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1. THIS IS AN INSTRUCTION FOR SAFE USE OF AUTOMATICEMBROIDERY MACHINES. READ THOROUGHLY BEFORE USE.

2. CONTENTS IN THIS INSTRUCTION MAY CHANGE, WITHOUTPRIOR NOTICE, FOR IMPROVEMENT OF MACHINE QUALITY ANDTHUS MAY NOT CORRESPOND TO THE MACHINE YOUPURCHASED. CONTACT YOUR SALES AGENT FOR INQUIRIES.

3. THIS IS DESIGNED AND MANUFACTURED AS AN INDUSTRIALMACHINE. IT SHOULD NOT BE USED FOR OTHER THANINDUSTRIAL PURPOSE.

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Contents

1. MACHINE TYPES AND SPECIFICATIONS ................................................................................... 6

1.1) MACHINE TYPES ................................................................................................................................. 61.2) MODELS ................................................................................................................................................. 61.3) SPECIFICATIONS .................................................................................................................................. 61.4) PERIPHERALS ....................................................................................................................................... 6

2. SAFETY RULES ....................................................................................................................................... 7

2.1) SAFETY INDICATIONS ....................................................................................................................... 72.2) MACHINE DELIVERY ......................................................................................................................... 82.3) MACHINE INSTALLATION ................................................................................................................ 92.4) MACHINE OPERATION ....................................................................................................................... 92.5) REPAIR .................................................................................................................................................. 10

3. PRODUCT FEATURES ........................................................................................................................ 11

4. MACHINE INSTALLATION AND PRECAUTIONS ................................................................... 13

4.1) INSTALLATION CONDITION ........................................................................................................... 134.2) ELECTRICITY INSTALLATION ENVIRONMENT ....................................................................... 144.3) LEVELING THE MACHINE .............................................................................................................. 14

5. NOTICES RELATED TO OPERATION .......................................................................................... 16

5.1) SAFETY LABEL TYPES .................................................................................................................... 165.2) LOCATION OF SAFETY LABELS .................................................................................................... 17

6. NAMES OF MACHINE PARTS ......................................................................................................... 18

7. ACCESSORIES AND THEIR ASSEMBLY ................................................................................... 19

7.1) STAND ................................................................................................................................................... 197.2) OP BOX ................................................................................................................................................. 197.3) FLUORESCENT LIGHT ..................................................................................................................... 19

8. FUNCTIONS OF EACH PART AND MACHINE OPERATION ............................................. 20

8.1) BASIC OPERATION ............................................................................................................................ 208.2) NEEDLE-HOOK TIMING AND RELATED TIPS ............................................................................ 378.3) THREAD BREAK DETECTOR ASSEMBLY AND ITS FUNCTIONS ......................................... 44

9. EMBROIDERY METHODS ................................................................................................................. 46

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Contents

10. ERROR DISPLAY AND TROUBLESHOOTING ...................................................................... 47

10.1) MAIN SHAFT MOTOR ..................................................................................................................... 4710.2) X, Y-AXIS MOTORS ......................................................................................................................... 4710.3) COLOR CHANGE .............................................................................................................................. 4810.4) ENCODER .......................................................................................................................................... 4810.5) REPETITION WORK ........................................................................................................................ 4810.6) FLOPPY DISK .................................................................................................................................... 4910.7) MEMORY ........................................................................................................................................... 5010.8) CHENILLE HEAD ............................................................................................................................. 50

11. CONTROL BOX .................................................................................................................................... 51

11.1) MAIN CONTROL BOX ..................................................................................................................... 5111.2) MAIN SHAFT & X-Y MOTOR DRIVE (SANYO) ......................................................................... 5311.3) LIST OF ERRORS AND CAUSES IN MAIN SHAFT DRIVER &

X,Y SERVO MOTOR DRIVERS ...................................................................................................... 54

12. MAINTENANCE AND INSPECTION ............................................................................................ 55

12.1) CHECK POINTS FOR REGULAR INSPECTION ......................................................................... 5512.2) CLEANING ......................................................................................................................................... 5512.3) OIL SUPPLY ....................................................................................................................................... 58

13. ADJUSTING MAJOR PARTS OF THE MACHINE ................................................................. 66

13.1) ADJUSTING THE CHENILLE HEAD ............................................................................................ 6613.2) ADJUSTING THE TRIMMERS ....................................................................................................... 6713.3) ADJUSTING THE UPPER THREAD HOLDING UNIT ............................................................... 7013.4) PICKER ADJUSTMENT ................................................................................................................... 7113.5) ADJUSTING UPPER THREAD HOLDER ..................................................................................... 7213.6) ADJUSTING LOW-NOISE PRESSER FOOT ................................................................................. 7413.7) RELATIONSHIP BETWEEN PRESSER FOOT AND NEEDLE .................................................. 7513.8) CORRECT POSITION OF NEEDLE ............................................................................................... 7613.9) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE ......................................................... 7713.10) ENCODER ADJUSTMENT ............................................................................................................ 7713.11) NEEDLE BAR ADJUSTMENT ...................................................................................................... 7813.12) JUMP MOTOR ADJUSTMENT ..................................................................................................... 7913.13) ADJUSTING DRIVE BELT TENSION .......................................................................................... 8013.14) ADJUSTING X, Y SCOPE LIMITS ............................................................................................... 83

14. TROUBLESHOOTING ....................................................................................................................... 86

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MACHINE TYPES AND SPECIFICATIONS01

1.1) MACHINE TYPES

1.2) MODELS

1.3) SPECIFICATIONS

SWF / CA - 6 9 06 - 120Series

No. of Colors for Chenille Head

Y-Stroke

No. of Heads

No. of Needles for Standard Head

Machine

SWF/CA-6906-120

SWF/CA-6906-75

Heads(Pairs) Board×ContinuousAll Head

Emb. space (mm)Color

Standard Chenille

Head Interval (mm)

Table Size (mm)

6

6

SWF/CA-6912-75 12

9

9

9

6

6

6

480

400

500

2,849×4,900

1,955×4,900

1,985×8,025

1,200×2,880

750×2,880

750×6,000

1,200×480(230)

750×480(230)

750×500(230)

0.1 ~ 12.7 (mm)

Chenille Head Max. 600 rpm

Standard Head Max. 1000 rpm

AC Servo Motor X 2

Pulse Motor X 2 / Servo Motor(12Head)

1-Phase：200V, 220V, 240V (50~60Hz) / 3-Phase(12Head)

1.0 Kw

Stitch Length

Speed

Main Motor

X-Y Motor

Electricity

Power Consumption

1.4) PERIPHERALS

Standard

Standard

Color Touch Screen

2,000,000

Operation Box

Memory Capacity

SAFETY RULES02

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2.1) SAFETY INDICATIONS

The following set of safety rules categorized as , , and indicatespossibilities of physical or property damages if not fully observed.

DANGERWARNINGCAUTION

No. Names Content

CAUTION

WARNING

DANGER

CAUTIONUsers may be subject to physical or property damages ifnot fully observe the CAUTION.

Users may be subject to death or severe damages if notfully observe the WARNING.

Users may be subject to death or severe damages and

emergency if not fully observe the DANGER.

WARNING

DANGER

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2.2) MACHINE DELIVERY

ONLY TRAINED AND EXPERIENCED PERSONS, FAMILIAR WITH THERELEVANT SAFETY INSTRUCTIONS, SHOULD HANDLE THE MACHINE. MAKESURE TO FULLY OBSERVE THE FOLLOWING INSTRUCTIONS.

2.2.1) Delivery using a crane

1) The crane used should be strong enough to lift the machine. The nylon rope used should also be durable enough to support the machine weight.

2) Please hang the nylon rope on the rope hangers on the right and left sides of the body. 3) When hanging a rope to the crane, the slant angle of the rope should not exceed 40°at

the maximum.

2.2.2) Delivery using a forklift

1) Make sure that size and weight of the forklift is sufficient to support the machine. 2) Place the machine so that its center is on the fork arm. Lift the machine carefully from

behind so that the machine does not tilt to either side.

Make sure allpersons andobstacles are outof the way of themoving machine.

Warning mark Description

Max 40。

Nylon rope

DANGER

When unloading the machine from forklift or crane, make sure tomaintain the weight balance in order to prevent injury or machinedamages.WARNING

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2.3) MACHINE INSTALLATION

2.3.1) Machine malfunctions or physical damages may occur due tocondition of the installation environment. Make sure to meet thefollowing conditions.

1) The foundation (floor) under the machine must be strong enough to support theweight of the machine (approximately 3.5 tons).

2) Air conditioning can eliminate dust and humidity, which may cause pollution andcorrosion of the machine. Make sure your machine is regularly maintained.

3) Do not expose the machine to direct sunlight. (Long exposure to direct sunlight canfade the machine paint or deform the machine shape.)

4) Allow at least 50cm space on each side of the machine (right, left, rear) from the wallfor convenient maintenance.

2.4) MACHINE OPERATION

2.4.1) The machine has and labels on each riskyparts. Pay careful attention to the labels and make sure to observethem during operation.

1) Read thoroughly and fully understand the manual before operating the machine. 2) Dress for safety. Long and unbound hair, jewelry such as necklaces, bracelets, and

wide sleeves can get caught in the machine. Wear shoes with non-slip soles to preventslip-off accidents.

3) Check the scope of machine operation to see if there is no problem.4) Keep your hands or head away from the moving parts of the machine such as needle,

hook, take-up lever, and pulley when the machine is in operation.5) Do not remove the safety covers on the pulley or shaft when the machine is in

operation for your safety.6) Be sure the main power is turned off and the power switch is OFF before opening the

cover of any electrical components such as control box.7) Be sure the main switch is OFF before manually turning the main shaft.8) Turn OFF the machine when you thread needles or inspect the finished embroidery.9) Do not lean against the cradle or place your fingers near the pantograph guide

grooves. You may hurt your fingers when the frame moves.10) The machine noise may exceed 85db when it runs at the maximum speed.

WARNINGCAUTION

CAUTION

WARNING

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2.5) REPAIR

2.5.1) Only SWF-trained and designated engineers should perform repairwork.

1) Turn OFF the power before cleaning or repair. Wait for 4 minutes so the machineelectricity is completely discharged.

2) Do not change the settings or any parts on the machine without consulting with SWF.

3) Use only official SWF parts when repairing your machine or replacing parts.4) Re-install all safety covers when you are finished with the repair.

DANGER

It takes approximately 10 minutes after turning off the main switchbefore the electricity is fully discharged from main shafts and theX/Y drive box.CAUTION

Machine changes without consultation with SWF may cause risksto your safety when you operate the machine.

DANGER

PRODUCT FEATURES 03

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3.1) CHENILLE HOOKED NEEDLE’S RETURN TO THE ORIGIN

－ The hooked needle of the chenille embroidery machine can be automatically returned to the origin.

3.2) CHENILLE LOOPER’S RETURN TO THE ORIGIN

－ The looper of the chenille embroidery machine can be automatically returned to the origin.

3.3) 10.4"" LCD MONITOR － The operating panel is equipped with the 10.4" LCD monitor, which shows all information related to

embroidery work at a glance.

3.4) EXPANDED MEMORY

－ You can store maximum 100 designs and maximum 2 million stitches.

3.5) MIRROR IMAGE CONVERSION

－ You can turn the design from 0°to 359°by 1°and also mirror the design (reverse in the X direction).

3.6) ENLARGING AND REDUCING DESIGN

－ You can reduce or enlarge the design from 50% to 200% by 1% along the X, Y axis.

3.7) AUTOMATIC SELECTION OF NEEDLE BAR

－ You can select the order of the needle bars up to the 99th bar.

3.8) GENERAL REPETITION WORK

－ The same design can be repeated up to 99 times along the X, Y axis.

3.9) SPECIAL REPETITION WORK

－ Several designs can be repeated up to 64 times at different angles and directions.

3.10) AUTOMATIC OFFSET

－ The frame automatically returns to the offset point when the embroidery is finished, making it easier for youto switch the frames. You can select AUTOMATIC OFFSET at PARAMETER SELECT MODE to movethe frame automatically to the desired point, making it easier to do appliqués and to switch the frames.

3.11) MANUAL OFFSET

－ You can manually move the frame to the pre-selected point to do appliqués or change the frame duringembroidery work. The frame can be moved back to its original place by simply pressing certain buttons.

3.12) RETURN TO START

－ The frame can be moved back to the start point of the design during the embroidery.

3.13) NON-STITCHING

－ The frame and the needle bar can move backward and forward by the units of 1, 100, 1000, and 10000stitches and by color without stitching.

3.14) FRAME BACKWARD

－ When the thread breaks or runs out of track, you can move the frame back to the starting point of the designin the units of one to ten stitches.

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3.15) AUTOMATIC TRIMMING DEVICE

－ The automatic trimming device is performed according to the design and the machine set-up in order toenhance work productivity and quality of the finished product.

3.16) AUTOMATIC DETECTION OF UPPER AND LOWER THREAD BREAKS

－ The machine detects when the upper thread breaks or the lower thread is out of the needle and automaticallystops the machine.

3.17) FRAME CENTER

－ The machine moves to the center of the frame. This is easier if the design starting point is in the center.

3.18) AUTOMATIC RETURN TO STOP POINT IN UNEXPECTED BLACKOUT

－ When the power fails unexpectedly, the frame moves back to the exact point where the stitching stopped.This helps reduce the number of defects.

3.19) 3.5″″FLOPPY DRIVE (EMBEDDED)

－ A 3.5″floppy drive is embedded in the operation panel for you to read or store designs. (Both 2DD and 2HD disks can be used.)

3.20) EDITING

－ You can delete, change, or insert stitch data and function codes (jump, finish, trimming).

3.21) LANGUAGE SELECTION

－ You can select the language among Korean, English, Spanish, German, Dutch, Italian, Indian, Chinese, andTurkish.

3.22) The screen will indicate the cause of any machine stops.

3.23) The screen indicates RPM data.

3.24) FRAME MOVEMENT SPEED

－ You can adjust the frame speed to high, medium, or low.

3.25) The screen indicates the memory available for use.

3.26) You can use 2-binary and 3-binary tape codes.

3.24) OTHER BRAND CODES

－ The machine can automatically read designs of various formats stored in the floppy disk.

[ Readable Format ]

1. SST 4. FMC, FDR 7. EXP

2. DST, DSB, DSZ 5. ZSK

3. TAP 6. 10O

MACHINE INSTALLATION AND PRECAUTIONS04

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4.1) INSTALLATION CONDITION

4.1.1) Temperatures

1) When machine in operation: 0 ~ 40℃ (32 ~ 104℉)2) When machine is idle: －25 ~ 55℃ (－13 ~ 131℉)

4.1.2) Humidity

1) relative humidity : 45~85%

4.1.3) Grounding

Ensure the electricity is properly grounded.

4.1.4) Surrounding environment

Close any doors or windows near the machine to prevent direct sunlight, dust, and humidity.

4.1.5) Place of installation

Foundation (floor) under the machine must be sufficiently strong and flat concrete to support the weight of themachine.

4.1.6) Industrial environment classification

Installation and use of the machine must be performed in an industrial area.(SWF machines should be used in Class A environment)

Meet the conditions described in the manual when installing the machine. Failure to follow thedirections may result in unexpected machine malfunctions.

CAUTION

1) Do not let moisture drops on the machine.2) Provide air conditioning to control humidity and to prevent dust and corrosion.

CAUTION

Ensure properly grounding of the machine to avoid the possibility of electric shock. Use three-wire grounding (grounding resistance below 100 ohms).

DANGER

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4.3.1) Leveling the device

1) leveling－ Use the adjusting bolts installed at the four

stands to level the machine (front, rear, left,and right). Use a level gauge.

Adjusting bolts

Level gauge

Stand

Level base

4.2) ELECTRICITY INSTALLATION ENVIRONMENT

4.2.1) Input voltage (to be adjusted at installation)

200V, 220V, 240V(50~60Hz) / 3-Phase (12 Head)

4.2.2) Allowed voltage range

Within 10% of the voltage set

4.2.3) Electric capacity and power consumption

1.0 KW

4.2.4) Insulation resistance

Over 10M ohms (measured with 500V insulation tester)

4.3) LEVELING THE MACHINE

Check if the input voltage of the machine corresponds with the voltage supply before installingor operating the machine.

WARNING

1) Make sure to check the voltage supply where the machine will be installed.2) Install the cable away from the operator’s work space to prevent accident or injury.

WARNING

The machine must be accurately leveled (especially front-back) to prevent machine fromdeformation or needle from moving out of position.

CAUTION

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2) Locations of level gauge– Place the level gauges at the locations as in the figure below to maintain the balance of the machine.

3) Leveling fixation – When the left and right balancing is completed, turn the supporting bolt of the frame until it reaches the

level base and loosen it by turning in the reverse way by a 1/4 circle. – When the supporting bolt adjustment is completed, tightly fasten the nut for fixation.

Level Gauge

Nut

Level Gauge

Until the height difference between the four adjusting bolts becomes 10mm, use the spacer byholding it against the lower balancing base.

CAUTION

Do not place the level gauges on the square pipes and the table for maintaining the balance ofthe machine.

CAUTION

The supporting bolt at the center reduces the machine vibration and maintains its horizontalbalance.

CAUTION

Supporting bolt

NOTICES RELATED TO OPERATION05

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5.1) SAFETY LABEL TYPES

※※ NEEDLEInjury may be caused by moving needle.Ensure that the machine is in a stop condition before changing, threading or rethreading of needies or changing of needles.

※※ HIGH VOLTAGEFire or death may be caused by high voltage electric shock.Don’t open the cover except for service man assigned by SWF.When open the cover turn off power and wait for 6 minutes.

※※ HANDPhysical damage may be caused by interposition.While embroidery frame is running according to the direction ofembroidery frame may be injured your hands by gap between fixed bodyand embroidery frame.

※※ MACHINE MOVEInjury may be caused by winding.Be sure to turn off the power before cleaning, lubricating, adjusting orrepairing.

※※ MACHINE MOVEPhysical damage may be caused by winding.Don’t put your hands near the needle bar & take-up lever while machine isrunning.

※※ MACHINE MOVEMake sure that the power is turned off before conducting cleaning, oilsupply, adjustments or repairs. Otherwise, you may hurt your hands.

※※ MACHINE MOVEPhysical damage may be caused by winding.Don’t put your hands near the arrow while the main shaft is rotating

※※ Always use the thread guide when threading to enhance your productivityas shown in the figure.

① Turn off the main power before rotating the main shaft by hand!② Do not remove covers during operation!③ Turn off the main power before opening electricity-related boxes!

Make sure that the power is turned offbefore conducting cleaning, oil supply,adjustments or repairs. Otherwise, youmay hurt your hands.

WARNING

Have a full understanding of the labels attached to the machine to prevent any possibleaccidents.

CAUTION

CAUTION

Always use the thread guidewhen threading to enhanceyour productivity as shown inthe figure.

THREADGUIDE

① Turn off the main power before rotating themain shaft by hand!

② Do not remove covers during operation!③ Turn off the main power before opening

electricity-related boxes!

WARNING

Injury may be caused by movingneedle.

Ensure that the machine is in astop condition before changing,threading or rethreading ofneedies or changing of needles.

WARNING

WARNINGFire or death may be caused byhigh voltage electric shock.Don’t open the cover except forservice man assigned by SWF.When open the cover turn offpower and wait for 6 minutes.

Physical damage may be causedby interposition.While embroidery frame is runningaccording to the direction ofembroidery frame may be injuredyour hands by gap between fixedbody and embroidery frame.

WARNING

Physical damage may be caused bywinding.

Don’t put your hands near the needle bar & take-up lever while machine is running.

WARNING

Physical damage may becaused by winding.

Don’t put your hands near thearrow while the main shaft isrotating

WARNING

Injury may be caused by winding.

Be sure to turn off the powerbefore cleaning, lubricating,adjusting or repairing.

WARNING

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5.2) LOCATION OF SAFETY LABELS

[Front]

[Side]

[Back]

Injury may be caused by movingneedle.

Ensure that the machine is in astop condition before changing,threading or rethreading ofneedies or changing of needles.

WARNING

Physical damage may be caused bywinding.

Don’t put your hands near the needle bar & take-up lever while machine is running.

WARNING

Injury may be caused by winding.

Be sure to turn off the powerbefore cleaning, lubricating,adjusting or repairing.

WARNING

Make sure that the power is turned offbefore conducting cleaning, oil supply,adjustments or repairs. Otherwise, youmay hurt your hands.

WARNING

Physical damage may be causedby interposition.While embroidery frame is runningaccording to the direction ofembroidery frame may be injuredyour hands by gap between fixedbody and embroidery frame.

WARNING

WARNINGFire or death may be caused byhigh voltage electric shock.Don’t open the cover except forservice man assigned by SWF.When open the cover turn offpower and wait for 6 minutes.

Injury may be caused by movingneedle.

Ensure that the machine is in astop condition before changing,threading or rethreading ofneedies or changing of needles.

WARNING

Physical damage may becaused by winding.

Don’t put your hands near thearrow while the main shaft isrotating

WARNING

NAMES OF MACHINE PARTS06

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A. Machine Body

B. Table

C1. Thread stand

C2. Thread stand(chenille)

D. Main shaft drive motor

E1. Bed

E2. Bed(chenille)

F1. Arm 1

F2. Arm 1(chenille)

G1. Arm 2

G2. Arm 2(chenille)

H. Trimming drive box

I1. Color change

I2. Color change(chenille)

J. Upper thread holder

K. Head

L1. Thread tensionadjustment board

L2. Thread tension adjustmentboard(chenille)

M. Sub controller box

N. X-axis driving system

O. Y-axis driving system

P. Bar switch

Q. Embroidery frame

R. Controller box

S. Operation box

T. Thread release

ACCESSORIES AND THEIR ASSEMBLY 07

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7.1) STAND

1) Stand assembly (chenille)

7.2) OP BOX

7.3) FLUORESCENT LIGHT

Thread holding bar

Supporter

30

Spool plate

Bolts for supporter

Thread holding bar

Supporter

Spool plate

Bolts for supporter

- Regular Head - - Chenille Head -

- Rear -

FUNCTIONS OF EACH PART AND MACHINE OPERATION08

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8.1) BASIC OPERATION

8.1.1) Power on

1) Plug in the power cord of the embroidery machine. 2) Turn on the power switch. 3) Press the operation switch attached on the bar switch. 4) When the main power switch is “OFF”, the power is not supplied, although the operation switch is turn

“ON”.

Power operation switch

Main power switch

※※ Power Switch※※ When the emergency switch develops errors, the power switch detects them and ensure

that the machine remains turned off. This is designed to detect the breakdown of theemergency switch and prevent related accidents. NOTE

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8.1.2) For starting embroidery and stopping the machine

You can use START and STOP switches during machine operation in the following cases.

1) For starting or stopping the embroidery work

2) For moving the frame backward during embroidery work stop

Switch Machine Operation

Press START Machine starts and embroidery work begins.

Hold START Machine “inching (see Note1)”until you release the START switch.

Press STOP Machine stops.

Switch Machine Operation

Press STOP Frame moves backward in selected frame movement units (see Note 2)

Hold STOP Frame starts to move backward.

If you release STOP before the machine goes 10 of the selected

stitches, the machine will stop immediately (the machine moves in the

selected frame movement units). If you release the switch after the

machine traveled 10 of the selected stitches, the machine will continue

to move back.

Press STOP Press STOP again and the machine will stop moving backward.

3) For forward non-stitching during embroidery work stop

Switch Machine Operation

Press START Frame moves forward in selected frame movement units (see Note 2)

Hold START Frame starts to move forward.

If you release START before the machine goes 10 of the selected

stitches, the machine will stop immediately (the machine moves in the

selected frame movement units). If you release after the machine

traveled 10 of the selected stitches, the machine will continue to move

forward.

Press STOP Press STOP again and the machine will stop moving forward.

1) Non-stitching (floating) function is not available in the initial menu.2) To perform floating at the start of embroidery, press STOP switch. The machine will then go

into STOP MODE. Select FLOAT and set the number of non-stitching desired in the submenu.NOTE

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4) For backward non-stitching during embroidery work stopSame as START/STOP during embroidery work stop

8.1.3) Bar Switch operation

1) Bar switch to start the embroidery work or stop the machine during operation

2) Backward Frame Movement While the Embroidery Work is Stopped

You cannot perform non-stitching (floating) at the start of the embroidery because the functionis not in the start menu. To perform floating at the start, push the bar switch to left go intoSTOP MODE. Then select ““ FLOAT””and select the number of non-stitches desired in thesub-menu.

BUTTON OPERATION MACHINE OPERATION

Push to right Machine starts and embroidery work begins.

Hold to right Machine “inches (see Note1)”until you release the button.

Push to left Machine stops.

Bar Switch Operation Frame Movement

Push it to the left side once The embroidery frame moves backward by the feed unit (see Note2).

Push it to the left side continuously The embroidery frame starts moving backward.

If the bar switch is released before pushing it ten times, the machine will

stop immediately.

(The embroidery frame moves back by the feed unit (see Note2)).

If the bar switch is released after pushing it more than 10 times in a row,

the embroidery frame continues to move backward by the unit of 10

needles.

Push it to the right side and release it When the embroidery frame continues to move backward, push the bar

switch to the right side again to stop the backward movement of the

frame

1) “Inching” refers to low-speed embroidery at 100 rpm range, performed for stable stitchingwhen the machine is re-started after stop.

2) “Frame movement unit” refers to the “BK STITCH UNIT” in “Parameter Set-Up”. You canselect from 1 to 10 stitches (by 1 stitch).NOTE

CAUTION

1) For Chenille Embroidery 1) When trying to move the frame backward, while embroidery work is suspended, trimming

occurs first, and automatic backward movement of the frame follows next.NOTE

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3) Forward Frame Movement While the Embroidery Work is Stopped

4) For backward non-stitching while the embroidery work is stoppedSame as Bar Switch operation

5) Performing Work Other Than Embroidery If you want to perform a solenoid test, a thread break sensor test, or manual trimming, select the functionand press START.

Bar Switch Operation Frame Movement

Push it to the right side once The machine moves forward by the embroidery frame feed unit

(see Note2).

Push it to the right side continuously The machine starts moving forward.

When the bar switch is released before the embroidery frame moves

ten times, the frame is immediately stopped.

When released after the embroidery frame moves forward 10 times or

above in a row by the feed unit, the frame continues to move forward by

the unit of 10 needles.

Push it to the left side and release it While the embroidery frame continues to move forward, and the bar

switch is pushed to the left again, the forward movement of the

embroidery frame is stopped.

Select function Push Bar Switch to the right side

1) “Inching” refers to low-speed embroidery at a 100 rpm range, performed for stable stitchingwhen the machine is re-started after stop.

2) “Frame movement unit parameter” refers to the “BK STITCH UNIT” in “SET-UP 1”. You canselect from 1 to 10 stitches by 1 stitch.CAUTION

1) For Chenille Embroidery 1) When trying to move the frame backward, while embroidery work is suspended, trimming

occurs first, and automatic backward movement of the frame follows next.NOTE

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8.1.4) Change switch function of chenille head

1) On/off switch functionChenille head’s work can be adjusted by changing the position of the toggle switch.

– TopWhen fixing the fabric or starting embroidery work, place the chenille head at the top position to preventthe chenille head from being stuck to the fabric or embroidery frame.

– Normal operation (center)When the machine is in normal operation, place the toggle switch at the “Lamp On” position to make thelamp on.

– Lamp off (bottom)The “Lamp Off” function can make certain chenille heads fixed to the needle bar to make them disabledtemporarily.

8.1.5) Lamp on thread tension adjustment board

1) Switch– For normal operation, turn the toggle switch on to turn on the indicator lamp. – If the machine stopped after detecting a thread break, move the frame back to the location of the thread

break using STOP button and restart the machine to pick up stitching (design edit).

Top

Center

Bottom

If you want to move the frame back for any reason when a thread break has NOT occurred, pressthe toggle twice (OFF and ON again).

NOTE

25

－ The needle bar can be fixed at one position using the lamp-off function in order to disable specific heads.

2) Thread Break Detector LampLamp on a specific head will blink when thread break is detected at the head, while lamps on other headswill be turned off. You cannot turn the lamp on or off on the other heads using the toggle switch.

3) Deletion of Thread-Break Detection FunctionPoor function of the thread detecting roller due to foreign substances around it may result in wrong andfrequent detections, causing inefficiency of work. In this case, you can turn off the detecting function byturning on/off the toggle switch at the end of the thread tension adjustment board as shown in figure. Thiswill turn off the detecting function on the head you are working with.

Toggle switchLamp

Thread-break detection off switch

Thread detecting roller

ON

ON OFF

OFF

The upper thread holding device fixes the thread on the heads, whose toggle switches are off,and the heads unused for the embroidery at the moment, thus preventing thread escape fromthe needle.NOTE

Interference to the thread detector roller (due to foreign substances around the thread detectorroller, etc.) can cause the thread break lamp to blink.

CAUTION

26

8.1.6) Needle pause clutch function (jump)

When the manual jump clutch lever is pushedbackward, the machine is back to normaloperation. If the lever is pulled forward to the userside, the needle bar does not operate.

8.1.7) LED on color change box

Needle position lamp on the color change boxblinks at the using needle in operation. Needle setlamp on the box blinks when the needle reaches thecenter of the needle hole on the plate (the roller ison the straight line of the color change cam. See figure in below. The needle moves only whenthe both lamps blink – preventing machine errorsfrom incorrect needle position or color changefailure.

Manual jumpclutch lever

Color change motor

Needle position lamp

Needle set lamp

Needle plate

HeadONON

ON

ON

Roller

Lamp and the curve of the color change cam

ON

OFFOFF

OFF

N/set LEDNeedle position lamp

1) The trimmer and the take-up lever continue to move even when the needle bar is stopped bythe clutch. Avoid any operations, i.e. threading the needle or changing thread.

2) Long-time operation of the needle bar with the clutch may damage the bar controller.CAUTION

If any of the two lamps are off, adjust the half-turn film.

CAUTION

27

8.1.8) Chenille threading and tension adjustment

1) Chenille threading – Place the thread at the chenille head following the order below:

No. 1 thread tension adjusting device → No. 2 thread tension adjusting device → Thread take-up spring→ Needle plate → Hooked needleTo place the thread on the loop, thread the needle threading device and insert the device into the hole atthe looper bottom. Push it up to the top of the looper and leave 3~4cm of thread as a remaining thread.

Threading device3~4cm

Needle Plate

Main thread tension adjusting device

No. 2 thread tension adjusting device

No. 1 thread tension adjusting device

Embroidery frame

Pass thread through a needle using a threader, and use the manual trimming and manual colorchange functions to ensure easier threading.

CAUTION

28

2) Adjustment of chenille head’s thread tension – Loop stitch

Adjust the tension adjusting device to make each thread tension adjusting device have some 20~30g oftension.

– Chain stitch Adjust the tension of the main thread tension adjusting device to make the main thread tension adjustingdevice have some 40~50g of tension. (based on rayon #300)

3) Threading of the tension adjusting device

NO. 1 & No. 2 Thread Tension Adjusting Device

Pass the thread between thread guide disk and throughthe thread guide plates hole of the thread adjustingdevice.

Pass the thread between thread guide disk and throughthe thread take-up spring of the thread adjusting device.

Main Thread Tension Adjusting Device

Rotary tension disk

Thread tension should be re-adjusted depending on the fabric and thread types.

CAUTION

29

4) Upper threading of regular head

Upper thread stand

Upper thread (from the upper thread stand)

Sub thread adjuster

Thread tensionadjustment board

Thread detecting roller

Tale-up Spring Stopper

Take-up spring

Rotary tension disk

Main thread tensionadjuster

Upper thread guide

Thread guide (upper)

Take-up lever

Thread guide (middle)

Thread guide

Upper thread holding

Presser foot

Needle

30

Threading the sub tension adjuster

Feed it between the thread guide plates and throughthe hole in the axis of the thread adjusting device.

Wrap the thread around the detector roller one time.

Threading the thread detector roller

Thread guide disk(through the centerof shaft)

Thread detector roller

1 time rotation

Threading the main tension adjuster

Wrap the thread 1.5 times around the rotary tensiondisk (V-shaped groove.)

Feed the thread through upper thread holder plate inthe upper thread holding. Thread the thread guide andneedle. Fix the thread between the holder plate in theupper thread holding.

Threading around the needle

Rotary tension disk

1.5 timesrotation

Upper threadholder plate

5) Threading the tension adjuster of regular head

31

6) Upper Thread Tension AdjustmentThread tension adjustment is critical for producing high quality of the embroidery. A balance of 2/3 upperthread and 1/3 lower thread generally indicates good tension.

– The upper thread tension is controlled by suband main thread tension adjusters. Turnadjusting nut clockwise to increase thetension and counterclockwise to decrease thetension.

– The sub thread adjuster should control about2/3 of the upper thread tension.

– The main tension adjuster should handle theother 1/3.

– Set the tension of the sub thread adjuster sothe upper thread flows smoothly through therotary tension disks and into the rollers of themain tension adjuster.

Adjusting nut

Sub threadadjuster

Maintension

adjuster

2/3

1/3

1) If tension is too weakThe upper thread will loop, causing thread tangles or breaks.

2) If tension is too strong Puckering may occur as well as thread and needle breaks.CAUTION

1) If tension at the sub thread tension adjuster is too loose, the detector roller may not rotatewell and make wrong detections.

2) After adjusting the tension, check if the upper thread tension is what can be pulled with littleforce of around 100-120g.

3) After adjusting the tension, pull the upper thread to see if the detector roller rotates well.4) Adjust the tension constantly according to the type of thread and fabric used.

CAUTION

32

7) Take-up spring adjustment– Functions

Difference in the length of the upper thread pulled by the take-up lever and by the hook creates tension orlooping. The take-up spring absorbs the leftover of the upper thread. Increase the tension or the stroke ofthe spring to form tight stitches on the embroidery.

– Adjusting tension of the take-up springYou can adjust the tension of the take-up spring with its shaft. You can increase the spring tension byturning it clockwise, and decrease the tension by turning it counterclockwise.

– To adjust the stroke of the take-up springYou can adjust the stroke of the spring by moving the take-up stopper to right or left.

○○ Correct position of the take-up spring

The take-up spring stopper touches the spring Gap between the take-up spring stopper and the spring(due to dust or foreign substances in the stopper)

×× Incorrect position of the take-up spring

Stopper

Take-upspring

Thread tensionadjusting stud

33

8.1.9) LOWER THREADING AND TENSIONADJUSTMENT

1) Lower threading – Use cotton yarn (80# ~ 120#) for your lower

thread.– Lower threading into the bobbin case

Insert the bobbin into the bobbin case withthe thread coming out from the case slot.Pull the thread through the thread guide.

– To prevent lower thread tangles, trim thethread, leaving the length at 3-4cm, beforeinserting the bobbin into the hook.

2) Lower thread tension adjustment Adjust the tension of the lower thread using thebolt on the tension spring of the bobbin case.Turn the bolt clockwise to increase the tensionand counterclockwise to decrease the tension.

Bobbin case

Lower thread holder

Bobbin

Slot

3~4cm

Screw

Tension spring

Thread guide

Make sure the bobbin rotates clockwise when you pull the thread holding the bobbin case inyour left hand.

CAUTION

To check if the lower thread tension is adequate, hold the thread from the bobbin and jiggle thebobbin case lightly up and down. The thread should come out from its own weight and thetension should be 25-35g. CAUTION

34

8.1.10) BOBBIN WINDER

1) Bobbin winding– Insert the bobbin onto the shaft ① and manually wind the thread 5-6 times around the bobbin. Press

START button ② to wind the bobbin.– Bobbin winder will stop winding according to the embedded timer. But if you want to stop winding

before the bobbin automatically stops, press STOP button ③.

2) Adjusting thread volume on the bobbin– Fill the bobbin 80% and make sure the

thread is parallel to the bobbin as shown inthe figure.

– Thread volume on the bobbin can beadjusted using a TIME dial. Set it at MAX toincrease the volume.

80%

Knob

Thread guide

Thread guide screw

Winding shaftBobbin

Thread tensionadjustment screwSSTTAARRTT

SSTTOOPP

decrease

increase

Knob

1) Overfilling the bobbin may interfere with the smooth pull of the lower thread.2) For normal bobbin, 80% fill will render around 80m of lower thread.

CAUTION

35

3) Adjusting the bobbin winding condition– If the thread is not parallel to the bobbin,

adjust the body of the thread guide left andright.

– Adjust the tension of the bobbin windingusing the tension adjusting nut.

Thread guide

Thread tensionadjustment screw

Thread guidescrew

Winding the bobbin off-center or uneven as shown below can cause thread breaks, skippedstitches, or thread tangles.

CAUTION

Too tight tension of the bobbin winding can block smooth pulling of the thread and causethread breaks or short tails.

CAUTION

36

8.1.11) Things to consider when using an Floppy Disk or a USB memory stick

When handling this input/output device, the following instructions should be strictly observed.

▶ In case of using an FDD: – Place the FDD away from objects creating magnetism or magnets. ex) TV, radio, etc. – Keep the FDD away from heat, humidity, and direct sunlights. – Do not place heavy objects over the FDD. – Do not remove a diskette from the disk drive, while the disk formatting or the data input/output is

conducted. – Do not leave the disk drive cover stay open. – If the writing prevention tap is on, data input to the FDD is impossible. – If one diskette is used for multiple reading and writing activities, the diskette may develop errors. – Produce a backup diskette to safely keep important data.

▶ In case of using an USB memory– While the input/output work is in progress, do not remove the USB memory from the USB port.

8.1.13) Floppy disk and USB memory stick removal

Press the exit button to remove the disk from the FDD.In case of an USB, close the input/output window and remove the USB memory.

8.1.14) Operation related to embroidery design input/output

Embroidery design can be imported to the OP Box from outside by using a floppy disk, USB memory, CFcard or serial communications. Embroidery design output can be conducted by using a floppy disk and a USB memory.

8.1.12) Floppy disk and USB memory inserting

– Floppy disk inserting Press the arrow part to open the cover.Insert an FDD into the arrow direction.

– USB insertingInsert the USB memory into the USB port.

1) The floppy disk sold in the market can be used after formatting. But make sure of using a certified disk product.

2) In case of using a USB memory stick, its file system should be FAT 16. If it is FAT 32, the memory stick cannot be used.CAUTION

Do not remove a floppy disk from the FDD in the middle of formatting or data input/outputoperation.Otherwise, the stored data might be deleted. CAUTION

37

8.1.15) Return to stop position in unexpected blackouts

Your SWF embroidery machine automatically returns to the previous position when the power comes back onafter an unexpected blackout, thereby not affecting the quality of the embroidery. (See LCD Monitor User Manual)

8.2) NEEDLE-HOOK TIMING AND RELATED TIPS

8.2.1) Needle

1) Chenille series (CA-Series) – Choose appropriate hooked needle in line with fabric and thread type.– If the hooked needle used is inappropriate, the loop is not properly made or the skipped loop might

result.

2) Regular head (SA-Series)– It is very important to select the right needle for the type of thread and fabric used.– Inappropriate needles can cause bad embroidery, thread breaks, skipped stitches, etc.– For normal embroidery, use a DB×K5 needle.

8.2.2) Relationship between needle and thread

1) Chenille series (CA-Series) – The table below shows the types of hooked needles and threads used for chenille.

Chumetz

75

90

100

110

–

–

Organ

11

14

16

18

19

21

Diameter

0.75

0.9

1.0

1.1

1.2

1.3

Inner Diameter

1.0~1.2

1.1~1.3

1.2~1.4

1.3~1.5

1.4~1.6

1.5~1.7

Needle PlateDiameter (mm)

1.2~1.3

1.4~1.6

1.6~1.8

1.8~2.0

1.9~2.1

2.0~2.2

Rayon ThreadThickness

120

300

300, 600

600, 900

900

900 and more

Hooked Needle Nipple Needle Plate Thread

Do not remove a floppy disk from the FDD in the middle of formatting or data input/outputoperation.Otherwise, the stored data might be deleted. CAUTION

DB××K5 needle has an eye twice larger than that of DB1 (used for normal stitching). Use DB××K5 for normal embroidery.

CAUTION

38

2) Regular head (SA-Series)－ Inadequate selection of thread and needle may result in thread breaks, skipped stitches, as well as in bad-

quality embroidery.－ Refer to the following table of threads and needles used for normal embroidery.

US

0.25

0.27

0.29

0.32

0.34

0.36

Japan

9

10

11

12

13

14

Germany

65

70

75

80

85

90

Cotton #

70~80

50~60

36~40

Silk

100~120

80~100

60~70

Nylon

130~150

100~130

80~100

Rayon

70~100

100~130

130~150

Needle Size Thread Size

8.2.3) Changing the needle

1) Chenille series (CA-Series) – Completely remove the needle bar to replace

a chenille series needle.– Loosen the screw for the needle bar clamp

and completely separate the needle bar. – Loosen the needle fixing screw at the bottom

of the needle bar and disassemble theexisting needle.

Needle and thread most commonly used in embroideryThread : rayon yarn 120d/2.Needle : DB××K5 #11CAUTION

Needle fixing screw

Screw for the needle bar clamp

39

2) Regular head (SA-Series)– Make sure the needle is completely clear of the needle plate before changing it. If the needle is not clear

of the plate, use the main shaft handle, manually turn the main shaft to put the needle in the right locationfor change.

– Make adjustments to let the cross-section ofthe needle meet with the screw, and push theneedle inside until the very end.

NeedleOUT

NeedleIN

Needle plate

If the needle is not pushed throughly into the end of the hole, the needle might need to bereadjusted.

CAUTION

1) Turn OFF the machine according to the safety rules before turning the main shaft manually.2) Immediately remove the main shaft handle afterward: it is dangerous to operate the machine

with the handle inserted.CAUTION

Main shaft lever

40

– When inserting the needle, make sure thatthe groove of the needle is facing front.

– End tip of the needle should be insertedcompletely into the needle bar.

– When using special threads, such as artificialsilk, you might want to turn the groove ofthe needle to the right in order to minimizethe thread breaks.

Needle insert hole

Front groove ofthe needle

8.2.4) Relationship between needle and looper

1) Looper’s rotary angle The looper rotates clockwise and counter-clockwise at 250 degrees, and creates a loop by winding threadaround the hooked needle.

2) Stitch types There are two types of stitches. – Loop Stitch

The embroidery frame’s feed direction is same to the hooked needle’s direction. When the loop is created, the thread is automatically separated from the hooked needle.

– Chain StitchThe embroidery frame’s feed direction is opposite to the hooked needle’s direction. When the loop is created, the thread is not separated to move to the next stitch.

If the needle is not inserted all the way to the top of the needle bar hole, timing of the machinewill go off, causing broken needles and thread breaks.

CAUTION

41

Looper

(Looper Stitch) (Chain Stitch)

Looper

8.2.5) Relationship between needle and hook

– Adjusting timing between needle and hookDefault timing of the needle and the hook is set by the main shaft angle of 201°. Relationship between theneedle and the hook varies as below.

Top point of hookcircumference

Top edge ofneedle eye

Needle tip c

b

a

Top edge of the needle eye

Hook point

Lower dead stopof the needle

Hook point

a. At lower dead stop of the needle bar 2.3~3.7 mm

b. At needle-hook timing 1.8~2.2 mm

c. At needle-hook timing 0.5~1.5 mm

– Adjusting allowance in the hookThe hook can move right and left if there is anallowance in the lower shaft gear. Eliminate theallowance (gap) by turning the hook clockwise.Then adjust the timing.

Allowance (gap)

42

8.2.6) Adjusting gap between needle andhook point

– Gap between the hook point and the needleThe distance between the needle and the hookshould be 0.1-0.3mm at their closest interface.

– Thread skipThread skip occurs due to thread looping orinadequate balance or gap between the needleand the hook.

– AdjustmentThe closer the hook point is to the needle, thehook point will be inside the loop and threadingwill be more stable.

8.2.8) Functions by needle shape

Hole and groove of the needle vary by the sizeand type of the needle.– Front groove

It protects the thread from the friction heat ofthe sewing (which can cause thread breaks).

– Back groove It adjusts the hook timing according to theneedle movement, thus preventing threadskips.

Hook point

0.1~0.3mm

8.2.7) Functions of hooked needle

1) Hooked needle’s groove It creates loops by twisting the threads suppliedby the looper. – Loop Stitch

The hooked needle’s direction is same to theembroidery frame’s feed direction. Aftercreating a loop, it exits from the loop andcreate the next loop.

– Chain StitchThe hooked needle’s direction is opposite tothe embroidery frame’s feed direction. Thisproduces embroidery which is connected toeach other.

Backgroove

Needle eye

Front groove

1) Prevention of looping is important for stitching. Adjust the hook point as close to the needleas possible to achieve the perfect thread position.

2) If embroidery state is not good, move the needle slightly to the right. CAUTION

43

8.2.9) Different loop shapes

Shape of the loop varies by the type of thread or fabric. Unstable shape of the loop may result in skippedstitches. The following pictures show different shapes of loop formed by different types of thread.

8.2.10) Relationship between the take-up lever and the hook

Hook point timing is directly related to thread tension and thread breaks. The following pictures show thelocation of hook when the take-up lever starts to move up from the lower dead stop (main shaft rotation angle:291°).

1) Hook timing is fast (in the A range)

The hook starts to take the thread from the take-

up lever. Loop is small because the upper thread

is pulled. Stitches are made but stitch tension is

bad. Thread skips occur, where hook fails to go

through the loop.

2) Hook timing is slow (in the B range)

The hook starts to take the loop before the take-

up lever goes up. Thread skips don’t occur, but

thread breaks occur, because the take-up lever

moves faster than the thread coming off the hook.

Hook point

Cotton thread loop

Synthetic thread loop

Hook point

Too small

Too large

44

8.3) THREAD BREAK DETECTOR ASSEMBLY AND ITS FUNCTIONS

8.3.1) Functions

1) Chenille series The sensor attached to the looper base is used to detect thread breaks to prevent bad sewing.

2) Regular headThe thread detector prevents bad embroidery by detecting breaks of the upper or the lower threads. Thethread detection roller performs the detection.

(B)

(C)(A)

Groove of the hook

In normal hook timing, the hook should be in the (C) range.

CAUTION

Wrong detection can occur if the thread detection roller does not rotate smoothly.

CAUTION

45

8.3.2) Disassembling the thread detector

You will need to disassemble the thread-break detector unit when you to have to clean it for more smoothrotation. Remove the cover of the thread tension adjusting plate, separate the cables of the thread detectionboard, and unfasten the roller base bolts. The entire unit will be disassembled including the rollers and bushbearing.

Film

Roller base

Bush bearingRoller base screw

Thread detectorroller

1) When assembling the thread detection roller, check between the sensor groove and the filmon the thread detection board.

2) Thread detection may not work according to the location of the thread detection board.3) You can adjust the location of the board using the board base bolts.CAUTION

EMBROIDERY METHODS09

46

For more information on how to use the chenille embroidery machine, please refer to thechenille operating manual and the SA-series touch screen manual, which were published bySunStar.NOTICE

ERROR DISPLAY AND TROUBLESHOOTING10

47

10.1) MAIN SHAFT MOTOR

100

101

102

103

104

105

107

108

109

Main shaft stop

Main shaft motor drive

Main shaft motor overload

Trimming return

START switch

STOP switch

Valve

Air pressure

AC line

Main shaft doesn’t stop at 100°

Error in main shaft motor driver

Thread tangles in the hookError in needle bar controllerThread tangle in trimming

Trimming sensor doesn’t returnwhen trimming

START is pressed when turningpower on

STOP is pressed when turningpower on

Valve is opened

Air pressure is below standard(Sequin)

Problems in the joint board

Adjust the main shaft at 100°using lever.

Turn the main switch off and onagain.

Check hooks of all heads. Turnthe switch off and on again.

Check for errors in the trimmingsystem

Check START – connectorconnection

Check STOP – connectorconnection

Replace the joint board, etc.

No. Error Description Troubleshooting

10.2) X, Y-AXIS MOTORS

200

201

202

203

204

205

206

207

(＋X) frame limit

(－X) frame limit

(＋Y) frame limit

(－Y) frame limit

X-axis driver

Y-axis driver

Wiper return

Trimmer return

Frame reaches ＋X limit

Frame reaches －X limit

Frame reaches ＋Y limit

Frame reaches －Y limit

Error in X-axis driver

Error in Y-axis driver

Wiper solenoid doesn’t return

Trimmer motor doesn’t return

Move the frame －X

Move the frame ＋X

Move the frame －Y

Move the frame ＋Y

Turn the main switch off and onagain

Turn the main switch off and onagain

Repair the wiper mechanism

Repair the trimmer mechanism

No. Error Description Troubleshooting

48

10.3) COLOR CHANGE

300 Needle bar position Needle bar doesn’t come tocorrect position when changed

Move the needle bar manually.Check the load. Position it at thecorrect location.

No. Error Description Troubleshooting

10.4) ENCODER

400

401

Main shaft encoder A

Main shaft encoder Z

Error in signal in main shaftencoder A

Error in signal in main shaftencoder Z

Check encoder connection. Turnthe main switch off and on again.

Check encoder connection. Turnthe main switch off and on again

No. Error Description Troubleshooting

10.5) REPETITION WORK

501 Repetition set-up Off the repetition limit(X set-up)×(Y set-up)＞99

Change the set-up to(X set-up)×(Y set-up)＜99

No. Error Description Troubleshooting

49

10.6) FLOPPY DISK

600

601

602

603

604

605

606

607

608

609

610

611

612

613

614

630

640

650

No disk

No sector in disk

No design in disk

Remove protection tab

Damaged disk

No capacity

Disk out of drive

Bad sector in reading

Bad sector in writing

Unknown error

Disk error

ZSK design error

BARUDAN design error

Bad sector

OS installation error

Error in input data

Failure to find the network device

USB error

No disk in the drive

Disk is not formatted Disk is of different format

No design in the disk

Disk is write-protected

Disk is damaged

No extra space in the disk

Disk is removed during use

Bad sector in the disk

Bad sector in the disk

Unknown error during use

Unknown error during use

OS program file name doesn’texist or match

Error in the data from tape reader

Network device is not connected

USB drive is not ready

Insert the disk in the drive

Format or replace disk

Replace disk

Remove the protection tab

Format or replace disk

Replace disk

Insert disk and re-work

Format or replace disk

Format or replace disk

Format or replace disk

Replace disk

OS program file name isswf_tb.bin.If the name reads swf.tb.exe,change it.

Re-read from the tape reader

Check connection of the networkdevice

Check if the USB file system isFAT16

No. Error Description Troubleshooting

50

10.7) MEMORY

700

701

702

703

704

No embroidery data in thememory

Insufficient memory

Memory full

Design memory system

Bad memory battery

No embroidery data in thememory

Unable to copy data to memorydue to insufficient memory

100 memory rooms are full

Error in copy/delete betweenmemories

Run out of battery that keepsmemory data during power off.Unstable storage of data, i.e.number of stitches, X/Y position,etc.

Store data in memory via disk

Delete unnecessary data

Delete unnecessary data

RESET or turn the main poweroff and on again.

Consult the nearest SWF forbattery change (if battery outages are frequent,replace CPU board)

No. Error Description Troubleshooting

10.8) CHENILLE HEAD

900 Chenille main shaft motor’s stopposition error

The error occurs, when the mainshaft does not stop at the 35°direction.

Use the main shaft revolvinglever to adjust the main shaft stopangle.

No. Error Description Troubleshooting

CONTROL BOX11

51

11.1) MAIN CONTROL BOX

11.1.1) Inside the Control Box

① SMPS power ② Power for Jump Motor, picker & upper thread holder solenoid

①

②

52

11.1.2) Outside the Control Box

① Terminal for tape reader and winder② Fuse for tape reader and winder

①

②

53

11.2) MAIN SHAFT & X-Y MOTOR DRIVE (SANYO)

① X-axis driver② Y-axis driver③ Trimmer driver④ Joint board

①

②

③④

54

11.3) LIST OF ERRORS AND CAUSES IN MAIN SHAFT DRIVER & X,Y SERVOMOTOR DRIVERS

Excess current

Overload

Driver overheated

Excess voltage

Over speed

Error in control power

Error in sensor

Power voltage drop

Error in power voltage cable

Error in speed control

Excess variation

External overheat

Sub processor error

Recovery error

Memory error

Battery error(Only for absolute value encoder)

Error in driver or motor

Driver error or mechanical overload

Error in driver

Error in driver, error in power voltage

Error in parameter set, error in motor

Error in power voltage, error in driver

Driver error, wiring error, error in parameter set,error in motor, error in power voltage

Error in driver, error in power voltage

Driver error, wiring error

Driver error, motor error, sub tuning, error in powervoltage

Error in driver, error in parameter set, wiring error

Error in driver, wiring error

Error in driver

Error in driver, error in parameter set, mechanicalerror, error in wiring of recovery resistance terminal

Driver error, error in parameter set

Replace battery

Error in driver, error in parameter set

DISPLAY ERROR CAUSE

No. Light

MAINTENANCE AND INSPECTION12

55

12.1) CHECK POINTS FOR REGULAR INSPECTION

12.1.1) Clean, oil, and grease the set parts of the machine on a regular basis.

12.1.2) Inspect tension of each driver belt.

12.1.3) Failure to perform regular inspections can cause the following.

– Corrosion of P/C circuit board– Damage to the semi-conductor on P/C circuit board– Malfunction of the floppy disk drive– Ill connection of the connector– Abnormal wear-outs of machine parts due to insufficient oiling and greasing

12.2) CLEANING

Use the air compressor to clean each part of the machine.

1) Make sure that the power is turned off before checking or cleaning the machine. 2) Wait for some ten minutes after turning off the power for complete discharge, and then

conduct checking or cleaning. 3) Make sure to turn OFF and STOP the machine when performing inspection.CAUTION

If the machine is broken or develops mal-operation due to the negligence on regular checkup,SWF is not liable.

CAUTION

1) Make sure that the power is turned off before checking or cleaning the machine. 2) Wait for some ten minutes after turning off the power for complete discharge, and then

conduct checking or cleaning. 3) Properly adjust the frequency of cleaning depending on the usage conditions and nearby

environments.CAUTION

56

12.2.1) Cleaning method and cleaning cycle for machine parts

1

Needle plate,Trimmer area,

Thread holding area,Looper, Needle,

Looper drive gear,Looper gear section

1~2 times in a week

Chenille series

Reference Fig.No. Cleaning cycleNamesTypes

2Needle bar,

Needle bar sleeve,Needle

1~2 times in a week

1 Around the hook Every day

Regular head

2Guide rail to the

take-up lever of thehead

Once a week

Hook

Guide rail to thetake-up lever

57

3Around the movableblade and the fixed

bladeOnce in 3 days

Regular head

Reference Fig.No. Cleaning cycleNamesTypes

Lowerthreadholder

Fixedblade

Movableblade

1) In order to prevent the loss of nipple connection studs, make sure to disassemble thembefore cleaning the machine.

2) When cleaning the chenille bed, make sure to clean the area between the looper base andthe gear.

3) Use the trimming driving knob and a spanner for manual spinning for cleaning purpose. 4) Use the needle plate air gun to push inside dusts out by blowing wind. 5) To clean, remove the needle plate and pull the movable blade to the front (see picture).

After the cleaning, assemble back in the reverse order.

CAUTION

58

12.3) OIL SUPPLY

12.3.1) Oil supply

1) Use the SWF-provided sewing machine oil (Spindle Oil) or ISO-level VG18.

2) Manually oiling

Needle bar, needle bar sleeve

Needle motion lever, connection rod

Around the nipple connecting bracket

Needle bar and needle bar shaft

Inside the arm

Guide rail to the take-up lever _ 5jw

Take the bobbin case out of the hook. Feed small amount of oil on the raceway.

Once a week

Once a week

Once a week

Once a week

Once a week

①

②

③

①

②

③, ④

⑤

1

2

3

2

3

4

1

No.

ChenilleHead

Regularhead

Types Supply FrequencySupplying Place Reference Fig.

[Chenille head]

①

③

②

1) Make sure to turn the power OFF during oil supply.2) SWF is not responsible for machine damages or wear-outs caused by insufficient oiling.

CAUTION

59

Head ③

③

③

②

⑤

Oil hole ③

Arm

④

HookBobbin case

Raceway ①

※ Oil can’ be automatically supplied to③,④. Make sure of conductingmanual oil supply to these areasonce a week.

②

⑤

③

④

[Regular head]

1) Excess oil may stain the thread and the fabric.2) Run the machine without stitching for 2-3 minutes after oiling.3) Excessive oiling in the hook may cause trimming errors and thread breaks.CAUTION

60

3) Oil wick-based oil supply When supplying oil, fill up the oil until the oil wets the felt inside the oil tank.

– Oil supply position and supply frequency

1

Within the arm a. Thread take-up moving lever pin b. Pressor foot driving pinc. Needle bar driving shaft

Once per every two days

No. Supply FrequencySupplying Place

1) Use SunStar’s spindle oil or the oil with ISO viscosity level VG18. 2) Fill the oil until the height of the oil at the tank is between H(High) and L(Low).

CAUTION

61

12.3.2) Grease supply

1) Locations to be Supplied with Silicon Grease

1

Inside the chenille armDriving camLocation camGear

Looper driving gear 2~3 times a month ⑥, ⑦2

2~3 times a month

①②③

④, ⑤

No. FrequencyGrease Supplied Area Location

Make sure of turning the power off when supplying grease.

CAUTION

①

②

③

④

⑤

⑦⑥

62

2) Use high-quality mineral-base lithium grease

1

Inside the armTake-up lever drive cam Needle bar drive camNeedle bar controller Presser foot driver cam, take-up lever driver roller

Color change cam, color change-related gears Once in 6 months ⑥, ⑪2

Hook gear and lower gear in the rotary hook base Once in 6 months ⑦, ⑧3

Trimmer driver link and trimmer driver shaft bushing Once in 3 months ⑨4

Once in 6 months

①②③

④, ⑤

No. FrequencyGrease Supplied Area Location

②①④

⑤

③

Color change cam box

Half-turngear

Color change gear

Motor gear

Rotary hook base

Lower shaft

⑧⑦

⑨

Trimmer cam box

⑪

⑥

Regular greasing prevents machine noise and abnormal wear-out.

CAUTION

63

3) Use lithium - Type grease (JIS No. 2)(Brand Name : Albania No. 2)

4) Greasing the head drive LM guide

Head drive LM guide Once a month1

X, Y drive guide rail Once a month2

No. FrequencyGrease Supplied Area

Where togrease

Where togrease

[Upper cover opened]

Regular greasing prevents machine noise and abnormal wear-out.

CAUTION

64

5) Greasing the X, Y drive guide rail– Disassemble the frame from the table.– Unscrew the stainless cover and remove it.– Push the guide block farthest to the front of the machine.– Lift the timing belt with one hand and grease the entire guide rail.– Place the cover in the reverse order.

[Layout of X, Y drive guide rail]

[Zoom-in the guide rail layout]

Y-axis LM guide

X-axis LM guide

FrameStainless cover

Where to grease

Where to grease Where togrease

65

12.3.3) Drive belt tension

Too weak or too tight tension on the drive belt may cause machine malfunction or damages (abnormal wear-out of drive unit). Inspect the driver belt on a regular basis.

Belt on main shaft motor Once in 3 months

Once in 3 months

① Belt tension② Belt crack③ Belt wear-out④ Bearing damage ⑤ Wear-outs of rotating parts

①

1

Upper & lower shaft belt2

Once in 3 monthsX-axis timing belt 3

Once in 3 monthsY-axis timing belt4

No. Inspection Location for inspection Inspection cycle Reference Fig.

①

①

12.3.4) Main shaft driving belt disassembl

1) Loosen the screws for the upper shaft coupling,the bearing socket, and the upper shaft pulley todisassemble the main shaft connected to thecoupling.

2) Use the empty space to disassemble the mainshaft driving belt.

Upper shaftcoupling

Screw forthe uppershaft pulley

Turn OFF the main power when inspecting drive belt tension.

CAUTION

Inspect the tension in the direction of the arrows in the picture below.

CAUTION

ADJUSTING MAJOR PARTS OF THE MACHINE13

66

13.1) ADJUSTING THE CHENILLE HEAD

13.1.1) Nipple

1) Nipple height check– Turn off the machine power. – Set the chenille head’s main shaft angle at

185°by using the main shaft handle. – When the angle is set at 185°, check whether

the nipple and the needle plate are contacted. 2) Height adjustment

– Loosen the fixing screw for the nipple andadjust the nipple to make it contacted withthe needle plate.

Nipple

Nipple fixingscrew

Needle plate

185

13.1.2) Needle

1) Needle height adjustment – Set the needle height at 1 from the operation

panel. – Set the chenille head’s main shaft angle at

35°by using the main shaft handle. – When the main shaft angle was 35°, check

whether the distance between the end of theneedle and the needle plate is 2mm.

Hooked needle

Needle plate2mm

35

Turn OFF the main power when adjusting the machine.

DANGER

See the operation manual to lower the needle to the lowest position, and conduct theadjustment of the chenille head.

CAUTION

67

13.1.4) Pressor foot adjustment

1) Height check – Set the chenille head’s main shaft angle at

35°by using the main shaft handle. – Check whether the presser foot is properly

fixing the embroidery fabric. 2) Height adjustment

– Loosen the screw for the pressor foot holderand adjust the pressor foot to fix theembroidery fabric.

Presser foot

Embrodery fabric Needle plate

35

1) When adjusting the initial setting position of themoving mes, first of all check whether themoving mes is installed at the right position(The front end should be located at 2.5mm awayfrom the fixed screw for the fixed mes.)If the position of the moving mes isinappropriate, the upper thread separation andthe failure in cutting could result.

2) If the position of the moving mes isinappropriate, loosen the tightening screw forthe crank, and manually move the moving mesfor adjustment. When adjustment is completed, tightly fastenthe crank tightening screw. .

13.2) ADJUSTING THE TRIMMERS

13.2.1) Adjusting the Position of Movable Blade

The initial setting position of the moving mes means its starting position of motion and the basic position of determining trimming timing.

2.5mm

13.1.3) Needle locating position adjustment

1) Needle locating position height adjustment– Set the chenille head’s main shaft angle at

110°by using the main shaft handle. – Turn the nipple rotary gear when it is at the

lowest position, and check whether thehooked needle hole is rotating at the centerof the needle plate hole.

110

Nipple rotary gear

Needle

Needle plate hole

68

13.2.2) Adjusting Space between Movable Blade and Hook

To adjust a space between the movable blade and the hook, remove or insert a spacer (t 0.1) between the bladebase and the hook base. In the case of spacer removal, make sure to check if the hook does not interfere withthe movable blade.

Blade base

Spacer

Hookholder

Hookbase

Movable blade Fixed blade

69

13.2.3) Adjusting Blade Tension

Make sure to check and adjust the cross-tension of the movable and the fixed blades after replacement or repair.

– Checking the cross tensionManually move the movable blade and cut the upper and the lower threads. Check the cross-section of thethread cut.

– Adjusting the cross tensionAdjust the cross tension using the tension adjusting bolts of the fixed blade. Manually move the movableblade and make adjustment to the point, where it crosses in parallel with the cutting line of the fixed bladefrom its entry point to its return point.

L-wrench

Tension adjustingscrew

Fixed blade

Crank screw

Movable blade crank

Movable blade Fixed blade

Movable blade

Avoid excess cross-tension. Excess tension may cause errors or wear-out of the movableblade from overload at its entry or return point. By holding the thread fed from the bobbin caseafter trimming, the lower thread holder helps to make starting stitches after trimming. NOTE

Regularly clean the thread debris around the lower thread holder for efficient functioning of theholder.

CAUTION

70

13.2.4) Adjusting Trimmer Return Spring

1) FunctionThe trimmer return spring detects whether the movable blade has returned to its correct position aftertrimming. If the blade has not returned, it stops the machine to prevent damages on the needle and the blade.

2) AdjustmentAdjust the position of the sensor and the sensor unit so that the left edge (“side A”) of the sensor unit is atthe center of the left sensor when the movable blade is in its correct position (see picture A of Figure.). Make sure that the sensor unit does not interfere with the operation of the sensor (see picture B of Figure.).

13.3) ADJUSTING THE UPPER THREAD HOLDING UNIT

1) Checking the assembly of upper thread holding lever and upper thread holder plate① Stroke of the upper thread holder driver plate in the upper thread holder base should be 1mm from the

base when the upper thread holding solenoid is on.② If the space is shorter than 1mm, adjust the position of the upper thread holding solenoid up and down so

that the stroke of the plate is 1mm.③ If the solenoid is not adjusted with the above measure, you must adjust the position of the upper thread

holding lever. ④ To adjust the upper thread holding lever, remove the arm protection plate from the arm. Adjust the upper

thread holding solenoid over the center, and unscrew the lever. Support the arm protection plate with aflat plate so the lever touches the flat plate. Fasten the screw of the upper thread holding lever. Make surethat the upper thread holding lever is touching the axis of the upper thread holding solenoid.

⑤ Check if the lever moves smoothly left and right when you manually operate it.

Sensor fixing nut

1mm

2mm

Sensor unit

Trimmer return sensor device

Trimmershaft

Sensor

71

⑥ Install the arm guard plate and go through ① and ② to complete.

13.4) PICKER ADJUSTMENT

Incorrect position or volume of the picker may result in failures of separation of the upper and lower thread,trimming of both threads, and short upper thread after trimming.

Upper thread holding solenoid

②

Upper thread holding lever

Arm GuardPlate (R)

Upper thread holding lever screw

① 1mm

Upper threadholder base

Upper thread holderdriver plate

1) Adjusting picker positionManually move the picker so it touches thebobbin. Unfasten the picker screw and adjust thetip of the picker.

Picker

Picker screw

Correct pickerposition

If the upper thread holding unit does not function well, check if the upper thread holder driverplate of the unit moves smoothly when you manually move it. If not, adjust the position of theupper thread holding base.CAUTION

Bobbin case

72

2) Adjusting picker volumeAdjust the eccentricity of the picker stopper so thepicker slightly touches the bobbin you’re yourpress it with your hand.

Picker stopper

Picker

Picker stopper

13.5) ADJUSTING UPPER THREAD HOLDER

1) Adjusting Sensor Adjustment RingsMake the following adjustments if you find errors in the wiper return system. – Open the cover of the wiper motor. Of the two sensor adjustment rings, align the center of the sensor screw

in the rear ring with the #1 carve point on the fixed block on the cam shaft. Align the center of the sensorscrew in the front ring with the #2 carve point on the fixed block on the shaft.

– Adjust so the wiper return sensor is 1-1.2mm from the upper head of the sensor screw. Make sure to checkif the wiper return sensor turns on.

2) If the wiper does not move well, unscrew the driver link and adjust the wiper lever up and down. Unfasten thebracket screw so there is less overload from upper thread holder bracket. Adjust and fasten the bracket back atthe point where the wiper moves well.

Wiper return sensor

Sensor screw (rear)

Sensor screw (front)

#2 carve point

#1 carve point

Sensor adjustment ring

Fixed block on the cam shaft

73

3) After adjustment, run the color change to check if the wiper functions well at each needle bar.

4) If there occurs a trimming or jump problem on a particular head during the embroidery, operate the wiperclutch to protect the embroidery and the wiper.－ Press and turn the wiper clutch counterclockwise to operate the clutch.

Press and turn it clockwise to stop the clutch operation

Driver link

Bracket screw

Upper thread holder bracket

Wiper clutch

74

13.6) ADJUSTING LOW-NOISE PRESSER FOOT

1) Assembling the presser foot cam – Position the main shaft angle 178°. Put two assembler pins (ф3) into the assembler hole (ф3) of the presser

foot driver cam as shown in figure and into the assembler hole of the take-up lever driver cam (ф3). – Adjust the position of the presser foot driver cam so that the assembler pins move freely left and right.

Fasten three screws (M4×L35) snugly.

Pin hole (ф3)

Assembler pin(ф3)

Assembler holes

Screws (3) Presser footdrive cam

Take-up leverdriver cam

1) The assembly pin must smoothly move left and right after the cam is fixed with 3 screws.2) The assembler and the assembler pin are not for commercial sale.3) Contact your SWF dealership if you must adjust the presser foot cam.CAUTION

75

2) Adjusting the height of the presser foot– Check the relationship between the presser

foot, the needle, and the embroidery material.Turn the main shaft with the lever and positionthe needle bar at the lowest point (main shaftangle of 178°).

– Uncover the head and unscrew the presser footso it moves up and down. Place a 1mm-thickgauge on the needle plate. Softly push thepresser foot down onto the gauge and fix thescrew snugly.

13.7) RELATIONSHIP BETWEENPRESSER FOOT AND NEEDLE

1) Relationship between Presser Foot and Needle/Embroidery MaterialFor stable stitching, the presser foot must bepressing the embroidery material before the needlepierces into the material. The same is true forwhen the needle comes out of the material.

Presser footholder

Presser foot

Needle plate

Screw

1mm

Presser foot

Needle plate

Embroiderymaterial

NeedleOUT

NeedleIN

2) When the Presser Foot is Too High– Needle In

The left figure shows the presser foot fails to press the work material when the needle pierces into thefabric, causing an unstable needlework.

– Needle OutThe right figure shows the presser foot fails to press the work material when the needle comes out of thefabric. The embroidery material is lifted up along with the needle, making a gap between the fabric and theneedle plate. This may cause thread breaks, skipped stitches, or unstable stitching.

NeedleIn

NeedleOut

76

13.8) CORRECT POSITION OF NEEDLE

1) Make sure to check the position of the needle – it may change during machine delivery or leveling. First checkif the needle is bent. Then turn the main shaft lever to set the shaft at around 130°. Position the needle at thelower dead stop and check if the needle is at the center of the needle hole on the plate.

2) If the needle is not in the correct position, unscrew the brackets (2 screws) to adjust the head and the needle(see figure).

Lever

Bracket screwsHead

Needle plate

Needle plate

Check the needle position on all heads.

CAUTION

77

13.9) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE

1) The machine will stop automatically if either of the needle position lamp or the needle set lamp blinks on thecolor change box. In this case, adjust the half-turn film as below. － When the needle comes to the center of the needle hole on the plate, adjust the position of the color change

cam, using the manual knob, so that the roller is positioned at the center of the straight line of the cam asshown in figure. Open the half turn film cover and align the centers of the half turn sensor and the half turn film.

Half-turn film

Film screw

Color change motor

Roller

Color change cam

13.10) ENCODER ADJUSTMENT