SunStar KM-957 Series, KM-967 Series User Manual

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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.

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KM-957 Series

Post bed with driven roller foot, one-needle, drop-feed back tack sewing machine

KM-967 Series

Post bed with driven roller foot, two-needle, drop-feed back tack sewing machine

Page 2

Best Quality

Best Price

Best Service

SunStar CO., LTD.

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 3

Safety rules for machines ..................................................................................................................................... 4

1. Specification ........................................................................................................................................................... 8

1) Sewing machine ......................................................................................................................................................... 8

2) Servo motor .................................................................................................................................................................8

3) 470 motor ................................................................................................................................................................... 8

4) 470 motor controller ................................................................................................................................................... 8

5) Clutch motor ............................................................................................................................................................... 9

6) Peripheral automation devices (optional) .................................................................................................................. 9

2. Installation .............................................................................................................................................................. 10

1) Installation of machine head .................................................................................................................................... 10

2) Installation of oil tray (oil fan) ................................................................................................................................. 10

3) Installation of automatic knee lifting solenoid and power switch box ................................................................... 11

4) Lubrication ............................................................................................................................................................... 11

5) Adjustment of belt tension ....................................................................................................................................... 12

6) Installation of program unit (for automatic trimming type) ................................................................................... 12

7) Installation of belt cover .......................................................................................................................................... 12

8) Installation and adjustment of synchronizer (for automatic trimming type) ......................................................... 13

9) Description of back tack button (for automatic trimming type) ............................................................................. 14

10) Check for machine stop position (for automatic trimming type) ......................................................................... 14

3. Machine Adjustment

1) Inserting needle ........................................................................................................................................................ 15

2) Removing bobbin and bobbin case ......................................................................................................................... 15

3) Inserting lower thread .............................................................................................................................................. 16

4) Inserting bobbin ....................................................................................................................................................... 16

5) Routing upper thread ................................................................................................................................................ 16

6) Adjusting thread tension .......................................................................................................................................... 17

7) Adjusting roller presser foot height and pressure ................................................................................................... 19

8) Rotating roller shaft ................................................................................................................................................. 19

9) Adjusting automatic knee lifter (optional) .............................................................................................................. 19

10) Adjusting stitch length ........................................................................................................................................... 19

11) Adjusting feed cam ................................................................................................................................................ 20

12) Adjusting feed dog height ...................................................................................................................................... 20

13) Adjusting timing of needle and hook .................................................................................................................... 21

14) Adjusting clearance between upper side of hook stopper and of needle plate groove ........................................ 22

15) Adjusting clearance between hook and opener .................................................................................................... 22

16) Adjusting for thread trimmer ................................................................................................................................. 23

17) Exchanging movable knife and fixed knife .......................................................................................................... 26

18) Adjusting gear box ................................................................................................................................................. 26

19) Adjusting ascending amount of roller shaft clutch ............................................................................................... 27

20) Exchanging needle width gauge set ...................................................................................................................... 27

21) Adjustments for KM-957SR ................................................................................................................................. 28

4. Causes of Trouble and Troubleshooting

1) Sewing machine troubleshooting .............................................................................................................................29

5. Table drawing

1) KM-967 .....................................................................................................................................................................31

2) KM-967-7 ..................................................................................................................................................................32

Table of Contents

Page 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 will be killed or suffer severe physical injuries.

Instructions here must be observed, or the user could suffer fatal or severe physical injuries.

Instructions here should be observed, or the user could face physical injuries or mechanical damages.

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

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1-1) Machine

Transport

Danger

1-2) Machine

Installation

Caution

1-3) Troubleshooting

Danger

In need of troubleshooting, call a trained A/S engineer who has been educated by Sunstar.

ⓐ Be sure to turn the power off before cleaning and repair. And wait for about 4 minutes

until the machine discharges completely.

ⓑ Part of or the entire machine should not be modified without any consultation with our

company.

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 physical damages such as the machine’s dysfunction 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 particularly 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.

secure enough space for repair.

ⓔ Danger of Explosion

Don’t run the machine near places with any danger of explosion. Don’t run the machine near places with any danger of explosion, including places

where sprays like aerosol are used in large quantities or oxygen is dealt with, unless

the exact actions concerning the operation are guaranteed to avoid the explosion.

ⓕ Illuminators do not come with the machine due to the machine’s characteristics. So,

users should install the lighting apparatus around the working area.

[Note] The details about the installment of the machine are described in Part. 2

Installation.

Page 6

The KM-957/967 Series are manufactured for industrial use to sew textiles and other similar materials. When running the machine, users should observe the followings.

ⓐ Read thoroughly the manual before operation of the machine to fully understand the

details about its operation.

ⓑ Do not forget to wear garment suitable for safe work. ⓒ Keep your hands or any part of the body away from the running part of the machine like

the needle, hook, thread take-up spring, pulley, etc.

ⓓ Do not remove any type of cover during operation for safety reasons. ⓔ Be sure to connect the earthed line. ⓕ Before opening an electric box such as a control box, be sure to shut off the power supply

and make sure that the power switch is set to “off.” ⓖ Be sure to stop the machine when threading the needle or before checking after sewing. ⓗ Do not switch on the power supply with the foot on the pedal. ⓘ Do not 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 areas around a

high frequency welding machine.

1-4) Machine

Operation

Warining

Warning

ⓐ 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.

1-5) Safety Device

Warning

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.

ⓓ

ⓐ

ⓒ

ⓑ

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“Caution Mark”is attached to the machine for safety.

When running the machine, read the directions of “Caution Mark”carefully.

1-6) Position of

Caution Mark

1-7) Content of

“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 주 전원의 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 나 서 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]

Warning

Page 8

Usage

Presser foot height

Needle

Max stitch length Thread trimming

HookMax speed

1) Sewing machine

① KM-957 (Post bed with driven roller foot, one-needle, drop-feed back tack sewing machine) Series

KM-957-7

KM-957

KM-957SR

Thin & heavy materials

3,500 SPM

2,500 SPM

5㎜

󳣉

Standard

Manual : 7mm Auto : 12.6mm

DP×5 #14

(#8∼#23)

Model name

Usage

Presser foot height

Needle

Max stitch length

Thread trimming

HookMax speed

KM-967-7

KM-967

Thin & heavy materials

3,000 SPM

4.2㎜

󳣉

Standard

Manual: 7mm

Auto: 12.6mm

DP×17 #16

(#8∼#23)

Model name

② KM-967 (Post bed with driven roller foot, two-needle, drop-feed back tack sewing machine) Series

Specification

2) Servo motor

MODEL

SC55-1A

SC55-2A

SC55-3A

VOLT

1 Phase 110V

1 Phase 220V

3 Phase 220V

WATT

550W

HERTZ

50/60 Hz

3) 470 motor

MODEL

PM470

PHASE HERTZ VOLT

4) 470 motor controller

MODEL

PC470

VOLT

1 : 110V

2 : 220V

MODEL

SUB CLASS

001

Page 9

5) Clutch motor

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

400W

HERTZ

50/60 Hz

6) Peripheral automation devices (optional)

󳢯S 󳥁：Servo motor 󳢯E 󳥁：470 motor

USAGEMODELOPTIONAL DEVICE

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. It has different pedals for acceleration, thread trimming, presser foot and ascending pedal. Types consist of SPDL-1 and EDPL-1 for fixed speed, and SPDL-2 and EDPL-2 for variable speed.

SPF-7

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

󳢯Max stroke: 31mm 󳢯Input voltage: DC 24V (DC 24~46V) 󳢯Pressure at 10mm stroke: 24kg

Page 10

Installation

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 54kg. 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

Insert the machine head hinge ① into the bed holes. After aligning it with the rubber hinge ②, stand the machine on the rubber cushion ③ that is in the direction of the user.

[Figure 1]

[Figure 2]

2) Installation of oil tray (oil fan)

Move the twice inclined side of the oil fan ① so that it faces the user and use 6 nails to fix it to the bottom of the table ②.

Page 11

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 avoid contact with your

eyes or skin. Inflammation may be caused otherwise. Never drink lubricants since they can cause vomiting or diarrhea. Keep out of the reach of children.

▶ Operate the machine only after adding oil when the machine is being used for the first time

or has been left unused for a long time.

[Figure 3]

⑴ When attaching the power switch box ①, refer to Figure 3

to make sure that it is placed at the very center of the solenoid bracket ②.

⑵ Attach the solenoid to the table ④ following the assembly

blueprint in the solenoid box. Loosen the fixing nut ⑤ so that the center of the solenoid shaft ③ is aligned horizontally with the bottom side of the table ④ and adjust the position of the link ball ⑥. When the adjustment has been made, fasten the fixing nut tightly.

⑶ 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.

3) Installation of automatic knee lifting solenoid and power switch box

Power switch box

Controller box

4) Lubrication

Be sure to supply oil into the oil holes marked red and the oil holes in the friction parts before operating the machine as in Figure 4.

[Figure 4]

Page 12

6) Installation of program unit (for automatic trimming type)

⑴ Fix the bracket ② onto the program unit ①, using 4

fixing nuts ③.

⑵ Then, use 2 fixing bolts ④ to tightly fix the bracket ②,

where the program unit ① has been attached, along with

the back cover.

[Figure 6]

7) Installation of belt cover

⑴ Slightly loosen the belt cover fixing screws (four) ①. ⑵ As in Figure 8, insert the belt cover B between the belt cover supporting bushing ② and the washer ③ and fasten. ⑶ Lay the machine back and insert the belt cover A between the belt cover supporting bushing ② and the washer ③. Then,

fasten belt cover B with the clamp screw ④ and the two washers ⑤, then fasten belt cover A. (See Figure 8.)

[Figure 7] [Figure 8]

5) Adjustment of belt tension

After installing the motor, unfasten the fixing nuts ①,② up and down and tension will be created to the belt ④ due to motor ③ falling by gravity. Fasten the fixing nut ① initially and then fasten the fixing nut ② tightly.

[Figure 5]

④

①

②

③

⑤

Belt cover B

Belt cover A

③

①

②

Page 13

8) Installation and adjustment of synchronizer (for automatic trimming type)

(1) Installation of the synchronizer

󳦲 Installing on the servo motor (in-built synchronizer)

A synchronizer sensor is attached to the back side of the

arm. The appropriate clearance between the synchronizer

and the pulley is 1.2mm.

󳦳 Installing on the 470 motor (external synchronizer)

Insert the synchronizer ① that is assembled like in Figure 10 into the center shaft ② of the sewing machine as in Figure 11. Then, after fastening it to the fixed pole ③ that is already assembled to the belt cover, fasten the two fixing bolts ④.

Speed sensor film

Fixing washer

Fixing bushing

Fixing screws

Synchronizer

shaft

Fixing

washer

Clearance adjustment bushing

[Figure 9]

[Figure 10]

[Figure 11]

⑵ Adjustment of synchronizer

󳦲 For Servo motor (in-built synchronizer)

Adjust the up-stop position of the needle such that the white carved sign ② on the upper shaft bushing meets the line ③ that is formed when belt covers A and B are assembled when the needle has stopped in the air. That adjustment can be made by loosening the pulley’s clamp screw① on the side with N.U carved signs and moving it sideways.

[Figure 13][Figure 12]

Page 14

󳦳 For 470 motor (external synchronizer)

Turn the pulley manually to position the needle bar at the lowest point about to move back up. Then, loosen the fixed screws on the film as in Figure 10 on page 13 and align the “DOWN”film with the film adjustment baseline and the

sensor housing baseline as in Figures 14 and 15. Tighten the fixed screws just enough so that the film does not rotate.

In the same way, place the thread take-up lever at the highest point, then loosen the fixed screws again and adjust the

“UP”film as in shown the figure. Be careful that the “DOWN”film A that was tightened before does not move

when adjusting the “UP”film.

Figure 15 is an enlarged view of the film location. As in the figure, match the sensor to the end of the arrow.

Sensor Base

DOWN

Film Adjusting Base

Setting the film when the needle is in a up-

stop position

Setting the film when the

thread take-up lever is at

the highest point

Sensor

Baseline

Setting

Area

Film-Adjusting Arrow

[Figure 14] [Figure 15]

9) Description of back tack button (for automatic trimming type)

Fix the back tack button or reverse button① located beside the switch box of the table with wooden nail ②. When the machine is in a “stop”mode, you can change the up-down

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.

10) Check for machine stop position

(for automatic trimming type)

Check for the machine stop position after moving the needle up and down by pushing the reverse button ①. See whether

the line where belt cover A and B meet and the white carved

sign on the bushing are aligned when the needle is in an up

position. If not, adjustment to the photo film of the

synchronizer or to the location of the magnetic holder will

be necessary since there may be problems with the trimming. In other words, the needle’s up-stop position

should be identical with the stop position of the needle bar

after the trimming operation. (See Figure 16)

[Figure 16]

White

carved sign

Needle

Down

Page 15

Machine Adjustment

Caution

▶ Always turn off the power when mounting a needle.

▶ If the operator mistakenly steps on the pedal while the power is on, the machine will start

automatically and can result in physical injuries.

▶ When using clutch motor, be aware that the motor will continue to rotate for a while even after the

power is switched off due to inertia. Start to work on the sewing machine only after the motor has come to a complete stop.

Caution

▶ Turn off the power when adjusting the lower thread tension.

▶ If the operator mistakenly steps down on the pedal while switched on, the machine will start

automatically and can cause physical injuries.

▶ When using the clutch motor, be aware that the motor will continue to rotate for a while after the

power is switched off. Start to work only after the motor has come to a complete stop.

1) Inserting needle

As in Figure 17, move the needle upper end so that it directly touches the upper side of the stopper hole ② when the groove ① of the needle is facing inward. Then, use the fixing screw ③ to fix the position of the needle.

2) Removing bobbin and bobbin case

Place the needle ① in the highest position, and then like in Figure 18, open the hook covers ② on the left and right, lift the bobbin holder ③ to remove the bobbin case ④ and the bobbin ⑤.

[Figure 17]

[Figure 18]

[ KM-967 Series ]

[ KM-957 Series ]

Page 16

Caution

▶ Turn off the power switch when routing the upper thread.

▶ If the operator mistakenly presses down on the pedal while switched on, the machine will start

automatically and can cause physical injuries.

▶ When using the clutch motor, be aware that the motor will continue to rotate for a while after the power is

switched off. Start to work on the sewing machine only after the motor has come to a complete stop.

3) Inserting lower thread

⑴ Insert the bobbin ① into the bobbin case ②. ⑵ Pass the thread through the “A”part of the bobbin case

and pull out the thread from the lower thread tension adjustment plate ③.

⑶ Pull the thread end through “B”of the bobbin case ②

and insert the bobbin case into the hook.

⑷ The adequate length of the pulled-out lower thread is

50mm.

[Figure 19]

4) Inserting bobbin

Stop the needle ① at the highest position. Following the

Figure 20, insert the bobbin (where the thread is rolled onto) or the bobbin case ② into the hook ③. After laying down the bobbin holder ④, close the slide plates on the

right and left.

[Figure 20]

5) Routing upper thread

Place the thread take-up lever to the highest position and hang the upper thread like in Figure 21. The adequate length of

upper thread extending from the needle hole is 50mm for initial sewing.

[Figure 21]

(Model) a) KM-967-7 b) KM-967

(Model) a) KM-957-7 b) KM-957

Page 17

6) Adjusting thread tension

The result of the needlework depends on the sewing conditions such as the sewing material, used thread and stitch length. So

please adjust as desired.

[Figure 22]

- good sewing

- upper thread tension is strong while the lower thread tension is weak

- upper thread tension is weak while the lower thread tension is weak.

⑴ Adjusting the upper thread tension

Like in Figure 23, turning the tension adjustment nut ①

of the thread tension control assembly clockwise makes

the upper thread tension stronger and counterclockwise

makes it weaker.

⑵ Adjusting the lower thread tension

Like in Figure 24, turning the tension adjustment nut ①

of the hook clockwise makes the lower thread tension

stronger and counterclockwise makes it weaker.

⑶ Adjusting the thread take up tension

󳦲 Adjusting the thread take up stroke

As in Figure 25, loosen the stopper fastening screw ①, and turn the thread take up lever’s spring stopper ② clockwise

to make the stroke smaller and counter clockwise to make it bigger. The thread take up stroke is normally 5~10mm.

󳦳 Adjusting the thread take up tension

As in Figure 26, loosen the screw ① of the thread tension control assembly, and 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. The thread take up spring tension is normally 50~80g.

[Figure 23]

[Figure 24]

[Figure 25]

[Figure 26]

Strong

Small

Big

Weak

Strong

Weak

①

Weak

Page 18

[Figure 27]

⑷ Adjusting the thread release stroke. (for automatic trimming type)

If the upper thread falls out from the needle hole after trimming, check whether the plate ① opens while the trimming is in action. For the adjustment of plate opening level, put the solenoid ② in action, and adjust by moving solenoid collar ③ back and forth to make the opening of the thread tension adjusting plate① 0.8 mm. Also, when the thread release

solenoid is not in action, check whether the plates are closely adhered to each other.

(Caution) ※ If the plates do not open enough during trimming action

even when the assembling is correctly done, check

whether or not the upper thread length adjustment

volume, which is at the front of the control box, is low.

⑸ Adjusting the auxiliary thread tension control assembly

(automatic trimming type)

As in Figure 28, when the auxiliary thread tension adjustment nut ① is turned clockwise, the length of the

thread after trimming gets short. The other way makes

the thread long. The appropriate length of the upper

thread on the needle after trimming is 35~45mm. (This

can also be done by using the remaining upper thread

length adjustment volume of the control box.)

[Figure 28]

Small

Big

Caution

▶ 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 slip.

▶ When adjusting the machine with the switch on, be sure to be extremely cautions.

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

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

About 0.8mm

Page 19

7) Adjusting roller presser foot height and pressure

⑴ Adjusting the height of the presser foot

Loosen the pressure adjustment screw ① and the presser bar bracket fastening screw ②, and lift the presser bar lifter ③. Make the distance between the upper side of

the needle plate and the lower side of the presser foot

7mm. Then, tightly fasten the bracket fastening screw

②. Be sure that the presser bar does not move.

⑵ Adjusting the tension of the presser foot

Turning the pressure adjustment screw ① to the right

increases the presser foot tension, and turning it to the

left makes it weaker.

[Figure 29]

8) Rotating roller shaft

⑴ Raise the presser bar lifter. ⑵ Hold the roller presser foot bracket guide ① as in

Figure 30 and move it down and left. Then, there will

be some space to exchange the guage.

⑶ To restart, hold the roller presser foot bracket guide

① and turn it to the right direction.

[Figure 30]

9) Adjusting automatic knee lifter (optional)

First, loosen the solenoid cover fixing screw ①. If the joint connecting rod ② is moved clockwise, the

ascending amount of the presser foot grows. It falls

when turned counterclockwise. After the adjustment, tighten the fixing screw ① tightly.

[Figure 31]

10) Adjusting stitch length

⑴ As in Figure 32, press the stitch length adjusting button

① and turn the pulley ② slowly until you feel that the

button has entered the feed cam groove.

⑵ After the button ① has entered the feed cam groove,

continue turning the pulley ② to align desired stitch length marked on the pulley ring ③ with the carved sign ④ on the arm tray or the stitch length hole ⑤ on the belt

cover.

⑶ After the desired stitch length is set, take your hands off

the button ①. (The unit of the stitch length is mm.)

[Figure 32]

④ ③

①

⑤

②

Page 20

[Figure 33]

[Figure 34]

11) Adjusting feed cam

⑴ The adjustment of the feed cam body ① will determine the timing of the feed dog and the needle. Lay the machine back

and move the needle to its highest position. The standard position will be made when the baseline ② of the feed cam body ① is aligned with the carved sign ③ on the bottom of the bed.

⑵ If the feed dog is faster than the needle, loosen the feed cam body fixing screw ④ and turn the feed cam body in the

arrow direction and then tighten the feed cam body fixing screw ④.

Turn it in the opposite direction to make the feed dog faster then the needle.

12) Adjusting feed dog height

Loosen the wheel feed dog clamp screw ① and the wheel feed dog driving gear clamp screw ② and move the wheel feed dog fixing plate ③, the wheel feed dog ④, and the wheel feed dog driving gear ⑤ so that the upper side of the wheel feed dog ④ is protruding about 0.8mm from the needle plate top ⑥. The clearance between the wheel feed dog ④ and the wheel feed dog driving gear ⑤ is about 0.5mm.

Page 21

13) Adjusting timing of needle and hook

⑴ Adjusting the height of the needle and the timing of hook

Turn the pulley manually so that the needle will be 1.8mm from the lowest position. Then adjust so that the edge of the

hook will be directly in the center of the needle. The height of the needle bar can be adjusted by loosening the clamp screw ①. The hook timing is adjusted by loosening the lower shaft collar clamp screw ② and aligning the hook shaft gear ④ and the lower shaft gear ⑤ and fixing the lower shaft collar ③ so that it will not move. After this adjustment has been made, the hook edge will be placed 1mm above the needle’s thread hole top as in Figure 35.

⑵ Adjusting the clearance between the needle and the hook edge

When the needle goes up from the lowest point and the hook edge fits the needle center, loosen ①, ②, ③, ④, ⑤ in

Figure 37 so that the clearance between the hook edge and the needle groove inside is within 0.05~0.1mm when the needle bottom touches softly the needle guide plate ① of the hook as seen in figure 36. Adjust the left and right sides ⑥ of the hook tray. (After adjustment, tighten ①, ②, ③, ④, ⑤.)

[Figure 35]

[Figure 37]

Hook edge

1mm

1.8mm

[Figure 36]

Hook edge

Needle

Touching part

0.05~0.1mm

Page 22

14) Adjusting clearance between upper side of hook stopper and needle plate groove

As in Figure 38, the clearance between the upper side of hook stopper and needle plate groove is set to 1~1.2mm by default.

This clearance could impact the stitch tension and thread separation when trimming, so it needs to be checked. If there is a problem with the clearance, move the hook tray bushing ① up and down to adjust as in Figure 38, but move it cautiously after checking the assembly status of surrounding parts. The hook tray bushing ① is fixed with a fixing screw ② and when moving it vertically, adjust with the hook tray bushing fixing screw ②, hook shaft gear fixing screw ③, the bushing adjusting pin fixing screw ④ and the bushing adjusting pin ⑤. After completion, the hook shaft should turn smoothly without moving

vertically. Fix the lower shaft gear while the hook edge and the needle timing do not change.

[Figure 38]

[Figure 39]

15) Adjusting clearance between hook and opener

When the opener ② is pulled into the arrow direction to the max, the clearance between hook ① and opener ② should be

0.1~0.3mm. Loosen the opener position stopper clamp screw ③ and turn it left and right to adjust that.

Page 23

16) Adjusting for thread trimmer

⑴ Adjusting the trimmer driving part

󳦲 Fixing the position of trimming cam

󳡬 Turn the pulley using a hand to place the needle

bar ① at its lowest position.

󳡭 With the left side of the trimming cam ② softly

attached to the right side of the lower shaft medium bushing ③, turn the cam to align the base point ④ with the carved sign ⑤ in the lower shaft medium bushing crank.

󳡮 Fasten tightly 3 trimming cam fixing crews ⑥.

Now, turn the pulley using a hand to see whether or not the machine turns smoothly.

󳦳 Adjusting the trimmer link stopper (See Figure 41.)

󳡬 Once the necessary trimming for trimming cam lead is finished, make sure to turn the machine pulley to place the

trimming cam ③ in the right position, so that the roller① can enter the complementary straight line range ②. 󳡭 Press down the trimmer shake linkage ④ to make the roller ① come inside the trimming cam ③, ※ Adhere the stopper adjusting body ⑨ with the left equal point of trimmer shake linkage ⑥ to make the left equal

point of the roller ① adhere smoothly ⑤ to the left inside of the cam’s complementary straight line ②, and the

right equal point of the trimmer shake linkage ⑥ adhere ⑧ smoothly to the inside of the stopper ⑦. Once this is

done, tightly fasten 2 fixing screws ⑩. ※ Once such adjustments are made, the trimmer shake linkage ⑥ will not move even when shaken to its sides (the

roller is inside the cam). Make sure to check if the trimmer shake linkage ⑥ returns to its original position

quickly and smoothly when released. If not, proceed with horizontal adjustment of stopper ⑦ and the stopper

adjusting body ⑨. 󳡮 Check to see whether the trimmer shake linkage ⑥ and the stopper adjusting body ⑨ move lightly horizontally

when the trimmer is moved manually.

[Figure 40]

[Figure 41]

(complementary straight line)

trimming finishing point

movable knife operation

starting point

[Trimming cam lead]

Page 24

(2) Adjustment of linking device for movable knife shaft and the trimmer driving part

󳦲 When the previously explained adjustment of trimmer driving part is complete, it is in its normal position where the

trimmer shake linkage ① has returned to its up position after trimming action.

󳦳 First, loosen the fixing screw ② of the movable knife shaft (right), hold the initial assembling angle of the crank

(right)③ to be about 35°to the left from the perpendicular line ⑤ drawn to its center ④. To make sure that this position is maintained, adjust the length of the ball joint linking bar ⑥ which comes assembled to trimmer shake linkage ①. Also, adjust the fixing screw ② tightly. (※ For the adjustment of the ball joint linking bar ⑥, turn the linking bar ⑥ after loosening the nuts (left) ⑦ and (right) ⑧. Then turn the linking bar ⑥.)

󳦴 Then, loosen fixing screw ⑨ of the movable knife shaft crank (left), and in the same angle as the crank(right)’s ③

lower assembling angle ⑩, place the crank(left) ⑪. Loosen the fixing bolt ⑫ and the hinge screw ⑬ to adjust the length of the linking rod ⑭. Then tighten the fixing bolt ⑫ and the hinge screw ⑬.

⑶ Adjusting movable and fixed knives

󳦲 Adjusting the position of movable knife-edge and

hook 󳡬 As in 󳟆 in the Figure, loosen the movable knife

fixing screw ③ and adjust the movable knife so that the edge of the movable knife ① will be positioned in the center of the V-shape groove of the hook ②.

󳡭 Then adjust the distance between the bottom of

the movable knife ① and the top of the hook ② to be within 0.5mm. (※ After loosening the movable knife shaft collar clamp screw ④ and the movable knife shaft crank (right) clamp screw ⑤, adjust the movable knife shaft ⑥ vertically. Then tighten the clamp screws ④ and ⑤.)

[Figure 42]

[Figure 43]

V-shape groove

Page 25

󳦳 Adjusting movable knife and fixed knife

󳡬 As shown in Figure 44, move the movable knife ① and restore the position slowly. When doing so, fix the

position of the fixed knife ③ so that edge ④ of the fixed knife ③ touches the 3mm before the fixed knife

trimming point ②. 󳡭 After aligning the fixed knife ③ and the top of the movable knife ①, be sure to stick the upper side 󳟆 and bottom

side 󳟇 of the knife edge to the external side of the movable knife edge.

󳡮 Under the above conditions, tighten the fixed knife clamp screw ⑤. Be sure that the fixed knife does not move. 󳡯 After adjustment, move the trimmer manually once again to check the cross section of the fixed knife and the

movable knife as in the figure.

[Figure 44]

Cross section of the fixed knife and the movable knife

good

bad

Top side adhesion

Trimming point

Fixed knife base point

󳦴 Final fixing of the movable knife’s initial position

[Adjustment Order] ⓐ Manually turn the pulley to finish trimming of the trimming cam ④. Place the cam so that the roller ⑥ can enter the

complementary straight line ⑤.

ⓑ Slightly loosen the fixing screws ⑦⑧of movable knife shaft crank of both the left and the right. ⓒ Press the roller ⑥ inside the cam by operating the trimmer solenoid. Push the linking bar ⑨ to the right or the left crank

linking rod ⑩ to the left so that there is no excess room in each linking device. When this is done, the roller ⑥ gets to adhere to the right side of the cam’s complementary straight line ⑤, as can be seen in the picture ⑪. While maintaining this position, adjust to make the movable knives on the right and the left protrude about 0.5~1mm from the fixed knifeedge. Now, tightly fasten the crank fixing screws ⑦⑧on both sides.

ⓓ If the initial position of the movable knives of both sides are to be adjusted slightly, use the ball joint linking bar ⑨. If

only the movable knives are to be adjusted, use the linking rod ⑩.

※ The standard initial assembling position of the movable knife ① is where the movable knife-edge protrudes about 0.5~1mm ③

from the fixed knife edge ② when the trimming action is finished, that is, when the movable knife is in its initial stop position. When fixing the position of the movable knife, the following directions must be followed so that the power generated in the cam ④ is delivered without any loss to the trimming action.

[Figure 45]

(complementary straight line)

trimming

finishing point

Starting point of

movable knife’s

movement

Page 26

󳦵 Adjusting lower thread holder ※

When the movable knife ① has finished trimming and returned to its original position (arrow 󳟆), loosen the fixing screw ③ so that the clearance between the movable knife edge and the edge of the lower thread holder ② is about 8mm and the equal point of the lower thread edge is about 0.5mm inside (arrow 󳟇). Make sure to check whether the inside of the movable knife and the equal point of the lower thread holder edge is completely touching as in part 󳟈.

⑷ Checkpoints on the assembling status of other trimming

devices 󳦲 Check the starting point of the movable knife when

the trimming action takes place Operate trimming movement manually to check whether the thread take up lever is in the lowest or at least 16mm raised level when the movable knife starts working, like in Figure 47.

󳦳 Maintenance of fixed knife

When the thread does not get trimmed or if the trimmed section of the thread is sloppy, please check the edge condition of the fixed knife. If the edge of the knife is too dull, sharpen the edge using oil stone or sand paper.

17) Exchanging movable knife and fixed knife

⑴ Open the hook cover. ⑵ Loosen the screw ① and remove the fixed knife holder

cover ②.

⑶ Loosen the fixing screw ③ to disassemble the washer ④

and fixed knife ⑤. ⑷ Loosen the bolt ⑥ and dissemble the movable knife ⑦. ※ To assemble, follow the reverse order of disassembling.

18) Adjusting gear box

When adjusting the operating amount of the gear box ①, loosen the fixing nut ④ and ⑤ and adjust the distance between the gear box ① and the gear box body ② to be 8mm, and between the gear box ① and the gear box body (right) ③ to be 25mm. Lower the reverse lever fully when doing so and the standard clearance between ① and ② will be 3mm. Then, loosen the gear box stopper ⑥ and the fixing nut ⑦ and adjust the gear box stopper ⑥ so that the clearance between the gear box stopper ⑥ and the gear box body (left) ① is 0.2mm. Tighten the fixing nut ⑦.

[Figure 46]

[Figure 47]

about 16mm

Lowest point of thread take up lever

(OIL STONE) (SAND PAPER)

[Figure 48]

[Figure 49]

[Figure 50]

Page 27

19) Adjusting ascending amount of roller shaft clutch

Open the back cover and loosen the nut ① and adjust the

length of the joint linking bar C. Then, loosen the clamp screw ③ and push it so that it touches directly below the roller shaft transfer holder ④. After adjustment, tighten the nut ① and the clamp screw ③.

[Figure 53]

[Figure 51]

[Adjusting the left/right hook base]

When replacing with a wider or narrower gauge than the needle width in use, the hook edge and needle distance may not fit correctly. In this case, loosen the screws ①,②,③,④,⑤ as can be seen in the picture, and replace the feed dog or adjust the distance between the hook edge and the needle. Fasten after making the adjustments.

⑵ Assembling order

After assembling in the reverse order of disassembling, adjust in reference to the gear box assembly order on page 26.

20) Exchanging needle width gauge set

⑴ Disassembling order

[Caution] Turn off the power switch.

1. Open the hook cover.

3. Remove the needle.

7. Disassemble the post (needle plate bracket).

6. Disassemble the auxiliary needle plate and the main

needle plate.

5. Disassemble the needle guide.

4. Disassemble the needle holder.

2. Raise the presser bar lifter and turn the roller left.

[Figure 52]

Page 28

[Figure 54]

21) Adjustments for KM-957SR

⑴ Adjustment of Feed Dog Height

Slightly loosen the fixing screw for the wheel feed dog fixing plate①, the fixing screw for the middle gear②, the fixing screw for the wheel feed dog driving gear③, and the fixing screw for the wheel feed dog height adjusting pin④. And then adjust the wheel feed dog height adjusting pin⑤ to make the wheel feed dog protrude some 0.8mm from the needle plate face. Make sure to set the space between the wheel feed dog⑥, the middle gear⑦, and the wheel feed dog driving gear⑧ to be minimum to prevent backlash.

⑴ Adjustment of Feed Dog Balance

Slightly loosen the gear base fixing screw① and the needle plate fixing screw②, and adjust the balance of the gear base. To make the fine adjustment of the feed dog direction, use the four directions of the gear base adjusting screw③. This way, the leftward or rightward leaning or twist of the feed dog④ can be corrected. Next, adjust the needle plate⑥ to place the needle⑤ at its center.

[Figure 55]

Page 29

Causes of Troubles and Troubleshooting

1) Sewing machine troubleshooting

No Symptom Checkpoints Root cause Corrective action

Needle breaks

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

Needle is inserted into wrong position

Needle is bent

Bad timing of feed dog

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

Too big take-up lever

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 the end of the needle is broken

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

Reinsert the needle correctly

Change the needle

Adjust the timing of feed dog

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

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

Thread cuts

Poor thread adjustment

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

Page 30

No Symptom Checkpoints Root cause Corrective action

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

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

Trimming miss

Too short thread length after trimming

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

Page 31

Table Drawing

1) KM-967

Page 32

2) KM-967-7