User Manual
Contents
1. Figure 53 6 When the wiper D is in stand by position the distance between the wiper edge and the presser bar equal point should be about 3 mm To do so loosen the clamp screw 8 and vertically adjust the stopper Depending on the thread type there are cases where the thread cannot be routed to the wiper edge Hence it is necessary to bring the wiper into the range of the needle where the thread from the sewing material can be routed Make sure that the needle fixing screw does not get in the way of the wiper Figure 54 7 The trace of wiper edge is as the above picture Adjust the wiper edge by loosening the clamp screw and vertically adjusting the distance between the needle edge and wiper to 0 5 1mm 33 19 Replacing gauge set for needle width 34 1 Disassembling order Caution Turn off the power switch 1 Open the hook cover 2 Remove the needle 3 Disassemble the needle holder Turn it towards the arrowed direction for removal KM 867 series 4 Lift the presser bar lifter to raise the presser foot 5 Disassemble the presser foot 6 Disassemble the needle plate 7 Disassemble the feed dog Adjusting the left right hook base For KM 867 series When replacing with a wider or narrower gauge than the needle width in use the hook edge and needle distance need to be readjusted2. gt 4 aco o Syke Figure 46 29 C Final fixing of movable knife s initial position see figure 47 plement Trini o imming finishing point Movable knife operation starting point 0 5 1mm Trimming cam lead Figure 47 The standard initial assembling position of the movable knife is where the movable knife edge protrudes about 0 5 1 mm from the fixed blade edge when the trimming action is finished that is when the movable knife is in its initial stop position When fixing the position of the movable knife the following directions must be followed so that the power generated in the cam is delivered without any loss to the trimming action Adjustment Order a Turn the pulley manually to position the cam so that the roller can enter the complementary straight line right after the trimming cam finishes trimming b Slightly loosen the fixing crews 7 of the left and right movable knife shaft crank c With the roller inside the cam by pressing the trimmer shake linkage 9 push the ball joint linking bar or the left and right movable knife shaft linking bar slightly to the right so that there isn t any impact to each connecting device Then adjust the roller to protrude out about 0 5 1mm from the cam complementary straight line edge just line of the figure After the adjustment is made ti
3. Instructions here must be observed or the user may suffer fatal or severe physical injury N Caution Instructions here should be observed or the user may face physical injury 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 D This symbol means a must for safety SunStar a 1 1 Machine mobilization Danger Only personnel with a full understanding of the safety rules should move the 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 prevent accidents 1 2 Machine Installation Caution Because the physical damage such as the functional obstacles and breakdown are 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 careful of the nails in the wooden box 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 the direct rays of the sun Keep both sides and the backside of the machines off at least 50cm from the wall
4. tightly fasten the fixing screw Once such adjustments are made the trimmer shake linkage will not move even when shaken to its sides the roller is inside the cam Make sure to check if the shake linkage returns to up position 0 quickly and smoothly when released If not proceed with horizontal adjustment of stopper pin holder 27 28 C Fixing the position of the trimmer solenoid see figure 43 a When the whole trimmer shake linkage is in up position that is when it has come back to its original position after finishing trimming the distance 4 between the lower part of the roller and the equal point of the trimming cam 3 is about 0 8 1mm Assuming that this distance 4 never changes adjust the position of solenoid bracket horizontally where the solenoid housing is attached to make the solenoid stroke 4 mm Then tightly fasten with fixing screw 8 b After adjusting the solenoid stroke manually operate the solenoid shaft 9 towards the arrow direction See whether it returns to its original position fast and smooth when released If not proceed with horizontal adjustment of the bracket Solenoid Stroke Figure 43 Figure 44 A When the previously explained adjustment of trimmer driving part is complete it is in its normal position where the trimmer shake linkage 1 has returned to its up position after trimming action B First loosen the fixing screw of
5. 6 times starting from the bottom C Push the lever to make the pulley touch the V belt and then operate the machine D When the lower thread is fully wound to the bobbin pulley amp will automatically detach from the V belt E The adequate amount of thread wound to the bobbin is about 80 See figure 21 2 Adjustment of lower thread winding SunStar Figure 21 A If the lower thread winds irregularly unfasten the screw and adjust by moving to the left and right Fasten back the screw when the adjustment is complete B The amount of lower thread wound increases when the adjusting screw is turned clockwise and decreases when turned counter clockwise C The tension of the lower thread wound to the bobbin grows when the nut 8 is turned clockwise and drops when turned counter clockwise N Caution 4 Routing lower thread gt When adjusting the tension of the lower thread be sure to switch off the power supply If the user steps on the pedal by mistake the machine will start automatically and this might lead to physical injuries gt When using the clutch motor remember that the motor revolves for a while even after switching off the power supply due to inertia Make sure to start working only after the motor has come to a complete stop Applied Model Types A KM 857 B KM 867 A Insert the bobbin into the hook B Insert the
6. control assembly thread tension control assembly 6 threadlength adjustment assembly after trimming Thread take up stroke Thread take up stroke is too large Adjust the thread take up spring s stroke Thread release adjustment volume on the control box Volume is adjusted to too low Increase the volume adjustment 36
7. does not hold the lower thread the lower thread holder ballet Due to problems in the up stop starting to sew n or sewing is Check the up stop posmonrornernesdie nethraad Readjust the needle s up stop film Sewing take up lever pulls the upper thread NM skipped position of the needle out of the needle when the sewing postion starts Check The upper thread oil felt is pressing tension of upper Adjust the felt tension the thread too strongly thread The gap between the The height and distance between movable knife and the movable knife and the hook do icons Vi MOVADIS e Seung the hook not match P Check the tension of Tension and contact of movable Melon pane fixed knife and fixed knives are bad fixed knives 5 Trimming miss Direction of the needle Needle is not inserted correctly Insert the needle correctly Blade side of movable Scratch and abrasion of movable Replace movable knife or fixed and fixed knives and fixed knives knife Trimming cam timing of mmming eamus 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 Adjust the thread release stroke tension adjusting plate control plate is too small Too short Too strong tension on auxiliary Adjust the tension of the auxiliary thread tension
8. long The appropriate length of the upper thread on the needle after trimming is 35 45mm This can also be done by using the remaining upper thread length adjustment volume of the control box Figure 28 N Caution Be sure to place back safety devices and check whether they function properly after D disassembling and adjustments gt Use both hands when bending the machine backwards or returning it to the normal position Using only one hand can lead to severe hand injuries due to the weight of the machine Be sure to pay caution to safety when making adjustments with the power switch 2 gt The machine must be repaired and inspected only by trained technicians gt Qualified technicians or agent must perform electrical repairs or inspections 8 Adjusting height and pressure of the presser foot 1 Adjusting the height of the presser foot Loosen the pressure adjustment screw 1 and the presser bar bracket clamp screw Lift the presser bar lifter Make the distance between the upper side of the needle plate and the lower side of the presser foot 7mm Then tightly fasten the bracket clamp screw 9 See figure 29 Be careful not to turn the presser bar 2 Adjusting the tension of the presser foot Turning the pressure adjustment screw 1 to the right increases the presser foot tension and turning it to the left makes it weaker After ad
9. of hook stopper and upper side of needle plate groove Like in figure 36 the normal distance between the upper side of the hook stopper and the upper side of the needle plate groove is 1 1 2mm This distance may impact the thread separation during sewing adjustment and trimming hence it must be checked If the distance is not as recommended it has to be adjusted by moving the hood base bushing up and down as seen in figure 36 Make sure the adjustments are made after carefully observing the assembled position of the peripheral parts The hook base bushing is fixed in one position by a fixing screw D Hence the hook shaft gear 3 has to be unfastened in order to change the up down position When this is done it should move smoothly without the hook shaft moving up and down Also fix the lower shaft gear maintaining the hook edge and needle timing unchanged Figure 36 and opener Loosen the opener clamp screw 3 and turn the opener to the right and left so that the distance between the hook and the opener Q is 0 1 0 3mm when the opener is pulled to its max towards the arrowed direction See figure 37 Figure 37 SunStar 14 Replacing feed dog 1 For KM 857 series refer to figure 38 to replace the feed dog Figure 38 2 Feed dog replacement method for KM 867 series is very simple as they have adopted the quick change type str
10. oil stone or fine sand paper See figure 50 SunStar Figure 48 About10mm Point where the movable knife starts its movement Thread take up lever s lowest point Figure 49 OIL STONE SAND PAPER Figure 50 31 17 Replacing movable knife and fixed blade 1 Open the hook cover 2 Loosen the screw D and remove the fixed blade holder cover 3 Loosen the screw 3 and disassemble the washer and the fixed blade 4 Loosen the bolt and disassemble the movable knife 7 Wwe C WO X Assembling method is the reverse of disassembling method Ne Fb V 5 Figure 51 18 Adjustment of wiper d m A M eh gt p k Figure 52 1 Stop the needle in up stop position up stop needle position of the control after trimming 2 Set the stitch length dial at 2 3 When pressing with hand as in the above picture the wiper edge should protrude about 0 3 mm from the needle edge Loosen the four clamp screws to vertically adjust the solenoid 4 Route the thread onto the two needles 5 The position of the wiper edge D should look like the picture where the two hooks of the wiper can securely route the thread To do so loosen the clamp screws of the wiper and horizontally adjust the wiper D 32 SunStar About 0 3 mm
11. scratch on the needle Remove the scratch on the feed 9 hole of the feed dog dog Needle plate There is a scratch on the thread Remove the scratch on the needle case and around the needle plate plate Thread tension Upper and lower thread tensions Adjust the upper and lower thread are bad tensions 3 Poor thread Thread take up spring Thread take up spring tension is Adjust the thread take up spring adjustment tension inadequate tension Gap between opener The gap between the openerand Adjust the gap between the opener and hook hook is inadequate and hook Direction and height Needle is inserted into wrong Reinsert the needle correctly and of needle position push up to its highest level Upper thread Needle Bent needle Change the needle falls outwhen Threading Wrong direction Insert the thread in the right way 4 starting to sew or sewing is Hook timing The timing between the needle and Adjust the timing between the skipped hook is bad needle and hook Gap between the needle and the hook Needle and hook are too far apart Adjust the position of the hook 35 No Symptom Checkpoints Root cause Corrective action Ail The length of the remaining upper Increase the adjustment volume of trimming 9 thread is too short the upper thread on the control box After trimming lower thread holder Adjust the location and tension of Lower thread holder 9 Upper thread
12. the movable knife shaft right hold the initial assembling angle of the crank right 9 to be about 27 to the left from the perpendicular line drawn to its center To make sure that this position is maintained adjust the length of the ball joint linking bar and tightly fasten the fixing screw of the crank right For the adjustment of the ball joint linking turn the linking bar 6 after loosening the nuts left and right Nut left is left screw and nut right is right screw C Then loosen the fixing screw 9 of the movable knife shaft crank left and in the same angle as the crank right s lower assembling angle place the crank left 0 Unfasten the fixing bolt 2 and hinge screw to adjust the length of the connecting rod 2 and then fasten the fixing bolt 3 and hinge screw to make sure this position holds D When the linking device is connected as such the movement angles 8 of crank def and right during trimming movement results in an equal angle movements for left and right against the perpendicular lines and 9 that are drawn from the center line of both sides of the movable knife shafts Hence it can be said that the trimming movement is very light E For KM 857 7 refer only up to the assembling direction down to the movable knife shaft crank right SunStar 3 Adjusting movable knife and fixed blade See figure 45 A Adjusting the position of movable knife and
13. 05 3 phase 220V 400W 50 60 Hz HEC 1706 1 phase 220V 400W 50 60 Hz 5 Peripheral automation devices optional trimming type Optional Device Model Usage A solenoid operating structure where the presser foot gets lifted aut Mees yen automatically with pedal reverse gear stage 1 operation 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 Material Edge Sensor SEDG 1B to stop the machine without manual pedaling Available in two SEDG 2B types SEDG 1B for edge sensing type and SEDG 2B for thickness sensing type A device needed when only one operator runs several sewing Standing Pedal SPDL 1 machines Pedals for acceleration thread trimming presser foot SPDL 2 and ascending are built separately There are two types SPDL 1 for fixed speed type and SPDL 2 for adjustable speed type Installation NWaming gt Installation of the machine should be performed by a trained engineer 9S a Any electrical wiring must be performed by a qualified technician or agent The machine weighs over 53kg At least 2 persons should carry out the installing work gt Plug in after the installation is complete If the operator mistakenly steps down on
14. Film Adjustment Film Adjustment Down Film Adjustment Up Film Adjustment Figure 15 Figure 16 10 Reverse button function automatic trimming type If the reverse button 1 is pressed while sewing forward reverse sewing takes place immediately If the machine is stopped first and the button 1 is pressed before stepping the pedal to start the machine reverse sewing will take place from the start Also by pressing button while the machine is in stop position the high low position of the needle bar can be changed If the button D is pressed once when the needle bar is in down stop position the needle bar changes to up stop position Once again if the button D is pressed twice consecutively within 1 second the needle bar changes to down stop position In short it has both the reverse sewing and needle up down position change functions See figure 17 11 Checking stop position of the machine Thread take up lever up stop position automatic trimming type DE After changing the up down position of the needle by pressing the reverse button check the stop position of the machine Check whether the thread take up lever is in the highest position when the needle is in up stop position When the stop position is E incorrect there might be problems to the trimming function 5 hence the photo film location of the synchronizer must 3 corrected That is the needle up stop
15. To do so loosen the screws D make the adjustment and then fasten them back 2 Assembling order X After assembling in the reverse order of disassembling adjust the left and right hook base 1 Machine troubleshooting 4 Cause of trouble and troubleshooting SunStar No Symptom Checkpoints Root cause Corrective action Direction and height Needle is inserted into wrong Reinsert the needle correctly and of needle position push in to its highest level Needle Needle is bent Change the needle Feed dog timing Bad timing of feed dog Adjust the timing of feed dog Needle breaks Gap between needle and hook Bad timing of needle and hook Adjust the timing of needle and hook The heads of the needle and the hook interfere each other Adjust the location of the hook Wrong threading inserted from the Threading method eae Thread the needle correctly opposite side Needle Bent needle Change the needle Direction and height Needle inserted in the wrong of needle direction and height y Upper thread tension Too tight upper thread tension Reduce the tension of upper thread Lower thread tension Too tight lower thread tension Reduce the tension of lower thread 2 Thread breaks Thread take up stroke large stroke Adjust the stroke level There is a scratch on the hook Remove the scratch on the hook Hook edge edge Feed do There is a
16. User Manual KM 857 867 Series High post 1 2 needle drop feed needle feed sewing machine 2 S 0 0000 00 N SunStar 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 SUNSTAR MACHINERY CO LTD 25 050509 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 11e ee ree rena nena aaa nun 4 1 Specifications 1 Machine types retenir rrr tere B eoe denda 8 2 Specifications of the machine seen 8 3 Specifications of servo motor con
17. and fully the details about its operation Don t forget to put on garment suitable for safe work Keep your hands or a part of the body away from the running part of the machine like the needle hook thread take up spring and pulley etc Don t remove any kind of cover for safety while running the machine Be sure to connect the earthed line D Before opening the electric box such as a control box be sure to shut off the power supply and make sure that the power switch should be put on off amp When threading the needle or before checking after sewing be sure to stop the machine Don t switch on the power supply with the foot on the pedal Don t run the machine when the cooling fan is clogged Be sure to clean the air filter in the control box once a week If possible keep the machine away from strong electromagnetic fields like 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 Caution off the power switch during check ups or adjustments 1 5 Safety Device Caution amp 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 C Belt cover a device to prevent hands feet and clothing from getting jammed by the belt Finger guard a device to prevent fingers fro
18. ate length of upper thread extending from the needle hole is 50mm for initial sewing 3n R T o gie J 9 Figure 23 SunStar 7 Adjusting thread tension The result of the needlework depends on the sewing conditions such as the sewing material used thread and stitch length So please adjust as fit lt V4 Good sewing O x Strong upper thread tension with weak lower thread tension x pa Weak upper thread tension with strong lower thread tension 1 Adjusting the upper thread tension Like in figure 24 turning the tension adjustment nut of the thread tension control assembly clockwise makes the upper thread tension stronger and turning counterclockwise makes it weaker Figure 24 2 Adjusting the lower thread tension Like in figure 25 turning the tension adjustment nut 1 of the hook clockwise makes the lower thread tension stronger and turning counterclockwise makes it weaker Figure 25 19 3 Adjusting the tension of thread take up lever spring A Adjusting the thread take up stroke As in figure 26 loosen the stopper clamp screw D and turn the thread take up lever spring stopper clockwise to make the stroke smaller and counterclockwise to make it bigger The thread take up stroke is normally 5 10mm B Adjusting the thread take up tension As in figure 26 loosen the screw 3 of
19. e figure 7 Figure 7 6 Installation of program unit automatic trimming type 1 Fix the bracket onto the program unit D using 4 fixing nuts 2 Then use 3 fixing bolts to tightly fix the bracket where the program unit 1 has been attached along with the back cover see figure 8 Figure 8 7 Installation of belt cover 1 Attach belt cover A onto the back of the machine body as seen in figure 9 2 As seen in figure 10 assemble the belt cover support pin to the arm base and then attach the belt cover B to the machine Now if a bobbin winder is attached on the table lay down the machine body on its back and attach the belt cover 3 Fix the belt covers A and B as can be seen on part K of the figure 4 Fix the lower part of the belt cover B onto the machine bed like part of the figure Figure 9 Figure 10 13 8 Installation of thread stand As seen in figure 11 fix the thread stand to the table using the washer and nut on the right 9 Synchronizer assembling and its control method automatic trimming type 1 Installation of synchronizer Assemble in the order of marked number as can be seen in figure 12 Then following the figure 13 make adjustments to place the photo film at the center of the sensor housing by moving the shaft to the right and left Then tighten the 2 fixing sc
20. el Specifications 1 Machine Types No Model No Model Name 1 KM 857 High post type 1 needle drop feed needle feed sewing machine standard hook 2 KM 857 7 High post type 1 needle drop feed needle feed sewing machine with automatic trimmer standard hook 3 KM 867 High post type 2 needle drop feed needle feed sewing machine standard hook 4 KM 867 7 High post type 2 needle drop feed needle feed sewing machine with automatic trimmer standard hook 2 Specifications of the machine Hem Model type KM 857 KM 857 7 KM 867 KM 867 7 Purpose Medium material heavy material Max sewing speed 3 000SPM Max no of stitches 5mm Needle bar stroke 33 4mm Feed dog height 1mm Manual 7mm iced ki Knee S Automatic 13mm 13mm Post height 178mm Needle used DP x 17 18 14 22 Feeding method Low pressure circular automatic feeding Needle width gauge 1 16 1 1 6mm 25 4mm 3 Specifications of servo motor controller trimming type KM 857 7 KM 867 7 MODEL VOLT WATT HERTZ SC55 1B 1 phase 110V 550W 50 60 Hz SC55 2B 1 phase 220V 550W 50 60 Hz SC55 3B 3 phase 220V 550W 50 60 Hz SunStar 4 Specifications of clutch motor non trimming type KM 857 KM 867 MODEL VOLT WATT HERTZ HEC 1701 1 phase 220V 250W 50 60 Hz HEC 1703 3 phase 220V 380V 250W 50 60 Hz HEC 17
21. ghtly fasten the left and right crank fixing screws When willing to adjust only slightly the initial position of the left and right movable knives use the ball joint linking If only the left movable knife is to be slightly adjusted then use the linking bard 30 D Adjusting lower thread holder When the movable knife returns to its initial position after completing its trimming action arrow like in figure 48 adjust the lower thread holder by loosening the fixing screw 3 to make the distance between the movable knife edge and lower thread holder edge approximately 8mm and to make the middle point of the lower thread holder 2 edge to move 0 5mm towards inside arrow B Now make sure to check that the inner side of the movable knife and the middle point of the lower thread holder edge are closely adhered as can be seen in part 4 Checkpoints on the assembling status of other trimming devices A Check the starting point of the movable knife when the trimming action takes place Operate the trimming action manually to check whether the thread take up lever is about 10mm higher than its lowest point when the movable knife starts working as in figure 49 B Maintenance of fixed blade When the thread does not get trimmed or if the trimmed section of the thread is sloppy please check the edge condition of the fixed blade If the edge of the knife is too dull sharpen the edge using
22. hook a As in picture unfasten the movable knife fixing screw 3 to adjust the movable knife so that the edge of the movable knife D sits at the very center of the hook s 2 V shaped groove Tightly fasten after sideway adjustment b Adjust the distance between the movable knife and the upper side of the hook to be 0 5mm To adjust unfasten the clamp screw of the hood shaft gear and the clamp screw of the movable knife shaft collar Vertically adjust the movable knife shaft 6 and then tightly fasten the clamp screws Figure 45 B Adjusting movable and fixed knife See figure 46 a Like in figure 46 manually operate the movable knife and then slowly reposition it in its original place Now just like in the figure place the fixed knife so that the fixed knife edge touches 3mm before the movable knife s trimming point b Match the upper side of the fixed blade 3 and movable knife D Fully adhere the upper and lower parts of the fixed blade edge with the outer side of the movable knife edge c Under this condition tightly fasten the fixed blade clamp screw Be careful so that the fixed blade does not move d Once the adjustment is complete operate manual trimming once again to check the crossing of the movable and fixed knives crossing x The crossing between movable knife and fixed blade Matching upper side Good
23. justing make sure to Figure 29 tighten the fixing nut See figure 29 21 22 9 Adjusting needle and feed dog timing 1 After removing the needle lay down the machine on its back and remove the timing belt 2 Turn the pulley to align the highest position 3 of the pulley s thread take up lever with the position 4 of the arm Then rotate the timing pulley to align the bed base point with the timing pulley s base point 2 Hang the timing belt D in this position 3 After adjustment when the feed dog amp comes up from below the needle plate and the upper side of the feed dog meets the upper side of the needle plate 0 check to see if the needle descends and the needle point stops at about 3 4mm distance from the upper side of the needle plate as can be seen in the figure See figure 30 Figure 30 10 Adjusting height of the feed dog Turn the pulley to place the feed dog D in the highest point Loosen the feed dog base clamp screw 2 and move the feed dog base 3 up and down to make the feed dog 1 protrude out in parallel to the upper side of the needle plate 4 for about 1 mm See figure 31 About 1 mm Figure 31 SunStar 11 Adjusting needle and hook timing 1 Fixing the height of the needle bar Turn the pulley to place the needle bar in the lowest position Loosen the needle bar holding screw D adjust so that the needle ba
24. m contacting the needle SunStar 1 6 Position of Caution is adhered to the machine for safety Caution Mark In case of starting to run the machine read the directions of Caution carefully CAUTION D Position of Caution Mark 1 Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off main switch d 2 i amp J ema go RES mi IN ose ma 4 vH Wai HARE HEA M FAAS E Sunsta i gaa CAUTION i Hazardous voltage will cause injury Be sure to wait at least 360 seconds before opening this cover after turn off main switch gt and unplug a power cord ies 29 HRO sid 298 4 HHE jm sur Aes Ws zama c amp HA 108 OLAS He 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 2721 SSHHet Sere aA 830 ZHI DAI a Bl Hanni eA FMA Tew CAUTION 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 Mel Clo AMS zug SHE AHS Weld AH 2005 36022 7ILI
25. place the needle bar at its lowest position b With the left side of the trimming softly attached to the right side of the lower shaft medium bushing 2 turn the cam to align the base point with the carve 4 in the lower shaft medium bushing crank c Fasten tightly the trimming cam fixing crews 3 5 Now turn the pulley manjually to see whether or not the machine turns smoothly Figure 41 26 SunStar B Adjusting the stopper pin holder See figure 42 9 Complementary straight line Trimming finishing point Movable knife operation starting point Trimming Cam Lead The present stop position of the cam roller is inside the complementary straight line with the cam lead right before it exits having finished trimming action Figure 42 a Make sure to turn the machine pulley to place the trimming cam 3 in the right position so that the roller 1 can enter the complementary straight line range after finishing trimming marked in the trimming cam lead b Press down the trimmer shake linkage to make the roller D come inside the trimming cam 3 Adjust the holder to make the right equal point of the roller 1 adhere 5 smoothly to the inner right side of the cam s complementary straight line and the left equal point of the stopper pin adhere 8 smoothly to the inner left side of the stopper pin holder 2 Once this is done
26. position is the same as the 2 needle bar s stop position once the trimming action takes place So there is no problem with the timing of the trimming action Figure 18 See figure 18 See location detector adjustment on page 14 15 Adjustment of the machine N Caution In case of setting the needle be sure to switch off the power supply If the user steps on the pedal aD by mistake the machine will start automatically and this might lead to physical injuries When using the clutch motor remember that the motor revolves for a while even after switching off the power supply due to inertia Make sure to start working only after the motor has come to a complete stop 1 Inserting needle As in figure 19 place the upper end of the needle closely adhered to the upper side of the stopper hole with the needle groove O facing inward Fix the needle with a fixing screw Figure 19 2 Removing bobbin and bobbin case Place the needle in the highest position and then just like in figure 20 open the hook covers on the left and right Raise the bobbin holder 3 to remove the bobbin case and the bobbin Figure 20 3 Winding lower thread 1 Winding the lower thread A Insert the thread into the hole D and put it around the back of tension adjustment plate to the front side B Bring the thread towards the bobbin 3 and wind it around 5
27. r carved sign meets the end of the frame like in figure 32 then tighten the screw Lowest point of the needle bar when using 5 needle Crossing point of the hook edge and the needle center 1 8mm Figure 32 2 Adjusting the timing of hook edge and needle center crossing First set the stitch length DIAL to 2 5mm Adjust the hook gear clamp screw 0 so that like in figure 33 the hook edge fall sexactly at the center of the needle center when the needle bar is raised 1 8mm from its lowest position When this is done the hook edge will be placed at about 1mm above from the front of the needle thread hole Hook edge Imm Figure 33 23 12 Clearance adjustment between upper 13 Clearance adjustment between hook 24 3 Adjusting the distance between the needle and the hook edge Raise the needle from its lowest point so that the hook edge meets the needle center Like in figure 34 when the lower part of the needle meets the balance point of hook s needle guide plate 1 adjust the needle guide form adjust the distance between the hook edge and the inner side of the needle groove to 0 05 0 1mm Loosen D of figure 35 and move the hook base to the left and right for adjustment Needle Adhering part 0 05 0 1mm Figure 34 Figure 35 side
28. r finishing the adjustment tightly fasten the fixing nut 5 4 According to the installation position of knee lifting solenoid the operation noise operation load and presser foot elevation range Fi 2 may differ Please assemble so that the machine will operate smoothly SunStar 3 Installation of oil fan x Insert the projecting part of the oil fan into the respective machine holes on the lower side of the Nail table D and then push securely to the right Fix the oil fan to the four fixing spots 3 using 4 nails see figure 3 Figure 3 NCaution Be sure to plug in after finishing oil supply If the user steps on the pedal by mistake the machine will start automatically and this might lead to physical injuries gt When handling lubricant use safety goggle or gloves to prevent the lubricant from coming into contact with the eyes or skin This may cause inflammation And never drink lubricants They may cause vomiting or diarrhea Please keep out of the reach of children D Make sure to supply oil when using it for the first time or after not using it for a long time 4 Lubrication 1 Oil tank check As in figure 4 pour the oil into the oil hole 2 until the Q oil tank s oil level reaches the red maximum line D While using the machine replenish the oil immediately 2 E when the oil level goes down to the minimum le
29. rews 3 using the hexagonal wrench Note A As seen in figure 12 make sure that the marks DOWN and UP face the front when looking from the pulley side B Film adjustment is completed upon shipment 1 Photo film right and left adjustment I Figure 11 Figure 12 Thread take up lever up stop position Needle bar frame Figure 13 Figure 14 SunStar 2 Film adjustment of synchronizer A For new model type see figures 14 15 Manually turn the pulley so that the needle bar is placed where it starts rising from the lowest point Unfasten the film fixing screw in figure 15 and for DOWN film A align the film adjustment base line with the sensor adjustment base line as can be seen in 9 Then using the fixing screw D fasten only as much as to prevent the film from turning In the same method place the thread take up lever in the highest point Once again unfasten the fixed screw D and align the UP film B like B Now be careful not to move the previously set DOWN film A B For old model type see figure 16 Adjust in the same method as new model to make the right side of the film s projecting part aligned to the center of the sensor base line New model synchronizer Sensor adjustment base line Old model synchronizer d Film adjustment Photo sensor fixing screw Down
30. sss 19 8 Adjusting height and pressure of the presser 1 21 9 Adjusting needle and feed dog timing sss 22 10 Adjusting height of the feed dog sss 22 11 Adjusting needle and hook timing esses 23 12 Clearance adjustment between upper side of hook stopper and upper side of needle plate groove 24 13 Clearance adjustment between hook and opener 24 14 Replacing feed eee eo rts 25 15 Adjustment of safety device sse 26 16 Adjusting trimming device seen 26 17 Replacing movable knife and fixed blade 32 18 Adjustment Of Wiper i ooeneonteeoo oboe ooo o meer rene 32 19 Replacing gauge set for needle width 34 4 Cause of trouble and troubleshooting 1 Machine troubleshooting eene 35 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 NDanger Instructions here shall be observed strictly Otherwise the user may be killed or suffer severe physical injury NNaming
31. the pedal with the pug in the machine will start automatically and can cause physical injuries A Connect the ground earth wire An unstable connection may result in an electric shock or a malfunction Place the belt cover on top of the machine a Use both hands when bending the machine backwards or returning it to the normal position Using only one hand can lead to severe hand injuries due to the weight of the machine 1 Installation of machine head x Fix the two head hinges D to the bed Settle the machine onto the table where the hinge rubber and cushion rubber 3 are inserted see figure 1 Figure 1 2 Installation of knee lifting solenoid and power switch box 1 When attaching the power switch box refer to figure 2 to make sure that it is placed at the very center of the solenoid bracket 2 After attaching the solenoid onto the table unfasten the screw 4 to adjust the center of middle linking bar and the center of solenoid shaft in parallel position with the lower side of the table After the adjustment is over fasten the fixing screw Table tightly see figure 2 assembling position diagram can be found inside the solenoid box 3 The presser foot height of the sewing machine can be adjusted 7 after unfastening the fixing nut and then turning the middle linking bar 1 clockwise to raise and counterclockwise to lower Afte
32. the thread tension control assembly shaft and insert the driver into the groove D of the thread tension control assembly shaft Turn clockwise to make the spring tension stronger and counter clockwise to make it weaker The thread take up spring tension is normally 50 80g 79 MUS f NG 5 10mm Figure 26 4 Adjusting the thread release stroke automatic trimming type If the upper thread falls out from the needle hole after trimming check whether the plate opens while the trimming is in action For the adjustment of plate opening level put the solenoid in action and adjust by moving solenoid collar back and forth to make the opening of the thread tension adjusting plate 0 8 mm Also when the thread release solenoid is not in action check whether the plates are closely adhered to each other See figure 27 vmm Figure 27 Caution If the plates do not open enough during the trimming action even when the assembling is good check whether or not the upper thread length adjustment volume which is at the front of the control box is low 20 SunStar 5 Adjusting the auxiliary thread tension control assembly automatic trimming type As in figure 28 when the auxiliary thread tension adjustment nut D is turned clockwise the length of the thread after trimming gets short The other way makes the thread
33. thread through A part of the hook 2 and pull it out from the end of the lower thread tension adjustment plate 3 C The adequate length of the pulled out lower thread is 50mm Applied Model Types A KM 857 7 B KM 867 7 A Insert the bobbin into the bobbin case B Insert the thread through part of the hook and pull it out from the end of the lower thread tension adjustment plate 3 C Pass the pulled out thread through of the bobbin case and insert it into the hook D The adequate length of the pulled out lower thread is 50mm 17 5 Inserting bobbin Stop the needle 1 at the highest position Following the figure 22 insert the bobbin where the thread is rolled onto or the bobbin case into the hook After laying down the bobbin holder close the slide plates on the right and left Figure 22 When taking up the upper thread be sure to switch off the power supply If the user steps on the pedal by mistake the machine will start automatically and this might lead to physical injuries gt When using the clutch motor remember that the motor revolves for a while even after switching off the power supply due to inertia Make sure to start working only after the motor has come to a complete stop 6 Routing upper thread Place the thread take up lever to the highest position and hang the upper thread like in figure 23 The adequ
34. to secure enough space to repair Danger of Explosion Don t run the machine near the places with any dangers of explosion Don t run the machine near the places with any dangers of explosion including places where the spraying product like aerosol are used in large quantities or oxygen are dealt with unless the exact actions concerning the operation are guaranteed to avoid the explosion D Because of the characteristics of the machine illuminators are not equipped So users should install the lighting apparatus around the working area Note The details about the installment of the machine are described in No 2 Installations 1 3 Troubleshooting Danger If in need of troubleshooting call a trained A S engineer who has been educated by sunstar Before cleaning and repair be sure to turn off the power supply And wait for about 4 minutes untill the machine discharges completely Part or the entire machine should not be modified without any consultation with our company In case of repair change the damaged part into the standard article of our company After repair put back the safety cover that was removed while repairing 1 4 Machine Operation Caution KM 857 867 series are manufactured for industry use to sew textiles and other similar material In case of running the machine users should observe the following things Before operating the machine read the manual and underst
35. troller ss 8 trimming type KM 857 7 KM 867 7 4 Specifications of clutch motor non trimming type KM 857 867 9 5 Peripheral automation devices optional trimming type 9 2 Installation 1 Installation of machine head sse 10 2 Installation of knee lifting solenoid and power switch box 10 3 Installation of oil fan 11 LubriCatiQriz i hec dete rire ft entr ae rere eri ene Rete een 11 5 Adjustment of belt tension sees 13 6 Installation of program unit automatic trimming type 13 7 Installation of belt cover sees 13 8 Installation of thread stand sse 14 9 Synchronizer assembling and its control method automatic trimming type 14 10 Reverse button function automatic trimming type 15 11 Checking stop position of the machine automatic trimming type 15 3 Adjustment of the machine 1 Inserting needle eerte ttr n 16 2 Removing bobbin and bobbin case sss 16 3 Winding lower thread sse 17 A ROUUNE lower thread o Re ore ene tens 17 5 Insertinp BOBBIN i iiie 18 6 Routing upper thread i enero o het ment 18 7 Adjusting thread tension
36. ucture Please refer to the following explanation and figure 39 Disassembling Order A Disassemble the needled B Disassemble the presser foot C Open the left and right hook covers D Disassemble the needle plate E Unfasten 2 of the feed dog fixing bolts for about 3 cycles F Using a driver lift the feed dog and take it out Figure 39 Assembling can be done in the reverse order Make sure that the feed dog is securely inserted before tightening the fixing bolt 25 15 Adjustment of safety device When there is overload in the machine during the operation the safety device pulley and the lower shaft get separated thereby not passing the driving power of the upper shaft to the lower shaft Hence major parts are protected from damage In this case the power switch needs to be turned off and the cause of the overload needs to be removed Then lay down the machine on its back and turn the pulley while pressing the latch button Safety device pulley D and the lower shaft will come back to its original position The load in which the safety device gets activated can be adjusted by turning the adjusting screw clockwise for large load and left for small load See figure 40 Figure 40 16 Adjusting trimming device 1 Adjusting the trimmer driving part A Fixing the position of the trimming cam See figure 41 a Turn the pulley manually to
37. vel nm back to the red maximum level D Make sure to check Eee the oil level once a day Figure 4 11 2 As in figure 5 make sure to supply oil into the oil holes marked in red and into each friction part before moving the sewing machine dug Kd CDs EAS C Figure 5 3 Supply level adjustment of oil supply terminal The amount of oil supplied from the arm s oil tank to the front and middle bushing of the lower shaft and the front busing of the horizontal push stick can be adjusted using the adjustment screw of the oil supply terminal D The amount of oil supply decreases when turned clockwise and increases when turned counterclockwise see figure 6 Figure 6 4 As test operation run the machine for 10 minutes at about 1 500 SPM For the first 4 5 days of using the machine operate the machine at less than 2 400 SPM per minute Then start using at normal pace This will help maintain good performance of the machine along the way SunStar 5 Adjustment of belt tension Once the motor is installed when the fixing nuts D fully unfastened on both sides tension is created to the belt 4 due to the weight of the motor 3 At this moment fasten the fixing nut D first then fasten the fixing nut tightly Se
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