SunStar KM-570BL User manual

SSUUNNSSTTAARR MMAACCHHIINNEERRYY CCOO..,, LLTTDD..
User’s
Manual
KM-570BL
1 needle, drop feed,
needle feed sewing machine
KM-570BL-7
1 needle, drop feed,
needle feed sewing machine
with automatic thread trimmer
KM-572BL
2 needle, drop feed,
needle feed sewing machine
KM-572BL-7
2 needle, drop feed,
needle feed sewing machine
with automatic thread trimmer
R
1) For proper use of the machine, thoroughly
read this manual before use.
2) Keep this manual in a safe place for future
reference in case the machine breaks down.
MMMMEE--006600771100

Best Quality
Best Price
Best Service
SSUUNNSSTTAARR MMAACCHHIINNEERRYY CCOO..,, LLTTDD..
R
1. Thank you for purchasing our product. Based on the rich expertise and
experience accumulated in industrial sewing machine production, SUNSTAR
will manufacture industrial sewing machines, which deliver more diverse
functions, high performance, powerful operation, enhanced durability, and
more sophisticated design to meet a number of user’s needs.
2. Please read this user’s manual thoroughly before using the machine. Make
sure to properly use the machine to enjoy its full performance.
3. The specifications of the machine are subject to change, aimed to enhance
product performance, without prior notice.
4.
This product is designed, manufactured, and sold as an industrial sewing
machine. It should not be used for other than industrial purpose.

Safety Rules for Machine .......................................................................................................................................... 4
1. Specification ............................................................................................................................................................... 8
1) Sewing machine ............................................................................................................................................................. 8
2) Motor .............................................................................................................................................................................. 8
3) Peripheral automation devices (optional) ..................................................................................................................... 8
2. Installation ................................................................................................................................................................... 9
1) Installation of machine head ......................................................................................................................................... 9
2) Installation of power switch box ................................................................................................................................... 9
3) Oil supply ..................................................................................................................................................................... 10
4) Belt tension adjustment ............................................................................................................................................... 10
5) Installation of program unit (Trimmer Type) .............................................................................................................. 11
6) Installation of belt cover .............................................................................................................................................. 11
7) Installation of thread stand .......................................................................................................................................... 11
8) Installation of knee lifting pad .................................................................................................................................... 12
9) Installation of air pressure related parts and checking their functions (optional) ..................................................... 12
3. Adjustment of the Machine ............................................................................................................................. 13
1) Inserting the needle ...................................................................................................................................................... 13
2) Removing bobbin ........................................................................................................................................................ 13
3) Winding the lower thread ............................................................................................................................................ 14
4) Routing the upper thread ............................................................................................................................................. 14
5) Adjusting the thread tension ........................................................................................................................................ 15
6) Adjusting the tension of the presser foot .................................................................................................................... 17
7) Stitch length adjustment .............................................................................................................................................. 17
8) Adjusting timing of needle and hook .......................................................................................................................... 17
9) Clearance adjustment between hook and opener ....................................................................................................... 18
10) Adjusting feed dog height ......................................................................................................................................... 19
11) Adjusting the auxiliary presser foot and the upper feed presser foot ...................................................................... 19
12) Adjusting timing of the auxiliary presser foot, the upper feed foot and the needle ................................................ 21
13) Adjusting stroke of upper feed presser foot .............................................................................................................. 21
14) Adjusting safety device ............................................................................................................................................. 22
15) Adjusting the trimming device .................................................................................................................................. 22
16) Adjustment of Thread Release .................................................................................................................................. 25
17) Installation of Automatic Lap Lifting Device (optional) ......................................................................................... 25
4. Causes of Troubles and Troubleshooting ............................................................................................... 27
1) Sewing machine troubleshooting ................................................................................................................................27
5. Table drawing ......................................................................................................................................................... 29
Table of contents

44
Safety Rules for Machine
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]
Danger Instructions here shall be observed strictly.
Otherwise, the user will be killed or suffer severe physical injuries
Warning Instructions here must be observed, or the user could suffer fatal or severe
physical injuries.
Caution 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

55
1-1) Machine
mobilization
Danger
1-2) Machine Installation
Caution
1-3) Troubleshooting
Danger
In need of troubleshooting, it should be done by the trained A/S engineer of our company.
ⓐAhead of cleaning and repair, be sure to shut off the power supply. And wait for about 4
minutes till the machine discharges completely.
ⓑEven a part or all of the machine should not be modified without any consultation with
our company.
ⓒIn case of repair, you should change the damaged part into the standard article of our
company.
ⓓAfter repair, please put again the safety cover disjointed while repairing.
Only personnel with a full understanding of the safety rules should move the machines.
The following directions must be observed when delivering the machines.
ⓐAt least two persons should work together.
ⓑIn case the machine should be transported, please wipe the oil covered on the machine
to prevent accidents
Because physical damage such as the functional obstacles and breakdowns are likely to
occur according to the environment in which the machine is being installed. Therefore,
the following preconditions should be fulfilled.
ⓐPlease keep the order from top to bottom when unpacking the package. Especially,
mind that the nail on the boxes.
ⓑBecause machines are apt to be contaminated and corroded by dust and moisture, you
should install the climate controller and should clean the machines regularly.
ⓒKeep the machines out of the direct rays of the sun.
ⓓKeep both sides and the backside of the machines off at least 50cm from the wall to
secure enough space to repair.
ⓔDon’t run the machine near the places with the dangers of explosion. Don’t run the
machine near the places with the dangers of explosion, including the places where the
spraying product like aerosol are used in large quantities or oxygen are dealt with,
unless the exact actions concerning the operation are guaranteed to avoid the
explosion.
ⓕBecause of the peculiarity of the machine, any illuminators are not equipped. So,
users should install the lighting apparatus around the working area.
[Note] The details about the installment of the machine are described in
No. 2 Installations.

66
KM-570/572 series are manufactured for industry use to sew textiles and other similar
material. In case of running the machine, users should observe the following things.
ⓐAhead of operating the machine, please read the manual and understand fully the details
on its operation.
ⓑDon’t forget to put on the garment suited for the safe work.
ⓒKeep your hands or a part of the body away from the running part of the machine like a
needle, hook, thread take-up spring and pulley etc.
ⓓDon’t remove any kind of cover for safety while running the machine.
ⓔBe sure to connect the earthed line.
ⓕBefore opening the electric box such as a control box, be sure to shut off the power
supply and make sure that the power switch should be put on“off.”
ⓖWhen threading the needle or before checking after sewing, be sure to stop the machine.
ⓗDon’t switch on the power supply with the foot on the pedal.
ⓘDon’t run the machine when the cooling fan are not running. Be sure to clean the air
filter in the control box once a week.
ⓙIf possible, keep off from the strong electronic wave like a high frequency welding
machine.
1-4) Machine Operation
Warning
Warning
ⓐSafety Label: Suggestions while running the machine are stated.
ⓑThread take-up spring cover: the device to prevent the human body from touching the
thread take-up spring.
ⓒBelt cover: the device to prevent hands, feet and clothing from getting jammed by the
belt.
ⓓFinger guard: the device to prevent fingers from contacting the needle.
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.
ⓓ
ⓐ
ⓒ
ⓑ

77
“Caution”is attached to the machine for safety.
In case of starting to run the machine, read the directions of“Cautions”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 꺼주십시오.
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]
Caution

UsageModelOptional device
8
1) Sewing machine
1
Specification
2) Motor
①Servo motor controller
KM-570BL-7 KM-570BL KM-572BLKM-572BL-7
Purpose
Lubrication Method
Max. Sewing Speed
Max. No. of Stitches
Needle Stroke
Manual
Lap
Automatic
Hook
Needle
Automatic Backtacking Device
Automatic Trimmer
Bed Size
For Heavy Materials (sheet, bags, tents, sofas, etc.)
Automatic Lubrication
2,000spm
9mm
36mm
10.5mm
16mm
2~6mm
Horizontal 2.5x Hook
DP×17 #23 (#14~#25)
568×178mm
②Clutch motor
3) Peripheral automation devices (optional)
AUTO KNEE LIFTING
SYSTEM
PRODUCTION
COUNTER
MATERIAL EDGE
SENSOR
STANDING PEDAL
SCOUN-1
SEDG-1C
SEDG-2C
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-1C for edge sensing type and SEDG-2C 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.
When the pedal is placed at reverse step 1, the presser foot is automatically lifted. It is because the
machine has employed the pneumatic cylinder structure.
Presser Foot
Lift
Crossing Between Upper Feed Presser
Foot and Supplementary Presser Foot
Power Supply
Category
16mm (optional) 16mm (optional)
－－
Basic Supply
Basic Supply
1-phase 110/220V,
3-phase 220V
1-phase 110/220V,
3-phase 220V/380V
1-phase 110/220V,
3-phase 220V
1-phase 110/220V,
3-phase 220V
Basic Supply
Basic Supply
－
－
－
－
MODEL
SC55-1B
SC55-1B
SC55-3B
VOLT
1 Phase 110V
1 Phase 220V
3 Phase 220V
WATT
550W
550W
550W
HERTZ
50/60 Hz
50/60 Hz
50/60 Hz
MODEL
HEC-1706(1 Phase)
HEC-1705(3 Phase)
VOLT
110/220V
220/380V
WATT
400W
400W
HERTZ
50/60 Hz
50/60 Hz

9
2
Installation
1) Installation of machine head
※Insert hinge rubber①into the table. As described in“Figure 1”, put the oil pan corner in the middle of the head
supporting rubber②and attach the table. After putting the hinge ③in the bed hole, insert the hinge rubber①and install
the sewing machine in the table corner rubber cushion.
[Figure 1]
2) Installation of power switch box
When attaching the power switch box①, as shown in “Figure 2”,
attach it to lower right corner of the table.
①
[Figure 2]
Warning
▶In case of installing the machine, it should be performed by the trained engineer.
▶In case of wiring work, be sure to leave the work to an expert or an agent.
▶The machine weight over 42kg. At least 2 persons should carry out the installing work.
▶Plug in after finishing the installing work. In case the user press on the step by mistake, the
machine runs automatically. By doing so, it can cause the physical injuries.
▶Connect the earthed lines.
Imperfection of the connection of the earthed lines gives rise to an electric shock or malfunction.
▶Set the belt cover on top of the machine.
▶In case of bending the machine backward or returning to the original condition, be sure to use
both hands. If you use only one hand, it causes physical injuries by slipping.
①
②
③
④

10
[Figure 3]
3) Oil supply
(1) Fitting the magnet to remove chips (iron powder).
Find the magnet for chip removal①in the accessory box and attach it to the oil pan as in “Figure 3.”
※Do not use the magnet for other purposes. Operating the sewing machine without the magnets may cause malfunction
and adverse effects to its durability.
(2) Filling the oil pan with lubricants
A. Fill the lubricant up to the“H” point.
B. You should use the exclusive oil provided by“SUNSTAR” for industrial sewing machines or TELLUS C10” of the
Shell company.
C. If the oil lever drops to the“L” level, replenish it to the“H” point.
D. Change the lubricant once every two weeks.
4) Belt tension adjustment
After installing the motor, if you sufficiently loosen the
fixed nuts ①and ②, tension in the belt④will occur
naturally because of the weight of the motor③. At this
moment, tighten the fixed nut①and use fixed nut ②to fix
it firmly. (See figure 4)
[Figure 4]
④
③
①
②
Caution
▶Be sure to plug in after finishing oil supply.
If the user press on the step by mistake, the machine runs automatically. By doing so, it can
cause the physical injuries.
▶In case of treating the lubricant, don't bring the lubricant into contact with eyes or the skin. Its
contact can cause an inflammation. And don't drink the lubricant. It can cause vomiting or
diarrhea. And Keep it out of the reach of the children.
▶Be sure to run the machine after supplying oil in case you should start to run it for the first time,
or in case it has not been used for a long time.
①

11
7) Installation of thread stand
As shown in“Figure 7”, assemble the thread stand①,
insert it in the table hole, and use the fixed nut②and
washer③to fix it.
[Figure 7]
6) Installation of belt cover
A. Set the groove at the bottom of belt cover“A”① to be
aligned with the groove of the head of the belt cover
supporting screw②, and insert the cover into the groove.
Use the belt cover fixing screws ③(2EA) to fix the
cover to the body of the machine.
B. Insert the belt cover“B”② into the belt cover“A”①
while maintaining the balance. Use the belt cover fixing
screws (3EA) to fix the belt covers to the body of the
machine.
[Figure 6]
5) Installation of program unit (Trimmer Type)
A. Use 4 fixed screws③to fix the bracket ②on the
program unit①
B. In the program unit①, use two fixed bolts ④to tightly
fix the assembled brackets②.
[Figure 5]
③
①
②
④
①
②
③
④
①
②
③

12
8) Installation of knee lifting pad
A. Find the lap lifting pad (ass'y) ①in the accessory box
and insert it into the shaft of the oil pan's control body
②.
B. Loosen bolt ③and maintain knee-lifting pad in vertical
position to tighten it.
[Figure 8]
9) Installation of air pressure related parts and checking their functions (optional)
(1) Installation
As shown in the figure, after fixing the air pressure filter
on the bracket, use the neck screw to fix the bracket on
the lower side of the table.
(2) Air pressure adjustment
a) Adjust the pressure by taking out and lifting the air
pressure filter①knob ②.
b) After adjusting the air pressure to. 0.49㎫(5㎏f/㎠)
turn the knob ②to its original position and the
adjustment is over.
[Figure 9]
①
②
Caution
▶In need of regulating the machine with the switch on or with the air injected, please pay special
attention to your safety.
▶Please adjust air pressure to 0.5Mpa.
①
②
③

13
1) Inserting the needle
As in Figure 10, while the needle groove①is headed inward, place the upper end of the needle to closely contact the upper
stopper hole②, and then fix the needle by using the fixing screw③.
2) Removing bobbin
Place the needle ①in the highest position.
As in Figure 11, open the sliding plate②and erect the hook③and the bobbin holder④to separate the bobbin⑤(see Figure
11).
3
Adjustment of the Machine
[Figure 11]
[Figure 10]
Caution
▶In case of setting the needle, be sure to switch off the power supply. In case the user press on the
step by mistake, the machine runs automatically. By doing so, it can cause the physical injuries.
▶In case of using the clutch motor, the motor revolves because of inertia for a while even after switching
off the power supply. Be sure to start to work only after the motor comes to a complete stop.
[ KM-570 BL ][ KM-572 BL ]
②
②
③
③①
③
④
③
①
②⑤

14
3) Winding the lower thread
Insert the bobbin ②into the hook ①. As seen in Figure 12,
insert the thread through 󳟆part of the hook and pull it out
from the end of the lower thread tension adjustment plate
③. And then pull the thread through the clearance ⑤
between the hook ①and opener ④. The adequate length of
the pulled-out lower thread on the slide plate is 50 mm.
[Figure 12]
Lower
thread About 50 mm
④
⑤󳟆
③
②①
4) Routing the upper thread
Place the thread take-up lever to the highest position and
hang the upper thread as in Figure 13.
※The adequate length of upper thread extending from the
needle hole is 50 mm for initial sewing.
[Figure 13]
Caution
▶In case of adjusting the tension of the lower thread, be sure to switch off the power supply.
If the users press on the step by mistake, the machine runs automatically. By doing so, it can
cause the physical injuries.
▶In case of using the clutch motor, the motor revolves because of inertia for a while even after
switching off the power supply.
Caution
▶In case of taking up the upper thread, be sure to switch off the power supply.
If the users press on the step by mistake, the machine runs automatically. By doing so, it can
cause the physical injuries.
▶In case of using the clutch motor, the motor revolves because of inertia for a while.
Be sure to start to work only after the motor comes to a complete stop.
50mm

15
5) Adjusting the thread tension
(1) Adjusting the thread tension
As in Figure 14, turning clockwise the tension
adjustment nut ①of the thread tension control
assembly makes the upper thread tension stronger and
counter clockwise makes it weaker.
(2) Adjusting the lower thread tension
As in Figure 15, turning the tension adjustment screw
①of the hook clockwise makes the lower thread
tension stronger and counterclockwise makes it weaker.
[Figure 14]
[Figure 15]
(3) Adjusting the tension of thread take up lever spring
A) Adjusting the thread take up stroke
As in figure 16, loosen the stopper clamp screw ③, and turn the thread take up lever’s spring stopper ①clockwise to
make the stroke smaller and counter clockwise to make it bigger.
※The thread take up stroke is normally 10~14 mm.
[Figure 16]
Upper thread tension is weak
Upper thread tension is strong
Good sewing
①
①
Smaller
②
②
③
Bigger

16
B) Adjusting the thread take up tension
As in figure 17, loosen the screw ②of the thread
tension control assembly, and insert the driver into
the groove of the thread tension control assembly ③.
Turn clockwise to make the spring ①tension
stronger and counter clockwise to make it weaker.
(See Figure 17)
C) Adjusting the timing of the thread take up spring
tension
As in Figure 18, loosen the stopper screw ①, and
turn clockwise the guide plate ③for the thread take
up spring to make the timing of the spring ②faster
and counter clockwise to make it slower.
※The timing of the thread take up spring tension is
normal, when the guide plate is located in the
middle as can be seen in figure.
[Figure 17]
[Figure 18]
③
①
②
Strong
Weak
D) Adjusting the auxiliary thread tension control
assembly (for automatic trimming type)
As in Figure 19, when the auxiliary thread tension
adjustment nut ①is turned clockwise, the length of
the thread after trimming is short. The other way
makes the thread long.
※The appropriate length of the upper thread on the
needle after trimming is 35~45 mm.
[Figure 19]
②
①
③
①
35~45mm

17
6) Adjusting the tension of the presser foot
As in Figure 20, turning the pressure adjustment screw ①
clockwise makes the presser foot tension stronger, and
turning counter clockwise makes it weaker.
After adjusting, make sure to tighten the fixing nut ②.
[Figure 20]
[Figure 21]
7) Stitch length adjustment
As shown in“Figure 21”, the numbers that are shown in the
stitch length adjusting dial①are the stitch length
represented in“mm”. Find the stitch length you want by
adjusting it from left to right.
8) Adjusting timing of needle and hook
(1) Fixing the height of the needle bar
※Turn the pulley to make the needle bar be placed in its lowest position. Loosen the needle bar holding screw①in
Figure 23 to make sure that the needle bar carved sign ⓐmeets the end ⓑof the frame, then tighten the screw.
[Figure 22] [Figure 23]
Caution
▶After finishing dismantling or adjusting the safety devices, be sure to install it in the original
position properly and check whether it functions as desired or not.
▶In case of bending the machine backward or returning to the original condition, be sure to use
both hands. If you use only one hand, it can cause the physical injuries by slipping.
▶In case of adjusting the machine with the switch on, be sure to see that all is right.
▶In case of troubleshooting or checking the machine, it should be performed by the trained engineer.
▶In case of repair and checking related to electricity, be sure to leave the work to an expert or an agent.
①
②
Weaker
Stronger
①
ⓑ
ⓐ
The needle bar in the
lowest position
①

18
(2) Adjusting the timing of hook edge and needle center crossing
First, set the stitch length at“0”. Adjust the hook gear clamp screw ①in Figure 25 so that the hook edge fall exactly at
the center of the needle center when the needle bar is raised 2.4 mm from its lowest position as in Figure 24. When this is
done, the hook edge will be placed at about 1.5 mm above from the front of the needle thread hole.
[Figure 24] [Figure 25]
①
9) Clearance adjustment between hook and opener
Loosen the opener clamp screw ③and turn the opener ②to
the right and left so that the distance between the hook ①
and the opener ②is about 0.2mm as in Figure 28 when the
opener ②is pulled to its max towards the arrowed direction.
[Figure 28]
(3) Adjusting the distance between the needle and the hook edge
Raise the needle from its lowest point so that the hook edge meets the needle center. As in Figure 26, when the lower part
of the needle meets the balance point of the hook’s needle guide plate ①(adjust the needle guide form), adjust the
distance between the hook edge and the inner side of the needle groove to 0.05~0.1 mm. Loosen ①, ②and ③in Figure
27 and move the hook base ④to the left and right for adjustment. (After adjustment, fasten ①, ②and ③firmly.)
[Figure 26] [Figure 27]
0.05~0.1mm
Adhering part
Needle
①
Hook edge
①②
③
①
①
①②
③
④
①
②
0.2mm
③

19
10) Adjusting feed dog height
Turn the pulley so that the feed dog ①is positioned at its hight to adjust the feed dog ①. Loosen the fork clamp screw ④of
the feed dog base as in Figure 29 and move the feed dog base up and down so that the feed dog protrudes about 1 mm from
the needle plate top. After adjustment, fasten the clamp screw ④firmly.
11) Adjusting the auxiliary presser foot and the upper feed presser foot
※Both the auxiliary presser foot and the upper feed presser foot move up and down.
※It is normal that both of them move up and down to the same height.
※Take the following steps either to adjust the stroke of both to be the same or to make one of the two adjusted lower or
higher, depending on sewing materials.
(1) Adjusting the strokes of both to be the same
A) The vertical motion range of the supplementary presser foot①and the upper feed presser foot②is 2~6mm.
B) Loosen the adjusting hinge screw ③.
C) Vertically adjust the hinge screw③depending on sewing fabric. When the motion range is set large, move the
adjusting hinge screw③upward. Otherwise, move the adjusting hinge screw downward.
[Figure 29]
①②
About 1 mm
③
④
[Figure 30]
①
②
③
6mm
6mm
Increase
Decrease

20
󳡒Adjusting the auxiliary presser foot
※Loosen the pressure-adjusting screw ④and the bracket-fastening screw ⑤.
※Adjust the bracket-fastening screw ⑤so that the auxiliary presser foot①rise about 10.5 mm from the needle plate
top when the pressure lifter ③is raised.
(After adjustment, be sure to fasten the bracket-fastening screw ⑤first, and then adjust the pressure-adjusting
screw ④.)
※Affter the adjustment of the height of the auxiliary presser foot①, adjust the upper feed presser foot②.
󳡓Adjusting the upper feed presser foot
※Loosen up and down crank clamp screw ⑥when the pressure lifter ③is down.
※Move the needle bar close to its highest position.
※Adjust the height of the upper feed presser foot②to the sewing materials.
(2) Adjusting the height of the strokes of both different
[Figure 31]
②
①
⑥
④
⑤
③
10.5mm