SunStar KM-857 Series, 867 Series User Manual
1) FOR AT MOST USE WITH EASINESS,
PLEASE CERTAINLY READ THIS MANUAL
BEFORE STARTING USE.
2) KEEP THIS MANUAL IN SAFE PLACE
FOR REFERENCE WHEN THE MACHINE
BREAKS DOWN.
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USER
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KM-857,867 Series
High post, 1,2 needle, drop
feed, needle feed, sewing
machine.
Best Quality
Best Price
Best Service
SunStar CO., LTD.
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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.
2. 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.
Table of Contents
Safety rules for machines .............................................4
1.Specifications
1) Machine types....................................................................................8
2) Specifications of the machine ...........................................................8
3) Specifications of servo motor controller...........................................8
(trimming type: KM-857-7, KM-867-7)
4) Specifications of clutch motor
(non-trimming type: KM-857, KM-867)..........................................9
5) Peripheral automation devices (optional: trimming type)................9
2. Installation
1) Installation of machine head ...........................................................10
2) Installation of knee lifting solenoid and power switch box ...........10
3) Installation of oil fan........................................................................11
4) Lubrication.......................................................................................11
5) Adjustment of belt tension ..............................................................13
6) Installation of program unit (automatic trimming type) ................13
7) Installation of belt cover..................................................................13
8) Installation of thread stand ..............................................................14
9) Synchronizer assembling and its control method
(automatic trimming type)...............................................................14
10) Reverse button function (automatic trimming type)....................15
11) Checking stop position of the machine
(automatic trimming type).............................................................15
3. Adjustment of the machine
1) Inserting needle................................................................................16
2) Removing bobbin and bobbin case.................................................16
3) Winding lower thread......................................................................17
4) Routing lower thread.......................................................................17
5) Inserting bobbin...............................................................................18
6) Routing upper thread.......................................................................18
7) Adjusting thread tension .................................................................19
8) Adjusting height and pressure of the presser foot ..........................21
9) Adjusting needle and feed dog timing ...........................................22
10) Adjusting height of the feed dog...................................................22
11) Adjusting needle and hook timing................................................23
12) Clearance adjustment between upper side of
hook stopper and upper side of needle plate groove ...................24
13) Clearance adjustment between hook and opener .........................24
14) Replacing feed dog........................................................................25
15) Adjustment of safety device..........................................................26
16) Adjusting trimming device ...........................................................26
17) Replacing movable knife and fixed blade ....................................32
18) Adjustment of wiper .....................................................................32
19) Replacing gauge set for needle width ..........................................34
4. Cause of trouble and troubleshooting
1) Machine troubleshooting.................................................................35
4
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 may be killed or suffer severe physical injury.
Instructions here must be observed, or the user may suffer fatal or severe physical
injury.
Instructions here should be observed, or the user may face physical injury or
mechanical damages.
Danger
[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.
Warning
Caution
5
1-1) Machine
mobilization
Danger
1-2) Machine
Installation
Caution
1-3)
Troubleshooting
Danger
If in need of troubleshooting, call a trained A/S engineer who has been educated by
sunstar.
ⓐ Before cleaning and repair, be sure to turn off the power supply. And wait for about 4
minutes untill the machine discharges completely.
ⓑ Part or the entire machine should not be modified without any consultation with our
company
ⓒ In case of repair, change the damaged part into the standard article of our company
ⓓ After repair, put back the safety cover that was removed while repairing
Only personnel with a full understanding of the safety rules should move the
machine. The following directions must be observed when transferring the machine.
ⓐ At least 2 persons should move the machine together.
ⓑ In case the machine should be transported, wipe the oil covered on the machine to
prevent accidents.
Because the physical damage such as the functional obstacles and breakdown are
likely to occur depending on the environment in which the machine is installed.
The following preconditions must be met.
ⓐ Please unpack the machine package in order. Be careful of the nails in the wooden
box.
ⓑ Because machines are apt to be contaminated and corroded by dust and moisture,
install a climate controller and clean the machines regularly.
ⓒ Keep the machine out of the direct rays of the sun.
ⓓ Keep both sides and the backside of the machines off at least 50cm from the wall to
secure enough space to repair.
ⓔ Danger of Explosion
Don’t run the machine near the places with any dangers of explosion.
Don’t run the machine near the places with any dangers of explosion, including
places where the spraying product like aerosol are used in large quantities or oxygen
are dealt with, unless the exact actions concerning the operation are guaranteed to
avoid the explosion.
ⓕ Because of the characteristics of the machine, illuminators are not equipped. So, users
should install the lighting apparatus around the working area.
[Note] The details about the installment of the machine are described in No. 2
Installations.
6
KM-857/867 series are manufactured for industry use to sew textiles and other similar
material. In case of running the machine, users should observe the following things.
ⓐ Before operating the machine, read the manual and understand fully the details about its
operation.
ⓑ Don’t forget to put on garment suitable for safe work.
ⓒ Keep your hands or a part of the body away from the running part of the machine like the
needle, hook, thread take-up spring and pulley etc.
ⓓ Don’t remove any kind of cover for safety while running the machine.
ⓔ Be sure to connect the earthed line.
ⓕ 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.
ⓗ Don’t switch on the power supply with the foot on the pedal.
ⓘ Don’t run the machine when the cooling fan is clogged. Be sure to clean the air filter in
the control box once a week.
ⓙ If possible, keep the machine away from strong electromagnetic fields like high frequency
welding machine.
1-4) Machine
Operation
Caution
Caution
ⓐ Safety Label: Cautions that need to be heeded to during operation.
ⓑ Thread take-up spring cover: a device to prevent the human body from touching the
thread take-up spring.
ⓒ Belt cover: a device to prevent hands, feet and clothing from getting jammed by the belt
ⓓ Finger guard: a device to prevent fingers from contacting the needle.
1-5) Safety Device
Caution
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.
ⓓ
ⓐ
ⓒ
ⓑ
7
“Caution” is adhered to the machine for safety.
In case of starting to run the machine, read the directions of “Caution” carefully.
1-6) Position of
Caution Mark
1-7) Content of
“Caution”
Caution
CAUTION
경고
Do not operate without finger guard and
safety devices. Before threading, changing
bobbin and needle, cleaning etc. switch off
main switch.
손가락 보호대와 안전장치 없이 작동하지
마십시오.
실, 보빈, 바늘교환시나 청소전에는 반드시
주전원의 스위치를 꺼 주십시오.
CAUTION
경고
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.
고압 전류에 의해 감전될 수 있으므로 커버를
열 때는 전원을 내리고 전원 플러그를 뽑고
나서 360초간 기다린 후 여십시오.
CAUTION
경고
Do not operate without finger guard
and safety devices. Before threading,
changing bobbin and needle, cleaning
etc. switch off main switch.
손가락 보호대와 안전장치 없이 작동하지
마십시오.
실, 보빈, 바늘교환시나 청소전에는 반드시
주전원의 스위치를 꺼 주십시오.
CAUTION
경고
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.
고압 전류에 의해 감전될 수 있으므로 커버를
열 때는 전원을 내리고 전원 플러그를 뽑고
나서 360초간 기다린 후 여십시오.
[Position of Caution Mark]
1
Specifications
8
1) Machine Types
No. Model No. Model Name
2) Specifications of the machine
1
KM-857 High post type 1 needle, drop feed, needle feed sewing machine (standard hook)
2
KM-857-7 High post type 1 needle, drop feed, needle feed sewing machine with automatic trimmer
(standard hook)
3
KM-867 High post type 2 needle, drop feed, needle feed sewing machine (standard hook)
4
KM-867-7 High post type 2 needle, drop feed, needle feed sewing machine with automatic trimmer
(standard hook)
KM-857 KM-857-7 KM-867 KM-867-7
Purpose
Max. sewing speed
Max. no. of stitches
Needle bar stroke
Feed dog height
Post height
Needle used
Feeding method
Needle width gauge
Medium material - heavy material
3,000SPM
5mm
33.4mm
1mm
7mm
18mm
178mm
DP×17 #18(#14∼#22)
Low pressure circular automatic feeding
1/16″∼1″(1.6mm∼25.4mm)
3) Specifications of servo motor controller (trimming type: KM-857-7, KM-867-7)
Model type
Item
Presser foot
height
Manual
Knee
Automatic 13mm 13mm
MODEL
SC55-1B
SC55-2B
SC55-3B
VOLT
1 phase 110V
1 phase 220V
3 phase 220V
WATT
550W
550W
550W
HERTZ
50/60 Hz
50/60 Hz
50/60 Hz
9
UsageModelOptional Device
5) Peripheral automation devices (optional: trimming type)
Auto Knee Lifting System
Production Counter
Material Edge Sensor
Standing Pedal
SCOUN-1
SEDG-1B
SEDG-2B
SPDL-1
SPDL-2
A counting device which indicates the completed quantity on the
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
to stop the machine without manual pedaling. Available in two
types: SEDG-1B for edge sensing type and SEDG-2B for
thickness sensing type
A device needed when only one operator runs several sewing
machines. Pedals for acceleration, thread trimming, presser foot
and ascending are built separately. There are two types: SPDL-1
for fixed speed type and SPDL-2 for adjustable speed type.
SPF-3A
A solenoid operating structure where the presser foot gets lifted
automatically with pedal reverse gear stage 1 operation.
4) Specifications of clutch motor (non-trimming type: KM-857, KM-867)
MODEL
HEC-1701
HEC-1703
HEC-1705
HEC-1706
VOLT
1 phase 220V
3 phase 220V/380V
3 phase 220V
1 phase 220V
WATT
250W
250W
400W
400W
HERTZ
50/60 Hz
50/60 Hz
50/60 Hz
50/60 Hz
2
Installation
10
Warning
▶Installation of the machine should be performed by a trained engineer.
▶Any electrical wiring must be performed by a qualified technician or agent.
▶The machine weighs over 53kg. At least 2 persons should carry out the installing work.
▶
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 cause physical injuries.
▶Connect the ground (earth) wire. An unstable connection may result in an electric shock
or a malfunction.
▶Place the belt cover on top of the machine.
▶
Use both hands when bending the machine backwards or returning it to the normal position.
Using only one hand can lead to severe hand injuries due to the weight of the machine.
1) Installation of machine head
※Fix the two head hinges ① to the bed. Settle the
machine onto the table where the hinge rubber ② and
cushion rubber ③ are inserted. (see figure 1)
2) Installation of knee lifting solenoid and power switch box
(1) When attaching the power switch box ⑥, 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 ①and the center of
solenoid shaft
②
in parallel position with the lower side of the
table
③
. After the adjustment is over, fasten the fixing screw
tightly. (see figure 2): assembling position diagram can be found
inside the solenoid box.
(3)
The presser foot height of the sewing machine can be adjusted
after unfastening the fixing nut
⑤
and then turning the middle
linking bar
①
clockwise to raise and counterclockwise to lower.
After finishing the adjustment, tightly fasten the fixing nut
⑤
.
(4)
According to the installation position of knee-lifting solenoid, the
operation noise, operation load and presser foot elevation range
may differ. Please assemble so that the machine will operate
smoothly.
[Figure 1]
[Figure 2]
①
③
②
⑥
②
⑤
①
Oil Fan
④
③ Table
11
3) Installation of oil fan
※Insert the projecting part of the oil fan ② into the
respective machine holes on the lower side of the
table ①, and then push securely to the right. Fix the
oil fan to the four fixing spots ③ using 4 nails.
(see figure 3)
[Figure 3]
Nail
②
①
③
Caution
▶Be sure to plug in after finishing oil supply,
If the user steps on the pedal by mistake, the machine will start automatically, and this
might lead to physical injuries.
▶When handling lubricant, use safety goggle or gloves to prevent the lubricant from coming
into contact with the eyes or skin. This may cause inflammation. And never drink
lubricants. They may cause vomiting or diarrhea. Please keep out of the reach of children.
▶Make sure to supply oil when using it for the first time or after not using it for a long time.
4) Lubrication
(1) Oil tank check
As in figure 4, pour the oil into the oil hole
②
until the
oil tank’s oil level reaches the red maximum line
①
.
While using the machine, replenish the oil immediately
when the oil level goes down to the minimum level
③
,
back to the red maximum level
①
. Make sure to check
the oil level once a day.
[Figure 4]
②
①
③
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