CHAPTER 12

TROUBLESHOOTING

DANGER CAUTION Inspect/repair the machine by the guideline when in machine failures.

Error Type Cause Inspection & Repair Reference

Operation failure ① Loose belt tension / belt Adjust belt tension / change belt ※ Check
damage �main driver belt
�X-Y timing belt

② Power failure or short-circuit Check fuse in main shaft motor

of fuse and change fuse

③ Failure to sense signals for Run manual color change and Page 11-8 see 11-7)
needle position or 1 rotation check if signal lamps (needle set
lamp & needle position lamp)
blinks at correct needle position.
Adjust the half-turn film

④ Frame out of X or Y limit � Move frame back to within Page 11-13 see 11-12)
the limit
� Check limit switch

⑤ Red light on X/Y drive box Address the cause and press
RESET. Check if the lamp turns
green.

⑥ Machine doesn’t start with Check connection of START

bar switch switch

Incorrect Stop ① Loose tension on main Adjust belt tension Page 11-11 see 11-11)
Position driver belt

② Incorrect position of Adjust position or change Page 11-8 see 11-8)

encoder or bad encoder encoder

12-1
 Error Type Cause Inspection & Repair Reference

Bad Color ① Incorrect position of needle Refer to user’s manual Set main shaft angle back at
Change stop 100�, if you manually moved
it for cleaning, inspection or
repair.

② Failure to sense signals for Run manual color change and Page 11-8 see 11-7)
needle position or 1 rotation check if signal lamps (needle
set lamp & needle position
lamp) blinks at correct needle
position. Adjust the half-turn
film.

③ Incorrect position of needle Set it to the correct position

bar

④ Incorrect position of take-up Adjust so take-up lever is in ※ Unscrew the lever and
lever line with the other levers in the adjust so it is in line with
stop position (upper shaft the others on the guide
angle:100�) rail.

Take-up driver
lever screw

Take-up lever

⑤ Fuse failure for color Change fuse in joint board ※ Check fuse spec.
change motor or check connection F5 = 250V 1 A
Bad connection

12-2
 Error Type Cause Inspection & Repair Reference

Poor detection ① Failure of thread detecting Disassemble the roller and

of upper thread roller clean the roller and bush
bearing.

② Poor connection & quality Check the plate connection

of tension adjusting plate and change the circuit board

Bad jump ① Short-circuit of fuse for Change front fuse , in ※ Check fuse spec
jump circuit joint board , = 250V 20A
, = 250V 15A

② Bad solenoid and bad Check wiring and change

solenoid wiring solenoid

③ Bad connection Check connection

④ Switch failure on tension Change switch and circuit

adjusting board and bad board
circuit board

Bad stitch ① Bad design Correct design

quality

② Inadequate tension on X-Y Adjust tension

belt

③ Foreign substance in X-Y Clean the rail

rail

④ Failure of X/Y driver board Change circuit board

⑤ Heavy load on frame Reduce speed of main shaft

12-3
 Error Type Cause Inspection & Repair Reference

Thread breaks ① Stitch is too small/dense for Re-punch design tape Check design
thread

② Frequent thread break in � Re-punch after checking Page 7-101 see 7-5-9)
the same spot design
� Correct the stitches on
operation box

③ Inadequate needle size for Change needle Page 5-19 see 5-12)
thread

④ Needle damage (bent, Change needle

dent, worn)

⑤ Incorrect needle installation Re-install needle Page 5-19 see 5-12-3)

(height, direction, etc.)

⑥ Dirty needle (adhesive, Clean or change needle and Use minimum adhesive for
etc.) hook applique

12-4
 Error Type Cause Inspection & Repair Reference

Thread breaks ⑦ Bad thread (weak, uneven Change thread Check the thread used
thickness, poorly twisted,
old) ※ How to select thread
� Select soft thread with
even thickness
� choose left-twisted
thread

⑧ Right-twisted thread Change to left-twisted thread

� Z-direction: left twist

� S-direction: right twist

※ left-twist prevents
unraveling of the upper
thread in the counter-
clockwise rotation of the
hook

⑨ Excessive thread tension Adjust tension Page 5-9 see 5-6-2)

⑩ Tension imbalance Page 5-11 see 5-7-2)

between upper and lower
threads

⑪ Excessive tension & stroke Adjust tension and stroke Page 5-10 see 5-6-3)
on take-up spring

12-5
Error Type Cause Inspection & Repair Reference

⑫ Dent on thread path on Remove dent or change the Check rotary hook
hook and bobbin case case

⑬ Narrow space between Adjust space ※ Set it at 0.5-0.7mm for

hook holder and groove for smooth feeding of upper
hook holder (on hook) thread

7
~0.
0.5

Hook holder

⑭ Insufficient oil in hook Oil the raceway of hook

⑮ Poor timing of needle and Adjust timing Page 5-21 see 5-12-4)
hook

� Incorrect lower dead stop Adjust the lower dead stop Page 11-9 see 11-9-1)

� Dent on thread path ※ Check:

�Thread path in presser
foot
�Around needle hole on
needle plate
�Thread guide on the head
�Thread path in tension
adjuster

� Fabric moves on the frame Fix the material firmly

� Inadequate height of Adjust height Page 11-5 see 11-5)

presser foot
(does not press the work
material)

12-6
 Error Type Cause Inspection & Repair Reference

Skipped ① Bent needle

Stitches

② Inadequate needle size for Change needle Page 5-19 see 5-12-3)
thread

③ Incorrect installation of Adjust installation

needle

④ Poor timing of needle and Adjust timing

hook

⑤ Large gap between needle Incorrect lower dead stop Page 11-9 see 11-9-1)
groove and hook point

⑥ Adjust the lower dead stop Use whetstone to adjust hook

point or change hook

⑦ Damaged hook point

⑧ Thread feeding is interfered � Adjust thread tension Page 5-9 see 5-6-2)
� For lower thread, change Page 5-11 see 5-7-2)
bobbin or bobbin case

⑨ Inadequate thread Select right thread for

(twist, elasticity, and embroidery
flexibility)

⑩ Excessive tension or stroke Adjust stroke or tension Page 5-10 see 5-6-3)
on the take-up lever spring

⑪ Fabric moves with needle - Change presser foot spring

weak or damaged presser
foot (spring)

12-7
 Error Type Cause Inspection & Repair Reference

Poor stitch ① Weak upper thread tension Adjust tension Page 5-9 see 5-6-2)
tension

② Uneven upper thread Clean main and sub tension

tension due to foreign adjusters in the thread tension
substances adjusting plate

③ Weak lower thread tension Adjust tension Page 5-11 see 5-7-2)

④ Uneven lower thread Clean bobbin case and check

tension tension on bobbin spring

⑤ Thread thickness Change to quality thread

⑥ Poor timing of needle and Adjust timing Page 5-21 see 5-12-4)
hook

⑦ Insufficient oil in hook Oil the raceway of hook Page 10-3 see 10-3-1)

Needle breaks ① Bent needle Change needle Page 5-19 see 5-12-3)

② Bad quality needle

③ Tip of the needle is worn or

bent

④ Inadequate needle size

⑤ Needle touches the hook Space the needle and the hook Page 5-21 see 5-12-4)
point point

⑥ Incorrect installation of Correct the installation Page 5-19 see 5-12-3)

needle

⑦ Needle touches the needle � Check if needle plate is Page 11-7 see 11-6)
hole on the plate unscrewed
� Adjust the position of the
needle bar

12-8
 Error Type Cause Inspection & Repair Reference

Puckering ① Excessive thread tension Adjust tension Page 5-9 see 5-6-2)
Page 5-11 see 5-7-2)

② Excessive pressure of Change presser foot spring

presser foot

③ Needle failure - Change needle

worn out/damaged needle
tip
needle is too large for
thread

④ Needle hole is too large for Use adequate size of needle ※ SWF needle holes are
needle 2.0mm large.
SWF specification for
needle & thread are:

Cotton #50�#70
Rayon #75�#120
DB×K5 #9�#14

Trimming failure ① Short-circuit of trimming Check and change fuse ※ Check fuse spec
fuse , in joint board , = 250V 20A
, = 250V 15A

② Poor connection/quality of Check and change solenoid

trimming solenoid and solenoid connection

③ Bad connection Check connection

④ Trimming driver TR Change joint board

damaged

12-9
 Error Type Cause Inspection & Repair Reference

Trimmer return ① Poor connection of sensor Check connection

failure

② Bad circuit board Change circuit board

③ Bad sensor or sensor �Change sensor Page 11-3 see 11-2)

position. �Clean around the sensor
Dirty area around the �Adjust location of the sensor
sensor. unit

Short upper ① Movable blade is too fast or Adjust insert angle of movable Page 11-1 see 11-1-1)
thread after too slow to separate the blade (295�)
trimming due to upper thread
separation
failure

② Movable blade and rotary Adjust the distance Page 11-2 see 11-1-3)
hook are too close or too
far

③ Incorrect position of picker Adjust picker position Page 11-4 see 11-3)

④ Picker failure �Check and change fuse ※ Check fuse spec.

� , = 250V 20A
�Check/change solenoid and
solenoid connection , = 250V 15A
�Check connection and
change joint board

Thread break ① Upper thread is too short Adjust upper thread tension
before trimming �check main and sub
tension adjuster - remove dent using whetstone
�dent or damage to or sandpaper or change
movable blade movable blade
Check
for dent

12-10
 Error Type Cause Inspection & Repair Reference

① Lower thread is too short �Adjust or change bobbin Too short lower thread
�doesn’t unwind smoothly case spring cannot make stitches right
�Clean/check for dent in after trimming
thread guide on the bobbin
case

�too weak or too elastic Change lower thread

Short upper ① Upper thread is trimmed �Check upper thread tension

thread after too short and comes �Set LONG or MEDIUM The default is MEDIUM.
trimming unthreaded length of trimmed thread in See 7-5-3 SET-UP3
SET-UP 3

② Upper thread is trimmed �Set MEDIUM or SHORT

too long and thread tail length of trimmed thread in
remains on the embroidery SET-UP 3
�If upper thread is held due to
narrow velcro space in upper
thread holder, clean the
velcro

① Failure of movable and Check screws and crank driver

Thread is not cut fixed blades clamp screws of the movable
(at specific blade
head)

② Loose cross tension of the Check tension of fixed blade Page 11-2 see 11-1-3)
blades

③ Movable blade damaged Change movable blade

④ Incorrect return position of Adjust the position of movable Page 11-1 see 11-1-1)
movable blade blade

Stitch is not ① Short upper thread Adjust tension of lower thread Page 11-3 see 11-1-4)
formed after ② Short lower thread holder
trimming ③ Lower thread holder failure

12-11
 Error Type Cause Inspection & Repair Reference

Failure of upper ① Short-circuit of fuse (if all Check/change fuse , in ※ Check fuse spec
thread holder heads fail) joint board , = 250V 20A
solenoid
, = 250V 15A

② Poor connection/quality of Check/change solenoid &

solenoid connection

③ Bad connection Check connection

④ Poor quality circuit board Change thread detecting plate

in sub controller

Failure to hold ① Short strokes of upper Adjust stroke Page 11-4 see 11-4)
upper thread thread holder

② Upper thread holder Adjust the workload

overloaded

12-12