SunStar KM-857J Series User manual

USER S MANUAL
KM-857J SERIES
R
High Speed Post Bed, 1-Needle
Needle Feed Lock Stitch
Machine with Thread Trimmer
for Reinforcement
Stitch of Jean

Best Quality
Best Price
Best Service
SunStar CO., LTD.
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.

Table of Contents
Safety rules for machines .............................................4
1.Specifications
1) Machine types....................................................................................8
2) Specifications of the machine ...........................................................8
3) Specifications of servo motor controller...........................................8
(trimming type: KM-857J-7)
4) Specifications of clutch motor
(non-trimming type: KM-857J).........................................................9
5) Peripheral automation devices (optional: trimming type)................9
2. Installation
1) Installation of machine head ...........................................................10
2) Installation of knee lifting solenoid and power switch box ...........10
3) Installation of oil fan........................................................................11
4) Lubrication.......................................................................................11
5) Adjustment of belt tension ..............................................................13
6) Installation of program unit (automatic trimming type) ................13
7) Installation of belt cover..................................................................13
8) Installation of thread stand ..............................................................14
9) Synchronizer assembling and its control method
(automatic trimming type)...............................................................14
10) Reverse button function (automatic trimming type)....................15
11) Checking stop position of the machine
(automatic trimming type).............................................................15
12) Installing the Attachment for Reinforced Stitches (KM-857J Series)
..............................................................................................................16
3. Adjustment of the machine
1) Inserting needle................................................................................17
2) Removing bobbin and bobbin case.................................................17
3) Winding lower thread......................................................................18
4) Routing lower thread.......................................................................18
5) Inserting bobbin...............................................................................19
6) Routing upper thread.......................................................................19
7) Adjusting thread tension .................................................................20
8) Adjusting height and pressure of the presser foot ..........................22
9) Adjusting needle and feed dog timing ...........................................23
10) Adjusting height of the feed dog...................................................23
11) Adjusting needle and hook timing................................................24
12) Clearance adjustment between upper side of
hook stopper and upper side of needle plate groove ...................25
13) Clearance adjustment between hook and opener .........................25
14) Replacing feed dog........................................................................26
15) Adjustment of safety device..........................................................27
16) Adjusting trimming device ...........................................................27
17) Replacing movable knife and fixed blade ....................................33
18) Adjustment of wiper .....................................................................33
19) Replacing gauge set for needle width ..........................................35
20) Adjusting the Attachment for Reinforced Stitches (KM-857J Series)
..............................................................................................................36
4. Cause of trouble and troubleshooting
1) Machine troubleshooting.................................................................37

4
Safety Rules for Machines
Safety labels in the manual are categorized into danger, warning and caution.
Failure to follow the safety rules may result in physical injuries or mechanical damages.
The safety labels and symbols are defined as follows.
[The meaning of the safety labels]
Instructions here shall be observed strictly.
Otherwise, the user may be killed or suffer severe physical injury.
Instructions here must be observed, or the user may suffer fatal or severe physical
injury.
Instructions here should be observed, or the user may face physical injury or
mechanical damages.
Danger
[The meaning of symbols]
This symbol means a must-not.
This symbol means a must for safety.
This symbol means that an electric shock may be caused if the
instruction is not followed properly.
Warning
Caution

5
1-1) Machine
mobilization
Danger
1-2) Machine
Installation
Caution
1-3) Troubleshooting
Danger
If in need of troubleshooting, call a trained A/S engineer who has been educated by
sunstar.
ⓐBefore cleaning and repair, be sure to turn off the power supply. And wait for about 4
minutes untill the machine discharges completely.
ⓑPart or the entire machine should not be modified without any consultation with our
company
ⓒIn case of repair, change the damaged part into the standard article of our company
ⓓAfter repair, put back the safety cover that was removed while repairing
Only personnel with a full understanding of the safety rules should move the
machine. The following directions must be observed when transferring the machine.
ⓐAt least 2 persons should move the machine together.
ⓑIn case the machine should be transported, wipe the oil covered on the machine to
prevent accidents.
Because the physical damage such as the functional obstacles and breakdown are
likely to occur depending on the environment in which the machine is installed.
The following preconditions must be met.
ⓐPlease unpack the machine package in order. Be careful of the nails in the wooden
box.
ⓑBecause machines are apt to be contaminated and corroded by dust and moisture,
install a climate controller and clean the machines regularly.
ⓒKeep the machine out of the direct rays of the sun.
ⓓKeep both sides and the backside of the machines off at least 50cm from the wall to
secure enough space to repair.
ⓔDanger of Explosion
Don’t run the machine near the places with any dangers of explosion.
Don’t run the machine near the places with any dangers of explosion, including
places where the spraying product like aerosol are used in large quantities or oxygen
are dealt with, unless the exact actions concerning the operation are guaranteed to
avoid the explosion.
ⓕBecause of the characteristics of the machine, illuminators are not equipped. So, users
should install the lighting apparatus around the working area.
[Note] The details about the installment of the machine are described in No. 2
Installations.

6
KM-857J series are manufactured for industry use to sew textiles and other similar
material. In case of running the machine, users should observe the following things.
ⓐBefore operating the machine, read the manual and understand fully the details about its
operation.
ⓑDon’t forget to put on garment suitable for safe work.
ⓒKeep your hands or a part of the body away from the running part of the machine like the
needle, hook, thread take-up spring and pulley etc.
ⓓDon’t remove any kind of cover for safety while running the machine.
ⓔBe sure to connect the earthed line.
ⓕBefore opening the electric box such as a control box, be sure to shut off the power supply
and make sure that the power switch should be put on “off”.
ⓖWhen threading the needle or before checking after sewing, be sure to stop the machine.
ⓗDon’t switch on the power supply with the foot on the pedal.
ⓘDon’t run the machine when the cooling fan is clogged. Be sure to clean the air filter in
the control box once a week.
ⓙIf possible, keep the machine away from strong electromagnetic fields like high frequency
welding machine.
1-4) Machine
Operation
Caution
Caution
ⓐSafety Label: Cautions that need to be heeded to during operation.
ⓑThread take-up spring cover: a device to prevent the human body from touching the
thread take-up spring.
ⓒBelt cover: a device to prevent hands, feet and clothing from getting jammed by the belt
ⓓFinger guard: a device to prevent fingers from contacting the needle.
1-5) Safety Device
Caution
Always start the machine with safety covers in place since
fingers or hands could be injured or cut off by the belt. Turn
off the power switch during check-ups or adjustments.
ⓓ
ⓐ
ⓒ
ⓑ

7
“Caution” is adhered to the machine for safety.
In case of starting to run the machine, read the directions of “Caution” carefully.
1-6) Position of
Caution Mark
1-7) Content of
“Caution”
Caution
CAUTION
경고
Do not operate without finger guard and
safety devices. Before threading, changing
bobbin and needle, cleaning etc. switch off
main switch.
손가락 보호대와 안전장치 없이 작동하지
마십시오.
실, 보빈, 바늘교환시나 청소전에는 반드시
주전원의 스위치를 꺼 주십시오.
CAUTION
경고
Hazardous voltage will cause injury.
Be sure to wait at least 360 seconds before
opening this cover after turn off main switch
and unplug a power cord.
고압 전류에 의해 감전될 수 있으므로 커버를
열 때는 전원을 내리고 전원 플러그를 뽑고
나서 360초간 기다린 후 여십시오.
CAUTION
경고
Do not operate without finger guard
and safety devices. Before threading,
changing bobbin and needle, cleaning
etc. switch off main switch.
손가락 보호대와 안전장치 없이 작동하지
마십시오.
실, 보빈, 바늘교환시나 청소전에는 반드시
주전원의 스위치를 꺼 주십시오.
CAUTION
경고
Hazardous voltage will cause injury.
Be sure to wait at least 360 seconds
before opening this cover after turn
off main switch and unplug a power
cord.
고압 전류에 의해 감전될 수 있으므로 커버를
열 때는 전원을 내리고 전원 플러그를 뽑고
나서 360초간 기다린 후 여십시오.
[Position of Caution Mark]

1
Specifications
8
1) Machine Types
No. Model No. Model Name
2) Specifications of the machine
1 KM-857J High Speed Post Bed, 1 Needle Needle Feed Lock Stitch Machine for Reinforcement
Stitch of Jean(Standard Hook)
2 KM-857J-7 High Speed Post Bed, 1 Needle Needle Feed Lock Stitch Machine with Thread Trimmer
for Reinforcement Stitch of Jean (Standard Hook)
KM-857J KM-857J-7
Purpose
Max. sewing speed
Max. no. of stitches
Needle bar stroke
Feed dog height
Post height
Needle used
Feeding method
Needle width gauge
Medium material - heavy material
3,000SPM
5mm
33.4mm
1mm
7mm
15mm
178mm
DP×17 #18(#14∼#22)
Low pressure circular automatic feeding
1/16″∼1″(1.6mm∼25.4mm)
3) Specifications of servo motor controller (trimming type: KM-857J-7)
Model type
Item
Presser foot
height
Manual
Knee
Automatic 13mm
MODEL
SC55-1B
SC55-2B
SC55-3B
VOLT
1 phase 110V
1 phase 220V
3 phase 220V
WATT
550W
550W
550W
HERTZ
50/60 Hz
50/60 Hz
50/60 Hz

9
UsageModelOptional Device
5) Peripheral automation devices (optional: trimming type)
Auto Knee Lifting System
Production Counter
Material Edge Sensor
Standing Pedal
SCOUN-1
SEDG-1B
SEDG-2B
SPDL-1
SPDL-2
A counting device which indicates the completed quantity on the
program unit panel, including added, subtracted, corrected or
remaining quantity along with other performance rates
A device that senses the edge or thickness of the sewing material
to stop the machine without manual pedaling. Available in two
types: SEDG-1B for edge sensing type and SEDG-2B for
thickness sensing type
A device needed when only one operator runs several sewing
machines. Pedals for acceleration, thread trimming, presser foot
and ascending are built separately. There are two types: SPDL-1
for fixed speed type and SPDL-2 for adjustable speed type.
SPF-3A A solenoid operating structure where the presser foot gets lifted
automatically with pedal reverse gear stage 1 operation.
4) Specifications of clutch motor (non-trimming type: KM-857J)
MODEL
HEC-1701
HEC-1703
HEC-1705
HEC-1706
VOLT
1 phase 220V
3 phase 220V/380V
3 phase 220V
1 phase 220V
WATT
250W
250W
400W
400W
HERTZ
50/60 Hz
50/60 Hz
50/60 Hz
50/60 Hz

2
Installation
10
Warning
▶Installation of the machine should be performed by a trained engineer.
▶Any electrical wiring must be performed by a qualified technician or agent.
▶The machine weighs over 53kg. At least 2 persons should carry out the installing work.
▶ Plug in after the installation is complete. If the operator mistakenly steps down on the pedal
with the pug in, the machine will start automatically and can cause physical injuries.
▶Connect the ground (earth) wire. An unstable connection may result in an electric shock
or a malfunction.
▶Place the belt cover on top of the machine.
▶ Use both hands when bending the machine backwards or returning it to the normal position.
Using only one hand can lead to severe hand injuries due to the weight of the machine.
1) Installation of machine head
※Fix the two head hinges ①to the bed. Settle the
machine onto the table where the hinge rubber ②and
cushion rubber ③are inserted. (see figure 1)
2) Installation of knee lifting solenoid and power switch box
(1) When attaching the power switch box ⑥, refer to figure 2 to make sure that it is placed at the very center of the solenoid bracket.
(2)
After attaching the solenoid onto the table, unfasten the screw ④
to adjust the center of middle linking bar ① and the center of
solenoid shaft
② in parallel position with the lower side of the
table
③ . After the adjustment is over, fasten the fixing screw
tightly. (see figure 2): assembling position diagram can be found
inside the solenoid box.
(3) The presser foot height of the sewing machine can be adjusted
after unfastening the fixing nut
⑤ and then turning the middle
linking bar
① clockwise to raise and counterclockwise to lower.
After finishing the adjustment, tightly fasten the fixing nut
⑤ .
(4) According to the installation position of knee-lifting solenoid, the
operation noise, operation load and presser foot elevation range
may differ. Please assemble so that the machine will operate
smoothly.
[Figure 1]
[Figure 2]
①
③
②
⑥
②
⑤
①
Oil Fan
④
③Table

11
3) Installation of oil fan
※Insert the projecting part of the oil fan ②into the
respective machine holes on the lower side of the
table ①, and then push securely to the right. Fix the
oil fan to the four fixing spots ③using 4 nails.
(see figure 3)
[Figure 3]
Nail
②
①
③
Caution
▶Be sure to plug in after finishing oil supply,
If the user steps on the pedal by mistake, the machine will start automatically, and this
might lead to physical injuries.
▶When handling lubricant, use safety goggle or gloves to prevent the lubricant from coming
into contact with the eyes or skin. This may cause inflammation. And never drink
lubricants. They may cause vomiting or diarrhea. Please keep out of the reach of children.
▶Make sure to supply oil when using it for the first time or after not using it for a long time.
4) Lubrication
(1) Oil tank check
As in figure 4, pour the oil into the oil hole
② until the
oil tank’s oil level reaches the red maximum line
① .
While using the machine, replenish the oil immediately
when the oil level goes down to the minimum level
③ ,
back to the red maximum level
① . Make sure to check
the oil level once a day.
[Figure 4]
②
①
③

12
(2) As in figure 5, make sure to supply oil into the oil holes marked in red and into each friction part, before moving the
sewing machine.
(3) Supply level adjustment of oil supply terminal
The amount of oil supplied from the arm’s oil tank to the front and middle bushing of the lower shaft and the front
busing of the horizontal push stick can be adjusted using the adjustment screw
②of the oil supply terminal ① . The
amount of oil supply decreases when turned clockwise, and increases when turned counterclockwise. (see figure 6)
(4) As test operation, run the machine for 10 minutes at about 1,500 SPM. For the first 4~5 days of using the machine,
operate the machine at less than 2,400 SPM per minute. Then, start using at normal pace. This will help maintain good
performance of the machine along the way.
[Figure 5]
[Figure 6]
①②

13
5) Adjustment of belt tension
Once the motor is installed, when the fixing nuts ① , ② are
fully unfastened on both sides, tension is created to the belt
④ due to the weight of the motor ③ . At this moment, fasten
the fixing nut
① first, then fasten the fixing nut ② tightly.
(See figure 7)
[Figure 7]
④
③
①
②
6) Installation of program unit
(automatic trimming type)
(1) Fix the bracket ② onto the program unit ① , using 4
fixing nuts
③ .
(2) Then, use 3 fixing bolts
④ to tightly fix the bracket ② ,
where the program unit
① has been attached, along with
the back cover. (see figure 8)
[Figure 8]
①
②
④
③
7) Installation of belt cover
(1) Attach belt cover“A”onto the back of the machine body as seen in figure 9.
(2) As seen in figure 10, assemble the belt cover support pin ①to the arm base ②, and then attach the belt cover“B”to the
machine. Now, if a bobbin winder is attached on the table, lay down the machine body on its back and attach the belt
cover“B”.
(3) Fix the belt covers“A”and“B”as can be seen on part“K”of the figure.
(4) Fix the lower part of the belt cover“B”onto the machine bed like part“Q”of the figure.
[Figure 10][Figure 9]
“A”
“K”
①
②
“A”
“B”
“Q”

14
8) Installation of thread stand
As seen in figure 11, fix the thread stand ① to the table
using the washer and nut on the right.
[Figure 11]
①
9) Synchronizer assembling and its control
method (automatic trimming type)
(1) Installation of synchronizer
Assemble in the order of marked number as can be seen in
figure 12. Then, following the figure 13, make adjustments
to place the photo film at the center of the sensor housing①,
by moving the shaft ②to the right and left. Then, tighten
the 2 fixing screws ③using the hexagonal wrench④.
[Note]
A) As seen in figure 12, make sure that the marks “DOWN”
and “UP” face the front when looking from the pulley
side.
B) Film adjustment is completed upon shipment.
[Figure 12]
②
①
③⑤
DOWN
UP
④⑥
⑦⑧
[Figure 14][Figure 13]
①
Photo film (right and left
adjustment)
Thread take up lever
up-stop position
Needle bar frame
③
④
②

15
[Figure 15] [Figure 16]
(2) Film adjustment of synchronizer
A. For new model type (see figures 14, 15)
Manually turn the pulley so that the needle bar is placed where it starts rising from the lowest point. Unfasten the film
fixing screw
① in figure 15, and for “DOWN” film A, align the film adjustment base line with the sensor adjustment
base line, as can be seen in
ⓚ . Then, using the fixing screw ① , fasten only as much as to prevent the film from
turning. In the same method, place the thread take up lever in the highest point. Once again unfasten the fixed screw
① , and align the “UP” film B like ⓚ . Now, be careful not to move the previously set “DOWN” film A.
B. For old model type (see figure 16 )
Adjust in the same method as new model to make the right side
ⓚ of the film’s projecting part aligned to the center of
the sensor base line.
Down Film Adjustment Up Film Adjustment
[New model synchronizer] [Old model synchronizer]
ⓚ
B
①
A
Sensor
Sensor
base line
Sensor adjustment base line
Film adjustment
base line
Down Film Adjustment Up Film Adjustment
A
①
ⓚ
B
ⓚ
Photo sensor fixing screw
10) Reverse button function (automatic
trimming type)
If the reverse button ①is pressed while sewing forward, reverse
sewing takes place immediately. If the machine is stopped first
and the button ①is pressed before stepping the pedal to start the
machine, reverse sewing will take place from the start. Also by
pressing button ①while the machine is in stop position, the
high-low position of the needle bar can be changed. If the button
①is pressed once when the needle bar is in down-stop position,
the needle bar changes to up-stop position. Once again, if the
button ①is pressed twice consecutively within 1 second, the
needle bar changes to down-stop position.
In short, it has both the reverse sewing and needle up-down
position change functions. (See figure 17)
11) Checking stop position of the machine
(automatic trimming type)
After changing the up-down position of the needle by pressing
the reverse button, check the stop position of the machine.
Check whether the thread take-up lever is in the highest position
when the needle is in up-stop position. When the stop position is
incorrect, there might be problems to the trimming function,
hence the photo film location of the synchronizer must be
corrected. That is, the needle up-stop position is the same as the
needle bar’s stop position once the trimming action takes place.
So there is no problem with the timing of the trimming action.
(See figure 18) (See ‘location detector adjustment’ on page 14)
[Figure 17]
[Figure 18]
Thread take up lever up-stop position
Needle bar frame
①

16
12) Installing the Attachment for
Reinforcement Stitch (KM-857J Series)
(1) Disassemble the post cover ①.
(2) Replace the feed dog for reinforcement stitch ②and
assemble the post cover ①again.
(3) Install the needle plate for reinforcement stitch ③and the
presser foot for reinforcement stitch ④.
(4) Use the post cover ①and assemble the attachment for
reinforcement stitch ⑤.
[Figure 19]
④
③
②
①
⑤

17
3
Adjustment of the machine
Caution
▶In case of setting the needle, be sure to switch off the power supply. If the user steps on the pedal
by mistake, the machine will start automatically, and this might lead to physical injuries.
▶When using the clutch motor, remember that the motor revolves for a while even after switching off
the power supply due to inertia. Make sure to start working only after the motor has come to a
complete stop.
1) Inserting needle
As in figure 19, place the upper end of the needle closely
adhered to the upper side of the stopper hole ②, with the
needle groove
① facing inward. Fix the needle with a
fixing screw
③ .
[Figure 19]
2) Removing bobbin and bobbin case
Place the needle ① in the highest position, and then just like in figure 20, open the hook covers ② on the left and right. Raise
the bobbin holder
③ to remove the bobbin case ④ and the bobbin ⑤ .
[Figure 20]
②
③
①
②
③
③
⑤
③
⑤
①
②
①
③
④
②
③
②
②

18
3) Winding lower thread
(1) Winding the lower thread
A)
Insert the thread into the hole ① , and put it around the
back of tension adjustment plate
② to the front side.
B) Bring the thread towards the bobbin ③ , and wind it
around 5~6 times starting from the bottom.
C) Push the lever
④ to make the pulley ⑤ touch the V-
belt, and then operate the machine.
D) When the lower thread is fully wound to the bobbin,
pulley
⑤ will automatically detach from the V-belt.
E) The adequate amount of thread wound to the bobbin
is about 80%. [See figure 21]
4) Routing lower thread
(2) Adjustment of lower thread winding.
A) If the lower thread winds irregularly, unfasten the screw
⑥ , and adjust by moving to the left and right. Fasten back the
screw
⑥ when the adjustment is complete.
B) The amount of lower thread wound increases when the adjusting screw
⑦ is turned clockwise, and decreases when
turned counter clockwise.
C) The tension of the lower thread wound to the bobbin grows when the nut
⑧ is turned clockwise, and drops when
turned counter clockwise.
[Figure 21]
Caution
▶When adjusting the tension of the lower thread, be sure to switch off the power supply. If
the user steps on the pedal by mistake, the machine will start automatically, and this might
lead to physical injuries.
▶When using the clutch motor, remember that the motor revolves for a while even after
switching off the power supply due to inertia. Make sure to start working only after the
motor has come to a complete stop.
[Applied Model Types]
A. KM-857
B. KM-867
[Applied Model Types]
A. KM-857-7
B. KM-867-7
A. Insert the bobbin ①into the hook ②.
B. 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.
C. The adequate length of the pulled-out lower thread is 50mm.
A. Insert the bobbin ①into the bobbin case ②.
B. 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.
C. Pass the pulled-out thread through “B” of the bobbin case ②, and
insert it into the hook.
D. The adequate length of the pulled-out lower thread is 50mm.
①
⑥
③
⑤
⑧
②
⑦
④
80%
①
①
②
②
“B”
“A”
“A”
50mm
③
③
50mm

19
5) Inserting bobbin
Stop the needle ①at the highest position. Following the figure 22, 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 on the right and left ⑤.
[Figure 22]
6) Routing upper thread
Place the thread take-up lever to the highest position and hang the upper thread like in figure 23. The adequate length of
upper thread extending from the needle hole is 50mm for initial sewing.
[Figure 23]
Caution
▶When taking up the upper thread, be sure to switch off the power supply. If the user steps
on the pedal by mistake, the machine will start automatically, and this might lead to physical
injuries.
▶When using the clutch motor, remember that the motor revolves for a while even after
switching off the power supply due to inertia. Make sure to start working only after the
motor has come to a complete stop.
①
②
④
③
⑤
⑤
③
②
④①
②
④
③
②
④
③
⑤
⑤
50mm
50mm

20
7) 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 fit.
(1) Adjusting the upper thread tension
Like in figure 24, turning the tension adjustment nut ①
of the thread tension control assembly clockwise makes
the upper thread tension stronger and turning
counterclockwise makes it weaker.
[Figure 24]
(2) Adjusting the lower thread tension
Like in figure 25, turning the tension adjustment nut ①
of the hook clockwise makes the lower thread tension
stronger and turning counterclockwise makes it weaker.
[Figure 25]
①
strong
weak
weak
strong
strong
weak
①
- Good sewing
- Strong upper thread tension with weak lower thread tension.
- Weak upper thread tension with strong lower thread tension.