SunStar KM-1640BL-7 User Manual

Download

Page 1

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.

MMMMEE--112200991111

SSuunnSSttaarr CCOO..,, LLTTDD..

USER

’’

S MANUAL

KM-1640BL-7

Semi-direct, one-needle, upper & lower feed lock stitch machine with automatic thread trimmer with large hook

Page 2

Page 3

Best Quality

Best Price

Best Service

SSUUNNSSTTAARR CCOO..,, LLTTDD..

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.

This product is designed, manufactured, and sold as an industrial sewing machine. It should not be used for other than industrial purpose.

Page 4

Contents

1. Machine safety regulations --------------------------------------------------------------------- 6

1-1) Transporting machine --------------------------------------------------------------------------- 6 1-2) Installing machine --------------------------------------------------------------------------------- 6 1-3) Repairing machine -------------------------------------------------------------------------------- 6 1-4) Operating machine ------------------------------------------------------------------------------- 7 1-5) Safety devices ------------------------------------------------------------------------------------- 7 1-6) Caution mark position ---------------------------------------------------------------------------- 8 1-7) Contents of marks -------------------------------------------------------------------------------- 8

2. Names of main parts ------------------------------------------------------------------------------- 9

3. Specification

----------------------------------------------------------------------------------------- 10

3-1) Sewing machine --------------------------------------------------------------------------------- 10 3-2) Peripheral Automation Devices Specifications(options) ------------------------------ 10

4. Installation --------------------------------------------------------------------------------------------- 11

4.1) Installation place --------------------------------------------------------------------------------- 11

4.2) Machine delivery --------------------------------------------------------------------------------- 11

4.3) Bending the machine backwards ----------------------------------------------------------- 11

4.4) Table drawing ------------------------------------------------------------------------------------ 12

4.5) Installation of Sewing Machine Body ------------------------------------------------------- 13

4.6) Trial run (Pedal operation) -------------------------------------------------------------------- 17

4.7) Check for machine stop position ------------------------------------------------------------ 17

4.8) Reverse button function (for automatic trimming type) -------------------------------- 18

4.9)

Installation of Automatic Knee Lifter Solenoid(options) and Power Switch Box

-------- 18

5. Preparations for sewing ------------------------------------------------------------------------ 19

5.1) Installing needle --------------------------------------------------------------------------------- 19

5.2) Bobbin Insertion and Removal --------------------------------------------------------------- 19

5.3) Winding lower thread --------------------------------------------------------------------------- 20

5.4) Inserting upper thread -------------------------------------------------------------------------- 20

6. Sewing -------------------------------------------------------------------------------------------------- 21

6.1) Sewing --------------------------------------------------------------------------------------------- 21

6.2) Adjusting thread tension ----------------------------------------------------------------------- 21

7. Inspecting and checking ---------------------------------------------------------------------- 23

7.1) Regular Check Points -------------------------------------------------------------------------- 23

7.2) Cleaning ------------------------------------------------------------------------------------------- 24

Page 5

8. Maintenance and Adjustment of Sewing ----------------------------------------------- 25

8.1) Adjusting needle bar----------------------------------------------------------------------------- 25

8.2) Adjusting timing of needle and hook ------------------------------------------------------- 25

8.3) Adjusting lubrication of thread take-up spring part ------------------------------------- 26

8.4) Adjusting lubrication of hook ------------------------------------------------------------------ 26

8.5) Adjustment of Top Stop Position ----------------------------------------------------------- 26

8.6) Adjusting presser foot pressure ------------------------------------------------------------- 27

8.7) Adjusting stitch length -------------------------------------------------------------------------- 27

8.8) Adjusting feed dog height and inclination ------------------------------------------------- 28

8.9) Adjusting auxiliary presser foot and upper feed presser foot ------------------------ 28

8.10) Adjusting feeding amount of auxiliary presser foot ----------------------------------- 29

8.11) Adjusting feed cam----------------------------------------------------------------------------- 30

8.12) Adjusting for thread trimmer ---------------------------------------------------------------- 30

8.13) Adjusting blade pressure -------------------------------------------------------------------- 34

8.14) Exchanging movable knife ------------------------------------------------------------------ 34

8.15) Exchanging fixed blade----------------------------------------------------------------------- 34

8.16) Adjusting thread release---------------------------------------------------------------------- 35

8.17) Adjusting remaining amount of upper thread ------------------------------------------- 35

9. Causes of Troubles and Troubleshooting --------------------------------------------- 36

Page 6

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.

This indication should be observed definitely. If not, there will be a danger during the installation, conveyance and maintenance of the machine.

When you follow this indication, injuries from the machine can be prevented.

When you follow this indication, error on the machine can be prevented.

Caution

Warning

Danger

1-1) T ransporting

machine

Danger

1-2) Installing

machine

Warning

1-3) Repairing

machine

Caution

Those in charge of transporting the machine should have a full understanding of the machine. The following indications should be followed when the machine is being transported.

ⓐ More than 2 people must transport the machine. ⓑ To prevent accidents from occurring during transportation, wipe off the oil on the

machine compeletely.

The machine may not work properly or breakdown, if installed in certain places, Install the machine where the following qualifications agree. ⓐ Remove the package and wrappings from the top. Take special notice on the nails

on the wooden boxes.

ⓑ Dust and moisture stains and rusts the machine. Install an airconditioner and clean

the machine regularly.

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.

[Refer] Details for machine installation are described in 4. Installation.

When the machine needs to be repaired, only the assigned troubleshooting engineer educated at the company should take charge. ⓐ Before cleaning or repairing the machine, turn off the main power and wait 4

minutes till the machine is completely out of power.

ⓑ Not any of the machine specifications or parts should be changed without consulting

the company. Such changes may make the operation dangerous.

replacements.

ⓓ Put all the safety covers back on the machine after the machine has been repaired.

Page 7

KM-1640BL-7 Series were designed as industrial sewing machines to perform sewing on fabric, leather, and other similar materials. Please observe the following instructions during machine operation.

ⓐ Read through this manual carefully and completely before operating the machine. ⓑ 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.

ⓓ Keep the covers and finger guard on the machine during operation. ⓔ Be sure to connect the earthing conductor. ⓕ 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. ⓗ Do not step on the pedal when turning the power on. ⓘ If possible, install the machine away from source of strong electrical noise such as

high frequency welding machines

1-4) Operating

machine

Warning

Caution

[ Warning ] Keep motor cover in place before operating, turn off power before inspecting or adjusting.

1-5) Safety

devices

ⓐ Safety label : It describes cautions during the machine operation. ⓑ Thread take-up cover : It prevents any contact between body and take-up lever. ⓒ Motor cover : A device intended to avoid potential risks of getting hands, feet or

clothes jammed by the motor

ⓓ 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.

ⓐ

ⓒ

ⓔ

ⓓ

ⓑ

Page 8

Caution

1-7) Contents of

marks

Warning

Caution mark is attached on the machine for safety. When you operate the machine, follow the directions on the mark.

1-6) Caution mark

position

CAUTION

주의

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 주 전원의 스위치를 꺼 주십시오.

WARNING

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 나 서 360초간 기다린 후 여십시오.

CAUTION

주의

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 마 십시오. 실, 보빈, 바늘교환시나 청소전에는 반드시 주전원의 스위치를 꺼 주십시오.

WARNING

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 커버 를 열 때는 전원을 내리고 전원 플러그를 뽑 고 나서 360초간 기다린 후 여십시오.

Page 9

Names of main parts

① Presser Foot ② Reverse Button ③ Oil Window ④ Climb Dial ⑤ Thread Winder ⑥ Thread Stand ⑦ Pulley ⑧ Stitch Length Dial ⑨ OP Unit and Panel ⑩ Control Box ⑪ Oil Fan ⑫ Lap Switch

Safety Devices

⑬ Thread Take-up Lever Cover ⑭ Finger Guard

Motor Cover

[Fig. 2-1]

⑫

⑧

⑥

⑦

⑤

⑮

③

①

④

⑨

②

⑩

⑪

⑭

⑬

Page 10

Specification

Max 2,000 SPM

Max 9mm

DP×17 #22, DB×1 #22

73mm 38mm

2∼5.5mm

7mm

16mm

Vertical 2times Hook

Heavy materials Basic specifications Basic specifications

Options

Auto Lubrication

750W AC Servo motor

1 Phase : 100~240V 3 Phase : 200~440V, 50/ 60HZ

3.1) Sewing machine

Model Name

Item

KM-1640BL-7

UsageModelOptional device

3.2) Peripheral Automation Devices Specifications(options)

AUTO KNEE LIFTING SYSTEM

PRODUCTION COUNTER

MATERIAL EDGE SENSOR

STANDING PEDAL

SCOUND-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.

An essential device when one person is operating multiple sewing machines. Has different pedals for acceleration, thread trimming, presser foot and ascending pedal. Types consist of SPDL-1 for fixed speed, and SPDL-2 for variable speed.

SPF-7

A solenoid operating structure where the presser foot gets lifted automatically with pedal reverse gear stage 1 operation.

Speed Max stitch length Needle Thread take-up stroke Needle bar stroke Presser foot stroke

Manual

Auto

Hook Usage

Automatic trimmer

Auto Back Tack

Automatic presser foot lift device Lubrication Main Motor Power

Presser foot ascending amount

Page 11

Installation

4.1) 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

4.2) Machine delivery

1) There should be two people to move the machine, as in the Figure.

4.3) 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.

[Fig. 4-1]

[Fig. 4-2]

[Fig. 4-3]

•Only trained technicians should install and wire 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.

Caution

Page 12

4.4) 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.

[Fig. 4-4]

Page 13

[Fig. 4-5]

[Fig. 4-6]

[Fig. 4-7]

4.5.3) OP Panel

Fix the operating panel① to the bracket② using a bolt③ and then fix it to the upper part of the rear arm using a bolt④.

4.5) Installation of Sewing Machine Body

4.5.1) Installation of Hinge, Oil Pan and Machine

Insert the hinge rubber

①

into the table. After inserting the oil tray in the middle of head supporting rubber B②as

shown in the figure 1, install it into the table. Insert the machine head hinge

③

into the bed holes. By inserting it into the

hinge rubber

①

, stand the machine on the head support rubber A④and the head support rubber B②.

4.5.2) Installation of Knee Lift Pad

A. Insert a knee lift pad② in a knee support shaft

point① assembled in the oil pan and adjust the position for the user to fix it.

B. Insert a knee lift rod cap③ in the hole of the oil

pan as shown in the figure.

②

①

③

oil tray (oil fan)

②

①

④

③

①

③

①

②

③

④

Page 14

4.5.5) Pedal switch and connecting rod

1) Attach pedal switch ① to pedal switch bracket ② with four bolts ③.

2) As in the Figure, attach pedal switch bracket ② 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 length of the rod.

[Fig. 4-9]

4.5.4) Control Box

1) Attach the control box① undersurface of the table

with 4 bolts② as shown in the figure.

4.5.6) Adjustment of Belt Tension

Remove a hand pulley and a motor cover. Loosen the main motor bracket screw① and adjust the tension by moving the main motor bracket from side to side.

[Fig. 4-8]

[Fig. 4-10]

②

①

②

③

④

①

Page 15

4.5.7) Installation of Motor Cover

1) Cover A is assembled at the right end of the arm as shown in the figure. Then fix it to the arm using 5 screws①.

2) After assembling the cover A, assemble a hand pulley into the upper shaft.

3) Cover B is assembled at the back of the arm as shown in the [Figure 4-12]. Assemble a P/U bracket before assembling.

4) Fix is to the arm using 4 screws①.

5) Cover A and B are fixed with the screw② as shown in the [Figure 4-13].

①

[Fig. 4-11]

①

[Fig. 4-12]

②

[Fig. 4-13]

Cover Support Bar A

Cover Support Bar B (Two pieces)

②

Page 16

•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.)

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 doctor, if you mistakenly drink lubricant.

•Keep lubricant away from the reach of children and the youth.

Caution

4.5.8) Lubrication

A. Attachment of magnet for sweeping up chips

Attach the magnet for sweeping up chips included in the accessory box to the oil pump inside of the bed. (Refer to Figure 4-14) ※ Do not use the magnet for other usages. Running the sewing machine without the magnet could cause

mechanic problems and affect the endurance of the machine.

B. Inserting lubricant to oil tray (oil fan)

a) Fill the lubricant to “HIGH”position. (Refer to Figure 4-15) b) Please use SUNSTAR lubricant exclusive for industrial sewing machine or SHELL’s TELLUS C10. c) When the lubricant in use is at LOW position, fill it immediately to HIGH position. d) Most suitable period of changing lubricant is 1 time in two weeks.

[Fig. 4-15][Fig. 4-14]

oil pump

magnet

4.5.9) Thread spool stand assembly

Secure the thread spool stand assembly① onto the table using washer② and nut③ on the right side.

①

②

③

[Fig. 4-16]

Page 17

4.6) Trial run (Pedal operation)

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 neutral 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.

[Fig. 4-17]

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.

Caution

4.7) Check for machine stop position

Press a reverse button to move a needle up and down, then please check the regular position of the machine. Check the carving of the hand pulley is matched with the carving of the motor cover A when the needle is located on the upper stop position. If the stop position is wrong, remove the motor cover A and change the sensor plate position of the upper stop. The upper stop position of the needle is identical with the stop position of the needle bar after thread trimming.

[Fig. 4-18]

Reverse button

Carved

line

Carved line

Page 18

4.8)

Reverse button function (for automatic trimming type)

Pressing the 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 updown position of the needle bar by pressing the 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 needle bar in a low position.

[Fig. 4-19]

up-stop

position

down-stop

position

4.9)

Installation of Automatic Knee Lifter Solenoid(options) and Power Switch Box

1) Please ensure that the control box ① should be

placed in the middle of the solenoid bracket② by referring to the figure 4-20 when you attach the control box.

2) Attach the solenoid to the table④ following the

assembling instructions enclosed in the solenoid box. Then adjust the position of the link bowl⑥ by loosening a nut⑤ to make the center of the solenoid shaft ③ and the undersurface of the table to be horizontal. After adjusting, tighten the nut firmly.

3) The sound, operation load and the presser foot

lifting can change depending on the attachment state of the knee lift solenoid. Assemble to make it work smoothly.

[Fig. 4-20]

②

①

③

⑤

⑥

④

Page 19

Preparations for sewing

5.1) Installing needle

A. Insert the bobbin into the bobbin case. Later, insert

the thread into the thread groove① and place it under the spring④ of thread adjusting plate.

B. Inserting and removing the bobbin case

Insert into the hook by grabbing the bobbin case handle①. Pull out the handle① when you remove the bobbin. (The bobbin② removes itself when you release the handle.)

[Fig. 5-2]

Move the needle upper end so that it directly touches the upper side of the stopper hole② when the groove

① of the needle is on the left. Then, use the clamp screw③ to fix the position of the needle. (Refer to figure 5-1)

5.2) Bobbin Insertion and Removal

[Fig. 5-1]

Always turn off the power when mounting a needle. If the pedal is accidentally stepped, the machine might unexpectedly operate, causing injury.

Caution

Make sure to turn off the power switch when removing the bobbin case. If the pedal is accidentally stepped, the machine might unexpectedly operate, causing injury.

Caution

③

②

①

③

②

④

Page 20

5.4) Inserting upper thread

1) Place the thread take-up ① at its the highest position by turning pulley before inserting the upper thread.

2) The adequate length of upper thread extending from the needle hole is 50mm.

[Fig. 5-4]

5.3) Winding lower thread

1) Turn on the power switch.

2) Insert bobbin① into bobbin winder shaft②.

3) Wind thread on bobbin① several times in the arrow direction.

Push bobbin operating plate③ in the direction of bobbin.

5) When pressing pedal, the machine starts to operate and thread winds on bobbin.

6) When thread winding is done, bobbin operating plate ③ returns automatically.

7) Remove bobbin and cut thread with bobbin winder knife④.

※ To adjust the amount of bobbin winding, loosen

screw⑤ and adjust bobbin winder adjusting plate③.

[Fig. 5-3]

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.

Caution

Make sure that thread should be regulated to wind 90% of bobbin capacity.

Caution

Always turn off the power when inserting upper thread. If the pedal is accidentally stepped, the machine might unexpectedly operate, causing injury.

Caution

①

③

⑤

④

②

90%

Page 21

Sewing

6.1) Sewing

1) Press ON button of power switch ①.

2) Lamp on the control panel ② turns on and machine is ready to operate.

3) Control sewing conditions by using control panel ②. (See user’s manual of Fortuna IV.)

4) Step on the pedal to operate.

[Fig. 6-1]

•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 severe injuries.

- When inserting upper thread

- When replacing bobbin or needle

- When the machine not in use or the operator leaving the work place.

Caution

6.2) Adjusting thread tension

Sewing Type

Cause Troubleshooting

Good sewing in balance

Upper thread tension is too weak Lower thread tension is too strong

Upper thread tension is too strong Lower thread tension is too weak

Make upper thread tension strong or make lower thread tension weak

Make upper thread tension weak or make lower thread tension strong

When inserting and removing bobbin case, make sure to turn off the power switch. If the pedal is accidentally stepped, the machine might unexpectedly operate, causing injury.

Caution

①

②

Page 22

6.2.1) Adjusting upper thread

A. Thread control assembly

Like in Figure 6-2, turning the tension adjustment nut ① of the thread tension control assembly clockwise makes the upper thread tension stronger and counterclockwise makes it weaker . 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.

B. Adjusting the thread take up tension

As in Figure 6-2, insert the driver into the groove ② of the thread tension control assembly. Turn clockwise to make the spring tension stronger and counter clockwise to make it weaker.

[Fig. 6-2]

6.2.2) The tension of the lower thread becomes larger

when you turn clockwise the tension adjustment screw① and becomes smaller when you turn in counterclockwise. When hold the end of thread, make sure that the bobbin case② should drop by gravity in order to adjust the lower thread tension.

[Fig. 6-3]

①

②

④

①

②

Page 23

Inspecting and checking

•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.

Caution

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.

Caution

7.1) Regular Check Points

1) Cleaning, lubrication, and grease supply for particular areas should take place on a regular basis to keep the machine at the best conditions.

2) Check the tension of each driving belt.

3) When the regular checks are not properly performed, the following problems might result.

－ Abnormal abrasion of the oiled parts due to the lacking supply of lubricant and grease － Abnormal operation due to the dust and foreign materials stuck around the driving parts

4) If the machine was left unused for a long time, resume its operation after cleaning and maintenance activities.

Checklist Interval of inspection

Around the Hook, Thread trimming, Needle plate, Feed dog

cleaning(fluff, thread, a piece of cloth)

Check the oil amount( oil pan)

Check the oil flow at the front side of arm

Check hook lubrication

Check oil leak of the machine

Everyday

One/week

One/month

Page 24

7.2) Cleaning

7.2.1) Cleaning Frequency and Method

NO. Required Parts for Cleaning

Around Hook Thread take-up lever / thread tension adjusting device

Treatment of Waste Oil

Around of moving blade and fixed blade (Please remove dust on the moving and fixed blade under the needle plate with air.)

Daily

Once a week

Once a month

Three times a week

1 2

Cleaning Frequency

1) Make sure to turn off the power of the machine before cleaning.

2) The parts disassembled for cleaning should be assembled in the reverse order of disassembly.

Caution

Page 25

Maintenance and Adjustment of Sewing

8.1) Adjusting needle bar

As in Figure 8-1, place the needle bar in the lowest position by pulling out the needle bar adjusting hole rubber cover① and rotating the pulley, and then loosen the needle bar holder clamp screw② and move the needle bar such that the needle bar’s lowest position mark carved sign④ is aligned with the lower side of the needle bar lower bushing③ After fixing tightly the needle bar holder clamp screw② and place the rubber cover①.

8.2) Adjusting timing of needle and hook

As in Figure8-2, align the lower side of the needle bushing① with the fixed hook position carved line② marked in the needle bar. Then, loosen three hook fixing bolts③. When the hook edge④ is aligned with the center of needle, turn the loosened hook so that the clearance between the needle groove inside carved in the lateral side of the needle and the hook edge④ becomes 0.05~0.1mm. Later, tight again the three fixing bolts③.

[Fig. 8-1]

[Fig. 8-2]

•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 return them to original positions.

•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.

•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.

Caution

DB×1#22 DP×17#22

③

④

①

②

DB×1#22 DP×17#22

0.05~0.1mm

Page 26

8.3) Adjusting lubrication of thread take-up spring part

As in the figure 8-3, the more the point② of the control plate of oil flow① goes close to the center of hole of thread take-up crank shaft, the more oil comes. On the other hand, the more the point goes close to the corner⑤ of the link cam washer, the less oil comes. And when the point goes past the corner of the link cam washer④, the oil does not come out.

8.4) Adjusting lubrication of hook

A. Confirming the amount of lubrication

a) Perform an idle rotation for about 3 minutes of the

machine. Later, place the paper for confirming the amount of lubrication as in Figure 8-4 and rotate the machine for 5 seconds to confirm the amount of oil sprayed to the paper.

b) Perform 3 times of confirming the amount of

lubrication. The adequate adjusted amount is a state where the maximum and minimum amounts do not fall short of or exceed the amount shown in the picture.

(If the amount of lubrication is too small, it could

invite the hook seizure, and if the amount is too large, it could cause a contamination by oil.

B. Adjusting the amount of lubrication

When you turn clockwise(+)the lubrication adjustment screw① inserted in the front bushing of the lower shaft, the amount of oil will increase while turning to counterclockwise(-) will decrease the amount.

8.5) Adjustment of Top Stop Position

A. Remove the hand pulley and motor cover A. B. The top stop sensor plate① on the top stop position

is like in the figure and the upper shaft angle② should be upward.

C. Make sure that the position for carving② is upward

by adjusting the position of the top stop sensor plate.

[Fig. 8-3]

[Fig. 8-5]

about 0.5 mm about 1mm minimum adequate amount

maximum adequate amount

decrease

3~10mm

sprayed oil belt

paper for confirming the

amount of lubrication

oil tray(oil fan)

bed

hook

[Fig. 8-4]

①

②

Page 27

8.6) Adjusting presser foot pressure

As shown in Figure 8-6, the pressure of the upper feed presser foot becomes stronger when you turn the pressure adjustment screw① clockwise, and becomes weaker in case of turning it counterclockwise. After the adjustment, be sure to tight the fixing nut②. The auxiliary presser foot is same to the upper feed presser foot: the pressure increases when you turn the pressure adjustment screw③ clockwise, and becomes weaker in case of turning it counter clockwise. After the adjustment, be sure to tight the fixing nut ④. In case of fine adjustment, use the auxiliary pressure adjustment screw⑤.

8.7) Adjusting stitch length

As shown in Figure 8-7, the number marked in the stitch control dial① means the stitch width in mm. Adjust it in sideways and fix it to your desired number of stitch width.

[Fig. 8-6]

[Fig. 8-7]

•After disassembling and adjusting a safety device, always place it back to the original position and check whether it functions as intended.

•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.

•When adjusting the machine with the switch on, be sure to pay extreme caution.

•Only trained engineers must perform troubleshooting or inspection of the machine.

•For electrical repair or inspection, consult with qualified technicians or agent.

Caution

①

⑤

②

④

③

①

Page 28

8.8) Adjusting feed dog height and inclination

A. Adjust the height of the feed dog③ by loosening the clamp screw② of the leverage crank(front) and moving the

leverage crank(front)①.

T o adjust the inclination of the feed dog, loosen the fixing screw of feed dog inclination adjustment crank⑥in the horizontal pushing crank

④

first. Later, adjust it by rotating until 90 degree the feed dog inclination adjustment shaft⑤.

When you turn the shaft

⑤

clockwise, the front of feed dog goes up while the rear part of the feed dog is up with counter

clockwise direction.

(Refer to figure 8-8)

Check the height of feed dog③because the height of it changes after the adjustment of feed dog③.

[Fig. 8-8]

8.9) Adjusting auxiliary presser foot and upper feed presser foot

Normally , the auxiliary presser foot and the upper feed presser foot work vertically with a same height difference. In accordance with the material type, there are some cases in which run the auxiliary presser foot

①

and the upper feed

presser foot

②

at the same pace, or sometimes, at different paces. In these cases, please adjust the height as follows:

■

In case of running vertically the auxiliary presser foot and the upper feed presser foot at the same height

a) The vertical running range of the auxiliary presser foot

①

and the upper feed presser foot②is from 2 to 5.5 mm.

b) The vertical running amounts of the auxiliary presser foot

①

and the upper feed presser foot②are easily

adjustable from the climb device dial attached to the front side of the machine.

c) The dial

④

attached to the upper cover is a dial which controls the running amount dial③. Only when the numbers

③

and ④are identical, the auxiliary presser foot and the upper feed presser foot can be run at the same height. ex) When the running amount of the two presser feet are adjusted to 4mm

ex) First, adjust the number of the dial attached to the upper cover to 4, and make the number the dial at front

side of the machine 4. When you adjust the number from lower one to a higher, you should adjust the dial

④

first. In the reverse case, the adjustment of the dial③should be done first.

[Fig. 8-9]

Highest position of feed dog

①

②

④⑤

③

⑤

⑥

①

②

5.5mm

③

④

clockwise

front back

counter clockwise

Page 29

■

In case of running vertically the auxiliary presser foot and the upper feed presser foot at the same height

Adjusting the auxiliary presser foot

Loosen the presser bar pressure adjustment screw①and the bracket fixing screw②.

Adjust vertically the bracket fixing screw②so that the auxiliary presser foot④goes up by 8mm from the upper

side of the needle plate when the presser bar lifter

③

is up.

When the adjustment is finished, fix tightly the bracket fixing screw②and adjust adequately the pressure

adjustment screw

①

After adjust height of the auxiliary presser foot④, adjust upper feed presser foot.

Adjusting the upper feed presser foot

Place the thread take up at the lowest position and lower the presser bar lifter③.

Open the rubber cover⑤of the upper cover and loosen the clamp screw⑥.

A different adjustment of vertical running amount between the auxiliary presser foot④and the upper feed presser

foot

⑧

is possible by adjusting the presser foot vertical move crank⑦.

When the adjustment is finished, fix tightly the clamp screw⑥ of the vertical move crank, and place the rubber

cover⑤.

[Fig. 8-10]

8.10) Adjusting feeding amount of auxiliary presser foot

The normal proportion of feeding amount between the feed dog and the auxiliary presser foot is 1:1. You can adjust the feeding amount of the auxiliary presser foot in accordance with the conditions of materials in use. As in Figure 8-11, loosen the nut

①

and move upward the presser foot vertical

move control shaft

②

, and the feeding amount becomes smaller. If you move it downward, the amount increases. Be sure to tight the nut

①

when the adjustment is finished.

[Fig. 8-11]

①

②

④

⑤

⑥

8mm

⑧

③

⑦

①

②

Page 30

This sewing machine is run by the thread trimming driving method, which uses the cam attached to the lower shaft as driving force. Thus, if you rotate the machine with the thread trimming solenoid is in operation in time of the machine adjustment, the moving knife collides with the needle causing harms on the both parts. So, when you run the machine with the solenoid in operation, run only in the regular thread trimming course (down stop ~ up-stop of the needle bar).

Caution

8.11) Adjusting feed cam

The timing of the feed dog and the needle is determined by moving vertically the feed cam④. First, turn the pulley with hands to fix the needle bar to the highest point. The standard position will be when the center of the No. 1 fixing bolt

②

the presser foot vertical move cam

①

is aligned with the center line of the upper shaft③, the bottom of the No. 1 fixing bolt

⑤

of the feed cam④is aligned with the center line of the upper shaft③.

[Fig. 8-12]

8.12) Adjusting for thread trimmer

A. Structure of thread trimmer

The structure of the thread trimmer of this machine is as follows in Figure 8-13:

[Fig. 8-13]

①

③

②

④

⑤

slide arm

thread

trimmer cam

thread trimmer

solenoid base

thread trimmer

solenoid

stopper

thread release

table

thread trimmer

lever

thread trimmer following crank

movable

knife

fixed blade

stopper lever

clutch lever

thread cover

Page 31

Adjusting fixing blade and movable knife a) Like in Figure 8-14, the standard position is where

the cut part of the movable knife is aligned with the center of the fixed blade.

b) When part

ⓐ

becomes bigger in Figure 8-14, three pieces of threads are to be produced, causing the thread missing after the trimming. If part

ⓑ

becomes bigger, it can cause a trimming miss. So be cautious in adjusting the right position.

[Fig. 8-14]

[Fig. 8-15]

[Fig. 8-16]

Adjusting the trimmer driving part a)

The standard assembly position is shown in Figure 8-15.

b) Fix the thread trimming following crank to the

trimming shaft as shown in the figure.

c) Fix the stopper lever to the bed so that the lever can

smoothly rotate in a range where the gap of the trimming shaft does not occur.

Adjusting the thread trimmer solenoid a) Working amount of the thread trimming solenoid

①

The standard working amount of the thread trimming solenoid is 4.6mm as shown in Figure 8-16.

②

Use the thread trimming solenoid stopper nut to control the working amount.

movabl e knife

fixed

blade

thread trimming cam following crank

stopper lever

4.6mm

stopper nut

91.2mm

Page 32

b) Adjusting the thread trimming solenoid

①

First, loosen the solenoid link pin fixing screw. Later, fix the solenoid base clamp screw where the clutch lever moves smoothly. Then, attach the slide arm to the right side. Fix the thread trimming solenoid link pin fixing screw where the solenoid stopper is attached to the solenoid.

②

If you run the solenoid under this circumstance, a gap of 0.5mm occurs between the thread trimming following crank and the slide arm as shown in Figure 8-17. This state is the standard.

[Fig. 8-17]

Adjusting the thread trimming cam a) Under the thread trimming solenoid is in operation,

rotate the trimming cam clockwise and fix the cam when it connected with the roller. (Refer to Figure 8-18)

b) When the thread cam following crank returned by

stopping the operation of the thread trimming solenoid, the edge end between the cam and the roller should be from 0.5 to 1.0mm. It is the standard. (Refer to Figure 8-18)

[Fig. 8-18]

0.5~1mm

solenoid link fixing screw

solenoid link pin

solenoid base

solenoid base fixing screw

thread release cable fixing nut

thread trimming following crank

0.5mm

solenoid arm

Page 33

[Fig. 8-19]

The standard position of the thread trimming cam following crank before its operation is shown in Figure 8-19. If the position of the roller is changed, adjust it with stopper and perform the adjustment describe above in a~b.

Caution

0.6mm

Adjusting the position of blade a) Adjusting the position of the movable knife and the

fixed blade The standard position of the movable knife is 7.5mm from the needle center, and 5 mm for the fixed blade.

b) Adjusting the progress amount of the movable knife

①

If you run the machine putting the solenoid in the operation mode, the movable knife will rotate by the thread trimming cam. The standard will be where the cut part of the movable knife progresses 1.5 to 2mm from the end edge of the fixed blade when the progress amount of the movable knife is in its maximum.

②

Adjustment is available by using the thread trimming lever.

[Fig. 8-20]

[Fig. 8-21]

1~1.5mm

7.5mm

5mm

Page 34

8.13) Adjusting blade pressure

As in Figure 8-22, the standard is when the contact between the movable knife and the fixed blade begins.

In particular, when the cutting quality gets worse by using a thick thread, strengthen a little bit the tension of the fixed blade.

8.14) Exchanging movable knife

Place a needle at the top by turning the pulley when replacing the movable blade

①

and take off the needle

plate by loosening two fixed screws

②

indicated in the figure 8-24. When assembling the exchange, assemble it in reverse order of disassembling.

8.15) Exchanging fixed blade

When exchanging the fixed blade①, pick the washer

③

and the inner bobbin stopper④out by loosening the screw

②

indicated in the figure 8-25 then disassemble by

loosening the fixed blade screw

⑤

. When assembling the

exchange, assemble it in reverse order of disassembling.

How to adjust the tension of the fixed blade; loosen the nut

①

(for adjusting tension of fixed blade) using a wrench box as shown in the figure 8-23 and adjust it with the screw

②

(for adjusting tension).

After adjusting, tighten the nut

①

(for adjusting tension)

using a wrench box.

[Fig. 8-22]

[Fig. 8-23]

[Fig. 8-24]

[Fig. 8-25]

movable knife

3mm

wrench box

movable knife

fixed blade

Page 35

oil whetstone

fixed blade

In case that the thread is cut or the cut part of the thread is not neat, please confirm the cutting part of the fixed blade. If the bottom of the fixed blade is worn, sharpen the end of the blade using an oil whetstone.(Refer to Figure 8-26)

8.17) Adjusting remaining amount of upper thread

After thread trimming, adjust the spare upper thread amount of the needle with the auxiliary thread tension adjusting nut①. The remaining thread becomes shorter when you turn it right, and the thread becomes longer if you turn left. (Refer to Figure 8-28)

8.16) Adjusting thread release

Adjust such that the dish of upper thread tension controller opens about 1mm when the thread trimming solenoid is in the operation.

Adjustment is available by loosening the thread release cable fixing nut and wire. (Refer to Figure 8-27)

[Fig. 8-26]

[Fig. 8-27]

[Fig. 8-28]

If the gap of the control dish is too narrow, it invites the shortening of the upper thread causing a possible thread missing in the next work. If the gap is too wide, a bad thread tightening caused because the dish will be always open.

Caution

①

solenoid link fixing screw

open amount 0.5~1mm

0.5mm

thread trimming following crank

solenoid arm

thread release cable fixing nut

solenoid base

solenoid link pin

solenoid base fixing screw

Page 36

Causes of Troubles and Troubleshooting

1) Sewing machine troubleshooting

No Symptom Checkpoints Root cause Corrective action

Needle breaks

Thread breaks

Poor thread adjustment

Upper thread falls out when starting to sew or sewing is skipped.

Trimming miss

Too short thread length after trimming

Reinsert the needle correctly

Change the needle Adjust the timing of feed dog Adjust the timing of needle and hook

Adjust the timing of needle and hook Adjust the timing of needle and hook

Thread the needle correctly Change the needle Insert the needle correctly

Reduce tension of upper thread Reduce tension of lower thread Adjust take-up lever spring

Adjust the upper and lower thread tensions Adjust the thread take up spring tension

Adjust the gap between the opener and hook

Reinsert the needle correctly and push in to its highest level.

Change the needle Insert the thread in the right way. Adjust the timing between the needle and hook

Increase the adjustment volume of the upper thread on the control box

Adjust the location and tension of the lower thread holder.

Readjust the needle’s up-stop film position

Readjust the movable knife setting position

Correct the tension adjustment and surface contact of movable and fixed knives.

Insert the needle correctly Replace movable knife or fixed knife.

Adjust the timing of trimming cam Readjust the thread release stroke Adjust the trimming timing Adjust the thread release stroke

Adjust the tension of the auxiliary thread tension control assembly

Adjust the thread take up stroke Increase the volume adjustment.

Needle is inserted into wrong position

Needle is bent Bad timing of feed dog Bad timing of needle and hook

Bad timing of needle and hook Bad timing of needle and hook

Wrong threading Bent needle or broken needle tip Needle inserted in the wrong position

Too tight upper thread tension Too tight lower thread tension Loose upper thread

Upper and lower thread tensions are bad Thread take up spring tension is inadequate

The gap between the opener and hook is inadequate

Needle is inserted into wrong position

Needle is bent Wrong direction The timing between the needle and hook is

bad The length of the remaining upper thread is too

short After trimming, lower thread holder does not

hold the lower thread Due to problems in the up-stop position of the

needle, the thread take up lever pulls the upper thread out of the needle when the sewing starts

The height and distance between the movable knife and the hook do not match

Tension and contact of movable and fixed knives are bad

Needle is not inserted correctly Scratch and abrasion of movable and fixed

knives The timing of trimming cam is wrong Thread release stroke is too small Wrong trimming timing The opening on the thread tension control plate

is too small Too strong tension on the auxiliary thread

tension control assembly Thread take up stroke is too large Volume is adjusted to too low

Direction and height of needle

Needle Timing of feed dog Ascending level of needle

bar Height of needle Gap between needle and

hook Threading method Needle Direction and height of

needle Upper thread tension Lower thread tension Working capacity of take-up

lever spring Thread tension Thread take up spring

tension Gap between opener and

hook Direction and height of

needle Needle Threading Gap between the needle

and the hook Remaining upper thread

length after trimming Lower thread holder

Check the up-stop position of the needle

The gap between the movable knife and the hook

Check the tension of fixed knife

Direction of the needle Blade side of movable and

fixed knives Trimming cam timing Thread release stroke Trimming timing Opening of the thread

tension adjusting plate Tension of auxiliary thread

tension adjustment assembly Thread take up stroke Thread release adjustment

volume on the control box