USER'S MANUAL
Contents
1. 22 6 5 1 Presser foot pressure PPP 22 T Inspecting and checking M 23 SunStar 7 1 Daily cleaning meme eme eene 23 7 1 1 Cleaning Hmmm m e eem eee eee eene 23 7 1 2 Supplying oil e eee eem eee eene 24 7 1 2 1 Oil flow in gearbox eem mH emen 24 7 1 2 2 Oil flow in oil tank KM 2300M amp S Type e 25 25 7 2 Supplying grease KM 2300S amp FOJ m Hem 26 8 Maintenance and repair ENCEN ENAKE ENE ote 27 8 1 Adjusting thread take up spring emm mmm eme mee emen en 57 8 1 1 Position of thread take up spring emm emm eene 27 8 2 Adjusting right arm thread guide eee eme Se 8 3 Adjusting presser foot height gt 28 8 4 Adjusting wiper eem 28 8 5 Adjusting needle bar height eem eee eee en 29 8 6 Adjusting height and slope of feed dog ee 29 8 7 Needle and conveying timing eem eme eene ens 30 8 8 Needle and hook timing eem eee eee en ene 30 8 9 Adjusting trimming time ENEE 31 8 10 Adjusting and replacing knife mmm mm eee emen en 3 8 10 1 Adjusting fixed knife eem eee 3 8 10 2 Replacing movable knife emm Hee a 8 10 3 Replacing fixed knife Hee 35 8 11 Adjusting bobbin stopper eee meme eee eene enne ES 8 12 Adjusting oil flow in hook KM 2300M amp S mmm 33 8 13 Oil Supply Adjus2. 4 n case of light material sewing right arm thread guide 1 to the right The amount of thread in thread take up will decrease Figure 41 2 28 8 3 Adjusting presser foot height Standard height of presser foot is 5 5mm when presser foot is raised by pressing bar lifter 1 Put pressure on presser foot by loosening the nut and unfastening pressure adjusting nut 4 2 Raise presser foot with pressing bar lifter 2 3 Disassemble rubber cap 5 on the side board 4 Adjust presser foot at the height of 5 5mm by loosening bolt a little and adjusting position of pressing bar 7 5 Fasten the bolt 6 6 Assemble the rubber cap 5 7 Adjust presser foot pressure with pressure adjusting screw 4 Fasten the nut 3 8 4 Adjusting wiper 1 Turn the pulley manually and stop turning when it reaches at highest position of the thread take up lever 2 Loosen the two wiper shaft fixing screws on the wiper base and press the connecting link with the hand Then adjust the wiper shaft 3 so that the gap between the wiper and the needle is about 2mm and tighten the wiper shaft fixing screwQ 3 Next loosen the wiper fixing screw 4 and adjust wiper so that the gap between the lower end of the wiper and the end of the needle is about 2mm after which the wiper fixing screw 4 must be tightly fastened
3. Make sure that lubricant is not over the MAX carved line or that can cause an oil leakage S 3 Assemble the rubber cap 3 and push it down completely 24 Figure 34 Figure 35 7 1 2 2 Oil flow in oil tank KM 2300M amp SL Type 1 When the machine operation is normal check the position of oil gaugeQ in the oil window Don the left of reverse lever 2 It is normal that the upper part of oil gauge is between two orange carved lines 3 If the upper part of oil gauge is under the lower carved line supply lubricant by referring to 4 3 supplying oil 7 1 3 Checking 1 When needle is deformed or the end of needle is damaged change the needle 2 Check if upper thread is inserted correctly Refer to 5 5 Inserting upper thread 3 Run trial sewing Gunbtati Figure 36 Figure 37 a 25 7 2 Supplying grease KM 2300S amp 7 2 1 Supply grease 1
4. 4 1 3 Repairing machine 4 1 4 Operating machine TTC 5 129 Safety devices 5 1 6 Caution mark position er ee i 6 1 7 Contents of marks TT 6 2 Names of main parts M M 7 Specifications 8 4 Installation EELER EE EE EELER ENEE EE E 9 4 1 Table drawing Serer reer err reer ree er eer eer rr ee ee ee re ee 10 4 2 Installing machine body rr ee ee ee 11 4 3 Supplying ojl mmm eene 15 4 4 Trial run Pedal operation 16 4 5 Installation KM
5. SunStar USER S MANUAL KM 2300 2310 Senes Direct Drive High Speed 1 Lock Stitch Machine with an Automatic Thread Trimmer Been A aet 1 FOR AT MOST USE WITH EASINESS QUEUE PLEASE CERTAINLY READ THIS MANUAL Y BEFORE STARTING USE 2 KEEP THIS MANUAL IN SAFE PLACE FOR REFERENCE WHEN THE MACHINE BREAKS DOWN AR M CHINERY CO LTD MME 050627 1 RS LN 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 3 The specifications of the machine are subject to change aimed to enhance product performance without prior notice 4 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 CONTENTS 1 Machine safety regulations 4 1 1 Transporting machine ee 4 1 2 Installing machine
6. Figure 42 Figure 43 SunStar 8 5 Adjusting needle bar height When needle is placed at the lowest position align carved line 3 of needle bar with lower part of needle bar lower bushing 2 Be cautious of DA needle and DB needle position 1 pAx1 DBx 1 Turn pulley to put needle at the lowest position Heavy Materials 2 Detach rubber cover 3 on side board ES 3 Loosen clamp screw lightly to adjust needle bar 4 Fasten clamp screw 4 tightly 5 Install rubber cover 8 6 Adjusting height and slope of feed dog The maximum height of feed dog from the upper surface of needle plate is 0 8mm for KM 2300 A and Gtype and Imm for KM 2300 B and _ H type 1 Turn pulley to stop feed dog at the highest position 2 Bend the machine backward 3 Loosen fixing screw 2 and fixing screw lightly 4 Adjust feed dog height and slope by turning lifter crank eccentric shaft 1 and eccentric shaft 3 of feed dog bed crank 5 Refer to the right side figure to see movement direction of feed dog bed 6 according to rotation direction of each eccentric shaft 6 After finishing adjustment fasten fixing screws 2 and 4 by pushing eccentric shafts 1 and to the direction of shaft Figure 45 1 When feed dog slope is adjusted only with one eccentric shaft height of feed dog will change Therefore make sure to adjust two eccentric shaft 2 Moving position of fe
7. 4 Return the machine to its original position 1 Clear the table of tools N 2 With the right hand return the machine to its original position while grabbing sideboard with the left hand Figure 4 4 1 Table drawing Please use the table provided by Sunstar When using self made table the thick of table should be more than 40mm Please use table strong enough to sustain the weight of the machine 1 Table Drawing 9 seu o CBore Depth 20 a Thru The Lower Side Y Less aas ofthe Table T 1 1 Wit 4 S SIA Stand Mounting Position Pedal Switch Bracket Mounting Position Al 22221 10 7 Cable Outlet ESE F a HF SS E VEILED C1 ZZ gne 33 BT SECTION 140 9 SunStar BPO INS LOR RED DETAIL K SECTION C C SECTION D D OF BB 122 Figure 5 SunStar 4 2 Installing machine body 1 Control box 1 As in the Figure attach control box to the lower part of table with four bolts 2 Figure 6 2 Pedal switch and connecting rod 1 Attach pedal switch D to pedal switch bracket 2 with four bolts 3 2 As in the Figure attach pedal switch bracket to the lower part of table 3 Connect one end of the connecting rod 4 with pedal switch and the other end with pedal and then adjust len
8. Only use the Sunstar s genuine grease enclosed in the accessory box Serial number GP 001992 2 Make a hole on the frontal tip of the grease tube by using the cap 2 of the tube 3 Attach the enclosed grease feeder firmly to the tube Serial number GP 001994 4 Apply the grease to the place where the grease needs to be applied 5 If the grease is used up only buy and use the Sunstar s genuine grease Figure 38 7 2 2 Greaging cycle 1 Supply grease every six month after set up the macine 7 2 3 How to supply grease 1 Turn off the power KM 2300 SL amp FO KM 2300 2 Remove the screw 3 Supply grease until grease goto over arrow mark 4 Fasten the screws 5 Turn polley 5 10 times by hand 6 Wipe flowed grease 7 Turn on the power and start sewing Figure 39 26 SunStar p T 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 Caution For machine maintenance and repair consult with qualified technicians For electrical maintenance and repair consult with qualified technicians or agencies When safety devices are disassembled make sure to re
9. 2310 Series TC 16 5 Preparations for sewing n X 17 De 1 Installing needle cecocoooooooooooooooooooooooooosoooooooooosooosoooooocooosooooooooooooooooooooooooooooo 17 S Removing bobbin CASC iie hh hh htt ntn 17 5 3 Winding lower thread 18 5 4 Installing bobbin Iw 18 529 Inserting upper thread T 19 5 6 Using knee lifter pad emm e eem ee eene 19 6 Sewing 20 NS T oS 20 6 2 Back tack reverse sewing ee re 20 6 3 Adjusting thread tension 21 6 3 1 Lower thread tension Serer errr rrr errr 21 6 3 2 Upper thread tension re ee re ee ee 21 6 4 Adjusting upper thread length after trimming ee ee ee 22 6 5 Adjusting presser foot pressure ee er ee
10. lever pulls out the upper commences Check the Up stop KEES pp position of needle Adjust the up stop position of thread because the needle up and needle down position is too high 37
11. part of machine body with three screws 4 Figure 12 13 8 Thread stand 1 As in the Figure fix the thread to table amp 9 9 0 19 qi uc 9 9 Knee Lifter Pad 1 As in the figure attach knee lifter pad to the lower part of oil pan And then fix it with bolt 2 Loosen bolt to adjust position of knee lifter pad 10 Adjusting height of Presser Foot 1 Turn pulley to place feed dog in the lower part of needle plate 2 When presser foot is up make presser foot down by lowering presser bar lifting lever 3 Adjust the position of presser foot by using screw Figure 13 Figure 14 Figure 15 SunStar 4 The standard height is 10mm Maximum height is 15mm Standard 10 mm Max 15mm Figure 16 78 Supplying oil KEE Caution 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 When handling lubricants wear protective glasses or gloves to prevent lubricants from contacting with your eyes or skin Wash your hands in running water with soap when they are smeared with lubricant If lubricant is in the eye instantly wash it with running water and see a doctor Never drink lubricants since they can cause vomiting or diarrhoea Go to see a
12. projecting part of the bobbin Once the operation is completed check to see whether the bobbin stopper springs back lightly 8 12 Adjusting oil flow in hook KM 2300M amp type 1 Bend the machine body backward 2 If oil amount adjusting screw is turned clockwise in direction of the amount of oil supplied to hook will increase 3 If oil amount adjusting screw is turned counterclockwise in direction of the amount of oil supplied to hook will decrease SunStar Figure 55 Bobbin Stopper Adjustment Baseline Fixed Knife Movable Knife Figure 56 Figure 57 33 4 After turning idly the sewing machine for three minutes at an appropriate speed secure the oil flow checking paper as shown in Fig 58 and run the machine for about five seconds Then check the oil tape marked on the paper 5 Check the oil supply level three times The appropriate level of oil is when the oil level neither exceeds the maximum amount nor falls below the minimum level Insufficient oil would jam the hook whereas excessive oil would contaminate the sewing material with oil 8 13 Oil Supply Adjustment KM 2310 Series 1 Adjusting oil supply to thread take up lever 1 As in the figure when the punched mark on the oil volume adjusting pin head D is aligned with the hole of the needle bar crank the oil supply volume will become maximum As the oil volume adjusting pin is turned left o
13. pulley to raise needle bar by 10 20 from the lowest position 2 Push the trimming lever so that the thread trimming knife 3 on the hill of the movable knife is about 1 1 5mm more protruded than the end of the fixed knife 4 3 Push the trimming solenoid shaft 6 manually while the trimming cam fixing screw is loose At this point the appropriate distance between the initial trimming cam 7 and the roller single screw 15 0 5mm 4 Turn the trimming cam manually so that the edge 9 of the roller driving part on the trimming cam touches the roller 9 Then tighten the trimming cam fixing screw 5 Connect the return spring 8 10 Adjusting and replacing knife 8 10 1 Adjusting fixed knife 1 First loosen the fixed knife tension adjusting nut 1 with a wrench box and then loosen the tension adjusting screw 2 2 Adjust the tension adjusting screw of the fixed knife when the movable knife edge meets the fixed knife edge 3 Adjust knives so that the knife edges meet without too much tension 4 After adjustment make sure to tighten the tension adjusting nut 1 using the wrench box in the accessory box SunStar Figure 49 i i rt rib i LT TIT zi E EE LZ 7 0 Lower shaft Figure 50 Wrench Box Fixed Knife Movable Knife Figure 51 31 32 8 10 2 Replacing movable knife 1 To replace the movable knife D turn the pulley m
14. aligned with the middle line on the bearing cover carved line 5 Turning the lifter cam in the direction of will make conveying timing fast It is generally used to prevent puckering 6 Turning the lifter cam in the direction of will make conveying timing slow It is generally used to enhance the thread tightening a euer a e CUI IU EMEN S TTE UM e e Ti Tu e UMEN LUE CN UE UEM Le L 8 8 Needle and hook timing D Raise the needle bar from its lowest position by turning the machine pulley As in the figure align carved line 8 with the lower part of needle bar down bushing 2 and DBx1 DA x1 adjust the distance between the upper part of needle hole and the hook edge at 0 0 5mm 2 Loosen three fixing screws 5 and align the hook edge 3 DB x19 with the center of needle 2 Keep the hook edge 3 0 05 Heavy Materials 0 1mm away from the needle 4 3 Fasten three fixing screws 5 completely TN IT Figure 48 8 9 Adjusting trimming time 1 Turn
15. anually to place the needle at the highest position 2 Unscrew two moveable knife fixing screws 2 and remove them as shown in Fig 52 3 Follow these instructions in reverse order to assemble 8 10 3 Replacing fixed knife 1 To replace the fixed knife loosen the hook holder fixing screw 2 as in Fig 53 remove the washer and hook holder 4 and then unfasten the fixed knife fixing screw 2 Follow these instructions in reverse order to assemble 3 If the edge of the fixed knife is worn make sure to grind the knife edge with an oil grindstone as shown in Fig 54 Oil Grindstone Fixed Knife Figure 52 Figure 53 Figure 54 8 11 Adjusting bobbin stopper 1 If bobbin stopper is inserted too deeply into bobbin case lower remaining thread will be so short that bobbin cannot rotate As a result sewing may not be created in the next sewing 2 On the contrary if bobbin stopper is not inserted enough upper thread will missed from bobbin stopper during trimming and the length of remaining thread in needle will be short As a result sewing may not be created in the next sewing 3 If the trimming was done manually stop the machine when the edge of the fixed knife meets the bobbin stopper adjustment baseline that is marked on the top Loosen the bobbin catcher fixing screw 3 and adjust the bobbin stopper so that the contact surface of the bobbin stopper lightly touches the center of the
16. aution mark position CAUTION Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off main switch ANS Hay Ou See DA Al HI su SAMOS BEA T 7 AMO A ioc 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 29 BR 98 AE oc a dr HB yala NH Lute i 38052 7 F ops AID CAUTION 2 1 7 Contents of marks Caution mark is attached on the machine for safety When you operate the machine follow the directions on the mark H B mim Caution CAUTION IN x Do not operate without finger guard and safety devices Before threading changing bobbin and needle cleaning etc switch off main switch 27 SS hot eraat 830 A OH DI amp AIS S TRO ASAE ES a 1 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 Seu 9101 AME Voor H 22 he id Ae 41 e Lu 36022 10 e O18AIS CAUTION 1 SunStar CD Bobbin winder 2 Wiper 3 Presser bar lifting lever 4 Reverse button 5 Presser foot Control box CD Knee lifting pad Safety Devices 45 Thread take up cover d6 Finger guide Power switch Oil window Rev
17. checking To maintain proper performance of machine and use it for a long time clean machine regularly according to the following way Evan when machine is not in use for a long time clean according to the following way before using the sewing machine Turn off the power switch before operation Pressing pedal by mistake may operate machine and result in injuries When handling lubricants wear protective glasses or gloves to prevent lubricant from contacting with your eyes or skin Wash your hands in running water with soap when they are smeared with lubricant If lubricant is in the eye instantly wash it with running water and see a doctor Never drink lubricants since they can cause vomiting or diarrhea Go to see a doctor if you mistakenly drink lubricant Keep the oil out of the reach of children Keep the oil away from heat Use both hands when bending the machine backwards or returning it to the original position Using only one hand can lead to severe hand injuries due to the weight of the machine een rt rer eet rt Sl 7 1 Daily cleaning 7 1 1 Cleaning 1 Raise presser foot 2 Loosen two screws and disassemble needle plate 3 Remove dust in feed dog with a soft brush 4 Install needle plate with two screws Figure 32 5 After bending the machine backward turn pulley to place needle at the upper part of needle plate 6 Remove b
18. doctor if you mistakenly drink lubricant Keep the oil out of the reach of children Keep the oil away from heat Operate the machine only after supplying oil when the machine is used for the first time or has been left unused for a long time Only use genuine lubricant of this company Lubricant is in the accessory box 1 Turn over sewing machine seperates oil holes and rubber cap Use the oil can D inthe accessory box to supply lubricant into the oil holes Make sure not to pour the whole lubricant Pour oil to Max position of lubrication tank Figure 17 15 4 4 Trial run Pedal operation p 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Caution a 4 Make sure not to touch or press down parts that are operating or moving during operation Failure to follow the safety rules may result in physical injuries or mechanical damages L2 l I I I 2 1 Press pedal lightly to the position of B to check if the machine is operating low speed sewing 2 Press pedal to the position of C to check if the machine is operating high speed sewing 3 Press pedal backward and forward And then put the pedal at neu
19. e up the machine The machine weighs over 50 kg More than two persons should install the machine Do not plug in the machine until installation is completed If the operator mistakenly steps down on the pedal with the plug in the machine will start automatically and can cause physical injuries Use both hands when bending the machine backwards or returning it to the original position Using only one hand can lead to severe hand injuries due to the weight of the machine 1 Installation place 1 Do not install the machine near television radio or telephone or the operation of machine can be interfered with by the noise from the appliances 2 Connect the ground earth wire An unstable connection may result in malfunction 2 Machine delivery 1 There should be two people to move the machine as in the Figure Figure 2 3 Bending the machine backwards 1 Bend the machine backwards with two hands grabbing upper part of the body Make sure to press the lower part of the board leg of the machine or the whole body of machine falls backwards leading to physical injuries Figure 3 10
20. ed dog may change according to eccentric shaft adjusting position In this case adjust moving position of feed dog after loosening fixing screwG of feed dog bed crank NT 29 8 7 Needle and conveying timing Lower the feed dog D from its highest position by turning the pulley It is standard that the needle tip is positioned as in the figure when feed dog is aligned with surface of the needle plate 2 3mm KM 2300 m 4 The two surfaces of feed dog and needle plate are aligned p with each other The needle tip is about Imm down from the needle plate 2 KM 2300 B and 2300 A KM 2300 B The two surfaces of feed dog and needle plate are aligned with each other The distance between the needle tip and the surface of needle plate 2 is about 3mm Figure 46 Change in lifter cam stop position makes it possible to adjust conveying timing 1 Bend the machine body backward 2 Unfasten a little the two fixing screws 2 of the lifter cam D 3 Adjust the conveying timing by turning left and right the lifter cam D 4 The standard timing is when lifter shaft carved line 4 is
21. erse lever Stitch length dial 12 Pulley 13 Program unit 42 Thread stand ass y 17 Motor cover KM 2300 KM 2310 Light materials General materials General materials Heavy materials Micro Lubrication Type Heavy materials The B Heavy Material code can be used at the M micro oil supply type sewing machine only Full Dry Type Type Micro Lubrication Type Automatic oil supply KM 2300FA KM 2300FG KM 2300SA KM 2300SG KM 2300MA KM 2300MG KM 2300MB KM 2310G KM 2310B Light General Light General Light General Heavy General Heavy materials materials materials materials materials materials materials materials materials No Lubrication Needle Bar No Lubrication Micro Lubrication Type Automatic oil supply 3 500spm 4 000spm 4 000spm 5 000spm 4 000spm 5 000spm 4 500spm 5 000spm 4 500spm 0 75 0 85mm 1 1 2mm_ 0 75 0 85 5 5mm 15mm 15mm Option No Lubrication Hook Engineering Plastic Coated Race DBxiSF KN yH1 DBx1 14 Ste 08 14 SF KN 11 DBx 1 14 DB x 1 21 DB x 1 14 DB x 1 21 19 41 11 18 19 11 11 18 189 11 11 18 19 23 11 18 19 23 300mm Automatic Lubrication Hook 517mm x 178mm Built in the Machine Head 500W Direct Drive AC Servo Motor Provided Provided Provided 1 phase 100 240V 3 phase 200 240V 50Hz 60Hz SunStar Caution P Only trained technicians should install and wir
22. evere injuries When inserting upper thread When replacing bobbin or needle When the machine not in use or the operator leaving the work place p 6 1 Sewing 1 Press ON button of power switch 1 2 Lamp on the program unit 2 turns on and machine is ready to operate 3 Control sewing conditions by using program unit 2 See user s manual of Fortuna IV 4 Step on the pedal to operate Figure 26 6 2 Back tack reverse sewing 1 Pressing the reverse switch 1 or reverse lever will move sewing material backward Sewing material will go forward if either of them is not being pressed Figure 27 20 6 3 Adjusting thread tension When inserting and removing bobbin case make sure to turn off the power switch Pressing pedal by mistake may result in physical injuries or mechanical damages Good sewing n balance NENNEN Upper thread tension is too weak Make upper thread tension strong or Lower thread tension is too strong make lower thread tension weak Upper thread tension is too strong Make upper thread tension weak or Lower thread tension is too weak make lower thread tension strong 6 3 1 Lower thread tension 1 Adjust tension by turning te
23. gned to prevent bobbin from spinning idly during trimming Figure 21 17 5 3 Winding lower thread Make sure not to touch or press down parts that are operating or moving during thread winding Failure to follow the safety rules may result in physical injuries or mechanical damages Eel 1 Turn on the power switch 2 Insert bobbin into bobbin winder shaft 2 3 Wind thread on bobbin D several times in the arrow direction 4 Push bobbin lever 3 in the direction of bobbin 5 Raise presser bar with presser bar lifter 6 When pressing pedal the machine starts to operate and thread winds on bobbin 7 When thread winding is done bobbin lever 3 returns automatically 8 Remove bobbin and cut thread with bobbin winder knife x To adjust the amount of bobbin winding loosen screw and adjust bobbin winder adjusting plate Make sure that thread should be regulated to wind 8076 of bobbin capacity el Figure 22 When installing bobbin case make sure to turn off the power Pressing pedal by mistake may result in physical injuries or mechanical damages p 1 Turn pulley to place need
24. gth of the rod Figure 7 11 3 Oil Pan 1 Fix two head hinge rubber B D to the rear side of table with nails 4 2 Fix two head hinge rubber A to the front side of table with nails 4 3 Insert four head hinge rubber c 3 into four holes of oil pan 4 Place safely oil pan 5 assembled with cushion rubbers into the rectangular hole on the table 5 Insert knee lifting support cap 6 into oil pan s projecting hole as in the figure Figure 8 4 Hinge Rubber 1 As in the figure assemble two hinge rubbers on the table 2 As in the figure fix the hinge rubbers with nails 2 Figure 9 SunStar 5 Deflation Bushing cap 1 Remove deflation bushing cap 2 If deflation bushing is not removed oil may spill from gearbox cover 6 Machine body 1 Insert two hinges D firmly into the holes of the rear side of machine bed 2 Put machine body on the rubber cushion while putting hinges D on the hinge bed rubber 2 safe and sound 3 Insert the machine body sustaining pole 4 into table completely If the pole is not inserted completely that may cause accidents because the pole cannot sustain the weight of machine body firmly when the body bent backwards Figure 11 7 Program Unit 1 As in the Figure combine program unit 1 to bracket with three screws 2 2 Attach the combined bracket 3 to the upper
25. ine use Follow the following indications when operating the machine Read through this manual carefully and completely before operating the machine D Wear proper clothes for work Keep hands or other parts of the body away from the machine s operation parts needle shuttle thread take up lever pulley etc when the machine is operating d Keep the covers and finger guard on the machine during operation Be sure to connect the earthing conductor f Turn off the main power and check if the switch is turned off before opening electric boxes such as the control box Stop the machine before threading the needle or checking after work 5 Do not step on the pedal when turning the power on D If possible install the machine away from source of strong electrical noise such as high frequency welding machines Warning Keep motor cover in place before operating turn off power before inspecting or adjusting 1 5 Safety devices 8 Safety label It describes cautions during the machine operation b Thread take up cover It prevents any contact between body and take up lever c Motor cover A device to prevent hands feet and clothing from getting jammed by the motor d Label for specification of power It describes cautions for safety to protect electric shock during the motors rotation Voltage input use Hz Finger guard It prevent contacts between finger and needle 1 6 C
26. ing of needle and hook Adjust the timing of needle and hook Stitch skips Ascending level of needle bar Wrong timing of needle and hook Adjust the timing of needle and hook Gap between needle and hook Wrong timing of needle and hook Adjust the timing of needle and hook Remaining length of upper thread is short Adjust the thread adjusting device Due to bobbin racing during Racing proof spring trimming lower thread dropping of bobbin case from bobbin case becomes too short to go up 3 Replace the racing protection spring Unable to lift lower thread due to Adjust the working capacity of take weak take up lever spring up lever spring Take up lever spring 36 SunStar _ Tension not aligned between Adjust tension of movable and fixed Tension of fixed blade movable and fixed blades blade Lower thread Edge of movable and Abrasion in blade groove of fixed blades movableand fixed blades Replace movable and fixed blades Trimming errors Direction of needle Wrong needle insertion Reinsert the needle correctly Check the crossing of trimmer cam notch mark and blade Insufficient crossing quantity of Adjust the strokes of movable and movable and fixed blade fixed blades Upper thread is pulled out Too thick a needle for thread Check thickness of needle Too strong upper thread tension Adjust tension of upper thread Winen Sewing Take up
27. le at the upper part of needle plate 2 Wind thread on bobbin to the right and insert it into bobbin case 3 Pass thread through groove and then pass it through the lower part of tension spring 4 Pull thread out of the thread hole at the end of tension spring 2 5 Pull thread make sure that bobbin moves to the right as in the figure 6 After pulling the holder of bobbin case install bobbin case into hook Figure 23 SunStar 5 5 Inserting upper thread Caution Always turn off the power when inserting upper thread If the operator mistakenly steps on the pedal while the power is on the machine will start automatically and can result in physical injuries 1 Place the thread take up at its the highest position by turning pulley before inserting the upper thread so that it becomes easy to insert it and prevent it from falling out when the machine starts to operate 2 The adequate length of upper thread extending from the needle hole is 35 40mm Figure 24 5 6 Using knee lifer pad 1 Pressing knee lifter pad to the right will move presser foot 2 up and down Figure 25 19 Wear protective gears for safety Operation without them may lead to physical injuries Turn off the machine in the following situations If the operator mistakenly steps on the pedal with the plug in the machine will start automatically and can cause s
28. ner and clean the machine regularly c Keep the machine out of the sun Leave sufficient space of more than 50cm behind and on the right and left side of the machine for repairing EXPLOSION HAZARDS Do not operate in explosive atmospheres To avoid explosion do not operate this machine in an explosive atomsphere including a place where large quantities of aerosol spray product are being used or where oxygen is being administered unless it has been specifically certified for such operation D The machine is not provided with local lighting due to the feature of machine Therefore the illumination of the working area must be fulfilled by end user Refer Details for machine installation are described in 4 Installation 1 3 Repairing When the machine needs to be repaired only the assigned troubleshooting engineer machine educated at the company should take charge 8 Before cleaning or repairing the machine turn off the main power and wait 4 minutes till the machine 1s completely out of power D Not any of the machine specifications or parts should be changed Without consulting the company Such changes may make the operation dangerous Spare parts produced by the company should only be used for replacements d Put all the safety covers back on the machine after the machine has been repaired SunStar 1 4 Operating KM 2300 Series is made to sew patterns on fabrics and other similar materials for industrial mach
29. nsion control screw to the extent that bobbin case falls by gravity when holding the end of thread Strong Figure 28 6 3 2 Upper thread tension 1 Adjust upper thread tension after adjusting lower thread tension to make sure good sewing 2 Move presser foot down 3 Adjust upper thread tension by turning tension adjusting screw 2 of main thread controller Weak Strong Figure 29 SunStar 21 6 4 Adjusting upper thread length after trimming 1 During the trimming process main thread release tension 15 a not created but only auxiliary thread release tension 15 H TT created 2 The adequate length of upper thread after trimming is 35 40mm 3 Increasing auxiliary thread release D tension will make upper thread after trimming short and decreasing the tension will make it long Figure 30 6 5 Adjusting presser foot pressure Sewing style Corrective action Good sewing in balance A stitch is skipped Increase pressure Stitch lengths are not uniform Puckering Decrease pressure 6 5 1 Presser foot pressure 1 Make the presser foot pressure as weak as possible But as weak as for sewing material not to slide 2 Unfasten the pressure adjusting nut D A 3 Turn the pressure adjusting screw 2 to adjust presser foot N pressure d 4 Fasten the pressure adjusting nut D 2 NA SS 22 SunStar Inspecting and
30. obbin 4 7 Remove dust in hook 5 with a soft cloth And then check if hook is damaged 8 After removing bobbin from bobbin clean bobbin case 6 with a cloth 9 After inserting bobbin into bobbin case install bobbin case 6 in the machine Figure 33 23 7 1 2 Supplying oil 7 1 2 1 Oil flow in gear box Bend the machine body backward to check the oil flow in the gear box Since the height of oil in the oil window the gear box cover depends on the degrees at which the machine is bent bend the machine body backward with the body sustaining pole installed correctly See 4 2 7 Machine body Del Check the oil flow It is standard that the oil surface is in the middle of and MIN carved lines on the oil window on the gear box cover 0 Upon shipment about 150ml lubricant is in the gear box Check from the front the oil flow in the oil window D on the gear box cover 2 If the oil surface is lower than the MIN carved line supply oil in the following orders Supplying Oil Always use genuine lubricant of SunStar Lubricant is in the accessory box of the machine 1 Disassemble the air exhaust rubber cap 2 Pour lubricant so that oil surface is in the middle of MAX and MIN carved lines on the oil window on the gear box cover D Be careful not to make lubricant overflow
31. r right and becomes closer to the edge of the crank cam plate the oil supply volume grows smaller When the punched mark passes the edge of the crank cam plate no oil will be supplied 2 Adjusting oil supply to hook 1 As in the figure turn clockwise the oil volume adjusting screw D which is inserted into the low axis front bushing and the oil supply will increase If the oil volume adjusting screw is turned counter clockwise the oil volume will decrease 34 Oil Flow Checking Paper Resulting Oil Tape Resulting Oil Tape about 0 5mm about 1mm Minimum Maximum Optimum Level Optimum Level Figure 58 Figure 59 Figure 60 SunStar 8 14 Adjusting automatic knee lifter Option device 1 An automatic knee lifter will be attached to the sewing machine upon shipment 2 The lifting amount of the presser foot when automatically lifting the knee is controlled by the automatic knee lifting solenoid shaft crank 3 First loosen the solenoid cover fixing screw and remove the solenoid cover 4 4 If the solenoid shaft is moved left and the fixing screw is tightened when the solenoid crank shaft fixing screw is loose the lifting amount of the presser foot grows smaller and if it is moved right and the fixing screw is tightened the lifting amount of the presser foot grows bigger 5 Assemble the cover back after the adjustment is completed The presser foot lifting amo
32. rt automatically and can result physical injuries a 1 Turn the pulley of machine to raise needle bar to its highest position 2 Unfasten the fixing screw D 3 As in the figure insert needle straight to the end with the O Workers needle s long groove facing left and fasten the fixing screw side QD firmly S Needle s i long groove Figure 20 5 2 Removing bobbin case Always turn off the power when removing a bobbin case If the operator mistakenly steps on the pedal while the power is on the machine will start automatically and can result in physical injuries Lien T 1 Place needle at the upper part of needle plate by turning pulley 2 Remove bobbin case by pulling bobbin case holder 1 3 Let go of the holder to remove bobbin 4 The spring 3 inside bobbin case is desi
33. tment KM 2310 Series me eee 34 8 14 Adjusting automatic knee lifter Option device ere ere SEA RE EE EE 35 9 Causes of troubles and troubleshooting n M 36 Machine safety regulations Safety instructions on this manual are defined as Danger Warning and Notice If you do not follow the instructoins physical injuries and machine damages might be occurred Danger This indication should be observed definitely If not there will be a danger during the installation conveyance and maintenance of the machine Warning When you follow this indication injuries from the machine can be prevented Notice When you follow this indication error on the machine can be prevented 1 1 Transporting Those in charge of transporting the machine should have a full understanding of the machine machine The following indications should be followed when the machine is being transported 8 More than 2 people must transport the machine D To prevent accidents from occurring during transportation wipe off the oil on the machine compeletely 1 2 Installing The machine may not work properly or breakdown if installed in certain places Install the machine machine where the following qualifications agree Remove the package and wrappings from the top Take special notice on the nails on the wooden boxes b Dust and moisture stains and rusts the machine Install an airconditio
34. tral position of A to check if needle stops lower than the upper surface of needle plate in case that needle down stop is set 4 When pressing pedal to the position of D or pressing pedal the position of to D and then replacing pedal to the position of A needle will stop higher than the upper surface of needle plate after trimming 4 5 Installation KM 2310 Series 1 Installing magnet for chip metal powder removal 1 Take out the magnet for chip metal powder removal from the accessory box and attach it to inside the oil fan If the sewing machine is operated without the magnet it may cause abnormalities in the sewing machine Use of the magnet can improve machine durability 2 Lubricant supply to oil fan 1 Hill the oil fan with lubricant up to the HIGH mark 2 Use either the oil for SunStar industrial sewing machines or Shell s Tellus C10 as lubricant 3 When the lubricant level falls to Low the oil fan shall be refilled with lubricant until it reaches the HIGH mark again 4 Replace lubricant every two weeks 16 A E M M M M M Figure 18 Figure 19 SunStar Preparations for sewing 5 1 Installing needle 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 sta
35. turn them to original positions Use both hands when bending the machine backwards or returning it to the original position Using only hand can lead to severe hand injuries due to the weight of the machine Turn off the switch and pull the plug Pressing pedal by mistake may result in physical injuries Inspection maintenance repair Exchanging expendable parts such as needle hook knife Adjusting hook oil flow In case you operate the machine when the power is on please take special precaution UE 8 1 Adjusting thread take up spring 8 1 1 Position of thread take up spring It is standard that thread take up spring is at the place where the spring s movement range is 6 8mm from the upper surface of thread routing plate 3 with presser foot descending and G type For ID and type 4 6mm is standard 1 Lower presser foot 2 Loosen fixing screw 4 lightly 3 Adjusting position by turning thread control device 4 Fasten fixing screw 4 tightly Figure 40 8 2 Adjusting right arm thread guide 1 It is standard that clamp screw 2 is placed at the center of long hole of right arm thread guide For light For heavy material material 2 Loosen clamp screw and move right arm thread guide lt a a both sides to adjust 3 In case of heavy material sewing move right arm thread guide D to the left The amount of thread in thread take up will increase
36. unt for the automatic knee lifter is set at 15mm by default upon shipment Figure 61 35 Causes of troubles and troubleshooting 1 Sewing machine troubleshooting Direction and height of needle Needle is inserted into wrong direction Reinsert the needle correctly Needle is bent Replace the needle Bad timing of feed dog Adjust the timing of feed dog 1 Needle breaks Ascending level of needle bar Bad timing of needle and hook Adjust the timing of needle and hook Height of needle Bad timing of needle and hook Adjust the timing of needle and hook Gap between needle and hook Bad timing of needle and hook Adjust the timing of needle and hook Lower thread tension Too tight lower thread tension Reduce tension of lower thread Threading method Wrong threading Thread the needle correctly Bent needle or broken needle tip Replace the needle 2 Thread breaks Working capacity of take up lever spring Loose upper thread Adjust take up lever spring Direction and height of needle Needle inserted in the wrong position Insert the needle correctly Upper thread tension Too tight upper thread tension Reduce tension of upper thread Direction and height of needle Needle inserted in the wrong position Reinsert the needle in the right direction Bent needle or broken needle tip Replace the needle Threading Thread passing at wrong position Replace the needle Height of needle Wrong tim
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