CHAPTER 8
TROUBLESHOOTING
DANGER CAUTION Inspect/repair the machine by the guideline when in machine failures.
Error Type Cause Inspection & Repair Reference
Operation failure Loose belt tension / belt Adjust belt tension / change belt • Check main driver belt
damage • Check X-Y timing belt
Power failure or short- Check fuse in main shaft motor
circuit of fuse drive and change fuse
Failure to sense signals for Run manual color change and
needle position or 1 rotation adjust so that the operation box
indicates normal needle position
signal
Frame out of X/Y limit Correct start point of design
(when limit is set) (manually move frame so the
design comes within the limit)
Bad connection Check and re-plug the connector
Incorrect Stop Loose tension on main Adjust belt tension
Position driver belt
Incorrect encoder position Adjust encoder position or
or bad encoder change encoder
Error Type Cause Inspection & Repair Reference
Bad Color Incorrect position of needle Refer to user s manual Set main shaft angle back
Change stop at 100 , if you manually
moved it for cleaning,
inspection or repair.
Failure to sense signals for Run manual color change and
needle position or 1 rotation adjust so the operation box
indicates normal needle
position signal
Incorrect position of needle Set it to the correct position
bar
Incorrect position of take-up Adjust so take-up lever is in Unscrew the lever and
lever line with other levers in stop adjust so it is in line with
position (upper shaft the others on the guide rail.
angle:100 )
Fuse failure for color Change fuse F3 in joint board Check fuse rating
change motor or check connection
Bad connection
Error Type Cause Inspection & Repair Reference
Poor detection Failure of thread detector Disassemble roller. Clean roller
of upper thread roller and bush bearing gauge
Poor connection & quality Check the plate connection and
of tension adjusting plate change the circuit board
Bad jump Short-circuit of fuse for Change fuse F3 in joint board Check fuse rating
jump circuit
Bad solenoid and Check wiring and change
solenoid wiring solenoid
Bad connection Check connection
Switch failure on tension Change switch and circuit board
adjusting plate and on
circuit board
Bad stitch Bad quality tape data Adjust data
quality
Inadequate tension on X- Adjust tension
Y belt
Foreign substance in X-Y Clean the rail
rail
Power failure / X/Y circuit Change circuit board
board
Heavy load on frame Reduce speed of main shaft
Error Type Cause Inspection & Repair Reference
Thread breaks Stitch is too small/dense Re-punch design tape Check design
for thread
Frequent thread break in • Re-punch after checking design
same spot • Correct particular stitches
Inadequate needle size Change needle
for thread
Needle damage (bent, Change needle
dent, worn)
Incorrect needle installation Re-install needle
Dirty needle (adhesive, Clean or change needle and Use minimum adhesive
etc.) hook (applique)
Error Type Cause Inspection & Repair Reference
Bad thread (weak, Change thread Selecting thread
uneven thickness, poorly • soft, even thickness
twisted, old) tight, left-twisted
Right-twisted thread Change to left-twisted thread
• Z-twisted: left
• S-twisted: right
left- twist (prevents thread
unravelling as the rotary
hook rotates
counterclockwise)
Excessive thread tension Adjust tension
Tension imbalance Adjust tension and stroke
between upper and lower
threads
Excessive tension &
stroke on take-up lever
spring
Error Type Cause Inspection & Repair Reference
Dent on thread path on Remove dent or change Check rotary hook
hook and bobbin case
Narrow space between Adjust space Set it at 0.5-0.7mm for
hook holder and groove for smooth passage of
hook holder (on hook) upper thread
Insufficient oil in hook Oil the raceway of hook
Poor timing of needle and Adjust timing
hook
Incorrect lower dear stop Adjust the lower dead stop
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 fabric firmly
Inadequate height of Adjust height
presser foot (does not
press the work material)
Error Type Cause Inspection & Repair Reference
Skipped Bent needle
Stitches
Inadequate needle size for Change needle
thread
Incorrect installation of needle Adjust installation
Poor timing of needle and Adjust timing
hook
Large gap between needle
groove and hook point
Incorrect lower dead stop Adjust lower dead stop
Damaged hook point Use whetstone to adjust hook
point or change hook
Thread feeding is interfered • Adjust thread tension
• For upper thread, change
bobbin or bobbin case
Inadequate thread Select right thread for embroidery
(twist, elasticity, and flexibility)
Excessive tension or stroke Adjust stroke or tension
on the take-up lever spring
Fabric moves with needle - Change presser foot spring
weak or damaged presser
foot (spring)
Error Type Cause Inspection & Repair Reference
Poor stitch Weak upper thread tension Adjust tension
tension
Uneven upper thread tension Clean main and sub tension
due to foreign substances adjusters in the thread tension
adjusting plate
Weak lower thread tension Adjust tension
Uneven lower thread tension Clean bobbin case and bobbin
spring
Thread thickness Change to quality thread
Poor timing of needle and Adjust timing
hook
Insufficient oil in hook Oil the raceway of hook
Needle breaks Bent needle Change needle
Bad quality needle
Tip of the needle is worn or
bent
Inadequate needle size for
thread or fabric
Needle touches the hook Space the needle and the hook
point point
Incorrect installation of Correct the installation
needle
Needle touches the needle • Check if needle plate is
hole on the plate unscrewed
• Adjust the position of the
needle bar
Error Type Cause Inspection & Repair Reference
Puckering Excessive thread tension Adjust tension
Excessive pressure from Change presser foot spring
presser foot
Needle failure - Change needle
worn out/damaged needle
tip needle is too large for
thread
Needle hole is too large for Use adequate size of needle SWF needle holes are
needle 2.0mm, fit for threads
and needle of the sizes
below:
#50 ~ #70 cotton
#75 ~ #120 rayon
#9 ~ #14 DB K5
Trimming failure Short-circuit of trimming Check and change fuse F1, F3 in Check fuse rating
fuse joint board
Poor connection/quality of Check and change solenoid and
solenoid solenoid connection
Bad connection Check connection
Trimming driver TR Change joint board
damaged
Error Type Cause Inspection & Repair Reference
Short upper Movable blade is too fast Adjust insert angle of movable
thread after or too slow to separate blade (295 )
trimming from upper thread
failure to
separate
Incorrect position of picker Adjust picker position
Picker failure • Check and change fuse F1, F3 Check fuse rating
in joint board
• Check and change solenoid
and solenoid connection
• Check connection and change
joint board
Thread break Upper thread is too short Adjust upper thread tension
before trimming • check main and sub • remove dent using whetstone
tension adjuster on the or sandpaper
tension adjusting plate • change movable blade
• dent or damage to
movable blade
Check for dent
Lower thread is too short • adjust or change bobbin case Too short lower thread
• doesn t unwind smoothly spring cannot make start
• clean/check for dent in thread stitches after trimming
guide on the bobbin case
• too weak or too elastic • Change lower thread
Error Type Cause Inspection & Repair Reference
Short upper Short upper thread after • check upper thread tension The default is MEDIUM.
thread after trimming • set LONG or MEDIUM length of
trimming Upper thread is trimmed trimmed thread in data set-up
too short and comes
unthreaded
Upper thread is trimmed • set MEDIUM or SHORT length
too long and thread tail of trimmed thread in data set-up
remains on the embroidery • if upper thread is held by a
narrow velcro in upper thread
holder, clean the velcro
Thread is not Failure of movable and Check screws
trimmed fixed blades
Lose cross tension of the Check tension of fixed blade
blades
Movable blade damaged Change movable blade
Incorrect return position of Adjust the position of movable
movable blade blade
Failure of upper Short-circuit of fuse Check/change fuse F3 in joint Check fuse rating
thread holder board
solenoid
Poor connection/quality of Check/change solenoid &
solenoid connection
Bad connection Check connection
Poor quality circuit board Change thread detecting plate in
sub controller
Failure to hold Short strokes of upper Adjust stroke
upper thread thread holder
Upper thread holder Adjust the workload
overloaded
