User's Manual
Contents
1. 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 au Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off lt main switch AI ste ABA gO ASH OANA 4 Hel HETH Aeae HEA rir V J CAUTION A a Hazardous voltage will cause injury Be sure to wait at least 360 seconds before opening this cover after turn off main switch lt 4 z and unplug a power cord e ger AFO j a gag 4 oss AWS y uz Ag TI Aq Syne Eu m AHS te a sul UH B0774 7E GHAL M 1 7 Content of Caution CAUTION 5N a Do not operate without finger guard and safety devices Before threading Caution changing bobbin and needle cleaning etc switch off main switch 272 SSHhet HANZ 830 AtSotAl UAIS a 8l Hann EAE BIEAI FHA AAWE H FAI 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 Te ARO dt BNE secs HHE Ste HAS el me Bells mu LLM 36032 JIC amp OAAS J Specification 1 Sewing machine KM 640BL 7 Long arm type one needle2. Caution The standard position of the thread trimming cam following crank before its operation is shown in Figure 42 If the position of the roller is changed adjust it with stopper and perform the adjustment describe above in a b Figure 42 F Adjusting the position of blade a Adjusting the position of the movable knife and the fixed blade The standard position of the movable knife is 7 5mm from the needle center and 5 mm for the fixed blade Figure 43 b Adjusting the progress amount of the movable knife CD If you run the machine putting the solenoid in the operation mode the movable knife will rotate by the thread trimming cam The standard will be where the cut part of the movable knife progresses 1 5 to 2mm from the end edge of the fixed blade when the progress amount of the movable knife is in its maximum Adjustment is available by using the thread trimming lever Figure 44 25 17 Adjusting blade pressure A B As in Figure 45 the standard is when the contact between the movable knife and the fixed blade begins In particular when the cutting quality gets worse by using a thick thread strengthen a little bit the tension of the fixed blade In order to adjust the tension of the fixed blade loosen the tension adjustment nut with the wrench box and adjust the tension using the tension adjustment bolt 18 Exchanging movable knife To exchan
3. DOWN film with the film adjustment baseline and the sensor housing baseline as in Figures 17 and 18 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 Setting the film when Setting the film when the the needle is in a up thread take up lever is at stop position the highest point m 4 cow Film Adjusting Base Sensor Base Figure 17 Figure 18 Machine Adjustment N Caution gt 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 ED automatically and can result in physical injuries 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 come to a complete stop 1 Inserting needle Move the needle upper end so that it directly touches the upper side of the stopper hole when the groove of the needle is on the left Then use the clamp screw to fix the position of the needle Refer to figure 19 Figure 19 2 Adjusting needle bar P
4. saab diete dati data a erede e rever ens ee Cl dut 8 TySewimg machine s uico o emere e P PURI A PENE AUE RETI E AAEN N R EIRA EER ahud ht a aes 8 2 Servo dnotOr ae E SUO HOURN RR HERR RU RR EGRE TRE EE RE IR EERRG 8 BY ATO MOOK 3er ceto eere EE E ONEONE iive tivi evi u reve Ove v eei ue EE 8 AVA JO TMOLOR COM OM E AAR EAA AAA EAER RAE sa chats the coon ceca ches ca De cena e iet ATT 9 3 Clutch moto sss eadeatsesisiecsceecsnedcecndeneadcncestacendsecersedecesdecduradensseceds vencentancurseeseneandusovatessdceniousscsosnissescepinceseacsniearecesouest s 9 6 Peripheral automation devices Optional esent 9 VAL i cip MEMETRCRRT T PET 10 1 Installation of machine head 42 45 5 5 25299 9 irri rire titor itte tre rrt ote there beer er Pe RE 10 2 Installation Of power Switch DOR 158r terere rere rrt Ope aie ere be edi s 10 3 TUDE CATION eret trier ovi teth rie eter nr teo verte netiis ete vere NR 11 4 Adjustment Of belt tensiOfi 5 5 entere tereti ie e ERR ODD ORIG A ierat e e REIR ENS 11 5 Installation of program unit for automatic trimming type seesesessssessreesreesresstesstesstesstestrestesstesreertersrreserereenress 12 6 Installation of beltCoVer 35 50 e rr cire ire e ER RR ORO GRO ORE ETE Ee P ERE 12 7 Installation of synchronizer for automatic trimming type etntntntntnneentnnene 12 8 Check for machine stop position for automatic trimming type sese 13 O Rev
5. upper amp lower feed lock stitch machine with automatic thread trimmer with large hook KM 640BL Long arm type one needle upper amp lower feed lock stitch machine with large hook AS Model Name KM 640BL 7 KM 640BL Speed Max 2 000 SPM Max 2 500 SPM Max stitch length Max 9mm Needle DP x 17 22 DB x 1 22 Thread take up stroke 73mm Needle bar stroke 38mm Presser foot stroke 2 5 5mm Presser foot Manual 7mm ascending amount Auto 16mm Hook Vertical rotation hook Usage Heavy materials 2 Servo motor MODEL VOLT WATT HERTZ SC55 1A 1 Phase 110V 550W 50 60 Hz SC55 2A 1 Phase 220V 550W 50 60 Hz SC55 3A 3 Phase 220V 550W 50 60 Hz 3 470 motor PM470 MODEL PHASE HERTZ VOLT 1 14 P RUE 1 110V 1 11 ae 2 220V PM470 3 3 ade 3 380V 1 14 in 4 110V 220V 3 3 UE 5 220V 380V 4 470 motor controller PC470 A 001 MODEL VOLT MODEL SUB CLASS M 1 110V r 001 2 220V 5 Clutch motor MODEL VOLT WATT HERTZ HEC 1701 1 Phase 220V 250W 50 60 Hz HEC 1703 3 Phase 220V 380V 250W 50 60 Hz HEC 1705 3 Phase 220V 400W 50 60 Hz HEC 1706 1 Phase 220V 400W 50 60 Hz 6 Peripheral automation devices optional Optional device Model Usage AUTO KNEE LIFTING SYSTEM SPF 7 A solenoid
6. Perform an idle rotation for about 3 minutes of the b machine Later place the paper for confirming the amount of lubrication as in Figure 23 and rotate the machine for 5 seconds to confirm the amount of oil sprayed to the paper Perform 3 times of confirming the amount of lubrication The adequate adjusted amount is a state where the maximum and minimum amounts do not fall short of or exceed the amount shown in the picture If the amount of lubrication is too small it could invite the hook seizure and if the amount is too large it could cause a contamination by oil B Adjusting the amount of lubrication When you turn clockwise the lubrication adjustment screw D inserted in the front bushing of the lower shaft the amount of oil will increase while turning to counterclockwise will decrease the amount Figure 22 3 10mm paper for confirming the amount of lubrication oil tray oil fan sprayed oil belt sprayed oil belt minimum adequate amoun maximum adequate amount about 0 5 mm about 1mm t aly increase decrea Figure 23 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 physical injuries gt When using the clutch motor be aware that the motor will continue to rotate for a
7. 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 that an electric shock may be caused if the instruction is not followed properly aD This symbol means a must for safety SunStar 1 1 Machine Only personnel with a full understanding of the safety rules should move the mobilization machine The following directions must be observed when transferring the machine At least 2 persons should move the machine together In case the machine should be transported wipe the oil covered on the machine to Danger prevent accidents 1 2 Machine Because physical damages such as the machine s dysfunction and breakdown are Installation likely to occur depending on the environment in which the machine is installed the following preconditions must be met Please unpack the machine package in order Be particularly careful of the nails in the wooden box Caution Because machines are apt to be contaminated and corroded by dust and moisture install a climate controller and clean the machines regularly Keep the machine out of direct rays of the sun Keep both sides and the backside of the machines at least 50cm from the wall t
8. between the feed dog and the auxiliary presser foot is 1 1 You can adjust the feeding amount of the auxiliary presser foot in accordance with the conditions of materials in use As in Figure 33 loosen the nutQ and move upward the presser foot vertical move control shaft and the feeding amount becomes smaller If you move it downward the amount increases Be sure to tight the nut when the adjustment is finished Figure 33 21 15 Adjusting feed cam The timing of the feed dog and the needle is determined by moving vertically the feed cam First turn the pulley with hands to fix the needle bar to the highest point The standard position will be when the center of the No 1 fixing bolt of the presser foot vertical move cam is aligned with the center line of the upper shaft the bottom of the No 1 fixing bolt of the feed cam is aligned with the center line of the upper shaft Figure 34 16 Adjusting for thread trimmer A Structure of thread trimmer The structure of the thread trimmer of this machine is as follows in Figure 35 thread trimmer thread trimmer solenoid solenoid base fixed blade thread cover thread trimmer cam movable X I knife thread release table thread trimmer thread trimmer slide arm clutch stopper stopper lever following crank _ lever lever Figure 35 Caution This sewing machine is run by the thread trimming driving method which
9. solenoid is 4 6mm as shown in Figure 38 Use the thread trimming solenoid stopper nut to control the working amount na SSS Figure 38 23 b Adjusting the thread trimming solenoid D First loosen the solenoid link pin fixing screw Later fix the solenoid base clamp screw where the clutch lever moves smoothly Then attach the slide arm to the right side Fix the thread trimming solenoid link pin fixing screw where the solenoid stopper is attached to the solenoid If you run the solenoid under this circumstance a gap of 0 5mm occurs between the thread trimming following crank and the slide arm as shown in Figure 39 This state is the standard solenoid link pin solenoid link fixing screw solenoid base solenoid base fixing screw thread trimming following crank thread release cable fixing nut Figure 39 E Adjusting the thread trimming cam a Like in Figure 40 align the second timing carved line Green of the pulley with the arm s carved line b Under the thread trimming solenoid is in operation rotate the trimming cam clockwise and fix the cam when it connected with the roller Refer to Figure 41 c When the thread cam following crank returned by stopping the operation of the thread trimming solenoid the edge end between the cam and the roller should be from 0 5 to 1 0mm It is the standard Refer to Figure 40 Figure 41 24
10. uses the cam attached to the lower shaft as driving force Thus if you rotate the machine with the thread trimming solenoid is in operation in time of the machine adjustment the moving knife collides with the needle causing harms on the both parts So when you run the machine with the solenoid in operation run only in the regular thread trimming course down stop up stop of the needle bar 22 B Adjusting fixing blade and movable knife a Like in Figure 36 the standard position is where the cut part of the movable knife is aligned with the center of the fixed blade movable knife b When part 3 becomes bigger in Figure 36 three pieces of threads are to be produced causing the thread missing after the trimming If part becomes bigger it can cause a trimming miss So be cautious in adjusting the right position Figure 36 C Adjusting the trimmer driving part a The standard assembly position is shown in Figure 37 b Fix the thread trimming following crank to the trimming shaft as shown in the figure c Fix the stopper lever to the bed so that the lever can stopper lever smoothly rotate in a range where the gap of the inreaa trimming cam Tolowing crank trimming shaft does not occur Figure 37 D Adjusting the thread trimmer solenoid 4 6mm stopper nut a Working amount of the thread trimming solenoid D The standard working amount of the thread trimming
11. User s Manual KM 640BL 7 Long arm type one needle upper amp lower feed lock stitch machine with automatic thread trimmer with large hook KM 640BL Long arm type one needle upper amp lower feed lock stitch machine with large hook anaaa lt 0 0000 00 1 For proper use of the machine thoroughly read this manual before use 2 Keep this manual in a safe place for future reference in case the machine breaks down SUNSTAR MACHINERY CO LTD 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 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 SUNSTAR MACHINERY CO LTD Table of Contents Safety rules for machines ooo ccc cc ccssesesssssssssesesessesssssesessesesesesauesesesesseseseseseesssssesesesescseseeseacaeeneseaees 4 1 Specification
12. and hook Gap between needle and Bad timing of needle and hook Adjust the timing of needle and hook hook Threading method Wrong threading Thread the needle correctly Needle Bent needle or broken needle tip Change the needle Direction and height of Needle inserted in the wrong position Insert the needle correctly needle 2 Thread breaks f Upper thread tension Too tight upper thread tension Reduce tension of upper thread Lower thread tension Too tight lower thread tension Reduce tension of lower thread Working capacity of take up Loose upper thread Adjust take up lever spring lever spring Thread tension Upper and lower thread tensions are bad Adjust the upper and lower thread tensions Poor thread Thread take up spring Thread take up spring tension is inadequate Adjust the thread take up spring tension 3 tension adjustment Gap between opener and The gap between the opener and hook is Adjust the gap between the opener and hook hook inadequate Direction and height of Needle is inserted into wrong position Reinsert the needle correctly and push in to its needle highest level Needle Needle is bent Change the needle Threading Wrong direction Insert the thread in the right way Upper thread falls Gap between the needle The timing between the needle and hookis Adjust the timing between the needle and hook out when starting 209 the hook pag 4 to sew or sewing is Remaining upper thread The length of the remaining upper thread is too Increase th
13. becomes larger when you turn clockwise the tension adjustment screw and becomes smaller when you turn in counterclockwise When hold the end of thread make sure that the bobbin case should drop by gravity in order to adjust the lower thread tension B Inserting and removing the bobbin case Insert into the hook by grabbing the bobbin case handle D Pull out the handle D when you remove the bobbin The bobbin 2 removes itself when you release the handle Figure 25 17 N Caution gt Turn off the power switch when routing the upper thread If the operator mistakenly presses down on the pedal while switched on the machine will ab start automatically 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 Start to work on the sewing machine only after the motor has come to a complete stop 8 Routing upper thread Put the thread take up lever in the highest position and insert the upper thread as shown in the Figure 26 by numerical order Figure 26 9 Adjusting upper thread A Thread control assembly Like in Figure 27 turning the tension adjustment nut Upper thread tension is weak while the lower thread tension is weak e M WM HMM nnm uw 4 SS AO AW AW SS upper thread tension is strong iss the lower thread tension is weak ia Lai SUSSESSIRGESSESSS QD of the t
14. ckwise After the adjustment be sure to tight the fixing nut 2 The auxiliary presser foot is same to the upper feed presser foot the pressure increases when you turn the pressure adjustment screw clockwise and becomes weaker in case j E Figure 28 of turning it counter clockwise After the adjustment be sure to tight the fixing nut 4 In case of fine adjustment use the auxiliary pressure adjustment screw 11 Adjusting stitch length As shown in Figure 29 the number marked in the stitch control dial means the stitch width in mm Adjust it in sideways and fix it to your desired number of stitch width Figure 29 19 12 Adjusting feed dog height and inclination A Adjust the height of the feed dog by loosening the clamp screw 2 of the leverage crank front and moving the leverage crank front The adequate height from the upper side of needle plate to the end of feed dog is from 1 0mm to 1 2mm when the feed dog is in the highest point with the stitch is put to the maximum level B To adjust the inclination of the feed dog loosen the fixing screw of feed dog inclination adjustment crank in the horizontal pushing crank first Later adjust it by rotating until 90 degree the feed dog inclination adjustment shaft When you turn the shaft clockwise the front of feed dog goes up while the rear part of the feed dog is up with counter clockwise direction C Check the height of feed dog because the he
15. down you can perform reverse sewing from the beginning When the machine is in a stop mode you can change the up down position of the needle bar by pressing the 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 10 Adjustment of synchronizer A For in built synchronizer T up stop position 4 down stop position Figure 14 Adjust the up stop position of the needle by loosening the clamp screw on the side with N U carved signs and moving it sideways such that the white carved sign on the pulley is aligned with the carved sign of arm 4 when the machine is in up stop position Adjust the down stop position of the needle by loosening the clamp screw 2 on the side with N D carved signs and moving it sideways such that the needle bar stops in the point where it is about to up in the lowest position when the machine is in down stop position Refer to figure 15 and 16 Figure 15 B For 470 motor external synchronizer T up stop position 4 down stop position Figure 16 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 Figure 10 on page 13 and align the
16. e adjustment volume of the upper skipped length after trimming short thread on the control box 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 position Due to problems in the up stop position of the Readjust the needle s up stop film position of the needle needle the thread take up lever pulls the upper thread out of the needle when the sewing starts The gap between the The height and distance between the movable Readjust the movable knife setting position movable knife and the hook knife and the hook do not match Check the tension of fixed Tension and contact of movable and fixed Correct the tension adjustment and surface knife knives are bad contact of movable and fixed knives 5 Trimming miss Direction of the needle Needle is not inserted correctly Insert the needle correctly Blade side of movable and Scratch and abrasion of movable and fixed Replace movable knife or fixed knife fixed knives knives Trimming cam timing The timing of trimming cam is wrong Adjust the timing of trimming cam Thread release stroke Thread release stroke is too small Readjust the thread release stroke Trimming timing Wrong trimming timing Adjust the trimming timing Opening of the thread The opening on the thread tension control plate Adjust the thread release stroke Too short thread tension adjusting plate is too small G _ length after T
17. ension of auxiliary thread Too strong tension on the auxiliary thread Adjust the tension of the auxiliary thread trimming tension adjustment assembly tension control assembly tension control assembly Thread take up stroke Thread take up stroke is too large Adjust the thread take up stroke Thread release adjustment volume on the control box Volume is adjusted to too low Increase the volume adjustment 28 o gt them e 2 2 G 1 KM 640BL 315 805 Stand Mounting Position 80 311 5 159 0 5 53 5503 99 40 3 99 915 8 DP30 Head Rest Hole Clutch Motor Mounting Hole 20 2 66 33202 33 Dus Hole thru 535 o Keeping Rack Installation Place lt Treat keeping rack color same as table color 480 520 8 1200 23 82 Y SECTION A A AD 40 SECTION B B 29 2 KM 640BL 7 315 805 Stand Mounting Position 80 320 Bo 159 205 5720s 99 915 DP30 Head Rest Hole d 3340 2 33 917 Hole th
18. er A D and fix the back side with the fixing screw B Attach the belt cover B 4 to the table Please make sure that the belt do not intervene with the inside of the belt cover B 4j Figure 7 7 Installation of synchronizer for automatic trimming type A Installing on the servo motor In case of installing the servo motor in built synchronizer a synchronizer sensor is attached to the backside of the arm The appropriate clearance between the synchronizer and the pulley is 1 2mm zu Figure 6 Figure 8 Figure 9 B Installing on the 470 motor Assemble the parts in numerical order as shown in Figure 10 Later adjust the synchro shaft by moving it horizontally so that the photo film is located at the center of the photo interrupt Then fasten tightly with the two fixing bolts using a hexagonal wrench Caution a Start assembling after confirming that DOWN and UP marks are located in the frontal side from the pulley as shown in FIGURE 10 b Film adjustment is already set up in time of delivery pulley P L wrench it synchro shaft fixing screws 2 i synchro shaft photo film photo interrupt Speed sensor film Fixing washer Fixing bushing Fixing Synchronizer _ shaft Fixing Clearance cover washer adjustment bushing PC beholder Figure 10 Figure 11 C In case of using sewi
19. erse DUO L ulictiolsesesensonneno dee neeeneneueneemienedmidddnean ddddnD ORE 14 10 Adjustment of SynchrODBIZer 5 i REED RR RE RR TERRE TERRIER IRSE E let eel eet ees iet eee sehen 14 3 Machine Adjustment ccsessssssssssscsssssssscssscssssesessscssssessassncacssscseasassacsessacsusseseassssesessacsnsseseases 15 Hnserins needle d TE 15 2 Adj sting needle DAL uosonmoe ego oo oo rete treten reto etit te tense rete POE UE YO Eo UE S OA 15 3 Adjusting timing of needle and hook rettet tette eed Ponte raid 15 4 Adjusting lubrication of thread take up spring part sess EAE rara ae eioi sS 16 5 Adjusting lubrication of hook nectit tette nter rte talent te ere Pe RES EE IP LIE EH EORR 16 6 Winding and adjusting lower thread e treten rr e UR iiis YO Pe EAEE EEEE ER 17 7 Inserting and removing lower thread and adjusting tension essssseeeeeeeeetntentnteetntnnne 17 8 Routing Upper thread i e iet inerte b Pee rH E Aue EEE teo Pee Ae P ERE to br Ht toon tho re pot bbb te PAR LS 18 9 Adjusting Upper thread an ore Gear rette rae PE PIDE n D RR EO EE 18 10 Adjusting presser foot DressUTe i tton eerie eere eth erani ohio eben tenth iecit 19 TT Adqustmp stte length oett tr er ett o d p ap I ten Opto toes EE en t D RII Ide 19 12 Adjusting feed dog height and inclination sssini ERRANA entnnene 20 13 Adjusting auxiliary presser foot and upper feed presser foot sssssss
20. ge the movable knife turn the pulley with hands such that the needle can be located in the highest position and separate the needle plate And loosen the two fixing bolts of movable knife shown in Figure 47 and break it up In case of assembling the exchanged part please perform this in a reverse manner 19 Exchanging fixed blade 26 A When you exchange the fixed blade loosen first the inside stopper clamp screw to get the washer and inside stopper and dissemble by loosening the fixed blade clamp screw In case of assembling the exchanged part please perform this in a reverse manner movable knife fixed blade Figure 45 wrench box movable knife ae fixed blade Figure 46 Figure 47 Figure 48 B In case that the thread is cut or the cut part of the thread is not neat please confirm the cutting part of the fixed blade If the bottom of the fixed blade is worn sharpen the end of the blade using an oil whetstone oil whetstone Figure 49 20 Adjusting thread release A Adjust such that the dish of upper thread tension controller opens about 1mm when the thread trimming solenoid link fixing screw solenoid link pin solenoid base solenoid is in the operation B Adjustment is available by loosening the thread release cable fixing nut and wire Refer to Figure 50 solenoid base fixing
21. he machine 4 When you adjust the number from lower one to a higher you should adjust the dial first In the reverse case the adjustment of the dial should be done first 20 SunStar m Incase of running the auxiliary presser foot and the upper feed presser foot at different heights A Adjusting the auxiliary presser foot Loosen the presser bar pressure adjustment screw and the bracket fixing screw Adjust vertically the bracket fixing screw so that the auxiliary presser foot 4 goes up by 8mm from the upper side of the needle plate when the presser bar lifter 3 is up When the adjustment is finished fix tightly the bracket fixing screw and adjust adequately the pressure adjustment screw QD After adjust height of the auxiliary presser foot adjust upper feed presser foot B Adjusting the upper feed presser foot Place the thread take up at the lowest position and lower the presser bar lifter 3 Open the rubber cover of the upper cover and loosen the clamp screw A different adjustment of vertical running amount between the auxiliary presser foot 4 and the upper feed presser foot is possible by adjusting the presser foot vertical move crank 7 When the adjustment is finished fix tightly the clamp screw of the vertical move crank and place the rubber cover Figure 32 14 Adjusting feeding amount of auxiliary presser foot The normal proportion of feeding amount
22. hread tension control assembly clockwise makes the upper thread tension stronger and counterclockwise makes it weaker The result of the needlework depends on the sewing conditions such as the sewing material used thread and stitch length So please adjust as desired B Adjusting the thread take up tension As in Figure 27 insert the driver into the groove of the thread tension control assembly Turn good swing Jt Ada C441 LLA Fa SS DYN LO 13 Figure 27 clockwise to make the spring tension stronger and counter clockwise to make it weaker 18 SunStar N Caution gt After disassembling and adjusting a safety device always place it back to the original position Q and check whether it functions as intended 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 Q gt Only trained engineers must perform troubleshooting or inspection of the machine gt For electrical repair or inspection consult with qualified technicians or agent 10 Adjusting presser foot pressure As shown in Figure 28 the pressure of the upper feed presser foot becomes stronger when you turn the pressure adjustment screw clockwise and becomes weaker in case of turning it counterclo
23. ight of it changes after the adjustment of feed dog X front eese back clockwise J front remy BACK back X front Tp counter clockwise A Figure 30 13 Adjusting auxiliary presser foot and upper feed presser foot Normally the auxiliary presser foot and the upper feed presser foot work vertically with a same height difference In accordance with the material type there are some cases in which run the auxiliary presser foot 1 and the upper feed presser foot at the same pace or sometimes at different paces In these cases please adjust the height as follows m Incase of running vertically the auxiliary presser foot and the upper feed presser foot at the same height Figure 31 a The vertical running range of the auxiliary presser foot and the upper feed presser foot is from 2 to 5 5 mm b The vertical running amounts of the auxiliary presser foot 1 and the upper feed presser foot are easily adjustable from the climb device dial attached to the front side of the machine c The dial attached to the upper cover is a dial which controls the running amount dial Only when the numbers of and are identical the auxiliary presser foot and the upper feed presser foot can be run at the same height ex When the running amount of the two presser feet are adjusted to 4mm First adjust the number of the dial attached to the upper cover to 4 and make the number the dial at front side of t
24. lace the needle bar in the lowest position by pulling out the needle bar adjusting hole rubber cover and rotating the pulley and then loosen the needle bar holder clamp screw and move the needle bar such that the needle bar s lowest position mark carved sign 4 is aligned with the lower side of the needle bar lower bushing After fixing tightly the needle bar holder clamp screw and place the rubber cover bi m Q Figure 20 3 Adjusting timing of needle and hook As in Figure 21 align the lower side of the needle bushing QD with the fixed hook position carved line marked in the needle bar Then loosen three hook fixing bolts When the hook edge is aligned with the center of needle turn the loosened hook so that the clearance between the needle groove inside carved in the lateral side of the needle and the hook edge becomes 0 05 0 1mm Later tight again the three fixing bolts Figure 21 15 4 Adjusting lubrication of thread take up spring part As in the figure 22 the more the point of the control plate of oil flow D goes close to the center of hole of thread take up crank shaft the more oil comes On the other hand the more the point goes close to the corner of the link cam washer the less oil comes And when the point goes past the corner of the link cam washer the oil does not come out 5 Adjusting lubrication of hook A Confirming the amount of lubrication a
25. ng machines that have not been used for a long time or new products delivered a long time ago open the face plate and spray oil using lubricator to the thread take up connecting part D and fraction parts such as needle bar and pushing bar D When you do test running of machines run intermittently the machines for about 10 minutes at rotation of 1 500 spm E For the first 4 to 5 days run the machine less than 1 500 spm per minute and later run the machine at the normal rotation so that the machine can maintain its excellent function Figure 12 8 Check for machine stop position for automatic trimming type Check for the machine stop position after moving the needle up and down by pushing the reverse button See whether the carved line of pulley is aligned with the carved line of arm when the needle is in an up position If not adjustment to the location of the magnetic holder or to the photo film of the synchronizer will be necessary The needle s up stop position should be identical with the stop position of the needle bar after the trimming operation oe ay l menie wee ee sunStar Carved line Reverse button Figure 13 13 9 Reverse button function Pressing the 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
26. 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 the hinge rubber into the table After inserting the oil tray in the middle of head supporting rubber B as shown in the figure 1 install it into the table Insert the machine head hinge into the bed holes By inserting it into the hinge rubber D stand the machine on the head support rubber A and the head support rubber B oil tray oil fan Figure 1 2 Installation of power switch box Ng When attaching the power switch box D refer to Figure 2 to make sure that it is placed at the lower right of the table Figure 2 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 VY automatically and can cause severe injuries 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 GD 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 3 Lubrication A Attachment of magnet for sweeping up chips Attach the magnet for sweeping up chips included in the accessory box to the oil pum
27. o secure enough space for repair Danger of Explosion Don t run the machine near places with any danger of explosion Don t run the machine near places with any danger of explosion including places where sprays 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 D Illuminators do not come equipped with the machine due to the machine s characteristics 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 1 3 Troubleshooting If in need of troubleshooting call a trained A S engineer who has been educated by Sunstar amp Be sure to turn the power off before cleaning and repair And wait for about 4 minutes until the machine discharges completely Danger Part of or the entire machine should not be modified without any consultation with our company In case of repair change the damaged part into the genuine part of our company After repair cover the machine with the safety cover that was removed for repair 1 4 Machine Operation Caution The KM 640BL Series are manufactured for industrial use to sew textiles and other similar material When running the machine users should observe the following things Read the manual before operation of the machine to fully understand the details abo
28. operating structure where the presser foot gets lifted automatically with pedal reverse gear stage 1 operation A counting device which indicates the completed quantity on the program PRODUCTION COUNTER SCOUND 1 unit panel including added subtracted corrected or remaining quantity along with other performance rates SEDG 1B A device that senses the edge or thickness of the sewing material to stop MATERIAL EDGE SENSOR SEDG 2B the machine without manual pedaling Available in two types SEDG 1B for edge sensing type and SEDG 2B for thickness sensing type An essential device when one person is operating multiple sewing SPDL 1 machines Has different pedals for acceleration thread trimming presser STN PERAL SPDL 2 foot and ascending pedal Types consist of SPDL 1 and EDPL 1 for fixed speed and SPDL 2 and EDPL 2 for variable speed SS Servo motor E 470 motor Installation N Warning gt Installation of the machine should be performed by a trained engineer 9 gt Plug in after the installation is complete VY If the operator mistakenly steps down on the pedal with the pug in the machine will start automatically and can cause physical injuries A gt Connect the ground earth wire An unstable connection may result in an electric shock or a malfunction q gt Place the belt cover on top of the machine GD gt Use both hands when bending the machine backwards or returning it to the
29. p inside of the bed x Do not use the magnet for other usages Running the sewing machine without the magnet could cause mechanic problems and affect the endurance of the machine B Inserting lubricant to oil tray oil fan a Fill the lubricant to HIGH position Refer to Figure 4 b Please use SUNSTAR lubricant exclusive for industrial sewing machine or SHELL s TELLUS C10 c When the lubricant in use is at LOW position fill it immediately to HIGH position d Most suitable period of changing lubricant is 1 time in two weeks magnet Figure 3 Figure 4 4 Adjustment of belt tension After installing the motor unfasten the fixing nuts D up and down and tension will be created to the belt due to motor falling by gravity Fasten the fixing nut first and then fasten tight the fixing nut Figure 5 11 5 Installation of program unit for automatic trimming type A Fix the bracket onto the program unit using 4 fixing nuts B Then use 2 fixing bolts to tightly fix the bracket where the program unit I has been adjusted along with the back cover 6 Installation of belt cover A Fix the belt cover A D to the machine s body using 3 fixing screws You can assemble it more easily if you slightly incline the machine When the assembly of the belt cover A is finished insert the front side of the belt cover C 3 into the groove of belt cov
30. ru Keeping Rack Installation Place lt Treat keeping rack color same as table color 535 480 520 05 1200 a os 7 re e STI L I o x 105 SECTION A A e 40 SECTION B B 30
31. screw Caution If the gap of the control dish is too narrow it invites the shortening of the upper thread causing a possible thread missing in the next work If the gap is too wide a bad thread tightening caused thread trimming following crank because the dish will be always open thread release cable fixing nut 2 open amount 0 5 1mm Figure 50 21 Adjusting remaining amount of upper thread Adjust the remaining amount of upper thread is adjustable with the auxiliary thread tension adjusting nut The remaining thread becomes shorter when you turn it right and the thread becomes longer if you turn left Refer to Figure 51 A caumon VAN Do ni safol oy deorap Inout finger guard ond Beler Ihreoding e honaino Een cm needia civaning Sia uA niet Figure 51 27 1 Sewing machine troubleshooting Causes of Troubles and Troubleshooting No Symptom Checkpoints Root cause Corrective action Direction and height of Needle is inserted into wrong position Reinsert the needle correctly needle Needle Needle is bent Change the needle Timing of feed dog Bad timing of feed dog Adjust the timing of feed dog 1 Needle breaks Ascending level of needle Bad timing of needle and hook Adjust the timing of needle and hook bar Height of needle Bad timing of needle and hook Adjust the timing of needle
32. sseseeeeneenetee tnn 20 14 Adjusting feeding amount of auxiliary presser foot sss nentnnens 21 15 Adjusting feed CANT i t eerte eroe rette teer Rte Fe unte ME bre a rhe ene 22 NG Adjusting for thread rmirtlef sse secti eerie tritt te pem TRUE ORE EDU RSS 22 17 Adjusting blade pressure tetete tette tete tete to eto Ue e ER UE ER EE EE ANANN 26 Toy Exchangine moyable Ete os eere iret ere er or erroe done n EE I OR TREE DROPS 26 19 Exchanging fixed blade audiente terere tete tete iret eee eer e REPE PI E PU PEG Ge 26 20 Adjusting thread BC S OR 27 21 Adjusting remaining amount of upper thread eese eeeeetete tinte TEREPRE ttn tnn te tentent 27 4 Causes of Troubles and Troubleshooting essere 28 Ty Sewing m chime troubleshooting i e eee esee rete e RO DO EEIE AREATA TETERE a 28 5 Table drawing oerte eee eee ee 29 1 KMEO40BE iie dde raro mo de trapo Eoo pb bes ub orca fa dert nca ave FAR PALO EA PE 29 I ss eee NUR MUNERE 30 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 labels Danger Instructions here shall be observed strictly Otherwise the user will be killed or suffer severe physical injuries
33. ut its operation Do not forget to wear garment suitable for safe work Keep your hands or any part of the body away from the running part of the machine like needle hook thread take up spring pulley etc Do not remove any type of cover during operation for safety reasons Be sure to connect the earthed line D Before opening an electric box such as a control box be sure to shut off the power supply and make sure that the power switch is set to off amp Be sure to stop the machine when threading the needle or before checking after sewing Do not switch on the power supply with the foot on the pedal Do not run the machine when the cooling fan is clogged Be sure to clean the air filter in the control box once a week CD If possible keep the machine away from strong electromagnetic fields like areas around 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 Caution switch during check ups or adjustments 1 5 Safety Device Caution Safety Label Cautions that need to be heeded to during operation Thread take up spring cover a device to prevent the human body from touching the thread take up spring Belt cover a device to prevent hands feet and clothing from getting jammed by the belt Finger guard a device to prevent fingers from contacting the needle
34. while after the power is switched off Start to work only after the motor has come to a complete stop 6 Winding and adjusting lower thread A Winding lower thread Pass the thread thru the hole D from the rear to the frontal side of the tension adjusting dish 2 Bring the thread to the bobbin 3 and wind it clockwise 5 to 6 times from the bottom Push the lever so that the pulley touches the V belt and run the machine a b C d The pulley automatically is separated from the V belt when the lower thread is winded in the bobbin The adequate amount of the pulled out lower thread is about 80 Refer to Figure 24 e Figure 24 B Adjustment of winding lower thread a Incase that the lower thread is winded irregular loosen the bolt 6 and adjust by moving it sideways and tight it again b The amount of winded lower thread becomes larger when you turn adjusting screw clockwise and it becomes smaller in case of turning it counterclockwise c The tension of lower thread that winded in the bobbin can be adjusted by turning the nut it increases with clockwise turning and it decreases when you turn counterclockwise 7 Inserting and removing lower thread and adjusting tension A Insert the bobbin into the bobbin case Later insert the thread into the thread groove 3 and place it under the spring 4 of thread adjusting plate The tension of the lower thread
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