USER`S MANUAL
Contents
1. USER S MANUAL KM 235A B High speed single needle lockstitch sewing machine with automatic trimming devices With FORTUNA AC SERVO MOTOR 1 FOR AT MOST USE WITH EASINESS PLEASE CERTAINLY READ THIS MANUAL BEFORE STARTING USE FOR REFERENCE WHEN THE MACHINE BREAKS DOWN 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 CO LTD Safety rules for machines esis ashe detec ceases espace sss eee 4 1 Specifications Dy SO WI TAC NNG sann e sana yauasaucaavassiaasneasnesanecsaeasnactacasaacssanonissasesasavacnannsds asbansdnsbans O 8 2 Controller OF Servo MOO ruik cesses eee una i aka aus 8 j Peripheral automaton devices op ronal sisene ann E E Q auqa aaa akasikia atas 8 2 Installation Pisali orot hemn2. H H H I H H H i h H H H I i H i H H H H Hy H H H 4 03 CENTER base Keeping Rack Installation Place I lt Treat keeping rack color same as table color SECTION B B 4 TABLE DRAWING 25
3. Refrain from running the machine in the vicinity of risky places e g where a large quantity of aerosol spraying products or oxygen are handled unless specific guarantees are given otherwise for the operation of the machine to prevent explosion at such places The user should install an illuminator in the work area for the machine does not come supplied with any lighting apparatus due to the specific features of the machine Note Details of the machine installation are laid out in No 2 Installation When the machine is in need of repair only our authorized service technicians must handle it Before cleaning and repairing the machine shut off the power supply and wait four minutes for the machine to discharge completely 6 No part of the machine or specifications may be modified without prior consultation with our company Any such modification could risk safe operation of the machine In case of repair replace only with standard OEM parts from SunStar After repair put safety covers back on the machine 1 4 Machine operation Caution 1 5 Safety device Caution KM 235 Series are intended to be used for industrial purposes for sewing textiles and other similar materials Carefully study the following instructions before operating the machine Read the manual thoroughly and understand the instructions fully before use b Put on proper safety garments While the machine is in motion keep your hands or a
4. arm when the needle has stopped in the air That adjustment can be made by loosening the pulley s clamp screw A 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 E on the side with N D carved signs and moving it sideways See Figure 7 amp 8 Figure 7 Figure 8 12 7 Checking stop position of the sewing machine Press the button 2 to operate up down position of the needle and check the stop position of the machine When the needle stops in up stop position check if the end surface of the needle bar rear bushing and the carved mark at the lower end of the needle bar come within 0 2mm range Inaccurate stop positions can cause malfunctions in trimming function Be sure to adjust the photo film position of the synchronizer The needle up stop position and the needle bar stop position after trimming must be the same to ensure proper trimming timing Refer to Figure 14 Refer to synchronizer adjustment method on page 13 8 Functions of button Press the button during forward sewing to immediately perform reverse sewing To begin reverse sewing from the start stop the sewing machine and press the pedal while pressing the button and run the machine by pedaling You can change up down position of t
5. hinge into the bed hole and press it well with the rubber hinge Place it in an upright position on the rubber cushion at the corner as shown in the figure Refer to Figure 1 at 2 Installation of the knee lifting solenoid and the power switch box Table x Refer to the assembly position map in the knee lifting solenoid box VR Figure 1 A Attach the solenoid onto the table Loosen the fixing screw to bring the center of the middle connecting rod and the center of the solenoid shaft to form a parallel with the lower side of the table After adjustments firmly tighten the fixing screw Refer to Figure 2 B Loosen the fixing nut and turn the middle connecting rod in a clockwise direction to increase the lifting and turn it counterclockwise to decrease the lifting Figure 2 Firmly tighten the fixing nut after adjustments p Do not connect the power plug before lubrication is complete If the user mistakenly steps on the foothold the machine will start automatically and can cause physical injuries p When handling lubricants put on protective glasses or gloves to avoid contact with eyes or skin Otherwise inflammation can be caused Do not drink lubricants to prevent diarrhea and vomiting Be sure to keep the lubricants out of the reach of children p Be sure to feed oil when using the machine for the first time or when the machine has been left unused for a long time 3
6. operate the 0 5 1mm thread release Check if the thread guide dish of the thread adjusting device opens 0 5 1mm Make sure that the thread guide dishes coincide with each other after operation The stroke of thread release lever is 5mm Adjust so that when the cable wire is pulled 0 2mm the thread guide dish does not open and opens only when Figure 21 the cable wire is pulled 2 Smm Refer to Figure 21 9 Adjusting presser foot height and pressure A As described in Figure 22 take out the rubber cap of the faceplate Place the presser foot on the needle plate Loosen the screw of presser bar handle to adjust the height of the presser bar handle When the presser bar handle is lifted up the height of the presser foot will go down and when brought down the height will go up Run the presser foot lifter manually to lift the lower side of the presser foot 5 5mm off of the upper side of the needle plate y B As shown in Figure 22 turn the pressure adjusting Pe dep te I m screw clockwise to increase the pressure of the Figure 22 presser foot and turn it counterclockwise to decrease the pressure After adjustments make sure to tighten the fixing nut 17 10 Adjusting stitch length As illustrated in Figure 23 the number on the stitch adjusting dial shows the stitch length in mm Turn left and right to get a desired stitch length The stitch length will decrease when
7. spring Turn the tension adjusting screw clockwise to raise the tension of lower thread and turn it counterclockwise to reduce the tension Adjust the dropping tension of lower thread so that when you hold the end of the thread and drop the bobbin case the thread can come out only by a small margin due to weight Refer to Figure 17 B How to install separate the bobbin caseHold the bobbin case handle and insert it into the hook When taking out the bobbin hold the handle and pull The bobbin will come off when you let go of the handle Refer to Figure 17 p When routing upper thread turn the power switch off If the user mistakenly steps on the foothold the machine will start automatically and can cause injuries gt The clutch motor will continue to run for a while due to inertia even after you turn the power switch off Be sure to work with the sewing machine after the motor comes to a complete stop 7 Routing upper thread With the thread take up lever at its highest position route upper thread in sequence as shown in Figure 18 The appropriate length of upper thread dropping from the needle hole during initial sewing is 50mm Refer to Figure 18 Figure 18 8 Adjusting upper thread A Mann thread adjusting device Turn the nut of thread adjusting device in a clockwise direction to increase the upper thread tension and turn it counterclockwise to weaken the tension As tension adjustment
8. turned clockwise and increase when turned counterclockwise Figure 23 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 p When adjusting the machine with the switch on be sure to pay extreme caution p Only trained engineers must perform troubleshooting or inspection of the machine p For electrical repair or inspection consult with qualified technicians or agent 11 Adjusting feed dog height and inclination X Back a Front Clockwise direction Maximum height Back pes Front B as Front AG ay ron Counterclockwise direction 7 Figure 24 A To adjust the height of the feed dog unfasten the screw of the holder crank unit and move the holder crank unit To adjust the height set the stitch length at a maximum and lift the feed dog to the highest position At this point the standard height from the faceplate of the needle plate and the end of the feed dog should be 0 8mm for light sewing materials 1mm for medium heavy and 1 2mm for heavy sewing materials Refer to Figure 24 B To adjust the inclination of the feed dog loosen the screw of the horizontal pusher crank Use a driver to turn the inclinati
9. 7 if the bobbin catcher returns smoothly after trimming Figure 38 18 Adjusting the wiper As shown in Figure 39 loosen the wiper holder screw to bring in parallel with the left surface of the presser foot Assemble so that the lower side of the presser bar bushing is 13 5mm apart from the upper side of the PESSE par wiper holder as shown in Figure 40 Manually run the wiper and set a clearance between the lower side of the wiper and the gap in the upper side of the presser foot at i Presser foot Imm Fix with the screw By using two wiper shaft screws set a clearance of Figure 39 igure 2mm between the right side of the wiper and the left side of the presser foot when the wiper is not in motion Tighten with screws after adjustments Wiper holder Figure 40 22 SunStar ME CAUSE OF TROUBLES AND TROUBLESHOOTING 1 Sewing machine troubleshooting Direction and height Needle is inserted into wrong position of needle Needle is bent Change the needle Reinsert the needle correctly Bad timing of feed dog Adjust the timing of feed dog Needle breaks Ascending level of Bad timing of needle and hook Adjust the timing of needle and hook needle bar Height of needle Bad timing of needle and hook Adjust the timing of needle and hook Gap between needle Bad timing of needle and hook Adjust the timing of needle and hook and hook Direction a
10. Lubrication A Installing a magnet for removing metal chips Place the chip removing magnet from the accessory box onto the oil pump inside the bed Refer to Figure 3 Do not use the magnet for other purposes Operating the machine without the magnet can cause malfunctions Use the magnet to ensure durability of the machine B Feeding oil to the oil pan a Feed the oil to the HIGH mark Refer to Figure 4 b Be sure to use the oil for SunStar industrial use sewing machines or TELLUS C10 from SHELL c When the oil is down to LOW level during operation immediately fill up the oil to HIGH level d Replace oil at least once every two weeks 10 Oil pump Figure 3 Figure 4 4 Adjustment of belt tension After the motor is installed unfasten fixing nuts and to give tension to the belt generated by the weight of the motor At this point fasten the fixing nut and fixing nut Q consecutively Refer to Figure 5 5 Installation of the program unit A Fix the attachment plate Q on the program unit with three fixing nuts B Mount the unit firmly onto the machine head with two fixing bolts Refer to Figure 6 SunStar Figure 5 Figure 6 11 6 Assembly and adjustment of the synchronizer 1 For 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
11. aper away from peripheral feeding devices in order to prevent injuries 4 Adjusting the oil supply of thread take up unit As shown in Figure 15 the level of oil supply will increase when a dot Q in the lubrication adjusting pin Q aligns with the center hole of the thread take up lever crank shaft When you adjust the dot closer to a carved dot in the link cam the level of oil supply will decrease Also no oil will come out when you adjust the carved dot to move pass the carved dot The left right adjustment range of the lubrication adjusting pin is 90 Figure 15 5 Adjusting the oil supply of the hook As shown in Figure 16 the level of oil will increase as you turn the screw Q inserted in the lower shaft front bushing in a clockwise direction Turn it counterclockwise to reduce the oil supply Figure 16 p When adjusting lower thread tension be sure to turn the power switch off lf the user mistakenly steps on the foothold the machine will start automatically and can cause injuries gt The clutch motor will continue to run for a while due to inertia even after you turn the power switch off Be sure to work with the sewing machine after the motor comes to a complete stop 6 Placing lower thread and adjusting tension Figure 17 15 A Insert the bobbin Q in the bobbin case Insert thread into the thread groove and place it under the tension adjusting plate
12. ch motor will continue to run for a while due to inertia even after you turn the power switch off Be sure to work with the sewing machine after the motor comes to a complete stop Inserting a needle With the groove of the needle facing inwards press the needle tip against the upper side of the stopper hole Fix the needle with a tightening screw Refer to Figure 13 Adjusting a needle bar As shown in Figure 14 take out the rubber cap of the needle bar adjusting hole in the faceplate Turn the pulley to bring the needle bar to its lowest point and loosen the screw of the needle bar holder Adjust the needle bar to bring the lower side of the needle bar rear bushing to align at a carved mark where the lowest point of the needle bar comes to Then fix firmly with the screw and cover with the rubber cap Timing adjustment of the needle and hook As shown in Figure 14 align the lower side of the needle bar bushing with a carved mark in the needle bar Loosen three screws of the hook Turn the loose hook to align the upper tip of the hook with the needle center Set the distance from the inside of the groove to the upper tip of the hook at 0 05 0 lmm Re tighten with the three screws Figure 13 LC O gt O O 0 05 0 Imm Figure 14 SunStar p When checking lubrication of the thread take up unit and the hook keep your hands or oil check p
13. ctions 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 mark means a must not This mark means a must for safety This mark 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 At least two or more people should move the machine 6 Before delivering the machine thoroughly wipe off the oil on the machine to prevent accidents Physical damages such as functional difficulties or breakdowns may occur depending on installation conditions of the machines Be sure to heed the following conditions Remove the packing from top to bottom Watch out for nails on the wooden box b Install a climate controller and clean it regularly to prevent dust and moisture build up from contaminating and corroding the machines Keep the machines away from direct sunlight Keep a minimum distance of 50cm between the machine at both sides and backside and the wall to secure sufficient space for repair Do not operate the machine near areas with danger of explosion
14. e a ua anu a a tn sus aaa ae ua asan 16 9 Adjusting presser foot height and pressure 17 TO Adusi stik MEM OU uu y uu uu u umu uu Nuu a miu utana haah kunasa 526 18 11 Adjusting teed doe heisht and IMC Man hs u nun un aaea aa E E 18 V2 ANCjuSting th feod ui l kataka haapa mau aqna 19 13 Timing adjustment of trimming devices a 19 14 Tension adjustment ot th lix edbladeuup n u uu u texte adnate adn sels desks sce aia ase cate a a 21 15 Replaciie ne movable Dlad uuu uu l aa pn E E EA 21 TO Replacing the fixed Dade uuu uuu uu y uy uuu SSS kau uu m a um ks 21 1 ACMSHne thie DOD DIN CAlCNCE au ited sa isustis teases Mestalla bass had aasma auqa 22 1S Ad ustim the Wiper ceea A e E au E R 22 4 Cause of troubles and troubleshooting Ly Sew ihe machine troubleshootine sraa a uD nn aa saa 23 5 Table drawing scoot e ana aaa ispa a a aspas 25 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 Instru
15. e carved dot of the lower shaft middle bushing in the bed with the location dot of the trimming cam Tighten with two fixing screws Refer to Figure 26 B Fixing the B position of trimming drive gear a As shown in Figure 27 check how the trimming drive anes gear B is inserted into the stopper lever b With the stopper lever pressed against the stopper rubber of the stopper loosen two fixing screws c Move the trimming drive gear B and adjust the stopper up and down in order to align the thread release drive lever with the carved line of the trimming drive gear B Tighten two fixing screws firmly while the baselines are aligned with each other Figure 27 19 d After adjustments operate the trimming cam Q to OB see if the front side of the assembly gear is Trimming drive gear 0 5mm from the front side of the first gear of the B trimming cam Refer to Figure 28 Figure 28 e When the trimming cam Q is not in operation also check if the two gears Q are 1mm apart from each other as shown in Figure Refer to Figure 29 Figure 29 C Adjusting the operating amount of the movable blade a When the needle begins to rise from its lowest point by turning the pulley forward press the solenoid shaft With the shaft pressed in turn the pulley to bring the trimming drive gear B against the trimming cam gear When two
16. e ie k 02 ETEA A u aun DSDOSTDLOS DEDI ASS 9 2 Installation of the knee lifting solenoid and the power switch box 9 SVLADA ON aE ak aa amalan a Re TO Ere ST ae Q asna has 10 qA djastmoentol DCI TCM SION waite k u uu u u Nanas csaeesd asda taesnea ae ae a aes 1 J lns allatiomotr The pro ram WIIG Sg ah eatesle tasessleteursevusdeaen dacs aa a a a baaaie enei 11 6 Assembly and adjustment of the Synchronizer ua u asa a dees E EEEE E 12 7 Checking stop position of the sewing machine uay n u R EE E 13 5 Funcions of DUON D saseta ranni E EEEE EE saka 13 P Oa O li OI oaa aa TO TE T ONSA 13 3 Adjustment of the sewing machine piikerrin r a K umu 2 unus uuu uuuwimuaunihahaka a sunak skua ieee asas qat 14 2A US UN AMC IG b pa u a a a rtnctnn Dus deals da seals kaa aus ias ua quas aa 14 3 Timing adjustment of the needle and hook 14 4 Adjusting the oil supply of thread take up uni t 15 5 AGusinehecolsupplyof the MOOK uuu utu E r ee eii aia a 15 6 Placing lower thread and adjusting tension 15 JY ROUE UP Per cad ees aiaa span anhaaan asas aa 16 o justinoemppeonihr
17. fore running the machine CAUTION Location of caution mark a A Do not operate without finger guard and Safety devices Before threading changing bobbin and needle cleaning etc switch off main switch AMS Hot WNBA HO ASoral OAS Al HIE BETH AMIE HCA HAA AAE J AAA CAUTION a iu 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 To MEO ls 444 oong 7 H 2 Me AHS fen AA s41 Lute i 360471 7 Chel ALA 1 7 Contents of Caution mark CAUTION IN lt x Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off main switch SJS SS hot COLMA BO AtSotAl Di SAI a Hl Hi ulzSH LI SAMA FHH AALE JH FAHA Caution 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 Us ASO A Zaz SISS HH g he HAs WHW AS Shs mm T 36072 JICE UHAI I SPECIFICATIONS 1 Sewing machine Application For light and medium heavy materials For heavy materials 5 500 SPM a 500 SPM Maximum number of stitch Needle used DB x 1 14 ET 8 2 Controller of Servo Motor 3 Peripheral automation devices Name of option Application Auto knee lifting system SPF 2A Solenoid structure The presser foot lifts automatical
18. he needle bar by touching the button while the machine is in the stop mode When the needle bar is in its down stop position touch the button once lightly to change to up stop position When the needle bar is in its up stop position press the button twice within a second to change to down stop position The button can perform both reverse sewing and changing needle up down Refer to Figure 14 9 Functions of button SunStar Needle bar rear bushing Carved mark for needle bar up stop Button Button Figure 14 When you select the back tack function in the program unit and start sewing after pressing the button once as shown in Figure 14 the back tack function will not start but instead forward sewing will begin When you want to do back tack during sewing stop the machine and press the button once and start sewing then the back tack function as initially set in the program unit will begin When trimming is done after end back tack work stop the machine press the button once and start trimming The trimming function will begin without having the end back tack work performed beforehand Button for arbitrarily inserting deleting back tack 13 ADJUSTMENT OF THE SEWING MACHINE 1 2 3 p When installing a needle be sure to turn the power switch off If the user mistakenly steps on the foothold the machine will automatically start and can cause injuries p The clut
19. ly by 1 step backward pedal movement 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 edge sensor SEDG material to stop the machine without manual pedaling Available SEDG 2A in two types SEDG 1 for edge sensing type and SEDG 2 for thickness sensing type A device needed when only one operator runs several sewing machines Standing pedal SPDL 1 Pedals for acceleration thread trimming presser foot and ascending are SPDL 2 built separately Two types SPDL 1 and EDPL 1 for fixed speed type and SPDL 2 and EDPL 2 for adjustable speed type are available SunStar Pl INSTALLATION p The machines weigh over 35 kg As such two or more people should carry out the installation p Plug in only after the installation is complete If the operator mistakenly steps down on the pedal with the plug in the machine will start automatically and can cause physical injuries gt Connect the ground earth wire An unstable connection may result in an electric shock or a malfunction p Use both hands when bending the machine backward or returning it to the normal position Using only one hand can lead to physical injuries due to the weight of the machine 1 Installation of the machine head x Insert the head
20. nd height Needle inserted in the wrong of needle Insert the needle correctly position Upper thread tension Too tight upper thread tension Reduce tension of upper thread Lower thread tension Too loose lower thread tension Reduce tension of lower thread Operating capacity of take up lever spring Loose upper thread Adjust take up lever spring Threading method Wrong threading Thread the needle correctly Bent needle or broken needle tip Change the needle 2 Thread breaks Ascending level of Wrong timing of needle and hook Adjust the timing of needle and hook needle bar Height of needle bar Wrong timing of needle and hook Adjust the timing of needle and hook Gap bet ae 7 imi ap between needle Wrong timing of needle and hook Adjust the timing of needle and hook and hook Direction and height a Reinsert the needle in the right Needle inserted into wrong position _ of needle direction Bent needle or broken needle tip Change the needle Threading Thread passing at wrong position Thread the needle correctly 3 Stitch skips 23 as eNO PUPPEN reag Adjust the thread adjusting device Due to bobbin racing during Racing proof spring trimming lower thread dropping Change the racing protection 3 Stitch skips of bobbin case from bobbin case becomes too spring short to go up Unable to lift lower thread due to Adjust the working capacity of take weak take up lever spring u
21. ny part of your body away from moving parts e g needle hook thread take up lever and pulley etc Do not remove any form of safety covers while the machine is in use Be sure to connect the ground earth wire Before opening electric boxes such as the control box shut down the power supply and make sure the power switch is in off mode Stop the machine before threading the needle or checking after sewing work is finished D Never turn the power switch on with the pedal down Do not use the machine if the cooling fan is clogged Clean the air filter embedded in the control box at least once a week Keep the machine away from strong electromagnetic fields such as high frequency welding machines Always start the machine with safety covers in place since fingers or hands could be injured or cut off by the belt Turn off the power switch when conducting a regular check on the Caution machine Safety label Safety instructions for machine operations b Thread take up lever cover A device designed to prevent the human body from coming in contact with the thread take up spring Belt cover A device intended to avoid potential risks of getting hands feet or clothes jammed by the belt Finger guard A device built to keep fingers away from the needle SunStar 1 6 Location of Caution is attached on the machine for safety Read the directions of caution caution mark carefully be
22. of thread varies by TT Wa ANL A Z lt IK SS material type thread the number of stitch and other sewing conditions be sure to adjust the tension I gt A ZZ bha VII FA properly Refer to Figure 19 r CCC ESS SE ESS B Tension adjustment of thread take up spring Use a driver to turn the groove Q at the tip of the thread Figure 19 adjusting device shaft Turn it clockwise to increase the tension of the thread take up spring and turn it counterclockwise to decrease the tension See Figure 19 16 SunStar C Auxiliary thread adjusting device Turn the auxiliary thread tension adjusting nut clockwise to shorten the thread remaining in the needle after trimming Turn it counterclockwise to lengthen the remaining thread The appropriate length of upper thread that remains in the needle after trimming is 30 40mm See Figure 20 Figure 20 D Adjusting the operating amount of thread release The thread release function starts simultaneously with the movement of trimming cam As shown in Figure 21 move the thread release wire Q connected to the operating lever left and right to adjust the operating amount of thread release Loosen two fixing nuts bring the cable wire to the left and fix the nuts to increase the operating amount of thread release Bring the cable wire to the right and tighten the nuts to decrease the amount After l Opening amount adjustments firmly tighten back the nuts and
23. on adjusting shaft left and right up to 90 Turn the shaft clockwise to raise the rear of the feed dog and turn it counterclockwise to raise the front of the feed dog Refer to Figure 24 C The height of the feed dog changes as the inclination is adjusted Adjust the height of the feed dog afterwards SunStar 12 Adjusting the feed cam As shown in Figure 25 turn the pulley by hand to lower the end of the feed dog When it aligns with the upper side of the needle plate Q adjust the upper end of the needle hole of the needle to align with the upper side of the needle plate Q Also at this point the upper shaft carved line and the carved dot of the feed cam A will come in alignment with K as shown in Figure 25 Afterwards adjust the feed cam A and C by bringing the carved dot of the feed cam C and the upper shaft carved line in alignment with D At this point when the standard feed cam adjustment is complete the center of no 2 screw of the feed cam A and the center of no 1 screw of the feed cam C will have come in alignment Depending on the type of sewing materials however the center of no 2 screw and that of no 1 screw could be slightly off from a straight line Feed cam C Feed cam A Figure 25 13 Timing adjustment of trimming devices A Turn the pulley by hand to bring the needle bar accurately to its lowest point Bring th
24. p lever spring Upper thread Too tight upper thread tension Reduce tension of upper thread PO ORINK Too loose lower thread tension Increase tension of lower thread Lower thread Too weak upper thread tension Increase tension of upper thread OS sr x Too strong lower thread tension Decrease tension of lower thread Tension not aligned between Adjust tension of movable and fixed movable and fixed blade Take up lever spring Tension of fixed blade Edge of movable and Abrasion in blade groove of fixed blades movable and fixed blade Direction of needle Wrong needle insertion Reinsert the needle correctly Check crossing between trimming cam scales and blades Replace movable and fixed blade Trimming errors Insufficient crossing between the Set the stroke of the movable and fixed and movable blades the fixed blades Too tight upper thread tension Adjust upper thread tension Needle is too thick for the thread Check the needle thickness Upper thread comes off when sewing starts Check the needle up stop position The thread take up lever pulls out the thread due to too high needle Set the needle up stop position up down position 24 w tutal 4 3 CENTER base tr 2 99 915 DP30 entrance C1 635 THRU Cable Hole inp q ee eee 2 s ee H i f H 1 t H i f f H H H H H H H H H H H H H H H H H H H H Hy H H H
25. points on the trimming cam come to align with the carved point of the lower shaft middle bushing as shown in Figure stop the rotation of the pulley immediately The trimming lever screw should be unfastened as shown in Figure 31 b At this point press down the connecting link in Figure 31 When the cutting edge on the hill of the movable blade goes 1 1 5mm farther than the Figure 30 fixed blade upper tip fix the trimming lever screw 3 The stroke of the movable blade at this point is equivalent to the stroke when trimming begins Movable blade Fixed blade Figure 31 D Position setting of the safety device cam As shown in Figure 32 align the carved mark on the safety device cam with the carved mark on the outer part of the trimming cam Firmly tighten two screws 8 14 Tension adjustment of the fixed blade Loosen the fixed blade tension nut Q with a wrench box and unfasten the tension screw When the upper tip of the movable blade moves to align with that of the fixed blade as shown in Figure 33 adjust the fixed blade tension screw to ensure the two tips meet without difficulties After adjustments be sure to use the wrench box from the accessory box to fasten the tension nut 15 Replacing the movable blade Turn the pulley manually to bring the needle up to its highest position Take out the needle plate first and unfasten two fixed blade screws to remove the movable blade as
26. shown in Figure 34 When assembling the replacement parts follow this instruction in a reverse sequence 16 Replacing the fixed blade A Unfasten the inner spindle stopper fixing screw Q take out the washer and the inner spindle stopper and loosen the fixed blade Q screw to remove the fixed blade When assembling the replacement parts follow this instruction in a reverse sequence B If the edge of the fixed blade is worn out be sure to grind the edge against the oil whetstone SunStar Alignment of carved marks Figure 32 Wrench box Movable blade Fixed blade Figure 33 Figure 34 Figure 35 Fixed blade Oil whetstone Figure 36 21 17 Adjusting the bobbin catcher A Adjusting the bobbin catcher lever With the bobbin catcher lever not in motion unfasten the lever screw to bring the tip of the bobbin catcher lever against the end of the Bobbin catcher adjusting line connecting link as shown with in Figure 38 B Run the trimming function manually As the movable blade moves forward and the end tip of the fixed blade comes to align with the bobbin catcher adjusting line as shown in Figure 37 stop the machine At this point Fixed blade unfasten the bobbin catcher screw so that the contact Movable blade surface of the bobbin catcher touches smoothly with the middle of the projecting part of the bobbin 2 See Figure 3
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