User`s Manual KM-757
Contents
1. SunStar Users Manual KM 757 High speed two needle drop feed needle feed sewing machine with automatic thread trimmer KM 797 High speed two needle drop feed needle feed sewing machine with automatic thread trimmer for each needle 24 EX a ww astar warns 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 Thank you for purchasing our product The upgraded KM 757 km 797 Series built on valuable technology and experience drawn from years of production of automatic thread trimming sewing machines features new FORTUNA AC SERVO automatic thread trimming motor designed to fully realize the Mechatronics of the sewing machine industry This model guarantees to satisfy increasingly growing and sophisticated needs of the sewing industry by offering diverse functionalities excellent performance remarkable power enhanced durability and refined design Read all instructions in this manual thoroughly before proceeding with operation of the sewing machine to achieve maximum performance Note that specifications of this product may be changed at any time without prior notice for performance improvement SUNSTAR MACHINERY CO LTD LEO Wey Mm OTe Kk Safety rules for machines eene 4 1 Specification Dy Seuil T2. horizontally where the solenoid housing 6 is attached to make the solenoid stroke 5 4 mm Then tightly fasten with fixing screw 9 b After adjusting the solenoid stroke manually Ne operate the solenoid shaft towards the arrow direction See whether it returns to its original IUe 0l position fast and smooth when released If not proceed with horizontal adjustment of the bracket 2 2 Adjustment of linking device for movable knife shaft and the trimmer driving part See Figure 47 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 the movable knife shaft right hold the initial assembling angle of the crank right to be about 15 30 to the left from the perpendicular line 8 drawn to its center 17 To make sure that this position is maintained adjust the length of the ball joint linking bar which comes assembled to trimmer shake linkage QD Also adjust the fixing screw tightly x For the adjustment of the ball joint linking bar turn the linking bar after loosening the nuts left and right C2 is left nut and is the right nut C Then loosen fixing screw 8 of the movable knife shaft crank left and in the same angle as the crank right s lower assembling angle 9 place the crank left
3. LOW mark fill in to HIGH immediately D Once every two weeks is deemed the appropriate E Figure 3 interval for oil refills 3 For new machines that have been delivered a long ago or has not been used for a long period of time open the face plate and apply the oil spray 2 3 times to friction areas such as the thread take up lever linkage CD the needle bar and the presser bar 3 See Figure 4 Figure 4 11 4 For trial runs operate the machine at 1 500 spm for about 10 minutes at a time Be sure to check whether the oil window is being lubricated See Figure 5 5 Operate the machine at below 2 400 spm for the first 4 5 days and run the machine at normal speed thereafter to maintain the sewing machine in optimal condition 4 Adjustment of belt tension After installing the motor unfasten the fixing nuts D and tension will be created to the belt due to motor falling by gravity Fasten the fixing nut first now and then fasten the fixing nut tightly See Figure 6 5 Installation of the program unit Servo motor 1 Fix the bracket onto the program unit D using 4 fixing nuts 3 2 Then use 3 fixing bolts 4 to tightly fix the bracket where the program unit 1 has been attached along with the back cover See Figure 7 6 Installation of the belt cover 1 Before attaching the belt cover A to the machine body assemble in advance the rubber collar 1 and w
4. e KM 757BL 7S e KM 797BL 7S iil e KM 757BL 7N Z e KM 797BL 7N Figure 23 17 5 Inserting the bobbin Stop the needle 1 at the highest position Following the Figure 24 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 24 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 start automatically and can cause e 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 6 Routing the upper thread Place the thread take up lever to the highest position and hang the upper thread like in Figure 25 The adequate length of upper thread extending from the needle hole is 50mm for initial sewing Figure 25 18 SunStar 7 Adjusting the 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 desired good sewing upper thread tension is strong while the lower thread tension is weak upper thread tension is weak while the lower thread tension is weak 1 Adjusting the upper thread tension Like in fig
5. 0 Tightly fasten the fixing bolt to make sure this position holds D When the linking device is connected as such the movement angles OOO of crank left and right during trimming movement results in an equal angle movements for left and right against the perpendicular lines 8 and that are drawn from the center line 7 of the two movable knife shafts Hence it can be said that the trimming movement is very light Figure 47 SunStar 3 Adjusting movable and fixed knives A Adjusting the position of movable knife edge and hook stopper See Figure 48 a When a movable knife 1 passes the front side of the hook stopper adjust the distance 4 to be within 0 05 2 mm range like part 3 The upper surface of the movable knife edge should be set up 0 2mm below the upper side of hook stopper x Given that the fixed knife is pressing down the movable knife b Clearance adjustment of the movable knife edge and hook stopper front side Loosen the needle plate Place the hook stopper in the hanging position to the needle plate Holding the hook with the hand manually operate trimming movement so that the movable knife edge is matches the stopper front side 3 Loosen the fixing screw of the movable knife shaft eccentric bushing In the lower side hole 9 of the eccentric bushing stick in a thin driver or adequate pin and turn right and left This will make the position of the movable knif
6. 32 Figure 32 21 10 Adjusting the height of the feed dog Turn the pulley to place the feed dog D in the highest point Loosen the feed dog base fastening screw and move the feed dog base up and down to make the feed dog protrude in parallel from the needle plate upper side by about 1 mm See Figure 33 about 1 mm oe d Figure 33 11 Adjusting the needle and hook timing 1 Fixing the height of the needle bar Turn the pulley to make the needle bar in the lowest position Loosen the needle bar holding screw D adjust so that the needle bar carved sign meets the end of the frame like in Figure 34 then tighten the screw Lowest point of needle bar when using a DP x 5 needle Cross section of hook edge and needle center Lowest point of needle bar when using a DP x 17 needle Cross section of hook edge and needle center 757 Series 797 Series Figure 34 2 Adjusting the timing of hook edge and needle center crossing A First set the stitch length of DIAL KM 757 757 7 797 797 7 types at 2 5mm and KM 757BL 757BL 7 797BL 797BL 7 types at 3 5mm Adjust the hook gear fastening screw 1 so that like in Figure 35 the hook edge falls exactly at the center of the needle center when the needle bar is raised 2 4mm from its lowest position When this is done the hook edge will be placed at about 1 1 5 mm above from the upper shaft of the needle Figure 35 thread hole
7. e e a a B EM oo o ime DPx5 14 11 422 DP x5 422 11 22 SunStar 2 Servo motor 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 3 470 motor PM470 pp x m9 qi MODEL PHASE VOLT 1 124 4 470 motor controller PC470 O B 0 Doom I M d m oom PC470 001 5 Clutch motor for non trimming type MODEL VOLT WATT HERTZ 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 8 Servo motor E 470 motor AUTO KNEE LIFTING SYSTEM SPF 4 A solenoid 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 unit PRODUCTION COUNTER SCOUN 1 panel including added subtracted corrected or remaining quantity along with other performance rates SEDG 1 A device that senses the edge or thickness of the sewing material to stop the MATERIAL EDGE SENSOR machine without manual pedaling Available in two types SEDG 1 for edge SEDG 2 sensing type and SEDG 2 for thickness sensing type Installation gt Plug in after the installation is complete If the operator mistakenly steps down on the pedal with the pug in the machine will start automatically and can caus
8. oil covered on the machine to prevent accidents Because physical damage such as the functional obstacles and breakdowns are likely to occur according to the environment in which the machine is being installed Therefore the following preconditions should be fulfilled 8 Please keep the order from top to bottom when unpacking the package Especially mind that the nail on the boxes D Because machines are apt to be contaminated and corroded by dust and moisture you should install the climate controller and should clean the machines regularly Keep the machines out of the direct rays of the sun Q Keep both sides and the backside of the machines off at least 50cm from the wall to secure enough space to repair Danger of Explosion Don t run the machine near the places with the dangers of explosion Don t run the machine near the places with the dangers of explosion including the places where the spraying product like aerosol are used in large quantities or oxygen are dealt with unless the exact actions concerning the operation are guaranteed to avoid the explosion D Because of the peculiarity of the machine any illuminators are not equipped So users should install the lighting apparatus around the working area Note The details about the installment of the machine are described in No 2 Installations In need of troubleshooting it should be done by the trained A S engineer of our company Ahead of cleaning an
9. 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 Film Adjusting Arrow ew S Film Adjusting Base Sensor Base 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 Sensor Baseline Figure 16 Figure 17 9 Check for the stop position of the sewing Thread taketo ever machine automatic thread trimmer up stop position Check for the machine stop position after moving the needle 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 position 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 timing of the trimmer See Fig 18 Refer to the explanation about the Adjustment of Location Detector
10. to vertically adjust the solenoid 3 4 Hang 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 hang the thread To do so loosen the clamp screws of the wiper and horizontally adjust the wiper QD about 3 mm Figure 56 6 When the wiper D is in waiting 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 and vertically adjust the stopper Depending on the thread type there are cases where the thread cannot be hung 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 hung Make sure that the needle fixing screw does not get in the way of the wiper Figure 57 7 The trace of wiper edge D is as the above picture Adjust the wiper edge D by loosening the clamp screw 4 and vertically adjusting the distance between the needle edge and wiper to 0 5 1mm 31 19 Replacing the gauge set for needle width 1 Disassembling order Caution Turn off the power switch 3 Disassemble the left and right needle holders KM 797 series 1 Remove the right and left slide plates 2 Remove the two needles O 3 Disassemble the needle holder a 0 turn it towards the arrowed direction i S for removal KM 757 series T eo gs a 4
11. 4 to make the roller 1 come inside the trimming cam e Adjust the holder 7 to make the right equal point of the roller adhere smoothly to the right inside of the cam s complementary straight line and the left equal point of the stopper pin adhere amp smoothly to the left inside of the stopper pin holder Once this is done tightly fasten the fixing screw 9 e Once such adjustments are made the trimmer shake linkage 4 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 its original position quickly and smoothly when released If not proceed with horizontal adjustment of stopper pin holder C2 complementary straight line trimming finishing point ie movable knife operation starting point Trimming cam lead x The present cam stop position still inside the complementary straight line of cam leading right before the roller drops out upon finishing trimming Figure 45 25 C Fixing the position of the trimmer solenoid ass y See Figure 46 a When the whole trimmer shake linkage is in up position that is when it has come back to its Serena original position after finishing trimming the d aor XO ol distance 4 between the lower part of the roller HR _4mm and the equal point of the trimming cam is about 0 8 1mm Assuming that this distance 4 never changes adjust the position of solenoid bracket
12. B In case of the 797 series if the height of the left and right needles are not the same or if the Figure 35 situation where the needle bar is raised 2 4 mm but the hook edge is not placed about 1 1 5 mm from the upper shaft of the needle thread hole is not true loosen the fixing screw of Figure 36 pull out the needle holder and adjust the needle holder position fixing screw 1 up Figure 36 and down to set the height of the needle 22 SunStar C Adjusting the distance between the needle and the hook edge Raise the needle from its lowest point so that the hook center meets the needle center Like in Figure 37 when the lower shaft of the needle meets the balance point of the hook s needle guide plate adjust the needle guide form adjust the distance between the hook edge and the inner side of the needle groove to 0 05 0 1mm Loosen DOGO of Figure 38 and move the left and right of the hook base for adjustment Hook edge Needle poa P ai JE n 7 ME To a asd Adhering part 0 05 0 1mm Figure 37 Figure 38 12 Clearance adjustment between the upper side of the hook stopper and the upper side of the needle plate groove Like in Figure 39 the normal distance between the hook stopper and the upper side of the needle plate groove is 1 3mm This distance is adjusted by the thickness of the space washer that lies under the hook When the hook gear fixing screw is removed for repair or replacement make s
13. Lift the presser bar lifter to raise the presser foot e 5 Remove the presser foot 6 Remove the needle plate 7 Disassemble the feed dog 8 Lay down the sewing machine Adjusting the left right hook base When replacing with a wider or narrower gauge than the needle width in use the hook edge and needle distance may not fit correctly In this case loosen the screws D 00 as can be seen in the picture and replace the feed dog or adjust the distance between the hook edge and the needle Fasten after making the adjustments 2 Assembling order After assembling in the reverse order of disassembling adjust the left and right hook base 32 SunStar 4 Causes of Trouble and Troubleshooting 1 Sewing machine troubleshooting Root cause Corrective action Needle is inserted into wrong position Reinsert the needle correctly and push in to its highest level Needle is bent Change the needle Symptom Checkpoints Bad timing of feed dog Adjust the timing of feed dog Bad timing of needle and hook Adjust the timing of needle and hook Direction and height of needle Needle Needle breaks Feed dog timing Gap between needle and hook The heads of the needle and the hook interfere each other Threading method Wrong threading inserted from the opposite side Needle Bent needle Direction and height of Needle inserted in the wrong direction needle and height Thread breaks Upper thread tension Too
14. UP face the front when looking from the pulley side e Film adjustment is completed upon shipment I L Wrench Fixed Bushing lj Fixed Washer 14 Synchronization Shaft Fixed Ht Photo Fil Screws SE oe Photo Interrupter Speed Sensor Film Synchronization Shaft Fixing Screws 2 Location detector shaft Fixed Washer Clearance Adjusting Bushing Figure 12 Figure 13 13 2 Adjustment of the location detector A For Servo motor in built location detector Adjust the up stop position of the needle such that the white carved sign on the pulley is in a straight line with the carved sign on the arm when the needle has stopped in the air That adjustment can be made by loosening the pulley s clamp screw on the side with N U carved signs and moving it sideways Adjust the down stop position of the needle such that the needle is on the point of moving up when the needle bar is at the lowest point This adjustment can be made by loosening the pulley s clamp screw on the side with N D carved signs and moving it sideways See Figure 14 amp 15 P a Por i 4 Up Stop Down Position dd Stop Position Figure 14 Figure 15 B For 470 motor external location detectors 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
15. ar 3 back and forth to make the opening of the thread tension adjusting plate 1 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 29 Figure 29 Caution If the plates do not open enough during trimming action even when the assembling is correctly done check whether or not the upper thread length adjustment volume which is at the front of the control box is low b Adjusting the auxiliary thread tension control assembly automatic trimming type As in Figure 30 when the auxiliary thread tension adjustment nut 1 is turned clockwise the length of the thread after trimming is short The other way makes the thread 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 30 SunStar gt After disassembling and adjusting a safety device always place it back to the original position 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 gt Only trained engineers must perform troubleshooting or inspection of the machine gt For
16. asher 2 and fixing nail 3 on the to be attached side of the cover as can be seen in picture K of Figure 8 2 Attach belt cover A onto the machine body as can be seen on Figure 8 Now if a bobbin winder is attached on the table lay down the machine body on its back and attach the belt cover A 12 a f Figure 5 Figure 6 Figure 7 Figure 8 SunStar 3 Lastly fasten the belt cover B to the table as can be seen in Figure 9 Figure 9 7 Installation of the thread stand As can be seen in Figure 10 fix the thread stand to the table using the washer and nut on the right N 8 963 Figure 10 8 Assembly of the location detector and its control method 1 Installation of 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 4 7mm See Figure 11 igure 11 B Installing on the 470 motor external location detector After assembling the parts in the numbered order as in Figure 12 adjust the synchronization shaft horizontally such that the photo film is placed at the center of the photo interrupter as in Figure 13 Then fasten it tightly with two fixing screws using a hexagonal wrench Caution e As can be seen on figure 12 make sure that the marks DOWN and
17. cl ilie enosequ iuto dius bedient UA ERU EUN EIUSMO MU DUNEDIN UNE DUM UDIN NI g E AA O E E meena meneaetaat 9 PINE OEC LL LL 15 1 m 9 4 470 motor controller nennen enne enne nennen enne enne 9 5 Clutch motor for non trimming type 9 6 Peripheral automation devices Gptional sessseseenseeesecenecexsrazs tanta stipes NNE OARS ANa 9 2 Installation Ty Inistalllation of themachine head senses esinteii tei Mte tel iioii teli ta iicet ribi treten re aede eta dn 10 2 Installation of knee lifting solenoid and power switch box nnne tnter 10 SHOIDSUDDD Mere ee ee eee ne ee UNE 11 Dy whue nentol be eOrna E ee ee 15 5 Installation of the program unit Servo m0 tor eese testet ettt kosten toii t ai eoi aui ierat 12 or Installsuomrobtle DEI COVEI sida testis eles vd etre ec eiei oobi e eenaa n ieu ua ia ids 12 7 Installation of the thread Staind esoeesiepettastr taire revo er IUE Re ste tenet at meen cde ae edema 13 8 Assembly of the location detector and its eontrol method externas 13 9 Check for the stop position of the sewing machine automatic thread trimmer MM 14 10 Reverse button function automatic thread trimmer 15 3 Adjustment of the machine 1 Inserting the needle corre rere re re rr rr TTT Tr Tr rr rrr rr TR 16 2 Remove DobbI am DODDIECHSO e notet etre eer Cre ne ee 16 3 Windins heloneriiread nimii tere re
18. d repair be sure to shut off the power supply And wait for about 4 minutes till the machine discharges completely D Even a part or all of the machine should not be modified without any consultation with our company C In case of repair you should change the damaged part into the standard article of our company Q After repair please put again the safety cover disjointed while repairing 1 4 Machine Operation Warning 1 5 Safety Device Warning KM 757 797 series are manufactured for industry use to sew textiles and other similar material In case of running the machine users should observe the following things Ahead of operating the machine please read the manual and understand fully the details on its operation D Don t forget to put on the garment suited for the safe work Keep your hands or a part of the body away from the running part of the machine like a needle hook thread take up spring and pulley etc Don tremove 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 When threading the needle or before checking after sewing be sure to stop the machine D Don t switch on the power supply with the foot on the pedal D Don t run the machine when the cooling fan are not running Be sure to clean the air filte
19. e physical injuries gt Connect the ground earth wire An unstable connection may result in an electric shock or a malfunction 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 1 Installation of the machine head Insert the hinge rubber 1 into the table and fix the oil fan into the center of the machine head support rubber B 2 as in Figure 1 and attach it to the table After attaching the machine head hinge to the bed insert it into the hinge rubber 1 and install the sewing machine on the machine head support rubber A 4 and machine head support head B SSASASSS OS Oil fan 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 1 and the center of solenoid shaft in parallel position with the lower side of the table After the adjustment is over fasten the screw tightly See Figure 2 An assembling position diagram can be found inside the solenoid box 3 The presser foot height of the sewing machine can be adjusted after unfastening the fixing nut 5 and then turning the middle linking bar D clockwis
20. e shaft 4D change hence changing the distance 4 When the clearance adjustment is finished tightly fasten the fixing screw 7 of the bushing c The adjustment of crossing height 2 between the hook stopper upper side and movable knife edge upper side 6 1s possible to certain degree by adjusting the movable knife base washer 2 or by changing the position of movable knife shaft collar S as can be seen in figure 49 Figure 48 27 B Adjusting movable and fixed knife See Figure 49 28 a Like in Figure 49 adjust the position of the fixed knife 3 so that the fixed knife right side edge matches the movable knife inner side edge b The initial assembling position of the movable knife is where the movable knife edge protrudes about 3 mm from the edge of the fixed blade Please check the final fixing of the movable knife initial position on page 29 c The surface adhesion conditions of fixed blade edge and movable knife upper side have huge impact on its trimming capacity Please note the various cases of movable fixed knife surface adhesion conditions on the picture Correcting the adhesive conditions of movable and fixed knives e Like in Figure 49 operate manual trimming movement with color ink on the movable knife edge By checking the ink trace remaining on the movable knife the surface adhesion condition of the movable fixed knives can be tested If the surface adhesion is not very good same
21. e to raise and counterclockwise to lower After finishing the adjustment tightly fasten the fixing nut 4 According to the installation position of knee lifting solenoid the operation noise operation load and presser foot elevation range may differ Please assemble so that the machine will operate smoothly Figure 2 10 SunStar P 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 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 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 Oil supply 1 Installing chip remover magnet Attach the magnetic chip remover 1 that is in the accessory box to the oil fan See Figure 3 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 2 Lubricating the oil fan A Fill the lubricant up to the HIGH mark See Figure 3 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
22. e upper end of the needle closely adhered to the upper side of the stopper hole with the needle groove D facing inward Fix the needle with a fixing screw Figure 20 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 while after the power is switched off Start to work only after the motor has come to a complete stop 2 Removing bobbin and bobbin case Place the needle D in the highest position and then like in Figure 21 open the slide plates 2 on the left and right lift the bobbin holder 3 to remove the bobbin case and the bobbin 5 Figure 21 SunStar 3 Winding the lower thread 1 Winding the lower thread A Push the thread through the hole and wind it from the back to the front of the tension adjusting plate B Bring the thread toward the bobbin 3 and wind the thread around the bobbin about 5 6 times in the clockwise direction C Push the lever so that the pulley will touch the V belt operate the machine D Once the lower thread is wound around the bobbin the pulley automatically pulls apart from the V belt E About 80 of the bobbin should be wound with the lower thread See Figure 22 Figure 22 2 Adjusting lower th
23. ece hut a tuu oadnedte 17 D Rousne uie lower uedd serienn iina ea E E SE 17 E AAO E oe eee ect eee eee 18 6 Routing the upper INR RTT TODO LLLI RR 18 zi diusdms tie Dead eion startet tana ate nant ete MI LUDUM UE e tiene atte b 19 8 Adjusting the height and pressure of the presser foot eren ntetete intente tante tan teta tont 2 9 Adjusting the needle and feed dog timing eene eene tetente tenente intente tenen tan teint 2 10 Adjusting the height of the feed dog aeisi eSEE tente tone tonto ton totos tette to tn 95 11 Adjusting the needle and hook timing eeseeeesereeerereseseressseressseeeenssersnsnersnsneesnsseesnneressnertensnsreesnstensnertesnerensseresesereees 55 12 Clearance adjustment between the upper side of the hook stopper and the upper side of needle plate groove 23 13 Clearance adjustment between the hook and ODener emen 23 14 Operation of needle bar left right stop KM 797 series eene 24 15 Adjusting oil flow in the hook and the face plate eene nen nennen 24 IAE Vok USHA tye the tminn device EE EE etc eee eee ce Tee ee ene ere ee eer 25 17 Replacing movable kiile and fixed blade lt stssciecsessececsesztecyescnenascosetactsensecnscaseeoessses sens seoserascasenressensecarenneeensneeeacte 30 18 Adatas Oe Wiper eseeeseenieussnrsdeucrttestivesiqektsetieniipetdeetisetepuiEnotiosplessiudpiees ted iieptudq escultor Asc gnis Prapssbiente pde 3 19 Replacing the gauge set for needle WIUL esssietiptenapitepii scribentis
24. electrical repair or inspection consult with qualified technicians or agent 8 Adjusting the 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 fastening screw and lift the presser bar lifter 3 Make the distance between the upper side of the needle plate and the lower side of the presser foot 4 7mm Then tightly fasten the bracket fastening screw 2 See Figure 31 Be careful not to turn the presser bar lt about 7 mm 2 Adjusting the tension of the presser foot Turning the pressure adjustment screw to the right Figure 31 increases the presser foot tension and turning it to the left makes it weaker After adjusting make sure to tighten the fixing nut See Figure 31 9 Adjusting the needle and feed dog timing After removing the needle lay down the machine on its back and remove the timing belt Turn the pulley to align the highest position 3 of the pulley s thread take up lever with the position A Then rotate the timing pulley to align the bed base point with the timing pulley s base point Hang the timing belt in this position After adjustment when the feed dog amp comes down and the needle 9 goes up check whether the needle tip 9 matches the needle plate upper side at the moment that the feed dog upper side and the needle plate upper side 0 match each other See Figure
25. finger guard and safety devices Before threading changing bobbin and needle cleaning Caution etc switch off main switch amp J g BEH HAZ 830 AtSotAl DIHAL Al tdHl HE n HIU StAAHE BCA SAMBO AALE H FAAI 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 je ASO Sol AME Boose HHE SHE AHS ugl H4 S078 27 LIM 36022 JOE UHAI Specification 1 Sewing machine Ww weno Meme High speed two needle drop feed needle feed standard hook sewing machine with automatic thread trimmer 470 motor 6 KM757BL7N High speed two needle drop feed needle feed double hook sewing machine with automatic thread timmer 470 motor 8 _KI 797 78 Highspeed two needle each drop feed needle feed standard hook sewing machine with automatic thread timmer Servo moto 9 KMT97 N High speed two needle each drop feed needle feed standard hook sewing machine with automatic thread timmer 470 motor Model Name KM 757 KM 757 7S KM 757 7N KM 757BL KM 757BL 7S KM 757BL 7N Usage sid General to heavy material Max sewing speed 3 000 SPM Max no of stitches Needle bar stroke 33 4 mm 7 mm Feed dog height 1mm Presser 15mm BUMP er ef 1 tm DPx5 14 11 22 DP x5 22 11 22 Automatic lubrication 1 6mm 8mm use Caner ncaymaterl presser Mawai fm Eo
26. k linking rod to the left so that there is no excess room in each linking device When this is done the roller gets to adhere to the right side of the cam s complementary straight line as can be seen in the picture 2 While maintaining this position adjust to make the movable knives on the right and the left protrude about 3mm from the fixed blade edge Now tightly fasten the crank fixing screws on both sides If the initial position of the movable knives of both sides are to be adjusted slightly use the ball joint linking bar 0 If only the movable knives are to be adjusted use the linking rod Trimming cam lead i trimming starting point of movable complementary U7 finish point knife movement E Movable knife initial assembling position straight line Figure 50 D Adjusting lower thread holder See Figure 51 The position of lower thread holder 1 is set by fixed blade and bolt Like in the picture loosen the bolt and place the lower thread holder D edge at the lower side of the movable knife D about 8mm apart from the movable knife edge Make sure to check that the right and left upper sides of the lower thread holder is tightly adhered to the lower side of the movable knife Figure 51 29 4 Checkpoints on the assembling status of other trimming devices A Check the starting point of the movable knife when the trimming action takes
27. method is used to adjust the tension of movable fixed knives please use the following methods adjusting the amount and position of the washer in the lower side of the movable knife base horizontally adjusting the assembling position of movable knife shaft collar and correcting the shape of fixed blade 9 setting position Checking the surface adhesion C x Apply color ink on the upper side of the movable knife edge n n w Q good bad bad NSE Figure 49 SunStar C Final fixing of the movable knife s initial position See Figure 50 The standard initial assembling position of the movable knife is where the movable knife edge protrudes about 3mm 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 Manually turn the pulley to finish trimming of the trimming cam Place the cam so that the roller can enter the complementary straight line p Slightly loosen the fixing screws of movable knife shaft crank of both the left and the right Press the trimmer shake linkage to enter the roller inside the cam Push the linking bar 9 to the right or the left cran
28. ngth after trimming is too short upper thread on the control box Lower thread holder After trimming lower thread holder does Adjust the location and tension of the not hold the lower thread lower thread holder Check the up stop Due to problems in the up stop position Readjust the needle s up stop film position of the needle of the needle the thread take up lever position Upper thread falls out when starting to sew or sewing is skipped pulls the upper thread out of the needle when the sewing starts Check the oil felt tension The upper thread oil felt is pressing the Adjust the felt tension of upper thread thread too strongly 33 The gap between the The height and distance between the Readjust the movable knife setting movable knife and the movable knife and the hook do not match position hook Check the tension of Tension and contact of movable and Correct the tension adjustment and fixed knife fixed knives are bad surface contact of movable and fixed 5 Trimming miss knives Direction of the needle Needle is not inserted correctly Insert the needle correctly Blade side of movable Scratch and abrasion of movable and Replace movable knife or fixed knife and fixed knives fixed 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 t
29. on page 13 Figure 18 14 SunStar 10 Reverse button function automatic thread trimmer 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 up down position of the needle bar by pressing the reverse 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 Figure 19 needle bar in a low position In short the button delivers two functions one for reverse sewing and the other for converting vertical position of the needle See Figure 19 jh MEMO 15 Adjustment of the Machine 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 automatically and can result in physical injuries Qo 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 the needle As in Figure 20 place th
30. place Operate trimming movement manually to check whether the thread take up lever is in the lowest or at least 2 5 mm raised level when the movable knife starts working like in Figure 52 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 oil stone or sand paper See Figure 53 OIL STONE 17 Replacing movable knife and fixed blade See Figure 54 1 Lift the presser foot 1 and open the slide plate lefts right and front 4 2 Disassemble the needle plate 5 3 Loosen the fixing screw to disassemble the washer 7 fixed blade 8 and lower thread holder 9 4 Loosen the fixing screw 0 and dissemble the movable knife 1D x To assemble follow the reverse order of disassembling 30 0 2 5mm Point where the movable knife starts its Thread take movement up lever s lowest point Figure 52 SAND PAPER Figure 53 Figure 54 SunStar 18 Adjusting the wiper about 0 3 mm about 0 3 mm Figure 55 1 Set the needle at the up stop position at the needle position on the control after trimming 2 Set the stitch length at dial 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 Q
31. r in the control box once a week If possible keep off from the strong electronic wave like a high frequency welding machine Always start the machine with safety covers in place since fingers or hands could be injured or cut off by the belt Turn off the power switch during check ups or adjustments Warning Safety Label Suggestions while running the machine are stated D Thread take up spring cover the device to prevent the human body from touching the thread take up spring C Belt cover the device to prevent hands feet and clothing from getting jammed by the belt Q Finger guard the device to prevent fingers from contacting the needle PETTE BYU gt 009990 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 AN PUN A Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off main switch i 1 gR fe as a2 agana 20 es sv BY 0009 99 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 Jer MFO A 2 88 ea 7 g We AAS deu AA ESOS LIA 36047 EE S OAA 1 7 Content of Caution CAUTION IA a i Do not operate without
32. read a If the lower thread is not being wound evenly loosen the screw 6 and adjust it by moving it left and right Then tighten the screw again b The lower thread is wound more if the adjusting screw is turned clockwise and less if turned counterclockwise c The tension of the lower thread being wound around the bobbin becomes tighter if the nut is turned clockwise and looser if turned counterclockwise 4 Routing the lower thread Applicable model Applicable models e KM 757 MET e KM 797 e KM 757BL Bc e KM 797BL e KM 757 78 iS Zee KM 79778 e KM 757 7N ENG e KM 797 7N E C B 1 Insert the bobbin D into the hook 1 Insert the bobbin D into the bobbin case For KM 757 7S and 2 Insert the thread through A part of the hook and pull KM 97 7N it is crucial to insert the bobbin in the turning direction as it out from the end of the lower thread tension adjustment in the picture plate 2 Insert the thread through A part of the hook and pull it out 3 The adequate length of the pulled out lower thread is from the end of the lower thread tension adjustment plate 3 50mm 3 Pass the pulled out thread through B and C of the bobbin case 2 as can be seen on the picture and hang it onto the lower thread holding spring Then pull it out through the thread hole 4 The adequate length of the pulled out lower thread is 50mm Applicable models Applicable models 50
33. rectis ti ere RUE ete ui pSEH ers eee n as pesqetob spi eiq 25 4 Causes of trouble and troubleshooting 1 Sewing machine troubleshooting MPO 33 5 Table drawing C 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 Instructions here shall be observed strictly Otherwise the user will be killed or suffer severe physical injuries Instructions here must be observed or the user could suffer fatal or severe physical injuries Instructions here should be observed or the user could face physical injuries or mechanical damages The meaning of symbols This symbol means a must not This symbol means a must for safety This symbol means that an electric shock may be caused if the instruction is not followed properly 1 1 Machine mobilization 1 2 Machine Installation Caution 1 3 Troubleshooting SunStar Only personnel with a full understanding of the safety rules should move the machines The following directions must be observed when delivering the machines 8 At least two persons should work together b In case the machine should be transported please wipe the
34. rimming timing Opening of the thread The opening on the thread tension Adjust the thread release stroke tension adjusting plate control plate is too small Tension of auxiliary Too strong tension on the auxiliary thread Adjust the tension of the auxiliary thread thread tension tension control assembly tension control assembly adjustment assembly Thread take up stroke Thread take up stroke is too large Adjust the thread take up stroke Thread release Volume is adjusted to too low Increase the volume adjustment adjustment volume on the control box Too short thread length after trimming 34 w 315 805 80 SunStar an fe i Of 917 Clutch Motor Mounting Hole j r Hole thru Head Rest Hole i ia T 66 0 2 33202 33 in eee a ZZZ Ly Ss Va B Treat keeping rack color j same as table color LEZZZZZgZZ2 22 i Q SECTION B B Draw SECTION A A Table 35
35. tight upper thread tension Reduce the tension of upper thread 2 Poor thread 3 adjustment Lower thread tension Too loose lower thread tension Reduce the tension of lower thread Too large stroke Adjust the stroke level There is a scratch on the hook edge Remove the scratch on the hook edge There is a scratch on the needle hole of Remove the scratch on the feed dog the feed dog There is a scratch on the thread case Remove the scratch on the needle plate and around the needle plate Upper and lower thread tensions are bad Adjust the upper and lower thread tensions Thread take up spring Thread take up spring tension is Adjust the thread take up spring tension tension inadequate Gap between opener and The gap between the opener and hook is Adjust the gap between the opener and hook inadequate hook Direction and height of Needle is inserted into wrong position Reinsert the needle correctly and push in to its highest level needle Needle Needle is bent Change the needle Wrong direction Insert the thread in the right way Thread take up stroke Hook Feed dog Needle plate Thread tension Threading Hook timing The timing between the needle and hook Adjust the timing between the needle and is bad hook Gap between the needle Needle and hook are too far apart Adjust the position of the hook and the hook Remaining upper thread The length of the remaining upper thread Increase the adjustment volume of the le
36. ure 26 turning the tension adjustment nut of the thread tension control assembly clockwise makes the upper thread tension stronger and counterclockwise makes it weaker Figure 26 2 Adjusting the lower thread tension Like in figure 27 turning the tension adjustment nut 1 of the hook clockwise makes the lower thread tension stronger and counterclockwise makes it weaker Figure 27 19 20 3 Adjusting the tension of thread take up lever spring A Adjusting the thread take up stroke As in figure 28 loosen the stopper fastening screw D and turn the thread take up lever s spring stopper Se y H7 I p en 4 Y 2 clockwise to make the stroke smaller and counter clockwise to make it bigger The thread take up stroke is normally 5 10mm B Adjusting the thread take up tension As in figure 28 loosen the screw 3 of the thread tension control assembly and insert the driver into the groove of the thread tension control assembly Turn clockwise to make the spring tension stronger and counter clockwise to make it weaker The thread take up spring tension is normally 30 70g Figure 28 4 Adjusting the thread release stroke for automatic trimming type If the upper thread falls out from the needle hole after trimming check whether the plate 1 opens while the trimming is in action For the adjustment of plate opening level put the solenoid in action and adjust by moving solenoid coll
37. ure to put back the space washer that was used originally The thickness of the washer may differ by machine Y NAN Ng Pa Bi e Figure 39 13 Clearance adjustment between the hook and opener Loosen the opener fastening screw and adjust the opener 2 to the right and left so that the distance between the hook D and the opener is 0 2mm when the opener is pulled to its max towards the arrowed direction See Figure 40 Figure 40 23 14 Operation of needle bar left right stop KM 797 Series 1 When stopping the left needle bar Place the needle bar trimming direction lever to the L left position Stop 2 When stopping the right needle bar Place the needle bar trimming direction lever to the R right position Stop 3 When switching to two needle sewing Vertically press the needle bar return pressing plate The needle bar trimming direction lever will return automatically x The needle bar trimming direction lever can be used even during operation However don t use this function when the needle bar is in the highest position It works safely from the point when the needle bar is about 3 mm below the highest point Figure 41 15 Adjusting oil flow in the hook and the face plate 1 Hook oil level check Check whether the amount of oil sprinkled from the Non oxidized oil hook for 10 seconds is as is on Figure 42 To adjust the amount of oil suppl
38. y turn the oil supply screw on the hook base to the right to decrease the oil supply and to l l l White paper the left to increase the oil supply See Figure 42 2 Face plate oil level check Figure 42 If there is excessive or insufficient amount of oil QD Q provided to the face plate from the thread take up lever hinge pin loosen the face plate oil level adjustment screw fixing nut and adjust the face plate oil level adjustment screw D After adjustment tighten the fixing nut See Figure 43 Figure 43 24 SunStar 16 Adjusting the trimming device 1 Adjusting the trimmer driving part A Fixing the position of trimming cam See Figure 44 a Turn the pulley with hand to place the needle bar at its lowest position b With the left side of the trimming cam D softly attached to the right side of the lower shaft medium bushing turn the cam to align the base point 3 with the carve in the lower shaft medium bushing crank c Fasten tightly the trimming cam fixing screws 3 Figure 44 5 Now turn the pulley with hand to see whether or not the machine turns smoothly B Adjusting the stopper pin holder See Figure 45 a Once the necessary trimming for trimming cam lead is finished make sure to turn the machine pulley to place the trimming cam 3 in the right position so that the roller can enter the complementary straight line range b Press down the trimmer shake linkage
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