USER`S MANUAL - Keystone Industrial Sewing Machine Co., Inc
Contents
1. Fig 31 12 Height and inclination Adjustment of Feed Dog 1 Height adjustment of the feed dog x For KM 350 530 Series users the stitch length adjusting dial must be set to 0 here The height of the feed dog is adjusted by moving the lifter crankD after the lifter crank fixing screwQ is loosened The standard height from the top face of the needle plate to the top of the feed dog when the stitch length dial is at its maximum and the feed dog is at its highest point is 0 6 0 7mm for very thin materials 0 75 0 85mm for general materials and 1 1 2mm for heavy materials See Fig 32 0 6 0 7mm or very thin materials Feed Dog Needle Plate Kl ey NI Ag general materials NY 1 2mm For heavy materials Fig 32 2 Inclination adjustment of the feed dog A To adjust the inclination of the feed dog first loosen the feed dog support shaft fixing screw in the horizontal pushing crank and adjust by turning feed dog support shaft up and down in the direction of the arrow with a driver Turning the feed dog support shaft amp clockwise will raise the front part of the feed dog while turning it counterclockwise will lower the front part of the feed dog See Fig 33 B The standard inclination of the feed dog is when the carved sign on the feed dog support shaft is horizontally in line with the horizontal pushing crank as in picture in Fig 33 However to prevent puckeri2. SUNSTAR MACHINERY CO LTD Keystone Sewing Machine Company Inc Contents Safety Rules for Machines 00r00or00rovoronnennnonnannvrensnennennnsnnenspennensnnnnensnannenspvnnenspvnnensvpnnenspannensnnneserenensnrenenserenenes 4 1 Specifications 1 Automatic trimmer e0rr0rrrrrnrrnnrnrrnnnnnnnannnnnannannnnnnnnnnnasnnsnasnnsnnsnnsnnsnnsnsnnsnnsnnennsnnsnnsnnsnnsnnsnnennsnnsnnennennsnnsnnsnnenennennennennenen 8 ON Servo AE NERE EE E REE 8 JE Ge Gee ee eee eee me en tee ncreern eterno n ncn tent tenrerne tree ten ecroR anette ae eee ee Seen e enter een ere erat 9 EE ete se et eet EEE lg cd seca cesisdcesscnaSaxgandanscdncesegensectbasscanutnentauieensened 9 5 Peripheral automation devices optional ssssveereessssrervennsessereennsssesreensesseseennsssesreensessessennessereersessessessennseseeseensessesrt 9 2 Installation gd ee ERE RE RE EE NES 10 2 Chip discharge plate sssssssssssssssssssscssnsnseseenssnsarecsnennuerenntenssseenneanseessntnntensennsonsneeneeossoaensansavassnabsensasensnenuvensensnuoasoate 10 3 Resistance box for knee lifting solenoid s r essssvereensssvesvennssseeseenssssessenssssesseensssssssenssssessenssssssesseenssssessenssssesseenssssssre 11 EE use EEE EE 11 5 Belt tension adjustment L E E E E EENT r S 12 OPE 12 P Belt COVE TT sen cetsasnnenkoes tend tans this teesianngannts 13 8 Location detector assembly and adjustment s s sssssscsesessssesecesssseteceessn
3. SunStar USER S MANUAL KM 250 KM 350 Series High Speed 1 Needle Drop Feed Automatic Thread Trimmer High Speed 1 Needle Drop Feed Needle Feed Automatic Thread Trimmer Keystone Sewing Machine Company Inc 833 N 2nd Street Philadelphia PA 19123 USA KM 506 KM 530 Series a Saat ae High Speed 1 Needle Drop Feed PE Knife Attached Automatic Thread www keysew com Trimmer High Speed 1 Needle Drop Feed Needle Feed Knife Attached Automatic Thread Trimmer 1 For use with maximum ease please be sure to read this manual thoroughly before use 2 Keep this manual for reference in case of machine malfunction or breakdown MME 070426 SUNSTAR MACHINERY CO LTD 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 The specifications of the machine are subject to change aimed to enhance product performance without prior notice This product is designed manufactured and sold as an industrial sewing machine It should not be used for other than industrial purpose
4. 1 Automatic Trimmer 1 KM 250 1 needle high speed drop feed Series Description Usage Bes eran een Needle Type Presser Foot Height thi 3 200 SPM DB 1x 9KN KM 250AU 7S for ultra thin and new materials 2 500 SPM 4 mm o 18 manual 5 5 mn knee 14 thi 3 200 SPM DB 1x 9KN KM 250AU 7N for ultra thin and new materials 2500 SPM 4 mm 19 18 manual 5 5 mn knee 14 i 5 500 SPM DB 1 x 414 KM 250A 7S Ifor thin materials for general use 5 000 SPM 4 9 18 manual 5 5 mm knee 14 KM 250A 7N for thin materials for general use 259 SPN 4 118 manual 5 5 mn knee 14 2 i 4 000 SPM DB 1 x 21 KM 250B 7S for medium to heavy materials 3500 SPM 7 420425 manual 5 5 mn knee 14 i l 4 000 SPM DB 1 x 21 KM 250B 7N for medium to heavy materials 3500 SPM 7 420425 manual 5 5 mn knee 14 KM 250BH 7S for heavy materials 3000 SPN 7 mm rae fa manual 5 5 nn knee 14 KM 250BH 7N for heavy materials Er SPM 7 m 90 fa manual 5 5 nm knee 14 2 KM 350 1 needle high speed drop feed Series Description Usage es een gg Needle Type Presser Foot Height KM 350A 7S for thin materials for general use 409 SPN 4 mm OHA manual 5 5 mn knee 13 KM 350A 7N for thin materials for general use 4090 SPM 4 Gora manual 5 5 mm knee 13 i
5. lever spring grows tighter when the driver is turned clockwise and looser when turned counterclockwise 3 Auxiliary thread adjuster Turn the auxiliary thread tension adjusting nut in clockwise direction to make the remaining thread length Fig 27 on the needle after trimming shorter and in counterclockwise direction to make it longer as shown in Fig 27 The appropriate length of the upper thread remaining after trimming is 30 40mm 4 Thread release control The thread release takes place simultaneously with the movement of the trimming solenoid As seen in Fig 28 the amount of thread release is controlled by moving the fixed position of the thread release wireQ which is connected with the clutch lever left and right Loosen the two fixing nuts and pull the cable wireQ to the left Then fasten the nuts to release the thread to a large extent If the cable wire is pushed to the right and the nuts tightened the thread release happens on a lesser scale After adjustment tighten the nuts once again and check whether the opening of the thread guide plate of the thread adjuster is about 0 5 Imm when the thread releaser is in operation There should be no opening when the thread releaser is not in operation the thread guide plates should be touching back to back The moving stroke of the thread release lever is 11mm Adjust such that the thread guide plates do not open when the cable wire is pulled about 0 8mm and
6. 4 000 SPM DB 1 x 21 KM 350B 7S for heavy materials 3000 SPM 5 20 25 manual 5 5 mn knee 13 f 4 000 SPM DB 1 x 21 KM 350B 7N for heavy materials 3 000 SPM 5 20425 manual 5 5 mn knee 13 KM 350BL 78 for heavy materials 3 200 SPM 6 190105 manual 5 5 nn knee 14 3 KM 506 1 needle knife attached drop feed Series Description Usage ae P a A Needle Type Presser Foot Height KM 506 7S for general use 09 SPN 5 mm AS manual 5 5 mm knee 13mm KM 506 7N for general use 209 SPN 5 mm ed manual 5 5 nm knee 13mm 4 KM 530 1 needle knife attached drop feed Series Description Usage et yes Needle Type Presser Foot Height KM 530 75 for general use 09 SPM 5 mm EN manual 5 5 mm knee 13nm KM 530 7N for general use 09 SPM 5 mm ray manual 5 5 mm knee 13mm 2 Servo Motor MODEL VOLT WATT HERTZ SC55 1A single phase 110V 550W 50 60 Hz SC55 2A single phase 220V 550W 50 60 Hz SC55 3A triple phase 220V 550W 50 60 Hz Keystone Sewing Machine Company Inc SunStar 3 470 Motor PM470 MODEL PHASE HERTZ VOLT 1 14 ae 1 110V 1 1 5 50Hz i 3 3 6 60Hz p ped PM470 3 3 4 nie 3 380V 1 14 5 8002 4 110V 220V 3 3 3 000 5 220V 380V 4 470 Motor Controller PC470 A 001 MODEL VOLT MODEL SUB CLASS PC470 DN A 001 2 220V 5 Peripheral Automation Devices Optional Name Model Usage
7. A device that operates with a solenoid by lifting the presser foot Auto Knee Lifting System SPF 5 qoy automatically at pedal reverse gear 1 A counting device which indicates the completed quantity on the Production Counter SCOUN 1 program unit panel including added subtracted corrected or remaining quantity along with other performance rates A device that senses the edge or thickness of the sewing material to SEDG 1 Material Edge Sensor SEDG 2 stop the machine without manual pedaling Available in two types SEDG 1 for edge sensing type and SEDG 2 for thickness sensing type A device needed when only one operator runs several sewing SPDL 1 machines Pedals for acceleration thread trimming presser foot Standing Pedal SPDL 2 and ascending are built separately Two types SPDL 1 and EDPL 1 for fixed speed type and SPDL 2 and EDPL 2 for adjustable speed type are available S servo motor E 470 motor Keystone Sewing Machine Company Inc 2 Installation NWarning 2 gt The machine must be installed by a trained technician only OG Anysietieal wiring must be performed by aqualiied technician oragent _ gt me machines weigh over 33 ka As such two or more people should carry out the installation 2 pb Plug in only 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 cau
8. s s csccsssssesnesssesecoresssesesnsonssseennenssseeonnonsvassbenensvasseabeesuaseabuanssessannanvasoanoenssaseansastovers 24 19 Adjustment of bobbin catcher s esseeessssrassessssssasnessssssenessssssrssessssssssseessssssssserssssstseesessessressssssseeessssenssesssssssssessssens 24 IRER ecard eesenenrereeentoamesentninrint 25 21 Knife adjustment sssvesseevsssessoresssssrensserssserseeessssssseersssssssersssssssersssessserssssstseessssessessersereeresessssesssenssseeseeeeersessseseesesss 26 22 Use of chip discharge guide and auxiliary needle plate revsrevsrvvevvsvrrsrevsravsenssrssrevsresssensersseessenssenssesssessensssensee 27 23 Change of cutting Width sseesssessssssssnesssssessessssssssnessssssssessssssssnessssssssessssssesteesesssesssersssensserssssessnersssenseesssssssseessssees 27 4 Cause of Troubles and Troubleshooting 1 Sewing machine troubleshogting ir roe o a E E E EE EEE EE EE 29 Keystone Sewing Machine Company Inc Safety rules for machines Safety labels in the 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 marks UN Danger Instructions here shall be observed strictly Otherwise the user will be killed or suffer severe physical injuries N Warning Instructions here must be observed or the us
9. 15 Keystone Sewing Machine Company Inc SunStar 2 For 470 Motors Turn the pulley manually to position the needle bar at the lowest point about to move back up Then loosen the fixed screws on the film as in Fig 12 and align the DOWN film with the film adjustment baseline and the sensor housing baseline as in Fig 16 amp 17 Tighten the fixed screws just enough so that the film does not rotate In the same way place the thread take up lever at the highest point then loosen the fixed screws again and adjust the UP film as in shown the figure Be careful that the DOWN film A that was tightened before does not move when adjusting the UP film a Film Adjusting Arrow Film Adjusting Base Sensor Base Setting the film when Setting the film when the needleisina the thread take up lever Fig 17 down stop position is at the highest point Fig 16 10 Check for Stop Position of Sewing Machine Check for the machine stop position after moving the needle White Carved Sign up and down by pushing the reverse button See whether the carved sign on the arm and the white carved sign on the pulley are aligned when the needle is in an up position If not adjustment to the photo film of the location detector or to the location of the magnetic holder will be necessary since there may be problems with the trimming In other words the needle s up stop pos
10. knife edge is from 2mm forward to 3mm backward from the needle center 3 Adjusting the left right position of the knife A To adjust the left right position of the knife loosen the knife frame fixing screw and move the knife frame sideways B After loosening the knife frame fixing screw and adjusting the knife side so that it would touch the side of the needle plate tighten the fixing screw C If the knife is too close to the needle plate there may be an overload on the knife when in operation on the other hand if the adhesion is too weak there may be problems when cutting the material Therefore the lever must always be operated after adjustment to check whether the knife movement is smooth 26 Keystone Sewing Machine Company Inc SunStar 22 Use of Chip Discharge Guide and Auxiliary Needle Plate KM 506 530 Series 1 When Cutting and Sewing Simultaneously When cutting and sewing are done at the same time attach the chip discharge guideQ which is provided in the accessory box to the auxiliary needle plate with fixing screws See Fig 50 2 When Sewing Only When sewing is done alone without cutting remove the chip discharge guide upper and the insert the auxiliary needle plate cover which is provided in the accessory box into the chip discharge groove in the auxiliary needle plate See Fig 51 Fig 50 Fig 51 23 Change of Cutting Width 1 Disassembly A L
11. needle correctlyz 2 Thread breaks Upper thread tension Too tight upper thread tension Reduce tension of upper thread Lower thread tension Too loose lower thread tension Reduce tension of lower thread Working capacity of take up lever spring Loose upper thread Adjust take up lever spring Direction and height of needle Needle inserted in the wrong position Reinsert the needle in the right direction Needle Bent needle or broken needle tip Change the needle Threading Thread passing at wrong position Change the needle Ascending level of needle bar Wrong timing of needle and hook Adjust the timing of needle and hook Height of needle bar Wrong timing of needle and hook Adjust the timing of needle and hook Gap between needle and hook Wrong timing of needle and hook Adjust the timing of needle and hook 3 Stitch skips Remaining length of upper thread is short Adjust the thread adjusting device Racing proof spring of bobbin case Due to bobbin racing during trimming lower thread dropping from bobbin case becomes too short to go up Change the racing protection spring Take up lever spring Unable to lift lower thread due to weak take up lever spring Adjust the working capacity of take up lever spring Keystone Sewing Machine Company Inc 29 No Symptom Checkpoints Root cause Corrective action r Upper thread Too tight up
12. of the hook is 0 05 0 1mm then tighten the three fixing screws again Fig 20 As in Fig 21 oil flow is at its maximum when the markQ on the head of the oil flow control pin and the center of the hole on the thread take up lever crank shaft is directly aligned In contrast oil flow decreases when the mark is turned closer to the corner of the link cam washer Furthermore if the mark passes the corner of the link cam washer oil will not flow at all Keystone Sewing Machine Company Inc Fig 21 SunStar N Caution QB gt When checking the oil level in the hook keep your hands or oil flow checking paper away from any moving parts including transfer tools to avoid injury 5 Lubrication Adjustment of Hook 1 Checking the oil supply level of hook A After racing the sewing machine for three minutes at an appropriate speed secure the oil flow checking paper as shown in Fig 22 and run the machine for about five seconds Then check the oil tape marked 3 10mm on the paper B Check the oil supply level three times The Oil Flow Checking Paper appropriate level of oil is when the oil level neither Resulting Oil Tape Resulting Oil Tape exceeds the maximum amount nor falls below the minimum level Insufficient oil would jam the hook whereas excessive oil would contaminate the sewing about 0 5mm about 1mm Minimum Maximum platen wat il Op
13. solenoid in unit A Use four fixing screws to attach the bracket onto the program unit B Fasten the bracket onto the machine body using two fixing bolts and three clamp screws in the back lid of the machine See Fig 7 Fig 5 Fig 6 Fig 7 Keystone Sewing Machine Company Inc SunStar 2 Installing manual knee lifter A Use four fixing screws to attach the bracket onto the program unit B Fasten the bracket tightly using the three fixing screws in the back lid of the machine See Fig 8 Fig 8 7 Belt Cover 1 Use the clamp screwsQ in the machine body and the washer to fasten the belt cover A Installation of the belt cover will be easier if the sewing machine is laid down to an appropriate degree See Fig 9 Fig 9 2 Attach the belt cover B to the table Please exercise caution so that the belt does not get jammed inside the belt cover B See Fig 10 Fig 10 13 Keystone Sewing Machine Company Inc 8 Location Detector Assembly and Adjustment 1 Installing the location detector A Installing on the servo motor in built location detector A location detector sensor is attached to the back side of the arm The appropriate clearance between the location detector and the pulley is 0 5mm See Fig 11 2 Installing the 470 motor Fig 11 After as
14. ally effective for slippery material or thick material which are susceptible to jams 3 In contrast turning the needle feed connecting rod in O direction would decrease needle movement such that it would be smaller than the feed dog movement Fig 35 22 Keystone Sewing Machine Company Inc SunStar 15 Timing Adjustment of Trimmer 1 Turn the pulley manually and align the red carved signQ on the pulley and the carved sign on the arm 2 Separate the return spring White Dot Synchronization color point Fig 36 3 Push the trimming lever amp so that the thread trimming knife on the hill of the movable knife is about 1 1 5mm more protruded than the end point of the fixed blade 4 Push the trimming solenoid shaft manually while the trimming cam fixing screwQ is loose At this point the appropriate distance between the initial trimming cam and the roller single screw is 0 5mm oon D p TV eN G 0 5mm od Fig 37 5 Turn the mine cam pannal that the edge of Trimming Shaft the roller driving part on the trimming cam touches the roller Then tighten the trimming cam fixing screw Q 6 Connect the return spring Lower Shaft Fig 38 23 Keystone Sewing Mach
15. chine near areas with danger of explosion Refrain from running the machine in the vicinity of risky places e g where a large quantity of aerosol spraying products or oxygen are handled unless specific guarantees are given otherwise for the operation of the machine to prevent explosion at such places The user should install an illuminator in the work area for the machine does not come supplied with any lighting apparatus due to the specific features of the machine Note Details of the machine installation are laid out in No 2 Installation 1 3 Troubleshooting Danger When the machine is in need of repair only our authorized service technicians must handle it Before cleaning and repairing the machine shut off the power supply and wait four minutes for the machine to discharge completely O No part of the machine or specifications may be modified without prior consultation with our company Any such modification could risk safe operation of the machine Incase of repair replace only with standard OEM parts from SunStar After repair put safety covers back on the machine Keystone Sewing Machine Company Inc 1 4 Machine operation A Caution KM 250 Series are intended to be used for industrial purposes for sewing textiles and other similar materials Carefully study the following instructions before operating the machine Read the manual thoroughly and understand the instructions ful
16. e Ora o Keystone Sewing Machine Company Inc SunStar 1 6 Location of Caution is attached on the machine for safety Read the directions of caution caution mark carefully before running the machine CAUTION Location of caution mark AFT AN Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off lt q main switch aper Hane HAZA glo FEH DAA 2 Y Bil BjEDnstaL anoe HEM F WAA Aas FAS r N CAUTION aia Hazardous voltage will cause injury Be sure to wait at least 360 seconds before opening this cover after turn off main switch G and unplug a power cord l 20 UFA of ME ALn AWS Swe MAS Well MA 8008 BT y A 3077H 71021 S ALAS 1 7 Contents of caution CAUTION IA azn Do not operate without finger guard and safety devices Before threading Caution changing bobbin and needle cleaning etc switch off main switch 272 BSH OMAN 8101 ASS Ot AMG Bl Hanni SAAME HE FAO ASAE WW FAME CAUTION a 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 De MEAN Wo AMS Bese HH 22 HE AUS Weld AH 418 amp a UN 360242 JILL MMS Keystone Sewing Machine Company Inc 1 Specifications
17. er could suffer fatal or severe physical injuries N Caution Instructions here should be observed or the user could face physical injuries or mechanical damages The meaning of marks This mark means a must not This mark means that an electric shock may be caused if the instruction is not followed properly D This mark means a must for safety Keystone Sewing Machine Company Inc SunStar 1 1 Machine mobilization Danger Only personnel with a full understanding of the safety rules should move the machines The following directions must be observed when delivering the machines At least two or more people should move the machine Before delivering the machine thoroughly wipe off the oil on the machine to prevent accidents 1 2 Machine installation Caution Physical damages such as functional difficulties or breakdowns may occur depending on installation conditions of the machines Be sure to heed the following conditions Remove the packing from top to bottom Watch out for nails on the wooden box Install a climate controller and clean it regularly to prevent dust and moisture build up from contaminating and corroding the machines Keep the machines away from direct sunlight Keep a minimum distance of 50cm between the machine at both sides and backside and the wall to secure sufficient space for repair Do not operate the ma
18. g Machine N Caution DD while the power is on the machine will start automatically and can result in physical injuries come to a complete stop gt Always turn off the power when mounting a needle If the operator mistakenly steps on the pedal gt When using clutch motor be aware that the motor will continue to rotate for a while even after the power is switched off due to inertia Start to work on the sewing machine only after the motor has With the needle groove facing left insert the needle tip into the upper end of the stopper holeQ and fasten the needle with the clamp screwQ See Fig 19 Fig 19 As is shown in Fig 20 unscrew the rubber plugs in the needle bar adjustment hole that is on the face plate and turn the pulley so that the needle bar is in a down stop position Then turn loose the clamp screws on the needle bar handle move the needle bar such that the lowest carved sign on the needle bar is in line with the bottom of the needle bar lower bushing and tighten the clamp screws of the needle bar handle Lastly plug in the rubber plugs As can be seen in Fig 20 align the bottom of the needle bar bushing with the hook fixed position sign marked on the needle bar and loosen the three hook fixing screws Turn the hook so that the edge of the hook is in line with the needle center Adjust such that the distance between the inside of the groove on the needle side and the edge
19. he bobbin catcher operation lever is not working as in Fig 43 adjust the end of the bobbin catcher lever so that it is placed like at the end of the connecting link Then loosen the operation lever fixing screw and adjust Fig 43 24 Keystone Sewing Machine Company Inc SunStar 2 If the trimming was done manually stop the machine when the edge of the fixed knife meets the bobbin catcher adjustment baseline that is marked on the top Bobbin Catcher Adjustment Baseline Loosen the bobbin catcher fixing screwG and adjust the bobbin catcher so that the contact surface of the bobbin catcher lightly touches the center of the protruding part of the bobbin Once the operation is completed check to see whether the bobbin catcher springs back i Fixed blade lightly Movable Knife Fig 44 20 Wiper Adjustment 1 KM 250 7 KM 350 7 Series Turn the pulley manually and stop when the white carved signs on the arm and the pulley are aligned highest point of the thread take up lever Loosen the two wiper shaft fixing screws on the wiper base and press the connecting link with the hand Then adjust the wiper shaft so that the gap between the wiper and the needle is about 2mm and tighten the wiper shaft fixing screw Next loosen the wiper fixing screw and adjust so that the gap between the lower end of the wiper and the end of the needle is about 2mm after which the wiper f
20. ine Company Inc 16 Tension Adjustment of Fixed Blade 2e ai Wrench Box First loosen the fixed blade tension adjusting nut with a wrench box and then loosen the tension adjusting screwQ As in Fig 39 adjust the tension adjusting screw of the fixed Movable Knife blade when the movable knife edge meets the fixed knife a edge Adjust just enough so that the knife edges meet without too much tension After adjustment make sure to Fixed Blade D tighten the tension adjusting nut using the wrench box in Fig 39 the accessory box 17 Replacement of Movable Knife QD To change the movable knifeD turn the pulley manually to place the needle at the highest point Then remove the needle plate by unfastening the two movable knife fixing screws as seen in Fig 40 Follow these instructions in reverse order to assemble Fig 40 18 Replacement of Fixed Blade A To change the fixed knife loosen the inner spindle stopper fixing screwQ as in Fig 41 remove the washer and inner spindle stopper then unfasten the fixed knife fixing screw Follow these instructions in reverse order to assemble Fig 41 B If the edge of the fixed blade is worn make sure to grind the knife edge with an oil grindstone as shown in Fig Fixed Knife 42 Oil Grindstone Fig 42 19 Adjustment of Bobbin Catcher 1 Adjusting the operation lever of the bobbin catcher If t
21. ing screw B To prevent material jam make the feed dog movement a little faster than the needle movement To do this loosen the feed cam fixing screw and turn the feed cam in the arrow direction and then tighten the feed cam fixing screwQ KM 350 530 Series A If the feed dog movement is faster than the needle movement loosen the feed cam fixing screw and turn the feed cam in the arrow direction and then tighten the feed cam fixing screwQ B On the other hand if the feed dog movement is slower than the needle movement loosen the feed cam fixing screw and turn the feed cam in the opposite direction of the arrow and then tighten the feed cam fixing screwQ Needle Needle eedle Plat Needle Plate Feed Dog standard position Feed Dog standard position When the feed dog is fast When the feed dog is fast oe When the feed dog is slow When the feed dog is slow KM 250 506 Series KM 350 530 Series Fig 34 14 Adjustment of Needle Movement KM 350 KM 530 Series 1 The standard position is when the needle feed connecting rod is positioned at the carved sign marked on the horizontal pushing crank back 2 To increase the feed dog movement over the needle movement loosen nut and adjust the needle feed connecting rod in direction and then tighten nut The feed dog movement can increase about 20 in excess of the needle movement and this adjustment is especi
22. ition should be identical with the stop position of the needle bar after the trimming operation which would signify that there is nothing wrong with the operation Back Tack Reverse Button timing of the trimmer See Fig 18 Refer to the explanation about the Adjustment of Location Detector on page 14 11 Back Tack Button Pressing the back tack button or reverse button during forward sewing will start reverse sewing immediately When you stop the machine and restart it by stepping down on the pedal with the reverse button already pressed down you can perform reverse sewing from the beginning When the machine is in a stop mode you can change the Tt up down position of the needle bar by pressing the reverse 4 Down Stop Position Up Stop Position button Lightly pressing the button once when the needle is in a down stop position will stop the needle bar in a high position Pressing the reverse button twice within less than a second when it is in an up stop position will stop the needle bar in a low position In short the button delivers two functions one for reverse sewing and the other for Fig 18 converting vertical position of the needle See Fig 18 15 Keystone Sewing Machine Company Inc 3 1 Needle Insertion 2 Needle Bar Adjustment 3 Timing Adjustment of Needle and Hook 4 Lubrication Adjustment of Thread Take Up Lever Control and Adjustment of the Sewin
23. ixing screw must be tightly fastened See Fig 45 amp 46 Fig 45 Fig 46 2 KM 506 7 KM530 7 Series Set the stitch length adjusting dial to 2 Turn the pulley manually and stop when the white carved signs on the arm and pulley are in a straight line highest point of the thread take up lever At this point position the wiper so that the needle and the presser foot are about 2mm apart and then fix the position See Fig 47 Fig 47 25 Keystone Sewing Machine Company Inc 21 Knife Adjustment KM 506 7 KM 530 7 Series 1 Adjusting the height of the knife Fig 48 A The knifeQ is operated by the lever at the center of the sewing machine If the lever is pulled down the cutting and sewing of the material can be done simultaneously If the lever is pulled up sewing is done without cutting B Loosen the knife fixing screw when the lever is pulled down and adjust so that Area A of knife is about 0 5mm above the top face of the needle plate Then tighten the knife fixing screw 2 Adjusting the front back position of the knife Fig 49 A Set the stitch length adjusting dial to 0 x Itis a standard that the edge of the blade meets the center of the needle To adjust the front back position of the knife loosen the knife plate fixing screw and move the knife plate back and forth The adjustable width range of the
24. ly before use Put on proper safety garments While the machine is in motion keep your hands or any part of your body away from moving parts e g needle hook thread take up spring and pulley etc Do not remove any form of safety covers while the machine is in use Be sure to connect the ground earth wire Before opening electric boxes such as the control box shut down the power supply and make sure the power switch is in off mode amp Stop the machine before threading the needle or checking after sewing work is finished Never turn the power switch on with the pedal down Do not use the machine if the cooling fan is clogged Clean the air filter embedded in the control box at least once a week Keep the machine away from strong electromagnetic fields such as high frequency welding machines 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 when conducting a Caution regular check on the machine 1 5 Safety device A Caution Safety label Safety instructions for machine operations Thread take up spring cover A device designed to prevent the human body from coming in contact with the thread take up spring Belt cover A device intended to avoid potential risks of getting hands feet or clothes jammed by the belt Finger guard A device built to keep fingers away from the needl
25. ng adjust the feed dog to that the front is a little higher than the back as in picture in Fig 33 Also to prevent material jamming lower the front of the feed dog as in picture in Fig 33 C Adjustment of the inclination of the feed dog will result in a change in the height of the feed dog so recheck the height Higher front Front Feed Dog Back We j f aan a a a a D Da D Ma L Standard position r m Lower front Fig 33 21 Keystone Sewing Machine Company Inc 13 Feed Cam Adjustment The timing of the feed dog and needle is adjusted by turning the feed cam up and down When the pulley is turned such that the feed dog is lowered so that the top of the feed dog is aligned with the top of the needle plate the lower needle hole will come in direct line with the top of the feed dog This is the standard position For the KM 350 530 Series the standard is when the end of the needle is in line with the top of the feed dog when the top of the feed dog is aligned in height with the top of the needle plate x For KM 350 530 Series users the stitch length adjusting dial must be set to 0 here KM 250 506 Series A To have the appropriate amount of tension in the thread make the feed dog movement a little slower than the needle movement To do this loosen the feed cam fixing screwQ and turn the feed cam in the opposite direction of the arrow Then tighten the feed cam fix
26. oosen the needle fixing screw and remove the needle B Loosen the presser foot fixing screw and separate the presser foot C Loosen the needle plate fixing screw and separate the needle plate D Loosen the feed dog fixing screw and separate the feed dog E Loosen the auxiliary needle plate fixing screwQ and separate the auxiliary needle plated F Loosen the chip discharge guide lower fixing screw from the separated auxiliary needle plate and separate the chip discharge guide G Loosen the knife fixing screw and separate the knife Fig 52 27 Keystone Sewing Machine Company Inc 2 Assembly A Replace the chip discharge guide lower with the one fit for the desired cutting width and fix it with the auxiliary screw on the auxiliary needle plated B Fix the auxiliary needle platedd using two fixing screws on the bed C Fix the feed dog using the fixing screw D Fix the needle plate on the bed using two fixing screws x Turn the pulley manually to check whether the space between the feed dog and needle plate during feed doge movement is equal in all directions Then adjust the knife frame to adjust the knife position x Move the chip discharge guide lower q2 to the left and right so that it is placed 0 05mm from the knife plate side Then use the fixing screwQ to fix the position E Adjust the knife frame so that the pressure of the knifed and the needle plate side is appro
27. per thread If the operator mistakenly presses down on the pedal while switched on the machine will start automatically and can cause DB 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 Start to work on the sewing machine only after the motor has come to a complete stop 7 Routing Upper Thread Place the thread take up lever at the highest position and route the upper thread in the order indicated in Figures 24 and 25 KM 250 Series KM 350 Series Fig 24 Fig 25 Keystone Sewing Machine Company Inc SunStar 8 Upper Thread Adjustment 1 Main thread adjustment device e When the upper red is weak tt Ut bbb ls DVI 4 FESS The tension of the upper thread gets tighter if the tension adjusting nut as in Fig 26 is turned in a clockwise When the upper thread is strong ARIK KAY direction and it gets looser when turned in the opposite direction The tension of the thread should differ according to the sewing conditions which depend on the Weaker ts th SG material thread stitch length etc So the tension should SS be adjusted as seen fit for the conditions 2 Tension adjustment of thread take up lever spring As in Fig 26 use a driver in the thread adjustment shaft grooveQ to adjust the spring tension The thread take up Fig 26
28. per thread tension Reduce tension of upper thread does not sink Too loose lower thread tension Increase tension of lower thread 5 Lower thread Too weak upper thread tension Too strong lower thread tension does not sink Increase tension of upper thread Decrease tension of lower thread Tension of fixed blade Tension not aligned between movable and fixed blade Adjust tension of movable and fixed blade Edge of movable and fixed blades Abrasion in blade groove of movable and fixed blade Replace movable and fixed blade 6 Trimming errors Direction of needle Wrong needle insertion Reinsert the needle correctly ee poeng Insufficient crossing quantity of Adjust the stroke of movable and trimmer cam notch movable and fixed blade fixed blade mark and blade Too strong upper thread tension Adjust tension of upper thread Upper thread 5 pulled out Too thick a needle for thread Check thickness of needle when sewing Take up lever pulls out the upper p commences Check the Up stop thread because the needle up and Adjust the up stop position of position of needle rete needle down position is too high 30 Keystone Sewing Machine Company Inc MEMO Keystone Sewing Machine Company Inc
29. priate Then tighten the fixing screw Refer to the explanation about knife position adjustment F Attach the presser foot and tighten the fixing screwQ G Fix the needle with the fixing screw H Adjust the knife position adjusting plate to get the desired cutting width and tighten the fixing screw after adjustment x After assembly refer to the knife position adjustment instructions on page 24 and readjust Fig 53 Keystone Sewing Machine Company Inc 4 Cause of troubles and troubleshooting 1 Sewing machine troubleshooting SunStar No Symptom Checkpoints Root cause Corrective action Needle breaks Direction and height of needle Needle is inserted into wrong position Reinsert the needle correctly Needle Needle is bent Change the needle Bad timing of feed dog Adjust the timing of feed dog Ascending level of needle bar Bad timing of needle and hook Adjust the timing of needle and hook Height of needle Bad timing of needle and hook Adjust the timing of needle and hook Gap between needle and hook Bad timing of needle and hook Adjust the timing of needle and hook Threading method Wrong threading Thread the needle correctly Needle Bent needle or broken needle tip Change the needle Direction and height of needle Needle inserted in the wrong position Insert the
30. r foot 5 5mm Top Face of the Needle Plate will grow stronger when the tension adjusting screw is turned clockwise and weaker when turned Fig 29 counterclockwise Make sure to screw in the fixing nut after adjustment 10 Adjustment of Automatic Knee Lifter Optional An automatic knee lifter will be attached to the sewing machine at point of delivery The lifting amount of the presser foot when automatically lifting the knee is controlled by the automatic knee lifting solenoid shaft crank First loosen the solenoid cover fixing screw and remove the solenoid cover If the solenoid shaft is moved left and the fixing screw is tightened when the solenoid crank shaft fixing screw is loose the lifting amount of the presser foot grows smaller If the solenoid shaftG is moved to the right the lifting amount will grow bigger Assemble the cover back after the adjustment is completed The presser foot lifting amount for the automatic knee lifter will be set to 13mm by default at point of delivery Fig 30 20 Keystone Sewing Machine Company Inc SunStar 11 Stitch Length Adjustment As is shown in Fig 31 the number marked by the stitch adjusting dial signifies the stitch length in mm units Move the dial sideways to set it to the desired stitch length Turn it in clockwise direction and the stitch length will decrease while turning it counterclockwise will increase the stitch length
31. s 2 gt When handling lubricants wear protective glasses or gloves to avoid contact with your eyes or skin Inflammation may be caused otherwise Never drink lubricants since they can cause vomiting or diarrhea Keep out of the reach of children D gt Operate the machine only after adding oil when the machine is being used for the first time or has been left unused for a long time 4 Lubrication 1 Installing Magnetic Chip Remover A Attach the magnetic chip remover that is in the accessory box to the oil pump inside the bed See Fig 4 x Do not use the magnet for other purposes Use of the sewing machine without the magnet may cause malfunction and has a bearing on the machine s durability Fig 4 11 Keystone Sewing Machine Company Inc 2 Lubricating the oil fan A Fill the lubricant up to the HIGH mark See Fig 5 B The lubricant must be SUNSTAR s oil provided exclusively for industrial sewing machines or SHELL s Tellus C10 C If the oil in use is down to the LOW mark fill in to HIGH immediately D Once every two weeks is deemed the appropriate interval for oil refills 5 Belt Tension Adjustment Sufficient loosening of the fixed nuts after motor installation would create tension to the belt Tighten the fixed nut first and then tighten the fixed nut to an unmovable position See Fig 6 6 Program Unit 1 Installing automatic knee lifting
32. saenssonssoasoes 18 8 Upper thread adjustment bide bededaeessseua secede cedseessscbeesesceasedseessecdiece Sassa kaS NON SEs r saas EENES eses ini Ses nisasie badakad ere 19 9 Height and tension adjustment of presser ea A A E 20 10 Adjustment of automatic knee hifter ss sees ecccscccecesssscacssesesesesecsscscavanerepeveasooass suse daedsveesbebveesdcioonawib seas ceadeoeresensasenbapiess 20 11 Stitch length adj stment ssssssssssesssssssssesosssssssessossssssossossssssessossssseosssssssssesssssssessssoosessessesssssseseossessssseesssssosseorsisssesoss 21 12 Height and inclination adjustment of feed dog ssessseeeeeesssseeereesssseeensssssseeneesssseeenessssseeseessssseenesssssssreeesssssseeneesser 21 13 Feed cam adjustment s sevseressonesessssensverssssstseessssenssersaseesssessssessserssssetseessssesssersssssresssessssersserssrsesssessssesseeeeeresssseseesenst 22 14 Adjustment of needle movement sc sseeseeoseessenneonsseesnesnsensneannenvasenenseseseansesvessasnsssseneannesesseanseansessansnsasseass 22 15 Timing adjustment of trimmer ss essseessssrassessssssssnessssssssessssssessesssssstsseesssssssseesssssnseeseessssssessssessenessssenseessssssssnessstees 23 16 Tension adjustment of fixed h ge sv sete re en eedoGDGRGGGEN 24 17 Replacement of movable knife s eeessseesoserssssrtorersssssseerssssssseessssessessersssserssessssssesesesserseersessesseesessesseereessesseeneseses 24 18 Replacement of fixed blade
33. se physical injuries AN gt Connect the ground earth wire An unstable connection may result in an electric shock or a malfunction GD gt Place the belt cover on top of the machine GD Use both hands when bending the machine backward or returning it to the normal position Using only one hand can lead to physical injuries due to the weight of the machine 1 Machine head Insert the head hinge into the bed holes and fit it to the rubber hinge Then stand it on the rubber cushions in the four corners Fig 1 2 Chip discharge plate KM 506 530 Series Use the chip discharge plate installation guidelines included in the accessory box to attach the plate to the bottom of the table as in the figure Oil fan Fig 2 Keystone Sewing Machine Company Inc SunStar 3 Resistance box for knee lifting solenoid KM 1 7N 1 Installation A Attach the resistance box around the motor under the Automatic knee lifting solenoid table P we B Connect the connector from the solenoid to the resistance ET Resistance box box as shown in Fig 3 and then connect the line from er a i the resistance box to the control box TARN Sk Control box Fig 3 N Caution gt Plug in only after oil supply is finished If the operator mistakenly steps on the pedal with the plug in the machine will start automatically and can cause severe injurie
34. sembling the parts in the numbered order as in Fig 12 adjust the synchronization shaft horizontally such that the photo film is placed at the center of the photo interrupter as in Fig 13 Then fasten it tightly with two fixing screws using a hexagonal wrench Caution e Assemble after adjusting the position such that the letters UP and DOWN are facing the front side when seen from the pulley as is shown in Fig 12 e The film will already be adjusted by default Pulley R L Wrench Synchronization Shaft Fixed 7 Synchronization Shaft Photo Film Photo Interrupter Location Detector Fixed Clearance Adjusting Bushing fr Shaft Washer COVER PCB Holder Fig 12 Fig 13 9 Location Adjustment of Location Detector 1 For in built location detectors For the needle bar s upper stop position setting loosen the tightening screw on the side of N U punched mark of the pulley and set the white punched mark of the pulley in parallel with the punched mark of the arm at the desired upper stop position by moving the screw sideways For the needle bar s lower stop position setting loosen the tightening screw on the side of N D punched mark of the pulley and set the needle bar to stop at 2 5mm 3 0mm above from the needle bar s lowest position as the lower stop position by moving the screw sideways see Fig 14 and Fig 15 t Up Stop 2 ee Position Position Yj Fig 14 Fig
35. ssseceesnsueceessnuneceesnsureceessnnesectssnnanesenteeny 14 9 Location adjustment of location detector s rererererenenenenenenenennenenevevenenenenevenenenerenenenenenenenenenenenenenenenenenenenenenenenene 14 10 Check for stop position of sewing machine se s rrosserresnesnsssersasrersaraseessssrreneenssernsseenseptnsneesserrensensessnenessseseetennennere 15 11 Back tack Butt nssiesccasesssvsesecvewsnsuvedncccetenes tues vse cece deesavssessccutacnvencseceastua s set sven tues sees coeeencuestuans sees seee obassdeeeeeees EEEREN 15 3 Control and Adjustment of the Sewing Machine ERR en ep enfin Fg Peake Poh pence EVENE nc reece 16 2 Needle bar adjustment ssssssssesssssessssessessseseanecsssseennenssieecnnonssseennebnasesnntnnserecneconsnstoroonussssaabeavessosnosnvassaseeassssoanbanedsiee 16 3 Timing adjustment of needle and hook ss sssesssevsssssssnersssssssnesssssssssrerssssssseesessesssesssssssseessssesteesssssssssessssenssessesssssnerene 16 4 Lubrication adjustment of thread take up E 16 5 Lubrication adjustment of hook se ssesseevsssssasversssssseeessssssseersssssseeesssssssessessesesssersessesssenesseeseersersessensseresssersereessenneerere 17 6 Inserting lower thread and tension adjustment EE E secs neneaunnensnensh obsaces nadanenaueh AEON MAARE NENEA EEE EEEE 18 7 Routing upper Chr As sssssssseccccsssesrcessscececceesessssnssccsseessssnssscnaeeessenssessnensssessseseeeesssesssesssenseonsssnsssassnonssseseses
36. that the plates open when the cable wire is pulled about 8 11mm See Fig 28 11mm Opening 0 5 1mm Fig 28 19 Keystone Sewing Machine Company Inc N Caution gt After disassembling and adjusting a safety device always place it back to the original position and check whether it functions as intended D gt 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 gt When adjusting the machine with the switch on be sure to pay extreme caution 2 gt Only trained engineers must perform troubleshooting or inspection of the machine gt For electrical repair or inspection consult with qualified technicians or agent 9 Height and Tension Adjustment of Presser Foot 1 As in Fig 29 remove the rubber plug in the face plate and place the presser foot on the needle plate Then Weaker Stronger loosen the presser bar fixing screw and adjust the height of the presser bar The presser foot will fall when the presser bar is lifted and rise when the presser Se bar is moved down Move the presser foot lifter amp manually to place the bottom face of the presser foot 5 5mm above the top face of the needle plate and tighten P Q the presser bar fixing screws firmly 2 Tension adjustment As described in Fig 29 the tension of the presse
37. timum Level Optimum Level 2 Adjustment of the Oil Supply Level Turn the oil flow adjusting screw in the lower shaft front bushing in a clockwise direction for more oil flow Turn it counterclockwise for less oil Fig 22 N Caution gt Turn off the power when adjusting the lower thread tension If the operator mistakenly steps down on the pedal while switched on the machine will start automatically and can cause D 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 Start to work only after the motor has come to a complete stop 17 Keystone Sewing Machine Company Inc 6 Inserting Lower Thread and Tension Adjustment Fig 23 A After placing a bobbin in a bobbin case D push the thread through the thread groove and hook it under the tension adjusting plate spring To tighten the lower thread turn the tension adjusting screw clockwise turn it counterclockwise to loosen Adjust the tension of the lower thread so that it will fall slowly by gravity when the bobbin case is dropped while holding the end of the thread See Fig 23 B Inserting and Removing the Bobbin Case Hold the bobbin case handle and insert it into the hook Pull the handle to remove The bobbinQ will fall out if the handle is let go See Fig 23 N Caution gt Turn off the power switch when routing the up
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