INSTRUCTION
INSTRUCTIONINSTRUCTION
INSTRUCTION
Industrial
IndustrialIndustrial
Industrial
Sewing
SewingSewing
Sewing
Machines
MachinesMachines
Machines
Fourth edition : March 2001
No. 010012
DFB1404P,PMD
DFB1412P,PQ,PS
DFB1412PSM,PTV
DFB1012P,PSM
INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Thank you for your purchasing Kansai Special's DFB 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. SPECIFICATIONS
1-1 Stitch type
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1
1-2 Model
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1
2. NEEDLES & THREADING THE MACHINE
2-1 Needles
･･････････････････････････････････
1
2-2 Replacing the needle
･･････････････････････
1
2-3 To thread the machine
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2
3. MACHINE SPEED
3-1 Machine speed & direction in which the machine
pulley runs
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10
3-2 Motor & belt
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10
4. LUBRICATION
4-1 Oil
･････････････････････････････････････
11
4-2 To fill the machine with oil
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11
4-3 Replacing the oil and the filter element
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11
5. SEWING MACHINE INSTALLATION
5-1 Cutting the machine table
････････････････
12
5-2 How to install the machine
･･･････････････
17
6.
TIMING OF THE LOOPER TO THE
NEEDLES
6-1 Angle for installing the looper and position of the
looper holder bracket
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17
6-2 Looper left-to-right movement
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18
6-3 Looper setting distance
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18
6-4 Needle height
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19
7.
ADJUSTING THE TIMING OF THE RETAINER
LOOPER
7-1 Position of the retainer looper
････････････
19
7-2 Timing of the retainer looper to the needle ･20
8. ADJUSTING THE NEEDLE GUARD
8-1 Position of the needle guard
･･････････････
20
9.
ADJUSTING THE FEED DOG & STITCH
LENGTH
9-1 Feed dog height & tilt
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20
9-2 Stitch length
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21
10. ADJUSTING THE PRESSER FO O T
10-1 Presser foot pressure
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21
10-2 Position of the presser foot
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22
11. ADJUSTING THE REAR PULLER DEVICE
11-1 Manual lever
･･････････････････････････
22
11-2 To adjust the puller pressure
････････････
22
11-3 Adjusting the feeding amount of the rear
puller
･････････････････････････････････
22
12. ADJUSTING THE FRONT PULLER
DEVICE
12-1 To insert elastic and adjust the feeding amount
of the front puller
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23
13. ADJUSTING THE STITCH FORM ATIO N
13-1 Thread tension adjustment
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23
13-2 Position of the needle thread eyelets
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23
13-3 Adjusting the needle thread guard
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24
13-4 Position and timing of the looper thread
eyelet
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24
14. PSM MECHANISM
14-1 Types of cams
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24
14-2 Producing decorative stitches
････････････
25
14-3 Replacing the cams
････････････････････
27
14-4 Timing of spreaders
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27
14-5 Adjusting the spreaders
････････････････
28
15. PTV MECHANISM
15-1
Disassembling and reassembling the binder
28
15-2 Adjusting the binder up and down
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29
15-3 Position of the upper and lower fingers of the
binder
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29
16. CLEANING THE MACHINE
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1
【1】
SPECIFICATIONS
1111----1 Stitch type
1 Stitch type1 Stitch type
1 Stitch type
JIS401 double chain stitch machines
1111----2 Model
2 Model2 Model
2 Model
Model DFB1404P,PL,PMD DFB1406P,PL DFB1412P,PL
No. of needles 2~4 5~6 7~12
4 needle threads 6 needle threads 12 needle threads
No. of threads
4 looper threads 6 looper threads 12 looper threads
Type of tension set Mounted type Separate type Separate type
Puller width 55mm 79mm 79mm
Minimum gauge width 4.76mm (3/16 inch)
Maximum gauge width 38.1mm (1-1/2 inch) 70mm
【2】
NEEDLES & THREADING THE MACHINE
2222----1 Needle
1 Needle1 Needle
1 Needlessss
UO113GS of Schmetz or Organ
Select the proper needle for the fabric and thread.
< Needles and needle size >
Schmetz UY113GS Nm75 Nm80 Nm90 Nm100
Organ UO113GS #11 #12 #14 #16
2222----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 left of the machine (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.
2
2222----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 pages 3 to 9.
Incorrect threading may cause skip stitching, thread breakage and/or uneven stitch
formation. When threading the looper, tilt the looper holder toward the front of the
machine using the looper drawing bar.
■
To tilt the looper toward the front
1. Bring needle bar A to the top of its stroke.
2. Pay out the needle thread from the spool by pressing a finger down on needle threads
B.
3. Pull looper drawing bar knob C out to the left so that the looper holder is tilted
toward the front of the machine.
4. After the machine is threaded, replace the looper by pressing looper holder D into the
machine until it clicks.
< Note >
The looper pops out of the machine as soon as knob C is pulled, so do not bring your fingers
close to the looper.
3
■
Threading diagram for DFB1404
4
■
Threading diagram for DFB1406
5
■
Threading diagram for DFB1412
6
■
Threading diagram for DFB1412PSM
7
■
Threading diagram for DFB1412PQ
8
■
Threading diagram for DFB1012
9
■
Threading diagram for DFB1012PSM
10
【3】
MACHINE SPEED
3333----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 s tandard
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.
3333----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 on the right).
< Machine speed >
Model Maximum speed Standard speed
DFB1404P 4500 4000
DFB1412P 4000 3500
< Motor pulley selection table >
Machine speed (SPM) Motor pulley
outer diameter
(mm)
50Hz 60Hz
60 3150 2950
70 2300 3450
80 3300 3900
90 3700 4400
100 4100 (4900)
110 4500 (5400)
11
【4】
LUBRICATION
4444----1 Oil
1 Oil1 Oil
1 Oil
Use Kansai Special’s genuine oil.
(Part No. 28-611)
4444----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 pot 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, run the machine
to check the oil is splashing onto oil pot A.
4444----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 ti ghten screw
D.
4. Fill the machine with oil by referring to 4-2
shown above.
If filter element E is contaminated, proper oiling may not be perf orm ed.
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.
12
【5】
SEWING MACHINE INSTALLATION
5555----1 Cutting the machine table
1 Cutting the machine table1 Cutting the machine table
1 Cutting the machine table
■
1402-1404
13
■
1406-1412，1012
14
■
1412，1012PSM
15
■
1412PQ
16
■
1412PQSM
17
5555----2 How to install the machine
2 How to install the machine2 How to install the machine
2 How to install the machine
【6】
TIMING OF THE LOOPER TO THE NEEDLES
6666----1 Angle for inst
1 Angle for inst1 Angle for inst
1 Angle for installing the looper and position of the looper holder bracket
alling the looper and position of the looper holder bracketalling the looper and position of the looper holder bracket
alling the looper and position of the looper holder bracket
Insert the looper into the looper holder until bottom A of the looper touches looper holder
bracket B. Then tighten screw C.
When the looper passes the needle, there should be a clearance of 0~0.1mm between the
point of the looper and the scarf of the needle. Adjustment is made by loosening screw D
and moving the looper holder bracket left or right.
18
6666----2 Looper left
2 Looper left2 Loop er left
2 Looper left----to
toto
to----right movement
right movementright movement
right movement
When the looper passes the needle, the point of the
looper, moving to the right, should be 1.5mm
above the top of the needle's eye.
When the looper passes the needle, the point of the
looper, moving to the left, should be 3mm above
the top of the needle's eye.
■
For single chainstiching, when the looper enters
the needle thread loop, the point of the looper
should be 4mm above the top of the needle's eye.
■
To make this adjustment, remove the cover first,
loosen eccentric set screw D and then move
eccentric ball A.
6666----3 Looper setting dist
3 Looper setting dist3 Looper setting dist
3 Looper setting distance
anceance
ance
When the needle bar is at the bottom of its stroke,
set the distance from the point of the looper to the
center of the needle should be 3mm.
■
Adjustment is made by removing the cover and
loosening screw B on looper front-to-back lever A.
19
6666----4 Needle height
4 Needle height4 Needle height
4 Needle height
When the needle bar is at the top of its stroke, remove plug A on the side cover plate,
loosen screw C on needle bar clamp B with a hexagonal wrench and then move the
needle bar up or down as required .
< Standard needle ba r h eight D >
Stroke Standard model
34mm 13.5mm
【7】
ADJUSTING THE TIMING OF THE RETAINER LOOPER
7777----1 Position of the retainer looper
1 Position of the retainer looper1 Position of the retainer looper
1 Position of the retainer looper
Install retainer looper A so that its flat surface is
turned upward. At this time, there should be a
clearance of 0.5mm between the needle and the point
of the retainer looper. Adjustment is made by
loosening
B.
< Note >
After the above adjustment is made, check to make sure each needle drops correctly into the
center of each needle drop hole.
20
7777----2 Timing of the retainer looper to the needle
2 Timing of the retainer looper to the needle2 Timing of the retainer looper to the needle
2 Timing of the retainer looper to the needle
When the needle, moving from the top to bottom of its stroke, enters the triangle of the
looper thread, the retainer looper should be at the
extreme right end of its travel. To adjust the retainer
looper left to right, loosen screws A first. With the
retainer looper at the extreme left end of its travel, set
the clearance between the retainer looper and the right
side of the looper at approximately 0.5mm. Then set
the clearence between
the retainer looper and
the top surface of the
looper blade at 0.1mm.
After this adjustment
is made, tighten screws
A.
【8】
ADJUSTING THE NEEDLE GUARD
8888----1 Po
1 Po1 Po
1 Position of the needle guard
sition of the needle guardsition of the needle guard
sition of the needle guard
When the needle is closest to the needle guard, there
should be a clearance 0~0.1mm between the right side of
the needle and needle guard A.
Adjustment is made b y l oo se n i n g s crew B.
【9】
ADJUSTING THE FEED DOG & STITCH LENGTH
9999----1 Feed dog height & tilt
1 Feed dog height & tilt1 Feed dog height & tilt
1 Feed dog height & tilt
When the needle bar is at the top of its stroke, the feed
dog teeth should be 1~1.2mm above the top surface of
the needle plate. Adjustment is made by loosening
screw A.
Then check to see if the feed dog teeth is parallel with
the top surface of the needle plate. A d justment is mad e
with screws B and C.
< Note >
To adjust the standard type of needle guard, after positioning
the looper holder bracket (see 6-1) adjust the looper by
loosening the looper set screw. Then tighten screw B.
< Note >
When adjusting the height of the feed dog, tilt the looper
holder toward the front of the machine.
21
9999----2 Stitch length
2 Stitch length2 Stitch length
2 Stitch length
The stitch length can be adjusted from 2 to 5mm
with no step. The following table shows the stitch
length with the number of stitches within 1 inch
(25.4mm) and 30mm.
No. of stitches Stitch
length (mm)
within 1" within 30mm
2 13 15
3 8.5 10
5 5 6
■
To change the stitch length
1. Loosen bolt A while checking the direction in
which the bolt is loosened.
2. Insert a screwdriver from hole C.
To decrease the stitch length, turn screw B
clockwise. To increase the stitch length, turn
screw B counterclockwise.
3. After thi s adjustment is made by turning screw B , be su re to ti gh ten screw A.
【10】
ADJUSTING THE PRESSER FOOT
10
1010
10----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.
< Note >
Be sure turn off the motor when changing the stitch length.
22
10
1010
10----2 Position of the presser foot
2 Position of the presser foot2 Position of the presser foot
2 Position of the presser foot
Fit the presser foot onto the presser bar so that the
needle can drop correctly to the center of the needle
drop hole on the presser foot.
Adjustment is made b y l oo se n i n g s crew A.
The left-to-right play adjustment on the presser foot
is made by loosening nuts B.
Create a clearance of 0.5mm as shown in the
illustration on the right.
【11】
ADJUSTING THE REAR PULLER DEVICE
11
1111
11----1 Manual lever
1 Manual lever1 Manual lever
1 Manual lever
To position or remove the fabric, raise manual lever
A.
11
1111
11----2 To adjust the puller pressure
2 To adjust the puller pressure2 To adjust the puller pressure
2 To adjust the puller pressure
The puller pressure should be as light as possible, yet
be sufficient to feed the fabric smoothly.
To increase the pressure, turn adjusting knob D
clockwise. To decrease the pressure, turn adjusting
knob D counterclockwise.
11
1111
11----3 Adjusting the feeding amount of the rear puller
3 Adjusting the feeding amount of the rear puller3 Adjusting the feeding amount of the rear puller
3 Adjusting the feeding amount of the rear puller
Adjust the feeding amount of the rear puller
according to that of the feed dog. To increase the
amount, loosen nut G and move it to the left. To
decrease the amount, move it to the right.
23
【12】
ADJUSTING THE FRONT PULLER DEVICE
12
1212
12----1 To insert elastic and adjust the feeding amount of the front puller
1 To insert elastic and adjust the feeding amount of the front puller1 To insert elastic and adjust the feeding amount of the front puller
1 To insert elastic and adjust the feeding amount of the front puller
Insert elastic by opening/closing small roller C with
lever A (see the illustration).
Adjust the feeding amount of the front puller
according to that of the feed dog.
To decrease the amount, loosen screw B and move it
up. To increase the move it d o wn .
【13】
ADJUSTING THE STITCH FORMATION
13
1313
13----1 Thread tension adjustment
1 Thread tension adjustment1 Thread tension adjustment
1 Thread tension adjustment
Thread tension varies according to sewing conditions
such as the fabric, thread and stitch length to be used.
Tension on the needle thread can be adjusted with
nuts A. Tension on the looper thread can be
adjusted with nuts B. To increase the tension , turn
the nuts clockwise.
13
1313
13----2 Position of the needle thread
2 Position of the needle thread2 Position of the needle thread
2 Position of the needle thread eyelets
eyelets eyelets
eyelets
■
On 1402~1404, secure needle thread eyelet C at the
top end of the slot.
■
On 1406~1412, secure needle thread eyelet C at the
center of the slot.
< Note >
Adjust the needle thread eyelet s according to the thread
to be used. To tighten the needle thread, raise the
needle thread eyelets.
< Note >
The tension should be as light as possible, yet be
sufficient to produce uniform stit ches.
24
13
1313
13----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 top
surface of needle thread guard A should be level and
parallel with the centers of the eyes on needle bar eyelet
B.
13
1313
13----4 Position and timing of the looper thread eyelet
4 Position and timing of the looper thread eyelet4 Position and timing of the looper thread eyelet
4 Position and timing of the looper thread eyelet
When the point of the needle has reached the underside
of the looper blade while the needle bar is descending,
the looper thread eyelet bar should ascend. With the
looper thread eyelet bar at the bottom of its stroke,
adjust distance A between the eye on the looper thread
eyelet and the looper thread eyelet bar by referring to
the table below.
Thread type Distance A
Polyester (Tetoron) 8mm
Spun 10mm
Wooly 15mm
【14】
PSM MECHANISM
14
1414
14----1 Types of cams
1 Types of cams1 Types of cams
1 Types of cams
There are 9 types of cams from N o .1 to N o .9 (9 typ e s of s t an dard patterns).
Various kinds of decorative stitches can be produced by a combination of 2 cams.
The inside cam moves the upper spreader.
The outside cam moves the lower two spreaders and crosses spreader threads.
< Note >
Raising needle thread guard A increases the size of the
needle thread loop. Lowering needle thread guard A
decreases the size of the needle thread loop.
25
14
1414
14----2 Producing decorative stitches
2 Producing decorative stitches2 Producing decorative stitches
2 Producing decorative stitches
Install cam 1 on the outside to use the lower two spreaders. Install any one of cams
No.2 to No.9 on the inside to use the upper spreader. Thread spreaders' eyes marked
●
.
Following the above procedures automatically produces the decorative stitches below
(refer to decorative stitches N o.2 to N o .9 ).
No.1
No.1No.1
No.1
No.2
No.2No.2
No.2
No.3
No.3No.3
No.3
No.4
No.4No.4
No.4
26
No.5
No.5No.5
No.5
No.6
No.6No.6
No.6
No.7
No.7No.7
No.7
No.8
No.8No.8
No.8
No.9
No.9No.9
No.9
27
14
1414
14----3 Replacing the cams
3 Replacing the cams3 Replacing the cams
3 Replacing the cams
To replace outside cam B, remove nut A (note that
this nut has a left-hand thread).
To replace inside cam H, loosen screws C and D,
and remove the collar. Remove screw F from
lever S.
Then move lever S down in the direction of the
arrow.
14
1414
14----4 Timing of spreaders
4 Timing of spreaders4 Timing of spreaders
4 Timing of spreaders
To adjust this timing, set cam No.8 on the insi de
and No.1 on the outside. Then follow the
procedures below. Spreader K moves left to right
with the inside cam. Each of spreaders L and M
moves in the opposite direction with the outside
cam.
1. When the needle starts to move from the top
to the bottom of its stroke, adjust the cams so
that spreaders K, L an d M s to p mo vi n g.
Adjustment is made by loosening screws C
and J (see "Replacing the cams").
2. Position of spreader K
With spreader K at the extreme left end of its
travel, the third spreader's eye on spreader K
should be aligned with the center of the left
end needle. Adjustment is made by loosening
nut D for lever N (see "Replacing the cams").
3. Position of spreaders L and M
With spreader L at the extreme left end of its
travel, the forth spreader's eye on spreader L
should be aligned with the center of the left
end needle. Adjustment is made by loosening nut P for lever E (see "Changing the
cams").
With spreader L at the extreme right end of its travel, make sure the fifth
spreader's eye on spreader M is aligned with the center of the left end needle.
< Note >
Before installing new cams, be sure to grease the cam
grooves. Never loosen screws I and J. Otherwise the
timing of spreaders is changed.
28
14
1414
14----5 Adjusting the spreaders
5 Adjusting the spreaders5 Adjusting the spreaders
5 Adjusting the spreaders
The clearance between spreader K，L and M and needles should be 1~1.2mm.
Spreader up-and-down adjustment is mad e wi th s cre ws Q.
Spreader tilt adjus tmen t i s ma d e wi th s crews R.
【15】
PTV MECHANISM
15
1515
15----1 Disassembling and reassembling the binder
1 Disassembling and reassembling the binder1 Disassembling and reassembling the binder
1 Disassembling and reassembling the binder
■
To disassemble the binder
Remove screw A. Remove the binder by pulling it
toward you while referring to a rrows B and C.
■
To reassemble the binder
Fit the ends of upper fabric guides (F) onto lower
fabric guides (G). Move the binder down in the
direction of arrow H. Check that end D of the
screw touches the bracket. Then tighten screw A.
< Note >
When removing the binder, be careful not to damage
the ends of the fabric guides.
29
15
1515
15----2 Adjustin g th e bi n der up and down
2 Adjusting the binder up and down2 Adjusting the binder up and down
2 Adjusting the binder up and down
Adjust the binder up and down according to the
fabric to be used. Adjustment is made by
loosening screw A and wing screw I and turning
screw D as required.
After this adjustment is made, tighten screw A
and wing screw I.
15
1515
15----3 Position of the upper and lower fingers of the binder
3 Position of the upper and lower fingers of the binder3 Position of the upper and lower fingers of the binder
3 Position of the upper and lower fingers of the binder
Position upper and lower fingers so that distance
A is halved by each vertical center line of the
needles.
The line formed by the points of the upper and
lower fingers should be parallel with each
horizontal center line of the needles.
【16】
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.
< Note >
Adjust the position of J and K according to the
finished pin tuck.
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