seen in Fig 37). After the set screw
is loosened, turn the leveling eccentric ("F" Fig
37) with a screwdriver as shown until the level is
found. Retighten screw D.
1.0—1.2mm
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Adjustment Of The Stitch Length
The stitch length may be adjusted from 1.4 to 3.6
mm (stitch density of 7 to 18 stitches/inch). See
chart 3 for conversions from stitch length (mm)
to stitch density (stitches/inch).
Note
Before making any adjustments to the stitch
length, be sure the motor is switched off !
To change the stitch length, push the button
("A" Fig 38) with the left hand until it contacts
the inner machanism. While maintaining
pressure on the button, slowly turn the
handwheel clockwise with the right hand. At a
certain position the button will drop down
further. (The pin on the end of the button has
dropped into the notch on the stitch length
eccentric). While holding the button down, turn
the handwheel to adjust the stitch length.
Turning the handwheel clockwise (in the
direction of the "S" marked on the handwheel)
will make the stitch shorter. Turning the
handwheel counter-clockwise (in the "L"
direction) will make the stitch longer. The brass
stud ("B" Fig 39) is for reference when
adjusting and setting the stitch length.
Occasionally release the stitch length
adjustment button and check to determine if
the desired stitch length has been attained.
Note
Be sure the pushbutton, "A", has been fully
released before resuming sewing.
Chart 3
Stitch Length Stitch Density
3.6mm
7.0 ST/IN
2.4mm
10.5 ST/IN
1.4mm
18.0 ST/IN
1)1
13
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Adjustment Of The Differential Feeding
To obtain the required differential feeding,
loosen the hand nut ("A", Figs 40 and 41) and
move the lever ("B", Fig 40) up or down as
necessary. If the mark on lever "B" is lined up
with the "1" mark ("C" Figs 40 and 41) on the
gauge plate, the feeding will be the standard 1:1
ratio. By moving the lever up above the "1"
mark, the differential feed ratio can be
increased to a maximum of 1: 2. By moving the
lever down below the "1" mark, the differential
feed ratio can be decreased to a minimum of 1:0.7.
Retighten the hand nut "A".
It is possible to vary the differential feed ratio
during the sewing operation. To do this,
connect a chain, fastened to a foot pedal, to the
front of the lever (point "E", Fig 40). Next,
loosen the hand nut, "A". Then set the
differential range (maximum up and down
positions of the lever) with the stoppers ("D",
Fig 41). For this type of operation, do not
retighten the hand nut "A".
Chart 4
Fig 40
mBi
The maximum range of dif
ferential feed ratio is limited to
the stitch length used. Refer to
chart 4.
Stitch Length
Max. Ratio
Min. Ratio
3.6mm
1:1.2
1:0.7
2.5mm
1:1.6 1:0.7
2.0mm
1:1.8
1:0.7
1.4mm
1:2.0
1:0.7
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5. Presser /Foot Adjustments
-f Position Of The Foot
The presser foot must be set on the presser bar
such that the needles pass through the holes in
the presser foot with equal clearance on both
sides (see Fig 42). To adjust, loosen the clamp
screw ("A", Fig 42) and move right or left to
attain the correct position. Retighten the clamp
screw.
Presser Foot Lift Height
In the case of machines equipped with a top
cover looper, the presser should lift no higher
than 7mm, measured from the top surface of
the needle plate to the bottom of the presser
foot. When the presser is at full lift height, it
should never exert any pressure against the top
looper that may distort its shape. Machines
without a top cover looper may have a presser
foot lift height of up to 8mm.
To limit the presser lift height, there is a stop
screw ("B", Fig 44) positioned below the lifter
lever on the back of the machine. Loosen the
lock nut ("C", Fig 44) and position the head of
the screw up or down to change the lift range.
Turning the screw clockwise allows the foot to
lift higher. Turning the screw counter
clockwise decreases the amount of foot lift.
Retighten the lock nut after the proper foot lift
height has been attained.
Fig 42
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6. Stitching Adjustments
Position Of The Silicone Tank Eyelet
The standard position for the silicone tank
eyelet is such that the distance from the center
of the screw to the center of the thread holes
should be 15 to 20mm (see Fig 45). To adjust,
loosen the screw ("A", Fig 45) and move up or
down as needed. Retighten the screw securely.
Fig 45
6^ Adjustment Of The Needle Thread Take Up
At the time the needle bar is at its lowest
position, the take up should be horizontal. To
adjust, place the needle bar at its lowest
position, loosen the clamp screw ("D", Fig 46)
and position appropriately to level. Retighten
the clamp screw.
The distance from the eyelets to the first screw
("B", Fig 46) should be 55mm, as shown in Fig
46. To adjust the distance, loosen screws "B"
and "C" and move the take up eyelet to the
right or left as necessary. By increasing the
distance (moving the eyelet to the left), less
needle thread will be fed into the stitch. By
decreasing the distance (moving the eyelet to
the right), more needle thread will be fed into
the stitch. Retighten screws "B" and "C".
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Needle Thread Take Up Control
The stroke of the needle thread take up is
adjustable. This is done by repositioning the
drive lever located under the top cover of the
machine. The standard position is 5.5mm from
the face of the collar as shown in figure 47. To
adjust, remove the top cover. Loosen the clamp
screw ("A", Fig 47). Moving the drive lever closer
to the collar will increase the stroke, resulting in
larger needle loops. Moving the drive lever
farther away from the collar will decrease the
stroke, resulting in smaller needle loops.
Retighten the clamp screw securely.
The needle Thread Take Up Wire
The standard position of the needle thread take
up wire("B", Fig 48) is such that the top surface
of the wire is in-line with the center of the holes
in the needle bar eyelet ("A", Fig 48) when the
needle bar is at its lowest position. Height
adjustments to the take up wire may be made to
accommodate the different characteristics of
the various threads used. If a slick, stretchy
type of thread such as texturized polyester or
nylon is used, the position of the take up wire
may be raised to take out more thread and
improve the needle thread loop formation. If a
stiff, non-stretchy type of thread such as 100%
cotton is used, the height of the thread take up
wire should be lowered to prevent the formation
of needle thread loops that are too large. To
adjust the height of the take up wire, loosen the
screw ("C", Fig 48) and move the wire up or
down as needed. Retighten the screw.
5.5mm
17
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