User`s Manual KM-560
Contents
1. 805 78 40 58 A 3g Bo N o A El 4 93 CENTER base I gt Be 7 i H 160 0 2 5640 2 O a o Het Lio 2 99 915 DP30 AA O C1 DP4 l 217 i j oa E Y o i 3 NE O x a Eo oA i as ls 8 s Gg j i H 1 O 6 1 339 0 2 So e A A IA RE a ee ee ES E O a eS I E E TESE E a eel T 8 y j a 478 35 A 54 i i ze i i i H H i pe AA f t 4 93 CENTER 0 j Q Keeping Rack Installation Place j j i o 9 lt Treat keeping rack color La Y same as table color i Rol amp O nz Hegi 1180 B S SECTION B B S 2 o SSI ALLL O A Lo A Zo 0 SECTION A A e LO 342. location detector must be corrected That is the needle up stop position is the same as the needle bar s stop position ie sane ae once the trimming action takes place So there is no problem with the timing of the trimming action See Figure 19 Figure 19 See location detector adjustment on page 12 11 Reverse button function for automatic trimming type Ses If the reverse button is pressed while sewing forward reverse sewing takes place immediately If the machine is stopped first and the button is pressed before stepping the pedal to start the machine reverse sewing will take place from the start Also by pressing button while the machine is in stop position the high low position of the needle bar can be changed If the button is pressed once when the needle bar is in down stop position the needle bar changes to up stop position Once again if the button is pressed twice consecutively within 1 second the needle bar changes to down stop position That is 1t has both the reverse sewing and needle up down position change functions See Figure 20 Figure 20 14 SunStar 3 Adjustment of the Machine Always turn off the power when mounting a needle If the operator mistakenly steps on the pedal while the power is on the machine will start automatically and can result in physical injuries When using clutch motor be aware that the motor will continue to rotate for a while
3. tightly See Figure 4 5 Installation of belt cover 1 Before attaching the belt cover B to the machine body assemble in advance the rubber collar fixing washer and fixing screw on the to be attached side of the cover as can be seen in picture K of Figure 5 2 Lay down the machine on the back and then attach belt cover B onto the machine body See Figure 5 3 Fasten belt cover A Q to the machine body and the top cover with the fixing screw as can be seen in Figure 6 And make sure that the belt cover A keeps balance with the belt cover B that was already attached See Figure 6 10 Figure 3 Figure 4 Rubber collar Fixing washer Figure 5 Figure 6 4 Attach belt cover C to the table Make sure that the belt properly operates without interference from the belt cover C See Figure 7 6 Installation of the program unit for automatic trimming type 1 Fix the bracket onto the program unit using 4 fixing screws 2 Fasten fixing nuts to bracket bolts as done in 1 Make sure that there is 3 4 mm distance between the lower parts of fixing nuts and the program unit supporting bolts as can be seen in Figure 8 3 Finally fasten the program unit tightly to the machine head by using two fixing bolts See Figure 8 7 Installation of the thread stand As can be seen in Figure 9 fix the thread stand to the
4. table using the washers and nuts on the right SunStar Figure 7 Figure 8 4 00 4 or Figure 9 8 Assembly of the location detector and its control method for automatic trimming type 1 Installation of the location detector Assemble in the order of marked numbers as can be seen in Figure 10 Then following Figure 11 make adjustments to place the photo film at the center of the sensor housing Q by moving the shaft to the right and left Then tighten the 2 fixing screws 3 by using the hexagonal wrench Note A As can be seen on Figure 10 make sure that the marks DOWN and UP face the front when looking from the pulley side B Film adjustment is completed upon shipment Photo film horizontal adjustment Figure 10 Figure 11 2 Film adjustment of location detector A For new model type see Figures 12 13 Manually turn the pulley so that the needle bar is placed where it starts rising from the lowest point Unfasten the film fixing screw Q in Figure 13 and for DOWN film A align the film adjustment base line with the sensor adjustment base line as can be seen in amp Then using the fixing screw fasten the film only as tightly as to prevent it from turning In the same way place the thread take up lever at its highest point Once again unfasten the fixed screw and align the UP film B like o owest position Now be careful not to move the previously se
5. even after the power is switched off due to inertia Start to work on the sewing machine only after the motor has come to a complete stop 1 Inserting the needle 2 Removing bobbin As in Figure 21 place the upper end of the needle closely Place the needle in the highest position adhered to the upper side of the stopper hole with the And then as in Figure 22 after pressing the slide plate needle groove facing left Fix the needle with a fixing stopper open the slide plate and lift the bobbin screw 3 See Figure 21 holder to remove the bobbin 8 See Figure 22 Figure 22 Turn off the power when adjusting the lower thread tension If the operator mistakenly steps on the pedal the machine will start automatically and can cause physical injuries When using the clutch motor be aware that the motor will continue to rotate for a while after the power is switched off due to inertia Start to work only after the motor has come to a complete stop 3 Winding the lower thread Insert the bobbin 8 into the hook As seen in Figure 23 insert the thread through part of the hook and pull it out from the end of the lower thread tension adjustment plate And then pull the thread through the clearance 4D between the hook and opener 0 The adequate length of the pulled out lower thread on the slide plate is 50 mm Lower thread out 50 mm Figure 23 15 Turn off the power switch when
6. not the machine turns smoothly B Adjusting the stopper pin holder See Figure 51 25 Complementary straight line Lae finishing point ae Trimming Cam Lead x The present stop position of the cam roller is inside the complementary straight line with the cam lead right before it exits having finished trimming action Figure 51 Make sure to turn the machine pulley to place the trimming cam in the right position so that the roller can enter the complementary straight line range after finishing trimming marked in the trimming cam lead 2 Press down the trimmer shake linkage to make the roller come inside the trimming cam x Adjust the holder to make the right equal point of the roller adhere smoothly 8 to the inner right side of the cam s complementary straight line and the left equal point of the stopper pin adhere 8 smoothly to the inner left side of the stopper pin holder Once this is done tightly fasten the fixing screw x Once such adjustments are made the trimmer shake linkage will not move even when shaken to its sides the roller is inside the cam Make sure to check if the shake linkage returns to up position 0 quickly and smoothly when released If not proceed with horizontal adjustment of stopper pin holder C Fixing the position of the trimmer solenoid See Figure 52 CY tmm Solenoid stroke Lion Figure 52 26 SunStar D When t
7. routing the upper thread If the operator mistakenly steps on the pedal while switched on the machine will start automatically aD and can cause physical injuries gt When using the clutch motor be aware that the motor will continue to rotate for a while after the power is switched off due to inertia Start to work on the sewing machine only after the motor has come to a complete stop 4 Routing the upper thread Place the thread take up lever to the highest position and hang the upper thread as in Figure 24 The adequate length of upper thread extending from the needle hole is 50 mm for initial sewing 5 Adjusting the thread tension 1 Adjusting the thread tension As in Figure 25 turning clockwise the tension adjustment nut of the thread tension control assembly makes the upper thread tension stronger and counter clockwise makes it weaker Upper thread tension is weak VELA VIP Ob UTE A JESSE IES IAS SS Good sewing o HAA SH bbe OPS 140 TAY PSS FESS TESS OS Figure 24 2 Adjusting the lower thread tension As in Figure 26 turning the tension adjustment screw 2 of the hook clockwise makes the lower thread tension stronger and counterclockwise makes it weaker Figure 25 16 Figure 26 SunStar 3 Adjusting the tension of thread take up lever spring A Adjusting the thread take up stroke As in figure 27 loosen the stopper clamp screw and turn the thread take up lever s sprin
8. to supply oil into the oil holes marked red and the oil holes in the friction parts before operating the machine See figure 17 fe a os ZR _ des ESA DP FASO ME CE X Ge E AT J N ie fia Yi E E 2 y l Figure 17 13 4 Lubrication check at hook After 10 second operation of the machine check the amount of oil sprayed from the hook looks like the picture in Figure 18 The amount of oil for the hook can f The oil be adjusted by using the adjustment screw on the sprayed hook base The amount of oil supplied decreases when the screw is turned clockwise and increases when turned White paper counter clockwise see figure 18 Figure 18 5 For test operation run the machine for 10 minutes intermittently at about 1 500 SPM For the first 4 5 days of using the machine operate the machine at less than 2 400 SPM per minute Then start using at normal pace This will help good performance of the machine along the way 10 Checking stop position of the sewing machine for automatic trimming type After changing the up down position of the needle by pressing the reverse button check the stop position of the machine Check whether the thread take up lever is in the highest Thread take up lever up position when the needle is in up stop position When the 5 stop position stop position is incorrect there might be problems to the trimming function hence the photo film location of the
9. types SEDG 1B for edge sensing type and SEDG 2B for thickness sensing type SPDL 1 An essential device when one person is operating multiple sewing machines Has different pedals for STANDING PEDAL SPDL 2 acceleration thread trimming presser foot and ascending pedal Types consist of SPDL 1 for fixed speed and SPDL 2 for variable speed SENSOR MATERIAL EDGE SEDG 1C A device that senses the edge or thickness of the sewing material to stop the machine without manual SEDG 2C SunStar a Installation Plug in after the installation is complete If the operator mistakenly steps down on the pedal with the plug in the machine will start automatically and can cause physical injuries Connect the ground earth wire An unstable connection may result in an electric shock or a malfunction Use both hands when bending the machine backwards or returning it to the normal position Using only one hand can lead to severe hand injuries due to the weight of the machine 1 Installation of machine head Insert two machine head hinges into the bed holes After aligning it with the rubber hinge stand the machine on the rubber cushion that is in the direction of the user See Figure 1 Figure 1 2 Installation of knee lifting solenoid and power switch box for automatic thread trimming The place where the knee lifting solenoid box should be assembled is also included 1 When attaching the power switc
10. upper side of the feed dog and the upper side of the needle plate match each other Figure 33 8 Adjusting the position of the feed dog 1 Set the feed adjusting dial at 0 loosen the clamp screws of the vertical roller crank and the needle bar shake crank 4 Adjust the needle hole of the feed dog to be placed about 1 5 mm before the center of the hook and then fasten it firmly See Figure 34 s Mol N Figure 34 2 Turn the pulley for the needle bar to be at its highest position See Figure 35 3 Check whether the needle is bent If it is the needle should be replaced 4 Turn the pulley slowly to check whether the needle s edge falls exactly at the center of the needle hole of the feed dog x If not take the following steps A Open the back cover and loosen the clamp screw as can be seen in Figure 35 B Move minutely the needle bar frame to match the needle s edge with the center of the needle hole C After adjustment fasten the clamp screw firmly Te gt AAA p q LT TTT Figure 35 19 9 Adjusting timing of needle and hook 20 1 Fixing the height of the needle bar Turn the pulley to make the needle bar be placed in its lowest position Loosen the needle bar holding screw in Figure 37 to make sure that the needle bar carved sign meets the end of the frame then tighten the screw The needle bar in the lowest position Figu
11. EERE 8 III os 8 3 Peripheral automation device Optional nr ai E SEAE Eka EENEN EENE ENa 8 2 Weis Wea tO count 9 1 Installation of machine head ea cheap eae ceca nec aca cated aa eiii 9 2 Installation of knee lifting solenoid and power switch box for automatic thread trimming ooocccoccccncccnnacacinaninnnons 9 E DEUS ErE NE San Ere 10 4 Adj stment of Delt TENSION ai 10 5 Installation of belt COVer ase ao de 10 6 Installation of the program unit for automatic trimming type vrai 11 7 istallato orto aa e E a e E EEn eR 11 8 Assembly of the location detector and its control method for automatic trimming type c occonconcnicnicccncononnnnncnnons 12 IV CNS UM MUN ae e E E E E A O E E E 13 10 Checking stop position of the sewing machine for automatic trimming type coocoonconociccnocacanonononnnanonncnncnnonconnns 14 11 Reverse button function for automatic trimming type si setionsncsteanyetbaceitaptantonsaxarnadeeaesats 14 3 Adjustment of the Machine o ooococnnnnnnnnnninnnnicnnnnoninnncnnananonnnnaonn cnn ononarannn canon cnn onanannncncnncna ono 15 1 Inserting the needle AAA E O E E unre ee aetna ae 15 e y A 15 3 Winding the A e oo UA 15 4 Routing the upper thread A o o aianapenmseusaceiaawreetiae seers arauaese 16 5 Adjusting the thread tension id ici n 16 6 Adjusting the tension of the presser foot sescincdicacteecaussceasdwontnennancdinsaanoncstnioudsundeseiebuseoencduantasincsatsinctaiiniassniusTemnano
12. SunStar User s Manual KM 560 One needle drop feed needle feed sewing machine KM 560 7 One needle drop feed needle feed sewing machine with automatic thread trimmer Equipped with FORTUNA AC SERVO MOTOR SunStar dare devesa 1 For proper use of the machine thoroughly read this manual before use 2 Keep this manual in a safe place for future SUNSTAR MACHINERY CO LTD neko ices MME 050629 1 Thank you for purchasing our product Based on the rich expertise and experience accumulated in industrial sewing machine production SUNSTAR will manufacture industrial sewing machines which deliver more diverse functions high performance powerful operation enhanced durability and more sophisticated design to meet a number of user s needs Please read this user s manual thoroughly before using the machine Make sure to properly use the machine to enjoy its full performance 3 The specifications of the machine are subject to change aimed to enhance product performance without prior notice 4 This product is designed manufactured and sold as an industrial sewing machine It should not be used for other than industrial purpose SUNSTAR MACHINERY CO LTD Table of contents Safety rules for Machine ooo cccccscscescsecscsscsssscsscsecscssssessssesesssssscsssussecessesseseseeseseasaseuses 4 1 Specification si 8 MoT MACHINE gtd ances tac cna ance ep mca napa EEEE EE eG sme EE EEEE EE
13. alians 18 7 Adjusting the needle and feed dog timing cnica aid niega 18 8 Adjusting the position of the feed dog escunitaiii dsp 19 9 Adjusting timing of needle and hook siria alpaca 20 10 Clearance adjustment between the upper side of hook stopper and the upper side of needle board groove 21 11 Clearance adjustment between hook and opener ea 21 12 Adj sting teed d g height ia 22 13 Adjusting the auxiliary presser foot and the upper feed presser foot mini dis 22 14 Adjusting timing of the auxiliary presser foot the upper feed foot and the needle oo cece eeeseeseeteeteeeeeeens 24 15 Adjusting stroke OF upper feed presser foot rial ia doo 24 16 Adjusting safety device atrial a EE R R E sap eaaa reaa 25 17 Adjusting the trimming A iste ans boven opmren ecu beiec sae ds cbnssiocaidd seuss onyedinanewaeonsisesseeansakpannlaaidiebakenaed 25 18 Replacing movable knife and fixed knife ccosaroniacisincwiunicessieacddnssnsatsbcbsonsalssustionssts oni sbasasencintnsosncastsuesidespubeouuebaweepnratded 31 19 Adjusting thread release for automatic trimming type nesicanisionian arsenales 31 4 Causes of troubles and troubleshooting ooo ooconononnnoninininnnnninnicanonanocnnnnanacinanoninnos 32 1 Sewing machine troubleshooting dra 32 A EAT ooo ccc cccccscscscsscsscscsscsesscsscscsscsscscsssscsevssssesscsecsessssscsesscsssessassesecssssssssassssscssasaas 34 Safety Rules for Machine Safety labels in th
14. ary presser foot and the upper feed presser foot is up to 5 5 mm B Loosen the nut C Move the nut up or down depending on sewing materials Move it up to make the stroke increased or down to make it decreased D After adjustment check the timing adjustment explained in page 24 22 SunStar 2 Adjusting the height of the strokes of both different Figure 46 A Adjusting the auxiliary presser foot X Loosen the pressure adjusting screw and the bracket fastening screw x Adjust the bracket fastening screw so that the auxiliary presser foot rise about 10 5 mm from the needle plate top when the pressure lifter is raised After adjustment be sure to fasten the bracket fastening screw first and then adjust the pressure adjusting screw Xx Affter the adjustment of the height of the auxiliary presser foot adjust the upper feed presser foot B Adjusting the upper feed presser foot Loosen up and down crank clamp screw when the pressure lifter is down Move the needle bar close to its highest position Adjust the height of the upper feed presser foot to the sewing materials When the height of the upper feed presser foot is determined be sure to fasten the crank clamp screw and check the adjusting timing explained in 14 on page 24 23 14 Adjusting timing of the auxiliary presser foot the upper feed foot and the needle When the needle goes down the upper feed presser fo
15. bleshooting Needle is inserted into wrong position Reinsert the needle correctly and push in to its highest level Needle is bent Change the needle Bad timing of feed dog Adjust the timing of feed dog Direction and height of needle Needle 1 Needle breaks Timing of the feed dog Gap between needle and Bad timing of needle and hook Adjust the timing of needle and hook ngok The heads of the needle and the hook Adjust the location of the hook interfere each other Threading method Wrong threading Thread the needle correctly Needle Direction and height of needle Upper thread tension Lower thread tension 2 Thread breaks Working capacity of take up lever spring Hook Feed dog Needle plate Bent needle Change the needle Thread tension The direction and height of the needle Insert the needle correctly inserted is wrong Too tight upper thread tension Reduce the tension of upper thread Too tight lower thread tension Reduce the tension of lower thread Too much working capacity Adjust the stroke level There is a scratch on the hook edge Remove the scratch on the hook edge There is a scratch on the needle hole of the Remove the scratch on the feed dog feed dog There is a scratch on the thread case and Remove the scratch on the needle plate around the needle plate Upper and lower thread tensions are bad Adjust the upper and lower thread tension Thread take up spring tension is Adjust the thread tak
16. e manual are categorized into danger warning and caution Failure to follow the safety rules may result in physical injuries or mechanical damages The safety labels and symbols are defined as follows The meaning of the safety labels Danger Instructions here shall be observed strictly Otherwise the user will be killed or suffer severe physical injuries Warning Instructions here must be observed or the user could suffer fatal or severe physical injuries Caution Instructions here should be observed or the user could face physical injuries or mechanical damages The meaning of symbols This symbol means a must not This symbol means a must for safety This symbol means that an electric shock may be caused if the instruction is not followed properly 1 1 Machine mobilization 1 2 Machine Installation Caution 1 3 Troubleshooting instal Only personnel with a full understanding of the safety rules should move the machines The following directions must be observed when delivering the machines 2 At least two persons should work together In case the machine should be transported please wipe the oil covered on the machine to prevent accidents Because physical damage such as the functional obstacles and breakdowns are likely to occur according to the environment in which the machine is being installed Therefore the following preconditions should be fulfilled Please keep the order fro
17. e up spring tension inadequate The gap between the opener and hook is Adjust the gap between the opener and inadequate hook Needle is inserted into wrong direction Reinsert the needle correctly and push in to its highest level Needle is bent Change the needle Wrong direction Insert the thread in the right way Hook timing The timing between the needle and hook is Adjust the timing between the needle and bad hook Upper thread Gap between the needle Needle and hook head are too far apart Adjust the position of the hook falls out when ANA the hook starting to sew Remaining upper thread The length of the remaining upper thread is Increase the adjustment volume of the or sewing is length after trimming too short upper thread on the control box skipped Lower thread holder After trimming lower thread holder does not Adjust the location and tension of the lower hold the lower thread thread holder Check the up stop Due to problems in the up stop position of Readjust the needle s up stop film position position of the needle the needle the thread take up lever pulls the upper thread out of the needle when the sewing starts Check the oil felt tension The upper thread oil felt is pressing the Adjust the felt tension of upper thread thread too strongly Thread take up spring tension Poor thread adjustment Gap between opener and hook Direction and height of needle Needle Threading Su
18. ere is no excess room in each linking device When this is done the roller adheres to the right side of the cam s complementary straight line as can be seen in the picture While maintaining this position adjust the movable knives on the right and the left to protrude about 3mm from the fixed knife edge Now tightly fasten the crank fixing screws If the initial position of the movable knives of both sides are to be adjusted slightly use the ball joint linking bar O D Adjusting lower thread holder The position of lower thread holder is set by fixed knife and bolt As in the picture loosen the bolt 3 and place the lower thread holder edge at the lower side of the movable knife about 8mm apart from the movable knife edge Make sure to check that the right and left upper sides and of the lower thread holder is tightly adhered to the lower side of the movable knife Figure 57 4 Checkpoints on the assembling status of other trimming devices A Check the starting point of the movable knife when the trimming action takes place Operate trimming movement manually to check whether the thread take up lever is in the lowest or at least 2 5 mm raised level when the movable knife starts working See Figure 58 B Maintenance of fixed knife When the thread does not get trimmed or if the trimmed section of the thread is sloppy please check the edge condition of the fixed knife If the edge of the
19. g stopper clockwise to make the stroke smaller and counter clockwise to make it bigger The thread take up stroke is normally 10 14 mm 10 14mm Figure 27 B Adjusting the thread take up tension As in figure 28 loosen the screw of the thread tension control assembly and insert the driver into the groove of the thread tension control assembly Turn clockwise to make the spring tension stronger and counter clockwise to make it weaker See Figure 28 C Adjusting the timing of the thread take up spring tension As in Figure 29 loosen the stopper screw and turn clockwise the guide plate 8 for the thread take up spring to make the timing of the spring faster and counter clockwise to make it slower The timing of the thread take up spring tension is normal when the guide plate is located in the middle as can be seen in Figure 29 Figure 28 Figure 29 D Adjusting the auxiliary thread tension control assembly for automatic trimming type As in Figure 30 when the auxiliary thread tension ANO A adjustment nut is turned clockwise the length of a E the thread after trimming is short The other way ep makes the thread long Ca The appropriate length of the upper thread on the needle after trimming is 35 45 mm This can also be done by using the remaining upper thread length adjustment volume of the control box Figure 30 17 After disassembling and adjusting a safety device alwa
20. ghtly fasten the fixing screw of the bushing The adjustment of crossing height 2 between the hook stopper upper side and movable knife edge upper side is possible to certain degree by adjusting the movable knife base washer or by changing the position of movable knife shaft collar 8 as can be seen in Figure 55 SunStar B Adjusting movable and fixed knife As in Figure 55 adjust the position of the fixed knife so that the fixed knife right side edge matches the movable knife inner side edge 2 The initial assembling position of the movable ean ee f Checking the surface adhesion knife is where the movable knife edge protrudes about 3 mm from the edge of the fixed blade Make sure to check the final fixing of the movable knife initial position on page 29 3 The surface adhesion conditions of fixed blade edge and movable knife upper side have huge x Apply color ink on the upper side of the movable knife edge O good impact on its trimming capacity Please note the various cases of movable fixed knife surface adhesion conditions on the picture Correcting the adhesive conditions of movable and fixed knives As in Figure 55 operate manual trimming movement with color ink on the movable knife edge By checking the ink trace remaining on the movable knife the surface adhesion condition of Figure 55 the movable fixed knives can be tested If the surface adhesi
21. h box refer to Figure 2 to make sure that it is placed at the very center of the solenoid bracket 2 After attaching the solenoid onto the table unfasten the screw 4 to adjust the center of middle linking bar and the center of solenoid shaft in parallel position with the lower side of the table After the adjustment is over fasten the screw tightly See Figure 2 An assembling position diagram can be found inside the solenoid box 3 The presser foot height of the sewing machine can be adjusted after unfastening the fixing nut and then turning the middle linking bar clockwise to raise and counterclockwise to lower After finishing the adjustment tightly fasten the fixing nut 4 According to the installation position of knee lifting solenoid the operation noise operation load and presser foot elevation range may differ Please assemble so that the machine will operate smoothly Figure 2 3 Installation of oil fan Insert the projecting part of the oil fan into the respective machine holes on the lower side of the table and then push securely to the right Fix the oil fan to the four fixing spots using 4 nails See Figure 3 4 Adjustment of belt tension Once the motor is installed when the fixing nuts are fully unfastened on both sides tension is created to the belt 4 due to the weight balance of the motor At this moment fasten the fixing nut first then fasten the fixing nut
22. he whole trimmer shake linkage is in up position that is when it has come back to its original position after finishing trimming the distance between the lower part of the roller and the equal point of the trimming cam is about 0 8 1mm Assuming that this distance never changes adjust the position of solenoid bracket horizontally where the solenoid housing is attached to make the solenoid stroke 4 mm Then tightly fasten with fixing screw 2 After adjusting the solenoid stroke manually operate the solenoid shaft towards the arrow direction See whether it returns to its original position fast and smooth when released If not proceed with horizontal adjustment of the bracket minutely up and down and right and left 2 Adjustment of linking device for movable knife shaft and the trimmer driving part Figure 53 A When the previously explained adjustment of trimmer driving part is complete it is in its normal position where the trimmer shake linkage has returned to its up position after trimming action B First loosen the fixing screw 2 of the movable knife shaft hold the initial assembling angle of the crank to be about 15 30 to the left from the perpendicular line drawn to its center To make sure that this position is maintained adjust the length of the ball joint linking bar and tightly fasten the fixing screw of the crank For the adjustment of the ball joint linking bar turn the l
23. inking bar after loosening the nuts left and right Nut left is left screw and nut right is right screw C When the linking device is connected as such the movement angles of crank during trimming movement results in an equal angle movements for left 8 and right O Hence it can be said that the trimming movement is very light 27 3 Adjusting movable knife and fixed knife A Adjusting the position of movable knife edge and hook stopper 28 O O Figure 54 When a movable knife passes the front side of the hook stopper adjust the distance to be within 0 05 0 2 mm range like part 3 The upper surface of the movable knife edge 6 should be set up 0 2mm below the upper side of hook stopper gt Given that the fixed knife is pressing down the movable knife Clearance adjustment of the movable knife edge and hook stopper front side Loosen the needle plate Place the hook stopper in the hanging position to the needle plate Holding the hook with the hand manually operate trimming movement so that the movable knife edge is matches the stopper front side Loosen the fixing screw 7 of the movable knife shaft eccentric bushing x In the lower side hole of the eccentric bushing 8 stick in a thin driver or adequate pin 40 and turn right and left This will make the position of the movable knife shaft change hence changing the distance X When the clearance adjustment is finished ti
24. is removed to prevent damage of the hook and other major parts from the lood and the pulley and the clutch plate on the safety assembly are removed Then the driving force of timming belt on the upper shaft does not delivered to the lower shaft so only the pulley of safety assembly rotates idly In case that the safety assembly starts operating during the work turn power switch off and remove causing factors of load Later with safety button pressed turn the pulley to place the driving ball of safety assembly to its original position Adjust the intensity of the safety assembly spring by rotating safety assembly adjustment screws from side to side in accordance with working conditions Turning the screw to left makes the intensity stronger and right to make it weaker Make sure to give same pressure on the three screws Figure 49 17 Adjusting the trimming device 1 Adjusting the trimmer driving part A Fixing the position of the trimming cam See figure 50 Turn the pulley manually to place the needle bar at its lowest position 2 With the left side of the trimming cam softly attached to the right side of the lower shaft medium bushing turn the cam to align the The lowest point of the needle base point with the carve in the lower shaft Figure 50 medium bushing crank 8 Fasten tightly the trimming cam fixing crews 3 Now turn the pulley manually to see whether or
25. knife is too dull sharpen the edge using oil stone or sand paper See Figure 59 Lowest position of the Sand paper Oil stone thread take up lever Figure 58 Figure 59 30 SunStar 18 Replacing movable knife and fixed knife 1 Lift the presser foot and open the slide plate 2 Disassemble the needle plate 3 Loosen the fixing screw to disassemble the washer fixed knife and lower thread holder 7 4 Loosen the fixing screw 3 and dissemble the movable knife O x To assemble follow the reverse order of disassembling Figure 60 19 Adjusting thread release for automatic trimming type If the upper thread is pulled out of the needle hole after trimming check whether the thread tension adjusting plate separates during trimming To adjust the opening of the thread tension adjusting plate put the thread release solenoid at operation and move back and forth the solenoid shaft collar to make sure that the opening of the plate would be 0 8mm wide Also make sure that the plate is completely attached when the solenoid is not working See Figure 61 Note x If the plate does not open widely enough during trimming but properly assembled check weather the volume adjusting the remaining upper thread on the control box is too low my Tah ft if ENT SS Figure 61 31 4 Causes of Troubles and Troubleshooting 1 Sewing machine trou
26. m top to bottom when unpacking the package Especially mind that the nail on the boxes Because machines are apt to be contaminated and corroded by dust and moisture you should install the climate controller and should clean the machines regularly Keep the machines out of the direct rays of the sun Keep both sides and the backside of the machines off at least 50cm from the wall to secure enough space to repair Don t run the machine near the places with the dangers of explosion Don t run the machine near the places with the dangers of explosion including the places where the spraying product like aerosol are used in large quantities or oxygen are dealt with unless the exact actions concerning the operation are guaranteed to avoid the explosion Because of the peculiarity of the machine any illuminators are not equipped So users should install the lighting apparatus around the working area Note The details about the installment of the machine are described in No 2 Installations In need of troubleshooting it should be done by the trained A S engineer of our company Ahead of cleaning and repair be sure to shut off the power supply And wait for about 4 minutes till the machine discharges completely Even a part or all of the machine should not be modified without any consultation with our company In case of repair you should change the damaged part into the standard article of our company Afte
27. nStar The gap between the The height and distance between the Readjust the movable knife setting position movable knife and the movable knife and the hook do not match hook Trimmi l Check the tension of fixed Tension and contact of movable and fixed Correct the tension adjustment and surface 5 AEM TSS knife knives are bad contact of movable and fixed knives Direction of the needle of the needle Needle is not inserted correctly Insert the needle correctly ees side of movable Scratch and abrasion of movable and fixed Replace movable knife or fixed knife and fixed knives knives Trimming cam timing is bad Adjust trimming cam timing Stroke of thread release Stroke of thread release is too small Adjust the thread release stroke Wrong trimming timing Adjust the trimming timing Opening of the thread The opening on the thread tension control Adjust the thread release stroke tension adjusting plate plate is too small Tension of auxiliary thread Too strong tension on the auxiliary thread Adjust the tension of the auxiliary thread tension adjustment tension control assembly tension control assembly assembly Working capacity of take Too much working capacity Adjust the working capacity up lever spring Thread release Volume is adjusted to too low Increase the volume adjustment adjustment volume on the control box Too short thread length after trimming 33
28. ning this cover after turn off main switch and unplug a power cord 18 HH Col gus gt SHE AHS Wel LN 360 2t JICtEl 1 Specification 1 Sewing machine Heavy materials Ultra thin materials Vertical stroke of upper feed presser foot and auxiliary 2 5 5mm presser foot Presser foot height Manual 10 5 mm Knee 16 mm 2 horizontal rotations 2 5 times trimming hook 2 horizontal rotations 2 5 times trimming hook Reverse button amp Reverse lever Reverse lever Conveying device Unision feeding Needle Feed dog Upper feed presser foot Semi automatic drop oiler 1 Phase 110 220V 3 Phase 220V 1 Phase 110 220V 3 Phase 220 380V 2 Motor Servo motor controller MODEL VOLT SC55 1B 1 Phase 110V 50 60 Hz SC55 1B 1 Phase 220V 550W 50 60 Hz SC55 3B 3 Phase 220V 550W 50 60 Hz 2 Clutch motor HEC 1706 1 Phase 110 220V 400W 50 60 Hz HEC 1705 3 Phase 220 380V 400W 50 60 Hz 3 Peripheral automation devices optional A solenoid operating structure where the presser foot gets lifted automatically with pedal reverse gear AUTO KNEE LIFTING stage 1 operation SYSTEM SPF 4 max stroke 46 mm e input voltage DC 24V DC 24 46V e induction at 46 mm stroke 10kg PRODUCTION SCOUN 1 A counting device which indicates the completed quantity on the program unit panel including added COUNTER subtracted corrected or remaining quantity along with other performance rates pedaling Available in two
29. on is not very good same method is used to adjust the tension of movable fixed knives please use the following methods adjusting the amount and position of the washer in the lower side of the movable knife base horizontally adjusting the assembling position of movable knife shaft collar 8 and correcting the shape of fixed blade setting position C Final fixing of the movable knife s initial position imichi Starting point of the Finishing point Re 19 t of trimming movable knife movement Line graph of the trimming cam Figure 56 29 x The standard initial assembling position of the movable knife is where the movable knife edge protrudes about 3mm from the fixed knife edge when the trimming action is finished that is when the movable knife is in its initial stop position When fixing the position of the movable knife the following directions must be followed so that the power generated in the cam is delivered without any loss to the trimming action Adjustment Order Manually turn the pulley to finish trimming of the trimming cam Place the cam so that the roller 8 can enter the complementary straight line 2 Slightly loosen the fixing screws of movable knife shaft crank Press the trimmer shake linkage to enter the roller inside the cam Push slightly the ball joint linking bar O to the right so that th
30. ot 3 should adhere to the feed dog 2 before the needle edge adheres to the upper part of the feed dog The upper feed presser foot 3 should continue to adhere to the feed dog even when the needle edge going up and the upper part of the feed dog are detached with each other If not loosen the two up and down cam clamp screws to adjust right and left the fixed position of the up and down cam of the presser foot See Figure 47 When the needle goes down When the needle goes up Figure 47 15 Adjusting stroke of upper feed presser foot 1 As in Figure 48 the machine is adjusted to have the same amount of upper feed presser foot stroke 4 as the feed dog stroke The baseline of the shake crank is aligned with the baseline of the collar 2 Take the followings steps if the two base lines are not aligned or if it is necessary to adjust the stroke 4 of the upper feed presser foot to increase or decrease Upper feed IILIS E PD L Lower feed Figure 48 A Loosen nut B Move nut to the back of the horizontal roller to increase the stroke of the upper feed presser foot Move nut to the front of the shake crank to decrease it C After adjustment be sure to fasten nut 24 SunStar 16 Adjusting safety device If the load occurs by foreign substances on thread needle etc during the sewing operation the driving ball of safety assembly in Figure 49
31. r repair please put again the safety cover disjointed while repairing a 1 4 Machine Operation Warning 1 5 Safety Device Warning KM 560 series are manufactured for industry use to sew textiles and other similar material In case of running the machine users should observe the following things Ahead of operating the machine please read the manual and understand fully the details on its operation Dor t forget to put on the garment suited for the safe work Keep your hands or a part of the body away from the running part of the machine like a needle hook thread take up spring and pulley etc Don t remove any kind of cover for safety while running the machine Be sure to connect the earthed line Before opening the electric box such as a control box be sure to shut off the power supply and make sure that the power switch should be put on off When threading the needle or before checking after sewing be sure to stop the machine D Don t switch on the power supply with the foot on the pedal Don t run the machine when the cooling fan are not running Be sure to clean the air filter in the control box once a week O If possible keep off from the strong electronic wave like a high frequency welding machine Always start the machine with safety covers in place since fingers or hands could be injured or cut off by the belt Turn off the power switch during check ups or adjustmen
32. re 36 Figure 37 2 Adjusting the timing of hook edge and needle center crossing First set the stitch length at 0 Adjust the hook gear clamp screw in Figure 39 so that the hook edge fall exactly at the center of the needle center when the needle bar is raised 2 4 mm from its lowest position as in Figure 38 When this is done the hook edge will be placed at about 1 5 mm above from the front of the needle thread hole Shaft edge Y 2 4mm Figure 38 Figure 39 SunStar 3 Adjusting the distance between the needle and the hook edge Raise the needle from its lowest point so that the hook edge meets the needle center As in Figure 40 when the lower part of the needle meets the balance point of the hook s needle guide plate adjust the needle guide form adjust the distance between the hook edge and the inner side of the needle groove to 0 05 0 1 mm Loosen and in Figure 41 and move the hook base to the left and right for adjustment After adjustment fasten and firmly Hook edge PA Needle Ss cama E 3 in moe nA 8 MA 1 mE LIP q AO an mi CALDAS 0 05 0 1mm Figure 40 Figure 41 10 Clearance adjustment between the upper side of hook stopper and the upper side of needle board groove Like in figure 42 the normal distance between the upper side of the hook stopper and the upper side of the needle plate groove is 1 2 mm This distance can be adjusted by using the up and do
33. t DOWN film A of needle bar B For old model type See Figure 14 Adjust in the same way as for new model to make the right side hoc Figure 12 of the film s projecting part aligned to the center of the sensor base line New model location detector Sensor adjustment base line Old model location detector Film adjustment base line sensor base line Photo sensor Fixing screw DOWN Film DOWN Film Adjustment Adjustment Adjustment Adjustment Figure 13 Figure 14 12 SunStar Be sure to plug in after finishing oil supply If the user steps on the pedal by mistake the machine will start automatically and this might lead to physical injuries When handling lubricant use safety goggle or gloves to prevent the lubricant from coming into contact with the eyes or skin It can cause inflammation And don t drink the lubricant It can cause vomiting or diarrhea Please keep it out of the reach from children Make sure to supply oil when using it for the first time or after not using it for a long time 9 Oil supply 1 Oil tank check 2 Hook tank check Fill the oil tank only to the red maximum line Fill the hook tank only to the maximum line While See figure 15 using the machine replenish the oil immediately when the oil level goes down to the minimum level back to the red maximum level See figure 16 Figure 15 Figure 16 3 Lubrication Be sure
34. ts Warning Safety Label Suggestions while running the machine are stated Thread take up spring cover the device to prevent the human body from touching the thread take up spring Belt cover the device to prevent hands feet and clothing from getting jammed by the belt Finger guard the device to prevent fingers from contacting the needle O SunStar 1 6 Position of Caution is attached to the machine for safety Caution Mark In case of starting to run the machine read the directions of Cautions carefully CAUTION Position of Caution Mark EN A N Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off in switch ATE HSH WMA Blo Solr OJAI Bl Bos ZANE BEA AE H FAAS CAUTION 3 1 Hazardous voltage will cause injury Be sure to wait at least 360 seconds before opening this cover after turn off main switch and unplug a power cord ye MEO ol at 4HE ooog HE 9 ye HAS Hen He 3913 Eu y H 36027 ICE E 0AA e 1 7 Content of Cannon CAUTION IN Ca a Do not operate without finger guard and safety devices Before threading Caution changing bobbin and needle cleaning etc switch off main switch Jar BSH AAK SAOl AtSotdAl UNAI 2 8 Han HSHM HEA FARO ASAE MFAS CAUTION 3 1 Hazardous voltage will cause injury Be sure to wait at least 360 seconds before ope
35. wn adjustment of the bushing assembled under the hook It can be adjusted by loosening and After adjustment they should be fastened firmly When this is done make sure that the hook shaft gear moves smoothly without moving up and down Figure 42 11 Clearance adjustment between hook and opener Loosen the opener clamp screw and turn the opener to the right and left so that the distance between the hook and the opener is about 0 2mm as in Figure 43 when the opener 2 is pulled to its max towards the arrowed direction Figure 43 21 12 Adjusting feed dog height Turn the pulley so that the feed dog is positioned at its hight to adjust the feed dog Loosen the fork clamp screw of the feed dog base as in Figure 44 and move the feed dog base up and down so that the feed dog protrudes about mm from the needle plate top After adjustment fasten the clamp screw firmly bout 1 mm lt e Figure 44 13 Adjusting the auxiliary presser foot and the upper feed presser foot Both the auxiliary presser foot and the upper feed presser foot move up and down Itis normal that both of them move up and down to the same height Take the following steps either to adjust the stroke of both to be the same or to make one of the two adjusted lower or higher depending on sewing materials 1 Adjusting the strokes of both to be the same Figure 45 A The maximum height of the auxili
36. ys place it back to the original position and check whether it functions as intended Use both hands when pushing the machine backward or returning it to the original position Due to the weight of the machine your hand can get stuck in the machine if you should slip When adjusting the machine with the switch on be sure to pay extreme caution Only trained engineers must perform troubleshooting or inspection of the machine For electrical repair or inspection consult with qualified technicians or agent 6 Adjusting the tension of the presser foot As in Figure 31 turning the pressure adjustment screw clockwise makes the presser foot tension stronger and turning counter clockwise makes it weaker After adjusting make sure to tighten the fixing nut Figure 31 7 Adjusting the needle and feed dog timing 1 After removing the needle lay down the machine on its back and remove the timing belt Turn the pulley to coincide the highest point of the thread take up marked on the pulley with the base point marked on the arm In this state turn the timing lower pulley to adjust the baseline on the bed to the baseline of the timing lower pulley Then put the belt 8 See Figure 32 The highest position of oe take up lever i Figure 32 18 SunStar 2 As in Figure 33 check whether the needle tip matches the upper side of the needle plate at the moment when the
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