USER
S MANUAL
R
DPK-5
Post bed, 1 needle, lock stitch,
zigzag sewing machine
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.
Safety rules for machines
.......................................................................................................................................
4
1. Specification
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
1) Installation of machine head......................................................................................................................................10
2) Adjustment of belt tension.........................................................................................................................................11
3) Installation of belt cover ............................................................................................................................................11
4) Assembly of position detector ...................................................................................................................................12
5) How to install the knee lifter .....................................................................................................................................12
6) When the unit box is installed ...................................................................................................................................12
7) Cam replacement method (1-step, 2-step, 3-step) - optional ...................................................................................13
3. Adjustment of the Machine
1) Inserting the needle ....................................................................................................................................................14
2) Pressure adjustment .................................................................................................................................................14
3) How to remove the bobbin case ................................................................................................................................14
4) How to place the bobbin case....................................................................................................................................15
5) How to thread the bobbin case ..................................................................................................................................15
6) Lower thread winding and adjustment .....................................................................................................................15
7) Threading ...................................................................................................................................................................16
8) How to adjust the thread tension ...............................................................................................................................16
9) Adjustment of needle stitch width.............................................................................................................................17
10) Adjustment of backtack length................................................................................................................................17
4. Causes of Trouble and Troubleshooting
1) Sewing machine troubleshooting ..............................................................................................................................18
Table of Contents
44
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
55
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.
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
In case of repair, change the damaged part into the standard article of our company
After repair, cover the machine with the safety cover that was removed for repair.
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 machines 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.
Keep the machine out of direct rays of the sun.
Keep both sides and the backside of the machines at least 50cm from the wall to
secure enough space for repair.
Danger of Explosion
Dont run the machine near places with any danger of explosion.
Dont run the machine near places with any danger of explosion, including places
where sprays 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.
Illuminators do not come equipped with the machine due to the machines
characteristics. 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
The DPK-5 Series are manufactured for industrial use to sew textiles and other similar
material. When running the machine, users should observe the following things.
Read 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 and 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
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.
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.
77
Cautionis attached to the machine for safety.
In case of starting to run the machine, read the directions of Cautioncarefully.
1-6) Position of
Caution Mark
1-7) Content of
Caution
[Position of Caution Mark]
Caution
8
1) Sewing machine
DPK-5 (post bed, 1 needle, lock stitch, zigzag sewing machine)
1
Specification
2) Servo motor
MODEL
SC55-1A
SC55-2A
SC55-3A
VOLT
1 Phase 110V
1 Phase 220V
3 Phase 220V
WATT
550W
550W
550W
HERTZ
50/60 Hz
50/60 Hz
50/60 Hz
3) 470 motor
4) 470 motor controller
Model name
Use Max. speed Zigzag width Needle
Presser bar height
Hook
Lubrication
DPK-5/S
DPK-5/C
For heavy materials
For heavy materials
2,500 spm
2,500 spm
08mm
08mm
DP5(#11#14)
DP5(#11#14)
Up to 8mm
Vertical large hook (2x)
Vertical large hook (2x)
Manual
Manual
UsageModelOptional device
9
Auto Knee Lifting System
Production Counter
Material Edge Sensor
Standing Pedal
SCOUND-1
SEDG-1B
SEDG-2B
SPDL-1
SPDL-2
A counting device which indicates the completed quantity on the
program unit panel, including added, subtracted, corrected or
remaining quantity along with other performance rates
A device that senses the edge or thickness of the sewing
material to stop the machine without manual pedaling. Available
in two types: SEDG-1B for edge sensing type and SEDG-2B for
thickness sensing type
An essential device when one person is operating multiple
sewing machines. Has different pedals for acceleration, thread
trimming, presser foot and ascending pedal. Types consist of
SPDL-1 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
5) Clutch motor
6) Peripheral automation devices (optional)
S Servo motor
E 470 motor
10
2
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 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.
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.
1) Installation of machine head
Insert the machine head hinge into the bed holes. After
aligning it with the rubber hinge , stand the machine on the
rubber cushion that is in the direction of the user.
[Figure 1]
11
2) Adjustment of belt tension
After installing the motor, unfasten the fixing units , up
and down and tension will be created to the belt due to
motor failing by gravity. And fasten the fixing nut and
then the fixing nut tightly.
[Figure 2]
3) Installation of belt cover
(1) Fix the belt cover “A” on the sewing machine body
using the fixing screw and the washer .
(2) Fix the belt cover “B” on the table using the tapping
screw. Make sure that the belt does not interfere with
the belt cover “B”.
[Figure 3]
Belt cover A
Belt cover B
12
4) Assembly of position detector
(1) When the servo motor is installed
Connect it to the portable synchro pulley shaft. Use the
synchro fixing bar and the tightening screw to
prevent the portable synchro from moving left or right.
When the synchro is fixed, use the socket set bolt to
fix it to the pulley shaft.
(2) When the clutch motor is installed
The portable synchro is not needed.
[Figure 4]
6) When the unit box is installed
Needed when the servo motor is installed.
Fix the unit box bracket to the arm using the socket set
screw. Place the unit box wiring inside. Fix the unit
box using the connecting bolt.
[Figure 6]
Unit box
bracket
Unit box
5) How to install the knee lifter
The knee lifter replaces manual operation of the presser
foot.To install, assemble the knee lifter units as shown in
Figure 5. Then fix it onto the backside of the table with three
wooden screws.
[Figure 5]
13
7) Cam replacement method (1-step,
2-step, 3-step) - optional
To change from 1-step to 2-step, 3-step or zigzag, turn the
cam lever counter-clockwise and loosen the lever. After a
different cam is placed, turn the cam lever clockwise in full
and fix it.
[Figure 7]
Cam lever
14
3
Adjustment of the Machine
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.
1) Inserting the needle
Place the upper end of the needle closely adhered to the
upper side of the stopper hole , with the needle groove
facing inward. Fix the needle with a fixing screw.
[Figure 8]
3) How to remove the bobbin case
Turn the pulley in a counterclockwise direction to move the
thread take-up lever to its highest position. With your left
index and the second finger, push up the latch lever of the
bobbin case frame to remove the frame with the bobbin
case. Then push down the latch lever to remove the bobbin
case.
[Figure 10]
Hook
Bobbin case
2) Pressure adjustment
As in the figure, turn the pressure adjusting screw
clockwise and the pressure of the presser foot increases, and
vice versa. After adjustment is done, fasten the nut.
[Figure 9]
15
4) How to place the bobbin case
Turn the pulley until the needle bar comes to its highest
position. Bring the bobbin case towards the center stud in
the bottom of the bobbin case. Press the bobbin case until it
makes a clicking sound in the frame. Follow the instructions
carefully to protect the needle in the bobbin frame.
[Figure 11]
5) How to thread the bobbin case
Insert the bobbin case in the bobbin frame. Firmly fix the
bobbin in the frame, push the thread through the hole and
pull it into the lower part of the tension spring and the hole.
[Figure 12]
6) Lower thread winding and adjustment
(1) Winding the lower thread
A. The thread should come out through hole from the
back of the tension regulating dish towards the
front.
B. The thread should be taken to the bobbin and
wound clockwise 5 or 6 times from the bottom.
C. After pushing lever and letting pulley touch
the V-belt, run the machine.
D. If the bobbin winds all the lower thread, pulley is
automatically separated from the belt.
(2) Lower thread adjustment
A. When the lower thread is wound irregularly unscrew
, move it left to right, and tightly screw again.
B. The lower thread's winding amount can be adjusted. if
you turn the regulating screw clockwise it increases
and if you turn it counterclockwise it decreases.
C. For the lower thread's tension adjustment that winds
the bobbin, if you turn screw clockwise it becomes
stronger and if you turn it counterclockwise it
becomes weaker.
[Figure 13]
16
7) Threading
Your sewing machine comes with properly placed threads.
Therefore, the easiest and simplest way to re-threading is to
tie the thread that comes with the machine, with a new one.
Check if the knotted area of the old and new threads goes
through the needle hole smoothly.
CAUTION
Pull the thread 100mm out from the needle hole when
starting the sewing. If you need to replace the threads
completely, refer to the threading table and Figure 14.
[Figure 14]
[Figure 15]
[Figure 16]
8) How to adjust the thread tension
Accurate control of thread tension determines sturdiness and
elegance of completed seams. Tension is accurately
balanced when the needle engages the bobbin thread at the
center of the sewing material. To increase thread tension of
the needle, turn the screw clockwise and vice versa. If
you still cannot get a proper number of stitches, unfasten the
screw and turn the thread tension point to control the
tension of the thread take-up lever spring . For more
tension, turn the point in a counterclockwise direction
and for less, in a clockwise direction.
Adjusting screw
17
9) Adjustment of needle stitch width
(1) Not installed with 3-step cam
You can adjust the width of stitches by turning the dial
(A, Figure 17) in the center of the machine arm. If the
dial is set at 0, the machine will perform straight line
stitching. Turn the dial to the left to increase the width
and to commence zigzag sewing.
CAUTION
Stop the machine before rotating the dial (A).
[Figure 17]
Narrow
Wide
(2) Installed with 3-step cam
Loosen the socket set screw and move it vertically.
Using various length of link, the stitch width can be
adjusted.
[Figure 18]
Socket set
screw
10) Adjustment of backtack length
The inside dial in the figure is used to adjust the backtack
length. When the dial is turned clockwise, the backtack
length gets longer. When it is turned counter-clockwise, the
backtack length gets shorter.
[Figure 19]
Backtack
lever
18
4
Causes of Trouble and Troubleshooting
1) Sewing machine troubleshooting
No Symptom Checkpoints Root cause Corrective action
1
2
3
4
Needle breaks
Thread breaks
Sewing is
skipped
Upper thread
does not wind
Reinsert the needle correctly
Change the needle
Adjust the timing of feed dog
Adjust the needle and hook timing.
Adjust the needle and hook timing.
Adjust the needle and hook timing.
Thread the needle correctly
Change the needle
Insert the needle correctly
Reduce tension of upper thread
Adjust take-up lever spring
Reinsert the needle correctly and
push in to its highest level
Change the needle
Insert the thread in the right way
Adjust the needle and hook timing.
Adjust the needle and hook timing.
Adjust the needle and hook timing.
Adjust the thread adjusting device
Reduce the tension of upper thread
Enhance the tension of lower thread
Needle is inserted into wrong position
Needle is bent
Bad timing of feed dog
The needle and hook timing is bad.
The needle and hook timing is bad.
The needle and hook timing is bad.
Wrong threading
Bent needle or broken needle tip
Needle inserted in the wrong position
Too tight upper thread tension
Loose upper thread
Needle is inserted into wrong
direction
Needle is bent
Wrong direction
The needle and hook timing is bad.
The needle and hook timing is bad.
The needle and hook timing is bad.
The length of the remaining upper
thread is too short
Too tight upper thread tension
Too weak lower thread tension
Direction and height of
needle
Needle
Ascending level of
needle bar
Height of needle
Gap between the
needle and the hook
Threading method
Needle
Direction and height of
needle
Upper thread tension
Working capacity of
take-up lever spring
Direction and height of
needle bar
Needle
Threading
Ascending level of
needle bar
Height of needle bar
Gap between the
needle and the hook
5
Upper thread
falls out when
starting to sew
Adjust Tension of the upper thread
Correct the thickness of the needle
Find out needle top stop position
Tension of the upper thread is strong
Needle is too thick for thread
The position of Needle top and lower
Check for Needle top
stop position
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SunStar DPK-5/C User manual
- Category
- Sewing machines
- Type
- User manual
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