SunStar KM-757 User manual

SSUUNNSSTTAARR MMAACCHHIINNEERRYY CCOO..,, LLTTDD..
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.
User’s
Manual
KM-757
High speed, two needle, drop
feed, needle feed, sewing
machine with automatic
thread trimmer.
KM- 797
High speed, two needle, drop
feed, needle feed, sewing
machine with automatic
thread trimmer for each
needle.
MMMMEE--005500662299

Thank you for purchasing our product.
The upgraded KM-757 km-797 Series, built on valuable technology and
experience drawn from years of production of automatic thread trimming sewing
machines, features new FORTUNA AC SERVO automatic thread trimming motor
designed to fully realize the Mechatronics of the sewing machine industry.
This model guarantees to satisfy increasingly growing and
sophisticated needs of the sewing industry by offering diverse functionalities,
excellent performance, remarkable power, enhanced durability and refined design.
Read all instructions in this manual thoroughly before proceeding with operation of the
sewing machine to achieve maximum performance.
Note that specifications of this product may be changed at any time without
prior notice for performance improvement.
SSUUNNSSTTAARR MMAACCHHIINNEERRYY CCOO..,, LLTTDD..
Best Quality
Best Price
Best Service

Safety rules for machines ..................................................................................................................................... 4
1. Specification
1) Sewing machine ......................................................................................................................................................... 8
2) Servo motor ................................................................................................................................................................ 9
3) 470 motor ................................................................................................................................................................... 9
4) 470 motor controller ................................................................................................................................................... 9
5) Clutch motor (for non-trimming type) ...................................................................................................................... 9
6) Peripheral automation devices (optional) .................................................................................................................. 9
2. Installation
1) Installation of the machine head .............................................................................................................................. 10
2) Installation of knee lifting solenoid and power switch box .................................................................................... 10
3) Oil supply ................................................................................................................................................................. 11
4) Adjustment of belt tension ....................................................................................................................................... 12
5) Installation of the program unit (Servo motor) ....................................................................................................... 12
6) Installation of the belt cover .................................................................................................................................... 12
7) Installation of the thread stand ................................................................................................................................. 13
8) Assembly of the location detector and its control method ..................................................................................... 13
9) Check for the stop position of the sewing machine (automatic thread trimmer) ................................................... 14
10) Reverse button function (automatic thread trimmer) ........................................................................................... 15
3. Adjustment of the machine
1) Inserting the needle .................................................................................................................................................. 16
2) Removing bobbin and bobbin case ......................................................................................................................... 16
3) Winding the lower thread ........................................................................................................................................ 17
4) Routing the lower thread ......................................................................................................................................... 17
5) Inserting the bobbin ................................................................................................................................................. 18
6) Routing the upper thread ......................................................................................................................................... 18
7) Adjusting the thread tension .................................................................................................................................... 19
8) Adjusting the height and pressure of the presser foot ............................................................................................. 21
9) Adjusting the needle and feed dog timing ............................................................................................................... 21
10) Adjusting the height of the feed dog ..................................................................................................................... 22
11) Adjusting the needle and hook timing ................................................................................................................... 22
12)
Clearance adjustment between the upper side of the hook stopper and the upper side of needle plate groove
..... 23
13) Clearance adjustment between the hook and opener ............................................................................................ 23
14) Operation of needle bar (left, right) stop (KM-797 series) ................................................................................... 24
15) Adjusting oil flow in the hook and the face plate ................................................................................................. 24
16) Adjusting the trimming device .............................................................................................................................. 25
17) Replacing movable knife and fixed blade ............................................................................................................. 30
18) Adjusting the wiper ................................................................................................................................................ 31
19) Replacing the gauge set for needle width ............................................................................................................. 32
4. Causes of trouble and troubleshooting
1) Sewing machine troubleshooting ............................................................................................................................ 33
5. Table drawing ....................................................................................................................................................... 35
Table of Contents

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

5
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.
ⓔDanger of Explosion
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.

6
KM-757/797 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.
ⓓ
ⓐ
ⓒ
ⓑ

7
“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
CAUTION
경고
Do not operate without finger guard and
safety devices. Before threading, changing
bobbin and needle, cleaning etc. switch off
main switch.
손가락 보호대와 안전장치 없이 작동하지
마십시오.
실, 보빈, 바늘교환시나 청소전에는 반드시
주전원의 스위치를 꺼 주십시오.
CAUTION
경고
Hazardous voltage will cause injury.
Be sure to wait at least 360 seconds before
opening this cover after turn off main switch
and unplug a power cord.
고압 전류에 의해 감전될 수 있으므로 커버를
열 때는 전원을 내리고 전원 플러그를 뽑고
나서 360초간 기다린 후 여십시오.
CAUTION
경고
Do not operate without finger guard
and safety devices. Before threading,
changing bobbin and needle, cleaning
etc. switch off main switch.
손가락 보호대와 안전장치 없이 작동하지
마십시오.
실, 보빈, 바늘교환시나 청소전에는 반드시
주전원의 스위치를 꺼 주십시오.
CAUTION
경고
Hazardous voltage will cause injury.
Be sure to wait at least 360 seconds
before opening this cover after turn
off main switch and unplug a power
cord.
고압 전류에 의해 감전될 수 있으므로 커버를
열 때는 전원을 내리고 전원 플러그를 뽑고
나서 360초간 기다린 후 여십시오.
[Position of Caution Mark]

Usage
Max sewing speed
Max no. of stitches
Needle bar stroke
Feed dog height
8
Manual
Knee
Automatic
Needle
Lubrication
Needle width gauge
Presser
foot height
Model Name
Item KM-757BL-7NKM-757BL-7SKM-757BLKM-757-7NKM-757-7SKM-757
No Model No Model Name
1) Sewing machine
1 KM-757
2 KM-757-7S
3 KM-757-7N
4 KM-757BL
5 KM-757BL-7S
6 KM-757BL-7N
7 KM-797
8 KM-797-7S
9 KM-797-7N
10 KM-797BL
11 KM-797BL-7S
12 KM-797BL-7N
General to heavy material
3,000 SPM
5 mm
13 mm
DP×5 # 14 (#11 ~ #22)
1.6mm ~ 52.4mm 16mm ~ 50.8 mm 1.6mm ~ 38mm
DP×5 #22 (#11 ~ #22)
13 mm
7 mm
33.4 mm
1 mm
7 mm
15 mm
Automatic lubrication
Usage
Max sewing speed
Max no. of stitches
Needle bar stroke
Feed dog height
Manual
Knee
Automatic
Needle
Lubrication
Needle width gauge
Presser
foot height
Model Name
Item KM-797BL-7NKM-797BL-7SKM-797BLKM-797-7NKM-797-7SKM-797
General to heavy material
3,000 SPM
5 mm
13 mm
DP×5 # 14 (#11 ~ #22)
2.4mm ~ 15.9mm
DP×5 #22 (#11 ~ #22)
13 mm
7 mm
33.4 mm
1 mm
7 mm
15 mm
Automatic lubrication
1
Specification
High-speed, two needle, drop feed, needle feed, standard hook sewing machine
High-speed, two needle, drop feed, needle feed, standard hook sewing machine with automatic thread trimmer (Servo motor)
High-speed, two needle, drop feed, needle feed, standard hook sewing machine with automatic thread trimmer (470 motor)
High-speed, two needle, drop feed, needle feed, double hook sewing machine
High-speed, two needle, drop feed, needle feed, double hook sewing machine with automatic thread trimmer (Servo motor)
High-speed, two needle, drop feed, needle feed, double hook sewing machine with automatic thread trimmer (470 motor)
High-speed, two needle each, drop feed, needle feed, standard hook sewing machine
High-speed, two needle each, drop feed, needle feed, standard hook sewing machine with automatic thread trimmer (Servo motor)
High-speed, two needle each, drop feed, needle feed, standard hook sewing machine with automatic thread trimmer (470 motor)
High-speed, two needle each, drop feed, needle feed, double hook sewing machine
High-speed, two needle each, drop feed, needle feed, double hook sewing machine with automatic thread trimmer (Servo motor)
High-speed, two needle each, drop feed, needle feed, double hook sewing machine with automatic thread trimmer (470 motor)

UsageModelOptional device
9
6) Peripheral automation devices (optional)
(S : Servo motor E : 470 motor)
AUTO KNEE LIFTING SYSTEM
PRODUCTION COUNTER
MATERIAL EDGE SENSOR
SCOUN-1
SEDG-1
SEDG-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-1 for edge
sensing type and SEDG-2 for thickness sensing type.
SPF-4 A solenoid operating structure where the presser foot gets lifted automatically
with pedal reverse gear stage 1 operation.
3) 470 motor
MODEL
PM470
PHASE
1 : 1 󳤡
1 : 1 󳤡
3 : 3 󳤡
3 : 3 󳤡
1 : 1 󳤡
3 : 3 󳤡
HERTZ
5 : 50Hz
6 : 60Hz
5 : 50Hz
6 : 60Hz
5 : 50Hz
6 : 60Hz
5 : 50Hz
6 : 60Hz
5 : 50Hz
6 : 60Hz
VOLT
1 : 110V
2 : 220V
3 : 380V
4 : 110V / 220V
5 : 220V / 380V
PM470 󳣑󳣑󳣑
4) 470 motor controller
MODEL
PC470
VOLT
1 : 110V
2 : 220V B001
2) Servo motor
MODEL
SC55-1B
SC55-2B
SC55-3B
VOLT
1 phase 110V
1 phase 220V
3 phase 220V
WATT
550W
550W
550W
HERTZ
50/60 Hz
50/60 Hz
50/60 Hz
5) Clutch motor (for non-trimming type)
MODEL
HEC-1701
HEC-1703
HEC-1705
HEC-1706
1 phase 220V
3 phase 220V/380V
3 phase 220V
1 phase 220V
250W
250W
400W
400W
50/60 Hz
50/60 Hz
50/60 Hz
50/60 Hz
PC470 󳣑B 001

10
2
Installation
1) Installation of the machine head
Insert the hinge rubber ①into the table and fix the oil fan into the center of the machine head support rubber B ②as in Figure 1 and attach it to
the table. After attaching the machine head hinge ③to the bed, insert it into the hinge rubber ①and install the sewing machine on the machine
head support rubber A ④and machine head support head B ②.
[Figure 1]
[Figure 2]
2) Installation of knee lifting solenoid and
power switch box
(1) When attaching the power switch box ⑥, refer to Figure 2 to make
sure that it is placed at the very center of the solenoid bracket.
(2) After attaching the solenoid onto the table, unfasten the screw ④to
adjust the center of middle linking bar ①and the center of solenoid
shaft ②in parallel position with the lower side of the table ③. After
the adjustment is over, fasten the screw tightly.
(See Figure 2.): An assembling position diagram can be found inside
the solenoid box.
(3) The presser foot height of the sewing machine can be adjusted after
unfastening the fixing nut ⑤and then turning the middle linking bar
①clockwise to raise and counterclockwise to lower. After finishing
the adjustment, tightly fasten the fixing nut ⑤.
(4) According to the installation position of knee-lifting solenoid, the
operation noise, operation load and presser foot elevation range may
differ. Please assemble so that the machine will operate smoothly.
Oil fan
Caution
▶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 42kg. 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.

11
[Figure 3]
3) Oil supply
(1) Installing chip remover magnet
Attach the magnetic chip remover ①that is in the accessory
box to the oil fan. (See Figure 3.)
※
Do not use the magnet for other purposes. Use of the sewing
machine without the magnet may cause malfunction and has
a bearing on the machine’s durability.
(2) Lubricating the oil fan
A.
Fill the lubricant up to the“HIGH”mark. (See Figure 3.)
B.
The lubricant must be SUNSTAR’s oil provided exclusively
for industrial sewing machines or SHELL’s Tellus C10.
C. If the oil in use is down to the“LOW”mark, fill in to
“HIGH”immediately.
D. Once every two weeks is deemed the appropriate
interval for oil refills.
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 4]
(3) For new machines that have been delivered a long ago or has not been used for a long period of time, open the face plate
and apply the oil spray 2-3 times to friction areas such as the thread take up lever linkage ①, the needle bar ②and the
presser bar ③. (See Figure 4.)

12
4) Adjustment of belt tension
After installing the motor, unfasten the fixing nuts ①, ②
and tension will be created to the belt ④due to motor ③
falling by gravity. Fasten the fixing nut ①first now and
then fasten the fixing nut ②tightly. (See Figure 6.)
5) Installation of the program unit
(Servo motor)
(1) Fix the bracket ②onto the program unit ①, using 4
fixing nuts ③.
(2) Then, use 3 fixing bolts ④to tightly fix the bracket ②,
where the program unit ①has been attached, along with
the back cover. (See Figure 7.)
6) Installation of the belt cover
(1) Before attaching the belt cover“A”to the machine body,
assemble in advance the rubber collar ①and washer ②
and fixing nail ③on the to-be-attached side of the cover
as can be seen in picture“K”of Figure 8.
(2) Attach belt cover“A”onto the machine body as can be
seen on Figure 8. Now, if a bobbin winder is attached on
the table, lay down the machine body on its back and
attach the belt cover“A”.
[Figure 6]
[Figure 7]
[Figure 8]
④
(4) For trial runs, operate the machine at 1,500 spm for
about 10 minutes at a time. Be sure to check whether the
oil window is being lubricated. (See Figure 5.)
(5) Operate the machine at below 2,400 spm for the first 4-5
days and run the machine at normal speed thereafter to
maintain the sewing machine in optimal condition.
[Figure 5]

13
7) Installation of the thread stand
As can be seen in Figure 10, fix the thread stand ①to the
table using the washer and nut on the right.
[Figure 10]
①
(3) Lastly, fasten the belt cover“B”to the table, as can be
seen in Figure 9.
[Figure 9]
8) Assembly of the location detector and its
control method
(1) Installation of the location detector
A. Installing on the servo motor (in-built location detector)
A location detector sensor is attached to the back side of
the arm. The appropriate clearance between the location
detector and the pulley is 4.7mm. (See Figure 11.)
B. Installing on the 470 motor (external location detector)
After assembling the parts in the numbered order as in Figure 12, adjust the synchronization shaft horizontally such that
the photo film is placed at the center of the photo interrupter as in Figure 13. Then fasten it tightly with two fixing screws
using a hexagonal wrench.
[Caution]
󳢯 As can be seen on figure 12, make sure that the marks“DOWN”and“UP”face the front when looking from the pulley side.
󳢯Film adjustment is completed upon shipment.
Speed
Sensor Film Fixed Washer
Fixed Bushing
Fixed
Screws
Pulley L Wrench
PCB Holder
COVER
Photo
Interrupter
Photo Film
Synchronization Shaft
Synchronization
Shaft Fixing
Screws (2)
Location
detector
shaft Fixed Washer
Clearance-
Adjusting Bushing
[Figure 11]
[Figure 12] [Figure 13]

14
B. For 470 motor (external location detectors)
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 Fig. 12 and align the“DOWN”film with the film adjustment baseline and the sensor housing
baseline as in Fig. 16 & 17. 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.
DOWN
Film Adjusting
Base
Sensor Baseline
Setting Area
Film-Adjusting Arrow
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 Base
[Figure 16] [Figure 17]
[Figure 18]
9) Check for the stop position of the sewing
machine (automatic thread trimmer)
Check for the machine stop position after moving the needle up
and down by pushing the reverse button. See whether the carved
sign on the arm and the white carved sign on the pulley are aligned
when the needle is in an up position. If not, adjustment to the
photo film of the location detector 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, which would signify that there is nothing
wrong with the operation timing of the trimmer. (See Fig. 18.)
(Refer to the explanation about the Adjustment of Location
Detector on page 13.)
Thread take up lever
up-stop position
Needle
bar
frame
(2) Adjustment of the location detector
A. For Servo motor (in-built location detector)
Adjust the up-stop position of the needle such that the white carved sign on the pulley ③is in a straight line with the carved
sign on the arm ④when the needle has stopped in the air. That adjustment can be made by loosening the pulley’s clamp
screw①on the side with N·U carved signs and moving it sideways. Adjust the down-stop position of the needle such that
the needle is on the point of moving up when the needle bar is at the lowest point. This adjustment can be made by loosening
the pulley’s clamp screw ②on the side with N·D carved signs and moving it sideways. (See Figure 14 & 15.)
Up-Stop
Position
Down-
Stop
Position
[Figure 14] [Figure 15]

15
[Figure 19]
10) Reverse button function
(automatic thread trimmer)
Pressing the back tack button or reverse button ①during
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 ①already pressed
down, you can perform reverse sewing from the beginning.
When the machine is in a“stop”mode, you can change the
up-down position of the needle bar by pressing the reverse
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. In short, the button delivers
two functions: one for reverse sewing and the other for
converting vertical position of the needle. (See Figure 19.)
MEMO

16
3
Adjustment of the Machine
1) Inserting the needle
As in Figure 20, place the upper end of the needle closely
adhered to the upper side of the stopper hole ②, with the
needle groove ①facing inward. Fix the needle with a
fixing screw③.
KM-757 SERIES KM-797 SERIES
[Figure 20]
2) Removing bobbin and bobbin case
Place the needle ①in the highest position, and then like in Figure 21, open the slide plates ②on the left and right, lift the
bobbin holder ③to remove the bobbin case ④and the bobbin ⑤.
[Figure 21]
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.

17
[Figure 23]
4) Routing the lower thread
[Applicable model]
󳢯KM-757
󳢯KM-757BL
󳢯KM-757-7S
󳢯KM-757-7N
[Applicable models]
󳢯KM-757BL-7S
󳢯KM-757BL-7N
1. Insert the bobbin ①into the hook ②.
2. Insert the thread through“A”part of the hook ②, and pull
it out from the end of the lower thread tension adjustment
plate ③.
3. The adequate length of the pulled-out lower thread is
50mm.
1. Insert the bobbin ①into the bobbin case ②. For KM -757-7S and
KM-97-7N, it is crucial to insert the bobbin in the turning direction as
in the picture.
2. Insert the thread through“A”part of the hook ②, and pull it out
from the end of the lower thread tension adjustment plate ③.
3. Pass the pulled-out thread through“B”and“C”of the bobbin case
②, as can be seen on the picture, and hang it onto the lower thread
holding spring ④. Then pull it out through the thread hole ⑤.
4. The adequate length of the pulled-out lower thread is 50mm.
[Applicable models]
󳢯KM-797
󳢯KM-797BL
󳢯KM-797-7S
󳢯KM-797-7N
[Applicable models]
󳢯KM-797BL-7S
󳢯KM-797BL-7N
3) Winding the lower thread
(1) Winding the lower thread
A.
Push the thread through the hole ①and wind it from
the back to the front of the tension adjusting plate ②.
B. Bring the thread toward the bobbin ③and wind the
thread around the bobbin about 5-6 times in the
clockwise direction.
C. Push the lever ④so that the pulley ⑤will touch the
V-belt, operate the machine.
D.
Once the lower thread is wound around the bobbin, the
pulley ⑤automatically pulls apart from the V-belt.
E. About 80% of the bobbin should be wound with the
lower thread. (See Figure 22.)
(2) Adjusting lower thread
a. If the lower thread is not being wound evenly, loosen the screw ⑥and adjust it by moving it left and right. Then,
tighten the screw again.
b. The lower thread is wound more if the adjusting screw ⑦is turned clockwise, and less if turned counterclockwise.
c. The tension of the lower thread being wound around the bobbin becomes tighter if the nut ⑧is turned clockwise and
looser if turned counterclockwise.
[Figure 22]

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6) Routing the upper thread
Place the thread take-up lever to the highest position and hang the upper thread like in Figure 25. The adequate length of
upper thread extending from the needle hole is 50mm for initial sewing.
[Figure 25]
[Figure 24]
5) Inserting the bobbin
Stop the needle ①at the highest position. Following the Figure 24, insert the bobbin (where the thread is rolled onto) or the
bobbin case ②into the hook ③. After laying down the bobbin holder ④, close the slide plates ⑤on the right and left.
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.

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7) Adjusting the 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.
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.
(1) Adjusting the upper thread tension
Like in figure 26, turning the tension adjustment nut of
the thread tension control assembly clockwise makes the
upper thread tension stronger and counterclockwise
makes it weaker.
[Figure 26]
strong
strong
weak weak
(2) Adjusting the lower thread tension
Like in figure 27, turning the tension adjustment nut ①
of the hook clockwise makes the lower thread tension
stronger and counterclockwise makes it weaker.
weak strong
[Figure 27]

20
(3) Adjusting the tension of thread take up lever spring
A. Adjusting the thread take up stroke
As in figure 28, loosen the stopper fastening screw
①, and turn the thread take up lever’s spring stopper
②clockwise to make the stroke smaller and counter
clockwise to make it bigger. The thread take up
stroke is normally 5~10mm.
B. Adjusting the thread take up tension
As in figure 28, loosen the screw ③of the thread
tension control assembly, and insert the driver into
the groove ④of 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 30~70g.
(4) 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 ①opens while the trimming is
in action. For the adjustment of plate opening level, put the solenoid ②in action, and adjust by moving solenoid collar
③back and forth to make the opening of the thread tension adjusting plate ①0.8 mm. Also, when the thread release
solenoid is not in action, check whether the plates are closely adhered to each other. (See Figure 29.)
[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.
5~10mm
30~70g
small large
strong
weak
about 0.8mm
[Figure 28]
[Figure 29]
(5) Adjusting the auxiliary thread tension control
assembly (automatic trimming type)
As in Figure 30, 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 35~45mm. (This can
also be done by using the remaining upper thread length
adjustment volume of the control box.)
[Figure 30]
Bigger
Smaller