SunStar SWF E Series User Manual Download

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8-1

TROUBLESHOOTING

CHAPTER

CAUTION

DANGER

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

Error Type

Cause

Loose belt tension / belt
damage

Power failure or short-circuit
of fuse

Failure to sense signals for
needle position or 1 rotation

Red light on X/Y drive box

Machine does not start at
START

Loose tension on main
driver belt

Incorrect position of
encoder or bad encoder

Adjust belt tension / change belt

Check fuse in main shaft motor
and change fuse

Run manual color change and
check if signal lamps (needle set
lamp & needle position lamp)
blinks at correct needle position.
Adjust the half-turn film.

Address the cause and press
RESET. Check if the lamp turns
green.

Check connection of START
switch

Adjust belt tension

Adjust encoder position or
change encoder

Inspection & Repair

Reference

Operation failure

Incorrect Stop
Position

Summary of Contents for SWF E Series

Page 1: ...M MM ME E 0 09 90 09 92 29 9 USER S MANUAL FOUR HEADAUTOMATIC EMBROIDERYMACHINEWITH FLAT SIX HEADAUTOMATIC EMBROIDERYMACHINEWITH FLAT S Su un nS St ta ar r C CO O L LT TD D SWF E Series ...

Page 2: ...TENTS IN THIS INSTRUCTION MAY CHANGE WITHOUT PRIOR NOTICE FOR IMPROVEMENT OF MACHINE QUALITY AND THUS MAY NOT CORRESPOND TO THE MACHINE YOU PURCHASED CONTACT YOUR SALES AGENT FOR INQUIRIES 3 THIS IS DESIGNED AND MANUFACTURED AS AN INDUSTRIAL MACHINE IT SHOULD NOT BE USED FOR OTHER THAN INDUSTRIAL PURPOSE ...

Page 3: ...TOP 5 3 5 3 LAMP ON THREAD TENSION ADJUSTMENT BOARD 5 4 5 4 NEEDLE STOP CLUTCH 5 5 5 5 UPPER THREADING AND TENSION ADJUSTMENT 5 6 5 6 LOWER BOBBIN THREADING AND TENSION ADJUSTMENT 5 9 5 7 THREAD WINDER 5 10 5 8 PRECAUTIONS IN USING FLOPPY DISKS OR USB MEMORY STICKS 5 12 5 9 INSERTING FLOPPY DISKS AND USB MEMORY STICKS 5 13 5 10 DELETING FLOPPY DISKS AND USB MEMORY STICK 5 13 5 11 READING AND WRITI...

Page 4: ...ETURN SPRING 7 3 7 3 PICKER ADJUSTMENT 7 4 7 4 ADJUSTING UPPER THREAD HOLDER 7 4 7 5 ADJUSTING HEIGHT OF PRESSER FOOT 7 6 7 6 CORRECT POSITION OF NEEDLE 7 7 7 7 ADJUSTING HALF TURN FILM FOR COLOR CHANGE 7 8 7 8 ENCODER ADJUSTMENT 7 8 7 9 JUMP SOLENOID ADJUSTMENT 7 9 CHAPTER 8 TROUBLESHOOTING 8 1 ...

Page 5: ...ors CAUTION WARNING DANGER SAFETY RULES CHAPTER 1 ONLY TRAINED AND EXPERIENCED PERSONS FAMILIAR WITH THE RELEVANT SAFETY INSTRUCTIONS SHOULD HANDLE THE MACHINE MAKE SURE TO FULLY OBSERVE THE FOLLOWING INSTRUCTIONS 1 Using a crane Make sure that the crane is large enough to hold the machine Use a nylon rope of sufficient strength Place a wooden block at either side of the machine before tying the r...

Page 6: ...eight of the machine approximately 1 ton 2 Air conditioning can eliminate dust and humidity that can cause pollution and corrosion of the machine Make sure your machine is regularly cleaned 3 Long exposure to direct sunlight can cause the paint of the machine to fade or change of the machine shape 4 Allow at least 50cm 20 inches of space on each side of the machine for convenient maintenance Pleas...

Page 7: ...ear shoes with non slip soles 03 Clear all persons from the machine before turning on the power 04 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 05 Do not remove the safety cover on the pulley or shaft when the machine is in operation 06 Be sure the main power is turned off and the power switch is set...

Page 8: ... rotating Injury 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 Turn off the main power before rotating the main shaft by hand Do not remove covers during operation Turn off the main power before opening electricity related boxes Physical damage may be caused by interposition While embroidery ...

Page 9: ...changing of needles Fire 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 Notice Cover in the WARNING means all covers near operating part of the machine Injury may be caused by winding Be sure to turn off the power before cleaning lubricating adjusting or repairing ...

Page 10: ...he right range of the voltage supply before installing or operating the machine The voltage required is as follows 1 Input voltage to be adjusted when installing 100V 110V 120V 200V 220V 240V 2 Allowed range of voltage within 10 of the voltage set 3 Electric capacity and voltage consumption 640VA 440W 4 Insulation resistance over 10M ohms measured with 500V insulation tester INSTALLATION AND MACHI...

Page 11: ...he machine will be installed Install the cable away from the operator s work space to prevent accident or injury If the difference in heights of the four bolts is over 10mm place spacers beneath the lower adjusting bolts to make the heights even 2 Use a nut to fasten the bolts when the machine is horizontally leveled CAUTION The level gauge does not measure accurately on a square pipe or a table F...

Page 12: ...2 3 2 4 ASSEMBLY OF PERIPHERAL DEVICES 1 Assembling Upper Thread Stand Fig 2 4 Fig 2 5 Fig 2 6 2 Assembling Operation Box Spool plate Thread holder Operation box FDD Support Power Cable FDD Cable ...

Page 13: ...Change Upper thread holder Head Thread tension adjustment board Sub controller X axis driving system Y axis driving system Bar switch Frame Main controller box Operation box Encoder Main power switch 21 Lamp 22 Supporting bolt 23 Leveling base 24 Thread detector 25 Emergency power switch PARTS OF THE MACHINE CHAPTER 3 ...

Page 14: ...C OFFSET at PARAMETER SELECT MODE to move the frame automatically to the desired point making it easier to do appliques and to switch the frames 7 MANUAL OFFSET You can manually move the frame to the pre selected point to do appliques or change the frames during embroidery work The frame can be moved back to its original place by simply pressing the right buttons 8 RETURN TO START The frame can be...

Page 15: ...G You can delete change or insert stitch data and function codes jump finish trimming 16 INDIVIDUAL HEAD OPERATION You can work on the specific head with a broken thread 17 MACHINE STOPPAGE The screen will indicate why the machine has stopped 18 RPM The screen indicates rpm 19 FRAME SPEED SET UP You can adjust the frame speed to high medium or low 20 UNUSED MEMORY The screen indicates the memory a...

Page 16: ...the START STOP buttons and Bar switch to Start the embroidery work or stop the machine during operation Move the frame back during machine stop Move forward in design during machine stop non stitching Move backward in design during machine stop non stitching Do work other than embroidery Bar switch STOP Left Right START Fig 5 1 NOTE Emergency power switch detects emergency stop failures and preven...

Page 17: ...its If you press START after the machine traveled 10 of the selected stitches the machine will continue to move forward Press START one more time and the machine will stop moving forward MACHINE OPERATION START STOP during machine stop BUTTON OPERATION Press STOP Hold STOP Press STOP again Frame moves backward in selected movement units see Note 2 Frame starts to move backward If you press STOP be...

Page 18: ...GENCY STOP if you have to stop the machine immediately i e machine error EMERGENCY STOP will turn off the machine To restart the machine rotate the main shaft to 100 Turn the EMERGENCY STOP button off and then on again Fig 5 4 Fig 5 3 ...

Page 19: ... may block smooth rotation of the roller and cause wrong detection of thread break CAUTION 1 The take up lever continues to operate even when the head is turned off This movement can cause the upper thread to come out of the holder Use a rubber magnet to fix the unused upper thread NOTE If you want to move the frame back for any reason when a thread break has NOT occurred press the toggle twice OF...

Page 20: ...Turn the clutch 90 in the direction of the arrow to stop the needle bar CAUTION The trimmer and the take up lever continue to move even when the needle bar is stopped by the clutch Avoid any operations i e threading the needle or changing thread Long time operation of the needle bar with the clutch may damage the bar controller ...

Page 21: ...ment board Thread detecting roller Thread detecting board Take up lever spring Rotary tension disk Main thread tension adjuster Upper thread guide Thread guide upper Take up lever Thread guide middle Thread guide lower Upper thread holder spring Presser foot Needle Fig 5 7 NOTE Do NOT stand on the table when threading the upper thread stand The table may be damaged ...

Page 22: ...Threading the sub tension adjuster Threading the main tension adjuster Threading the thread detector roller Threading around the needle Wrap the thread 1 5 times around the rotary tension disk V shaped groove Wrap the thread clockwise around the thread guide disk Wrap the thread around the detector roller one time Fix the upper thread between the thread holder spring of the lower thread guide Thre...

Page 23: ...ent ⓐ Tension on the take up spring affects the thread tension Turn the tension adjusting stud clockwise to increase the tension and counter clockwise to decrease the tension ⓑ Adjusting stroke of the take up spring To adjust the stroke of the spring during embroidery work move the take up spring stopper to right or left as shown in Fig 5 11 stopper Thread tension adjusting stud CORRECT WRONG Take...

Page 24: ...the thread to tangle during stitching 2 Lower Thread Tension Adjustment Adjust the tension of the lower thread using the nut on the tension spring on the bobbin case Turn the nut clockwise to increase the tension and counterclockwise to decrease the tension CAUTION 1 Direction of the Bobbin Rotation Make sure that the bobbin rotates clockwise when you pull the thread holding the bobbin case in you...

Page 25: ... of the bobbin size in terms of diameter as in Fig 5 15 Bobbin thread volume is adjusted by the thread winder knob When the knob is turned clockwise the bobbin thread gets thicker When the knob is turned counter clockwise the bobbin thread gets thinner Fig 5 14 m in TIM ER START STOP max Knob Tension adjusting holder Tightening screw for the tension adjusting holder Bobbin axis Bobbin Thread tensi...

Page 26: ...breaks or short tails 3 Adjustment of bobbin thread status The thread should be wound around the bobbin in parallel Otherwise loosen the tightening screw for the thread winder s tension adjusting holder and move the thread guide body left or right for adjustment Adjust the thread tension on the bobbin using a tension adjuster nut Fig 5 17 Thread tension adjusting nut Tension adjusting holder Tight...

Page 27: ...rom the drive while formatting reading or writing the disk Do not open the cover of the disk drive Data cannot be written onto the write protected disks Repetitious reading and writing on a single disk may cause errors Save your important data on more than one disk for back up When using USB memory sticks Do not delete USB memory from the USB port when reading and writing with USB CAUTION 1 You ca...

Page 28: ...rnal devices such as floppy disks USB memory CF cards and serial port to read designs into the operation box For writing the designs onto floppy disks and USB memory sticks are available CAUTION Be careful not to remove the floppy disk from the drive when formatting reading or writing in order to prevent loss of data Fig 5 19 5 12 RETURN TO PREVIOUS LOCATION IN UNEXPECTED BLACKOUTS Your SWF machin...

Page 29: ...nge it If the needle is not clear of the plate manually turn the main shaft with a hand lever to put the needle in the right location for change 5 14 CAUTION DB K5 needle has an eye twice larger than that of DB1 used for normal sewing Use DB X K5 for normal embroidery CAUTION Needle and thread most commonly used in embroidery are DB K5 11 and rayon yarn 120d 2 Fig 5 20 Needle Size Thread Size US 0...

Page 30: ...e bar CAUTION 1 For special threads such as artificial silk turn the needle slightly to the right to prevent thread breaks see Fig 5 22 CAUTION 2 If the needle is not inserted all the way to the top of the needle bar hole timing of the machine will go off causing broken needles and thread breaks Fig 5 21 Fig 5 22 Needle insert hole Needle groove front ...

Page 31: ...e needle the hook point will be inside the loop and threading will be more stable Fig 5 23 Fig 5 25 Hook point 0 1 0 3mm Fig 5 24 Top edge of needle eye Top point of hook circumference Needle tip Top edge of the needle eye Hook allowance gap Hook point Lower dead stop of the needle Hook point a At lower dead stop of the needle bar 2 3 3 7 mm 1 8 2 2 mm 0 5 1 5 mm The figures may change according t...

Page 32: ...Prevention of looping is important for stitching Adjust the hook point as close to the needle as possible to achieve the perfect thread position If thread breaks or stitches are unstable turn the needle slightly to the right NOTE Shape of the loop varies by the type of thread or fabric Unstable shape of the loop may result in skipped stitches The following pictures show different shapes of loop fo...

Page 33: ... Timing Slow Hook Timing Fig 5 29 Too small Too large Fig 5 30 Fig 5 31 Groove of the hook is in the A range The hook point will take up the thread when the loop is too small Stitching will be faster than the take up movement As a result the thread tension will be too loose upper thread loop will be too small and skipped stitches will occur Groove of the hook is in the B range The hook point will ...

Page 34: ...sembling Thread Detector You will need to disassemble the thread break detector unit to clean Remove the cover of the thread tension adjusting plate separate the cables and unfasten the roller base joint screw The entire unit will be disassembled including the rollers and bush bearing CAUTION Make sure to correctly place the thread detecting roller to have the unit properly function Check between ...

Page 35: ...functions caused by insufficient cleaning or oiling CAUTION Turn OFF the main power before inspecting or cleaning of the following parts 1 2 3 Reference Fig NO Important Parts for Cleaning Cleaning cycle Every day Once a week How to Clean Remove the needle plate and insert the bobbin between the trimming solenoid flanger and stopper Turn the main shaft with a lever and the movable blade will move ...

Page 36: ...6 2 Fig 6 1 Hook Guide rail to the take up lever Movable blade Fixed blade Lower thread holder Trimming cam box ...

Page 37: ...ad breaks Fig 6 2 1 2 3 Take the bobbin case out of the hook Feed small amount of oil on the raceway Needle bar and needle bar shaft Inside the arm 3 4 times a day Once a week Once a week 4 Guide rail to the take up lever Once a week Where to Oil Oiling cycle Ref Fig No CAUTION Make sure to turn the power OFF during oil supply CAUTION Sun Star is not responsible for machine damages or wear outs ca...

Page 38: ...tomatic Greasing from Oil Tank Greasing Cycle once in 2 3 days CAUTION Use the SWF sewing machine oil Spindle Oil or ISO standard VG18 Make sure to fill the oil tank to the middle point between HIGH and LOW Fig 6 3 ...

Page 39: ... holder Hook gear and lower gear in the rotary hook base Blade cam Once in 3 months Once in 3 months Once in 3 months Once in 1 months Where to Grease Greasing cycle Reference Fig NO Make sure to turn OFF the main power during the grease supply CAUTION Rotary hook base Lower shaft Trimming cam box Fig 6 4 Places for supplying synthetic TM grease 1 2 Color change cam color change head roller Hinge ...

Page 40: ...ia No 2 CATUION Do NOT grease the parts not indicated needle bar hook etc 1 Head drive LM guide Once a month Where to Grease Greasing cycle Reference Fig NO Turn OFF the main power during the grease supply CAUTION Head drive LM guide upper cover opened ...

Page 41: ...ows in the picture below 6 4 DRIVE BELT TENSION Fig 6 6 CAUTION Turn OFF the main power when inspecting drive belt tension NO 1 2 3 4 Location for inspection Belt on main shaft motor Upper lower shaft belt X axis timing belt Y axis timing belt Inspection cycle Once in 3 months Once in 3 months Once in 3 months Once in 3 months Inspection Belt tension Belt crack Belt wear out Bearing damage Wear ou...

Page 42: ...d Unfasten the crank screw to adjust the location of the movable blade see Fig 7 1 Fasten the screws back 2 Adjusting the angle of the movable blade Unfasten the screws on the blade cam directly connected to the lower shaft Turn the lever to adjust the main shaft rotary angle at 295 Press the trimming solenoid and insert the trimming cam roller into the trimming cam Fig 7 2 Turn the cam and when t...

Page 43: ...ades after replacement or repair Checking the cross tension Manually move the movable blade and cut the upper and the lower threads Check the cross section of the thread cut Adjusting the cross tension Adjust the cross tension using fixed blade tension control screws see Fig 7 4 Manually move the movable blade and adjust that it crosses in parallel with the cutting line of the fixed blade from its...

Page 44: ...its correct position the needle and the blade may be damaged The trimmer return spring detects and stops the machine if the blade has not returned 2 Adjustment Adjust so that the sensor spring is around 2mm off the center of the sensor when the movable blade is in its correct position Fig 7 6 Adjust so that the sensor spring and the sensor are around 1mm apart Center of the sensor spring should al...

Page 45: ...ker stopper Bobbin case Picker screw Picker stopper Fig 7 7 Fig 7 8 7 4 ADJUSTING UPPER THREAD HOLDER Adjusting Sensor Adjustment Rings Make 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 Ali...

Page 46: ...ell After adjustment run the color change to check if the wiper functions well at each needle bar Driver link Bracket screw Upper thread holder bracket Fig 7 10 If there occurs a trimming or jump problem on a particular head during the embroidery operate the wiper clutch to protect the embroidery and the wiper Press and turn the wiper clutch counterclockwise to operate the wiper clutch Press and t...

Page 47: ...roidery material is lifted up along with the needle making a gap between the fabric and the needle plate This may cause thread breaks skipped stitches or unstable stitching Fig 7 12 Fig 7 13 Fig 7 14 Fig 7 15 Presser foot Embroidery material Needle out Needle in Needle plate Needle In Needle Out 3 Adjusting the Height of the Presser Foot Check the relationship between the presser foot and the need...

Page 48: ...r to set the shaft at around 130 Position the needle at the lower dead stop and check if the needle is at the center of the needle hole on the plate If the needle is not in the correct position unscrew the brackets two screws to adjust the head and the needle see Fig 7 16 CAUTION Check the needle position on all heads Fig 7 16 L wrench Needle plate Needle plate Needle plate Head Bracket screws ...

Page 49: ... the film CAUTION Manual color change must be performed at the upper shaft angle of 100 Manual color change at the upper shaft angles other than 100 may cause damage on the controller and the take up unit Fig 7 17 7 8 ENCODER ADJUSTMENT Adjust the encoder as below if the needle bar stops at an incorrect position Unfasten the two encoder coupling screws Turn the hand lever fix the upper shaft angle...

Page 50: ...d will interfere the needle If the space is smaller than 3 5mm the needle bar controller will hold the needle in the JUMP CODE 2 Adjusting the Installation Position assembling a solenoid installed bracket on the base plate Adjust so that the bracket is around 1 5mm from the base plate Fig 7 20 Fasten the bracket screw Incorrect position of the bracket will interfere with the needle movement as the...

Page 51: ...tension on main driver belt Incorrect position of encoder or bad encoder Adjust belt tension change belt Check fuse in main shaft motor and change fuse Run manual color change and check if signal lamps needle set lamp needle position lamp blinks at correct needle position Adjust the half turn film Address the cause and press RESET Check if the lamp turns green Check connection of START switch Adju...

Page 52: ...lamps needle set lamp needle position lamp blinks at correct needle position Adjust the half turn film Set it to the correct position Adjust so take up lever is in line with other levers in stop position upper shaft angle 100 Change fuse F3 in joint board or check connection Set main shaft angle back at 100 if you manually moved it for cleaning inspection or repair Unscrew the lever and adjust so ...

Page 53: ...oreign substance in X Y rail Failure of X Y driver board Heavy load on frame Inspection Repair Disassemble the roller and clean the roller and bush bearing Check the plate connection and change the circuit board Change front fuse F3 in joint board Check wiring and change solenoid Check connection Change switch and circuit board Correct tape Adjust tension Clean the rail Change circuit board Reduce...

Page 54: ...ent dent worn Incorrect needle installation height direction etc Dirty needle adhesive etc Inspection Repair Re punch design tape Re punch after checking design Correct the stitches on operation box Change needle Change needle Re install needle Clean or change needle and hook Check design Use minimum adhesive for applique Reference Thread breaks ...

Page 55: ...troke on take up spring Inspection Repair Change thread Change to left twisted thread Adjust tension Adjust tension and stroke Check the thread used How to select thread Select soft thread with even thickness Choose 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 Reference ...

Page 56: ... on the frame Inadequate height of presser foot does not press the work material Inspection Repair Remove dent or change the case Adjust space Oil the raceway of hook Adjust timing Adjust the lower dead stop Check Thread path in presser foot Around needle hole on needle plate Thread guide on the head Thread path in tension adjuster Fix the material firmly Adjust height Set it at 0 5 0 7mm for smoo...

Page 57: ...wist elasticity and flexibility Excessive tension or stroke on the take up lever spring Fabric moves with needle weak or damaged presser foot spring Inspection Repair Change needle Adjust installation Adjust timing Adjust the lower dead stop Use whetstone to adjust hook point or change hook Adjust thread tension For upper thread change bobbin or bobbin case Select right thread for embroidery Adjus...

Page 58: ... touches the hook point Incorrect installation of needle Needle touches the needle hole on the plate Inspection Repair Adjust tension Clean main and sub tension adjusters in the thread tension adjusting plate Adjust tension Clean bobbin case and check tension on bobbin spring Change to quality thread Adjust timing Oil the raceway of hook Change needle Space the needle and the hook point Correct th...

Page 59: ... trimming fuse Poor connection quality of trimming solenoid Bad connection Trimming driver TR damaged Inspection Repair Adjust tension Change presser foot spring Change needle Use adequate size of needle Check and change fuse F1 in joint board Check and change solenoid and solenoid connection Check connection Change joint board SWF needle holes are 2 0mm Check fuse spec Reference Puckering Trimmin...

Page 60: ... sensor clean around the sensor adjust location of the sensor unit Adjust insert angle of movable blade 293 Adjust picker position Check and change fuse F1 F3 Check change solenoid and solenoid connection Check connection and change joint board Adjust upper thread tension remove dent using whetstone or sandpaper or change movable blade adjust or change bobbin case spring clean check for dent in th...

Page 61: ...upper thread tension set or length of trimmed thread in data set up set or length of trimmed thread in data set up if upper thread is held due to narrow velcro space in upper thread holder clean the velcro Check screws and crank driver clamp screws of the movable blade Check tension of fixed blade Change movable blade Adjust the position of movable blade Check and replace F1 FF2 and F3 on the join...

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