MANUAL

Single Head Automatic

Embroidery Machine
(New Compact Type)
SWF/E- Series

MME-060310
SUNSTAR PRECISION CO., LTD.
1. THIS IS AN INSTRUCTION FOR SAFE USE OF AUTOMATIC
EMBROIDERY MACHINES. READ THOROUGHLY BEFORE USE.

2. CONTENTS 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.
 CONGRATULATIONS
on the purchase of your machine
SWF/E-T601C or SWF/E-T901C
SWF/E-T1201C or SWF/E-T1501C

and

WELCOME to the SWF FAMILY !!

Y
OUR SUCCESS IS IMPORTANT TO US. We want to be your partner in business where you machine
is concerned. Your machine is manufactured to the highest standards by the SunStar (SunStar Precision
Company, Ltd.Korea). Both the manufacturer and their United States distributors are dedicated to
product quality and customer care.

Taking the time to understand your machine, its maintenance needs, and its operation will make you more
comfortable with your purchase. Knowledge of your equipment and confidence in its operation can only benefit
your business from both a safety standpoint and in more efficient production.

We urge you to read your manual and mark any sections that you wish to discuss with your installation
technician, customer support or during any training session. Your manual pages are printed on one side only, so be
sure to make use of the space provided for making notes. While we have taken great care to make this manual as
complete and easy to understand as possible, we still welcome your comments and suggestions.

CONTACT INFORMATION:

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 TABLE OF CONTENTS

CHAPTER 1 SAFETY RULES ............................................................................................................. 1

Delivery of Your Machine
Installation
Machine Operation
Troubleshooting
Placement of Warning Stickers

CHAPTER 2 INSTALLATION AND MACHINE ASSEMBLY ........................................................... 7

Environment
Electricity
Leveling the Machine
Assembly of Peripheral Devices

CHAPTER 3 PARTS OF THE MACHINE .......................................................................................... 16

CHAPTER 4 FUNCTIONS AND FEATURES ................................................................................... 17

CHAPTER 5 BUTTON AND SWITCH OPERATION ....................................................................... 19

CHAPTER 6 THREADING AND TENSION ..................................................................................... 21

The Upper Thread Path
Threading the Machine
Tension control on Upper Thread
Take-up Spring
Bobbin Threading and Tension Adjustment
Bobbin Winder

CHAPTER 7 THE NEEDLE, THE HOOK AND THE STITCHES .................................................... 28

Stitch Formation
The Needle and Hook
The Needle
Changing the Needle
Relationship Between Needle and Hook
Relationship Between Take-Up Lever and Hook
Thread-Break Detecting Unit

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CHAPTER 8 MAINTENANCE AND INSPECTION .......................................................................... 37
Oil Supply
Grease Supply

CHAPTER 9 MACHINE ADJUSTMENTS ........................................................................................ 44

CHAPTER 10 TROUBLESHOOTING ................................................................................................. 57

CHAPTER 11 NEEDLE CHART .......................................................................................................... 67

CHAPTER 12 BACKING ...................................................................................................................... 68

CHAPTER 13 HOOPING AND TENSIONS ........................................................................................ 69

iii
 CHAPTER 1
SAFETY RULES
When operating a machine of any type, it is important to take precautions in order to safeguard
the user and the equipment. Whether the machine is owner operated or run by an employee,
procedures should be followed in order to ensure that the operator is not injured and the machine
is not damaged.

When moving, handling, installing or performing maintenance on your machine,

it is important to observe all DANGER signals.
DANGER

When operating the machine, observe all WARNING signs in order to protect
against personal injury.
WARNING

Follow all CAUTION signs to safeguard your machine during installation in your
work environment.
CAUTION

When operating the machine, observe NOTICE signs in order to protect the
machine from physical damage or breakdown.
NOTICE

Tips to help you learn about embroidery and produce quality embroidery.

TIP

1
 DELIVERY OF YOUR MACHINE

Safeguarding your machine begins with delivery. Only trained and experienced
persons, familiar with any special transporting instructions, should be employed
to move your new machine.
DANGER

1) When removing the crated machine from the

delivery truck, be sure to keep the crate in a
horizontal position to prevent damage to the
machine or injury to the workmen.

2) All workers should wear safety shoes and, when

moving the machine, be sure to hold the machine
by the handles on the right and left sides.

3) When using a forklift, make sure all helpers are

out of the way of the moving equipment. Make
sure that all obstacles in the path of the forklift
are removed. Ensure that the size and the power
of the forklift is sufficient to support the
machine. Place the machine in the center of the
forklift arm and lift it carefully to maintain the
weight balance.

2
 INSTALLATION

The foundation under the machine and the environment is very important.

CAUTION

1) Ensure that the floor has a structure that is strong enough to support the weight of the machine.
2) Air conditioning and air filtering eliminates humidity that can cause corrosion and also dust that can
block filters and screens. Make sure your machine’s environment is as clean as possible.
3) Direct sunlight can cause the paint of the machine to fade.
4) Allow at least 50cm(20 inches) of space on each side of the machine for safety and convenience. Keeping
the machine away from the wall allows room to move around the machine for maintenance and
threading. It is also a safeguard against things falling on or against the machine.
5) Explosion: DO NOT operate the machine when there are inflammable substances in the air.
6) Lighting: Secure sufficient lighting for the operator. Lighting is not part of the SWF machine.
7) Machine Overturn: DO NOT place the machine on unstable stands or tables. Machine fall may cause
serious injuries or machine damages. Abrupt stop during the machine delivery or external shocks may
also overturn the machine.

MACHINE OPERATION

The SWF machines are designed for applying embroidery to fabric and other
similar materials. Pay careful attention to the CAUTION and WARNING
stickers placed on the machine. They are intended to call attention to safety
WARNING rules. While operating the machine, please observe the following :

1) Dress for safety. Long, unbound hair, jewelry such as necklaces, bracelets, dangling earrings and wide
sleeves can get caught in the machine. Avoid wearing these items while operating the machine. Do not
lean near or against any moving parts.
2) Wear shoes with non-slip soles.
3) Clear all personnel away from the machine before turning on the power. Customers and those unfamiliar
with the machine, especially small children, should not be allowed near the machine at any time.
4) Keep your hands away from the moving parts of the machine such as the needle, hook, take-up lever,
pulley and bobbin case when the machine is in operation.

3
5) DO NOT remove the safety cover on the hand wheel and the shaft. Covers are meant to protect the parts
of the machine from dust and foreign objects as well as protect the operator.
6) Be sure the main power is turned off and the main switch is set to OFF before opening the cover of any
electrical component or control box.
7) Be sure main switch is OFF before turning the main shaft manually.
8) Although the machine has a STOP phase between thread trims, color changes, and frame movements,
you should not attempt to change or thread needles at that time. When changing or threading needles,
turn the machine off using the main switch or be sure you are at the end of any designs and the machine
is permanently paused until the operator activates the motor again.
9) DO NOT lean against the cradle or place your fingers near the guide grooves of the frame during
operation.

Observe the following to avoid damage to the machine or functional failures.

Take precautions during operation to help avoid accidents that result in
downtime which affects production and profit.
NOTICE

10) DO NOT put any objects on the table of the embroidery machine. The table is meant to hold the goods
being embroidered. NOT your tools and supplies. Objects that impede the movement of the pantograph
can not only damage the machine but also cause severe registration problems during stitching.
11) DO NOT use a bent or damaged needle. If you are unsure of the state of the needle, DO NOT use it.
WHEN IN DOUBT, THROW IT OUT.
12) Change your needle plate when switching from caps to flats and vice versa.
13) Lower the tabletop when stitching tubular goods, but remember to raise it when stitching flat goods. The
tabletop helps support the product. especially heavy jackets.

4
 TROUBLESHOOTING

If you should have any problems with your new machine, contact the A/S
Engineers at your SWF dealership. They are trained at SWF training centers
and are ready and able to assist you.
DANGER

1) Before cleaning or repairing the machine, turn off the main power and wait for four minutes so that the
machine electricity is completely discharged. NOTE : When doing any routine troubleshooting, be aware
that it takes about10 minutes after turning off the main switch before the electricity is fully discharged
from the X/Y main shafts and drive box.
2) DO NOT change the settings or any parts on the machine without confirmation from SWF or its
distributors.
3) Use ONLY SWF parts on your machine.
4) Be sure to replace all covers when you are finished with your cleaning or repairs.

CONTENTS OF WARNING STICKERS

Covers in the warning stickers refer to all covers near operating parts of the machine.

WARNING WARNING
· Injury may be caused by winding. · Injury may be caused by
· Be sure to check that safety cover moving needle.
is closed before running machine. · Ensure that the machine is in a
· Don’t put your hands near the stop condition before changing,
moving parts while machine is threading or rethreading of
running. needle or changing of needles.

This sticker warns against high voltage, electric shock and burn.
1) Only professional technicians should open any covers marked with this sticker.
2) Wait four minutes after turning the main switch to OFF before opening the cover.

5
 PLACEMENT OF WARNING STICKERS

WARNING STICKERS are placed on the machine as reminders to operate your equipment safely. When
operating your machine, be sure to observe the directions on ANY warning stickers.

WARNING [View from the right-front]

· Burn 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.

WARNING
· Injury may be caused by winding.
· Be sure to check that safety
cover is attached before running
machine.
· Don’t put your hands near the
moving parts while machine is
running

WARNING
· Physical damage may be caused
by winding.
· Don’t put your hands near the
arrow while the main shaft is
rotating

WARNING
· Physical injury may be
caused by crevice.
[View from the left-front]
· Don’t put your finger in a
chink on the table.

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

6
 CHAPTER 2
INSTALLATION AND MACHINE ASSEMBLY
Install you machine in an appropriate environment and with adequate and proper electrical supply.
Failure to follow directions may result in injury to the operator or damage to the machine.

ENVIRONMENT
1) Temperature : During machine operation the temperature should range between 0 and 40 degrees
Celsius(32-104 degrees Fahrenheit). When the machine is not in operation the temperature should fall
between-25 and 55 degrees Celsius(-13 and 131 degrees Fahrenheit).
2) Humidity : The relative humidity should fall between 45 and 90%

Do not let moisture drops on the machine.

Provide air conditioning to control humidity and to prevent dust and corrosion.
CAUTION

3) Height: 1,000m above sea (max)

4) Grounding: Ensure the electricity is properly grounded.

Properly ground the machine to avoid electric shock. Use a three-wire grounding
(grounding resistance below 100 ohms).
DANGER

5) Light : Close any doors and windows near the machine to protect from direct light as well as dust and
humidity.
6) Placement : Place the machine on a flat concrete floor that is strong enough to sustain the weight.

7
 ELECTRICITY
1) Grounding : Make sure that the electricity is properly grounded.

Electric shock can result if the machine is not properly grounded. Use a three-
wire grounding (grounding resistance : below 100 ohms)
DANGER

2) Input Voltage (regulate when installing) : 100V, 110V, 120V, 200V, 220V, 240V
3) Available Range of Voltage : On the transformers in the machine are wire taps that can be varied to match
the voltage of the facility. These must be set within 10% of the facility’s voltage.
4) Electric Capacity and Electric Power : Minimum input voltage(640 voltage amps is equivalent to 400
watts.) Each machine should have its own 20amp circuit breaker.
5) Insulation Resistance : The cover of the wires should have a resistance of more than 10 M ohms.
(Measure with 500V insulation tester)

1) Check the voltage supply where the machine is being installed.

2) Install the cable away from the operator’s work space to prevent accident or injury.
3) Have the electrical supply and its installation checked by a certified electrician for
WARNING safety’s sake.

6) Noise (LpAd) should measure 82.6dB (A) working 1200 SPM on SIO 10821-CA M1.

8
 LEVELING THE MACHINE
The machine must be leveled when it is installed. Balancing the machine horizontally protects the
needle from moving out of position.

1) When there is no stand attached. adjust the front,

rear, left and right of the machine using the level
adjusting bolt. When the machine is level,
tighten the fixing nut.

Nut

Adjusting
bolt

2) When there is a stand attached, insert the four

horizontally adjusting bolts into the holes on the
stand. Then place the four rubber mats (for
vibration prevention) under each of the bolts.
Adjust the bolts until the caster is raised above
Caster
the level of the floor. Use a level to adjust the
Nut machine using the horizontally adjusting bolts so
that the machine is level on all four sides. When
the machine is level, tighten down the fixing
Adjusting bolt
nuts.

Rubber

1) The machine must be balanced horizontally in all four directions : front, back, left and
right.
2) If the height of the four adjusting bolts varies over 10mm, use spacers beneath the
CAUTION lower bolts to make the heights even.

9
 Level Gauge
Level Gauge

Horizontal balance front and back Horizontal balance left to right

ASSEMBLY OF PERIPHERAL DEVICES

STAND ASSEMBLY
Detailed item connected with stand assembly desires to endure and offers ‘stand manual’.

10
 TABLE ASSEMBLY

1) When using the border frame, attach the table ⓑ

to the main body of the machine.

Table ⓑ

Table Screw

2) Attach the table ⓑ to the machine by inserting

the table supporting plate into the table pressing
plate as shown. When assembly is complete,
fasten it with the table fixing screw.

Table
ⓑ
Table Supportting Plate Table Pressing Plate
Table Screw

11
 DISASSEMBLING THE TABLE

1) Unscrew the fixing bolt and pull the table ⓑ

forward to disassemble it.

Table ⓑ

Table Screw

2) Attach the optional magnetic holder base to the

frame attachment plate as shown.

Screw

Magnetic
Embroidery Frame

Frame Connection Plate

Magnetic Holder Base

12
 TUBULAR TO BORDER FRAME CONVERSION

1) Disassemble the tubular attachment Plate from

the frame connection plate by unfastening the
fixing screws as shown.

Screw

Tubular Frame Attachment Frame

Connection
Plate

After removing the fixing screws, place them in a safe place to use when attaching
the tubular attachment.
CAUTION

2) Fasten the optional border frame to the

connection plate with the fixing screws. Tighten
Border frame
attachment Plus the screws snugly.
screw
Border frame

Frame
joint

13
 Installing Lamp (Optional)

1) Disassemble the cover on the left and install the

lamp as shown in the picture.

Lamp

14
 BORDER TO TUBULAR FRAME CONVERSION

1) Separate the border connection Plate from the

Border Frame frame connection plate by removing the fixing
Connection Plate
screws.
Screw

Border Frame

Frame
Connection
Plate

After removing the fixing screws, place them in a safe place to use when attaching
the tubular attachment.
CAUTION

2) Attach the tubular attachment plate to the frame

attachment with the fixing screws. Tighten the
screws snugly.

Plus screw

Tubular frame Frame joint

attachment

15
 CHAPTER 3
PARTS OF THE MACHINE

③
(21)
⑨ ⒕
⑩
⑧
④
⑦
⒃
①
⑭
⑥ ⒖ ⑬
⑤

⒔ ⑮

⒗
②

(22)

① Base ⑬ X-axis driving system

② Main power switch ⑭ X-axis pulse motor
③ Upper thread stand ⑮ Y-axis driving system
④ Main shaft drive motor ⒃ Y-axis pulse motor
⑤ Color change box ⒔ X/Y drive box
⑥ Arm ⒕ Encoder
⑦ Upper thread catcher ⒖ Joint circuit border
⑧ Head ⒗ Control box
⑨ Thread tension adjusting plate (21) Operation box
⑩ Lamp switch (22) Horizontal adjusting bolt
⑪ Cylinder bed
⑫ Table

16
 CHAPTER 4
FUNCTIONS AND FEATURES
1) EXPANDED MEMORY SIZE.
A maximum of 100 designs can be stored in your machine. The basic memory size is approximately
500,000 stitches. This can be expanded to two million stitches.

2) MIRROR IMAGE CONVERSION AND DESIGN DIRECTION

You can turn the design from one degree to 359 degrees. Your machine is also capable of mirror
conversion, reversing the design in the X and Y direction.

3) ENLARGING AND REDUCING THE DESIGN

The embroidery design can be reduced or enlarged in size from 50% to 200% along the X and Y axis in
increments of 1%.

4) AUTOMATIC SELECTION OF NEEDLE BAR

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

5) REPETITION OF DESIGNS
The same design can be repeated up to 99 times along the X and Y axis.

6) AUTOMATIC OFFSET
When the embroidery design is finished stitching, the frame automatically returns to the offset point to
make it easier to switch the frames.

7) MANUAL OFFSET
Appliques and switching frames during embroidery work is easier because the frame can be moved
manually to a point selected beforehand. After that, the frame can be moved back to its place by
pressing the proper keys.

8) RETURN TO START
The frame can be moved back to the beginning point of the design.

9) NON-STITCHING FUNCTION
The frame can be moved backward and forward in units of 1,100,1,000 and 10,000 stitches. The needle
bar can also be moved backward and forward by color without stitching.

10) FRAME REVERSAL

When the thread breaks or the needle becomes unthreaded, the frame can be moved in units of one to
ten stitches back to the beginning point of the design.

17
11) AUTOMATIC TRIMMING DEVICE
The trimming function is automatic, determined by the design and the setup of the machine.

12) AUTOMATIC DETECTION OF UPPER AND LOWER THREAD BREAKS

This device automatically stops the machine when the upper thread breaks, the thread pulls out of the
needle, or the bobbin thread runs out.

13) POWER FAILURE SAFEGUARDS

When the power fails unexpectedly, the frame moves to the exact point where the stitching stopped.
This can help reduce the number of product rejects.

14) 3.5 INCH FLOPPY DRIVE

A 3.5 inch floppy drive is included in the operation panel. Designs can be input by disks and can also be
saved to a disk in Tajima or SWF format. Both 2DD (Double-sided double density) and 2HD (Double-
sided high density) disks can be used.

15) EDITING
You can edit from the control panel. Stitch data and function code (jump, finish, trimming) can be
changed, inserted or deleted.

16) MACHINE STOPPAGE

The screen will indicate why the machine has stopped operating.

17) RPM
The revolutions per minute is indicated on the screen.

18) FRAME SPEED

The speed can be adjusted to high, medium and low.

19) MEMORY
The screen indicates how much memory remains.

20) TAPE CODE COMPATIBILITY

ZSK, and Barudan two binary tape code and Tajima three binary tape code can be edited.

21) CODES FROM OTHER MACHINE BRANDS

Various formats can be automatically edited from the floppy disks. These include SWF, Barudan,
Melco(EXP), Tajima, Happy, Toyota and ZSK.

18
 CHAPTER 5
BUTTON AND SWITCH OPERATION

EMERGENCY STOP BUTTON

Emergency Stop Switch

If you need to stop the machine due to something as simple as a thread break or as serious as hitting a frame,
press the EMERGENCY STOP button. The machine will stop immediately.

To restart the machine, rotate the main shaft to the 100 degree mark and then turn the EMERGENCY
STOP button to the right (see arrow in diagram).

19
ON/OFF BUTTON ON THREAD TENSION ADJUSTMENT
BOARD

OFF
ON
Thread detecting roller
Thread detection
delete

OFF
Lamp Toggle Switch
ON

For normal operation, press the ON/OFF button or throw the toggle switch to turn the machine on The light
will indicate that the machine is on. If you have a button, the light is in the button; if you have a toggle
switch, it is below the toggle switch

When the machine stops after a thread break is detected, you can move the frame backward to the location
of the thread break using the STOP button, and start the machine again to pick up the stitching. This is
essentially an edit of the design.

If you want to back the machine up for any reason when a thread break has NOT occurred, you must press
the ON/OFF switch twice. When the light is blinking, you can back up the machine to the desired location.

When an upper or lower thread break is detected the light on the head blinks. After fixing the thread and
backing up to the point of the break, press the START button to start stitching again.

On multi-head machines, you can turn one or more heads off by throwing the toggle switch to the off
position or pressing the ON/OFF button until the light goes off.

The take-up lever continues to operate even when the head is turned off. This
movement can cause the needles to become unthreaded. A rubber magnet bar
can be used to prevent the thread from pulling out of the needle.
NOTICE

20
 CHAPTER 6
THREADING AND TENSION
THE UPPER THREAD PATH

Thread guide
single screw

Thread guide spring

Thread guide
presser plate

Thread guide
base plate

Upper thread
(From thread stand)
Sub-tension
adjusting device
Thread tension
adjusting plate
Detecting roller
Thread take-up
spring stopper
Thread take-up spring

Rotary tension disk

Main-tension
adjusting device
Thread guide

Thread guide (Upper)

Thread Take-up lever

Thread guide (Middle)

Upper thread holder

Presser foot
Needle

21
 THREADING THE MACHINE

Wrap the thread around thread guide disk clockwise. Make sure
the thread falls between the tension discs.

Thread Guide Disk

(Pass through the
middle of shaft)

Wrap the thread around thread sensing roller one time.

Thread Sensing Roller

One turn

Wrap the thread 1.5 times around the main tensioner in the V-
groove between the rotary tension disks. Pass the thread through
the spiral thread guide, the upper and lower thread guide, up
through the eye of the thread take-up lever, down though the lower
thread guide and then down through the lower thread guide.

One and
half turn
Rotary Tension Disk

Place the upper thread between the upper thread holder ball of the
Thread Guide Thread
(Lower) Hook Spring thread guide (lower).

22
 TENSION CONTROL ON UPPER THREAD
Proper tension is an important factor in producing quality embroidery. If the upper tension is too loose,
looping and thread breaks may occur. If the tension is too tight, thread and needle breaks may occur as well
as puckering. A balance of 2/3 upper thread and 1/3 lower thread generally indicates good tension.

1) The upper thread tension is controlled by turning

the adjusting nut on the sub-tensions (pre- Adjusting nut
tensioners) and the main tension adjusting Sub tension
adjusting
device. Turn clockwise to increase the tension device
and counterclockwise to decrease the tension.

2) The sub-tension adjusters or pre-tensioners

should control about 2/3 of the tension while the
main tension adjusting units should handle the
other third. The pre-tensioners should be
adjusted so that the upper thread flows smoothly
through the disks and into the rollers of the main
tension adjusting units. The main tensioners are Main
tension
used to fine tune the tension. adjusting
device

You should have to use some force to pull the thread through the tension units if
adjusted correctly.
The tension should be around 100-120g.
WARNING

3) After the tension is adjusted on both the pre-tensioners and the main tension adjusting units, adjust the
tension settings on the pre-tensioners again if the tension is too light to allow for the upper thread flow.

Adjust the thread tension according to the type of thread used and target fabric.

WARNING

23
 TAKE-UP SPRING

The play between the pull of the upper thread by the

Thread tension take-up lever and the pull of the thread by the hook
adjusting
stud creates tension on the upper thread. If the tension of
the take-up spring is too tight, looping and loose
stitches may result.

If the tension of the take-up spring is too weak, and

the machine does not detect thread breaks, you can
increase the tension by turning the thread tension
adjusting stud clockwise.

If you want to change the relation between the

tension of the thread and the operating capacity of
the take-up lever, move the location of the take-up
spring detector to the right or left.

The take-up spring should touch the detector for

Take-up
spring proper thread break detection
detector

Thread
take-up
spring

Dirt, dust or other foreign material can accumulate

in the space shown, preventing the thread detector
from sensing the thread. Remove any accumulation
with crocus cloth, an emery board or other slightly
abrasive material.
Take-up spring
unable to connect
with thread detector
Our compact and newer systems use Wheel
Sensor for thread break detection. The older
systems use Spring Break Detection.

24
 BOBBIN THREADING AND TENSION ADJUSTMENT

Use cotton yarn (#80-#120) to wind your own

bobbins. You can also buy pre-wound bobbins in
cotton or polyester for use in your SWF machine.

Insert the bobbin into the bobbin case. Holding the

bobbin case in your left hand, place the bobbin in
3~4cm Lower thread
holder the case with the thread coming out in a toward the
right. Pull the thread across to the left under the
thread guide and pull it into the slot. Make sure the
Slot
thread pulls smoothly from the bobbin.
Adjusting screw

Trim the thread to 3-4 cm before inserting the

bobbin and case into the hook assembly. Long tails
Tension
spring
Bobbin can cause the bobbin thread to tangle when the
machine begins to stitch.
Thread guide

When holding the bobbin case in your left hand, the bobbin will turn clockwise
when you pull the thread.
NOTICE

Remove the bobbin thread from the pigtail and

jiggle the bobbin case lightly in an up and down
motion. The bobbin should come out of the bobbin
case and the case should drop about two inches Bobbin case
NOTICE
and then stop If you have a thread tension gauge,
set it to 25-35g.

25
 BOBBIN WINDER

Winding Lever

Winding Shaft

Insert the bobbin onto the shaft and wind the thread manually five or six times around the bobbin in the
desired direction. Press the lever to wind the thread.

Fill the bobbin 80% and make sure that the thread is
parallel to the bobbin.

80%

Be careful not to overfill the bobbin as this will interfere with the smooth flow of
the bobbin thread. Filling the bobbin to the recommended 80% capacity will
render approximately 80 cm of thread
CAUTION

You can adjust the amount of thread on the bobbin

by unfastening the screw of the adjusting plate and
moving it in a clockwise direction for more thread
and a counterclockwise direction for less thread.
After adjustment is completed, be sure to retighten
the adjusting plate screw.

Adjusting Plate

26
 For proper winding, the spool or cone of thread and
the bobbin being filled by that thread should be
parallel with each other. If this is not the case,
unfasten the nuts on the bobbin winder and adjust
the body of the bobbin winder until they are parallel.
Thread
Guide Body
Joint Screw

If the bobbin thread is wound off-center or uneven, as seen in these examples,

you may experience thread breaks, skipped stitches or birdnesting.

CAUTION

If the bobbin thread is wound too tight and the thread does not release smoothly,
you may experience thread breaks or short tails on the bobbin after trimming.
CAUTION

Rotation of the bobbin winder may become slower

Wrench(2.5mm)
with use. The joint screw of the winding wheel is set
so that it can be adjusted from 100 to 190 degrees.
Winding Wheel
Unscrew the joint screw of the winding wheel with
a wrench, move the winding wheel forward the
desired degree(s) and then refasten the joint screw
securely.

27
 CHAPTER 7
THE NEEDLE, THE HOOK AND THE
STITCHES

STITCH FORMATION

Understanding how a stitch is formed will help you understand hook timing and teach you to recognize
quality embroidery. It will also help you better understand the importance of tension and the roles the
different parts of the machine play in creating that tension and stitch. Stitch formation is the foundation of all
sewing; it is the same on all machines that sew.

The needle moves down, and when it reaches the lowest point, the thread slips into the groove of the needle,
protecting it from any friction generated between the needle and the fabric. (This is a very good reason to
make sure your thread passes through ALL guides and clips on the way to the eye of the needle!)

When the thread is pressed between the body of the needle and the fabric, a loop is formed with the thread.
(Different loops are formed, depending on the thread characteristics, needle shape and the type of fabric.
Unstable loops, a result of wrong needle/thread, needle/fabric or thread/fabric combinations can result in
skipped stitches.)

The point of the hook then approaches and penetrates the loop, enlarging it. The hook point should be
positioned as close to the needle as possible so the hook point can be located inside the formed loop,
allowing a stable locking of the thread.

The top thread then encircles the bobbin thread and a knot is formed, locking the top thread to the bobbin
thread. This knot or stitch is drawn into the fabric by the take up lever, which rising to its highest point,
tightens the thread with the help of the upper and lower thread tensions.

When the needle returns to the highest point, it begins the downward journey and the process begins again.

28
 THE NEEDLE AND HOOK

THE NEEDLE
The needle is a slender piece of steel with an
opening for thread called the eye and a point for
Needle Groove piercing fabric so the thread can pass thought the
fabric on the way to the bobbin housing. The needle
and thread not only need to pierce the substrate, but
Needle Eye also form the loop that helps create the stitch in the
correct place which is in the hook assembly.

The proper needle will get the thread where it needs

Scarf to be when that loop is formed. If the eye of your
needle is too big, your embroidery may look untidy.
If the loop is too small, the thread may break or fray
or, worse, make it look scuffed and worn.
Heavier fabrics need heavier needles to avoid deflection which causes breaks which can knock the timing
off. A delicate fabric needs a thinner blade to avoid destroying the fabric.

Take a two foot section of thread. Thread your needle on it and raise and lower
the ends. The thread should move easily through the eye.
TIP

Needle size should conform to the thread weight. 40 weight thread, the most commonly used, calls for
approximately a 75/11 size needle. For normal embroidery use a DB×K5 needle. DB×K5 is a needle with
a reinforced blade and a larger eye that is used for most fabrics. It also has a longer groove to cradle the
thread on the way down which guards against fraying. The longer scarf allows for a more forgiving
registration process.

Mark your needle and case with a marker so you can tell at a glance which they
are.
TIP

Sharp points tend to damage fibers at high speeds. Less lint is produced when there is less fabric damage.
On heavy fabric and cap seams, a sharp needle works best. Sharps are best with small lettering. They create
a crisper letter. A longer needle with a larger eye is available for metallics, reducing thread breaks and frays
due to drag on the thread through the small oval eyes.

29
Machine embroidery needles come in sharp points for piercing heavy, tightly woven fabric and ball points,
which glide between the fibers of the knits.

The size of yarn being pushed aside with the ball point determines the size of the needle. Light ball points
(SES) are good for polo shirts, medium points (SUK) are good for fleece. The SKF or heavy ball point is
seldom used except for elastic goods.

You should always select the proper needle for the job. The target material and the thread help determine the
needle to be used for the job. If the proper needle is not used problems, including but not limited to looping,
and thread breaks, can occur. Most materials call for ball point needles.

Needles are classified by system type, blade size, and type of point. Blade sizes range from 60/8 to 110/18
depending on the system.

Place your commonly used threads on the thread posts that are hardest to access-
in the center of the rack. Place the colors you change most often on the posts that
are easiest to reach. Consider keeping different size needles in a multi-needle
machine. Put ballpoints in half and sharps in half to be ready for all jobs. You
TIP
can place threads used in a job on neighboring needles to minimize machine
movement between colors.

Keep a large eye needle for metallic thread on the machine at all times. You can designate needles
for different thread weights as well. For faster production work, thread jobs on neighboring
needles to minimize machine movements between colors.

Combine cotton bobbin thread and a small sharp needle with 60 weight thread for sharp, crisp
lettering.

30
 CHANGING THE NEEDLE
Make sure that the needle is clear of the needle plate before attempting to change it. If the needle is not clear
of the needle plate, use the hand wheel to raise the needle.

Needle
Needle Plate
Hand Wheel

STOP THE MACHINE BEFORE TURNING THE HAND WHEEL MANUALLY.

CAUTION

Needle Insert Hole When inserting the needle, be sure that the groove is
in the front and the scarf in the back. Improper
insertion of the needle will prevent the machine
from stitching correctly. A toothpick or other non-
metal item can be used to hold it straight while
tightening the set screw. The shaft of the needle
Needle Groove should be inserted completely into the needle bar.

If the needle is not inserted all the way to the top of the needle bar hole, the
timing of the machine will be off. Broken needles and thread breaks can result.
CAUTION

Turning the needle slightly to the right at a very

slight angle can help the point of the hook catch the
thread with greater ease during the formation of the
stitch. This is particularly helpful when using
specialty threads.

31
 RELATIONSHIP BETWEEN NEEDLE AND HOOK
The relationship between the needle and the hook is called timing. Timing between the needle and the hook
is correct when the main shaft is 200 degrees.

It is a good idea to use a Size 11 needle when adjusting the timing. Although
needle size increases toward the front – the scarf and the back dimension
remaining the same – it is just good insurance to use this popular size, and use it
TIP each for each timing procedure.

THE ROTATING HOOK ASSEMBLY

The hook assembly, located beneath the throat plate, is the home of the bobbin case and bobbin. The inside
of the hook assembly is called the basket, and is surrounded by the assembly raceway. The basket cradles the
bobbin in the case after it has been placed on the shaft of the hook assembly.

The hook assembly has a hook point that is used by the sewing head to lock the top thread to the bobbin
thread to form the stitch. As the machine is sewing, the bobbin in the case and the needle moves with the
point of the hook. The timing of the passage of the hook point and the point of the needle is extremely
important. If the hook approaches the loop too early, the hook point will not intercept the loop. The loop will
be formed after the hook point has passed the needle, which will result in skipped stitches, and broken
thread. If the hook approaches the loop too late, the loop will not be available when the hook point reaches
the needle. Again, skipped stitches and broken thread will be the result.

Gap of Hook

The hook can move from the right to the left

according to the allowance of the lower shaft gear.
When the timing is correct, there is no movement
CAUTION when turning the hook clockwise.

32
 Upper Point of Hook Point
Hook Circumference Top Edge of Needle Eye Hook Point
Top Edge of
Needle Eye
Needle Tip c
a
b

Lowest Point of
Needle Stroke

The eye of the needle should be just below the point of the hook(b,c). The eye should look like a teardrop
hanging from the point of the hook. If the eye is above or below, the needle bar may need adjusting. If the
needle bar is too high, the loop will be formed above the hook point : too low, and the loop will form below
the hook point. In both cases, skipped stitches will result. Needle bar height (a) rarely changes unless you
crash a hoop. If one needle on a head is skipping stitches, needle bar height is most likely the culprit. If all
are skipping, check the hook timing. Before you do anything change the needle, check the thread path and
clean the bobbin case.

The point of the hook should be directly behind the

Hook Point needle. The gap between the point and the scarf of
the needle (indentation on the back of the shaft)
should be between 0.1 and 0.3 mm. A good test is to
run a piece of paper between the needle and point of
the hook. One piece of paper should fit with no
deflection. Two pieces of paper, however, should
0.1~0.3mm
deflect the needle. This measurement is important
because if the hook passes too close to the needle,
broken needles can result as well as broken thread
and damaged hooks. If the hook passes too far from
the needle, skipped stitches may result, as the hook
point may not penetrate each loop that is formed. lf it
is far enough away, there will be no stitches formed
at all.

33
 The size of the eye of the needle-and the size of the
needle groove varies-between different sizes of
Needle Groove needles.

The front groove of the needle cradles the thread

and protects it from the heat of sewing friction
Needle Eye
(which can result in thread breaks.).

The back groove of the needle (scarf) helps regulate

the hook timing and prevent looping. Prevention of
Scarf
looping is important for quality stitching, so the
hook point should be adjusted as close to the needle
as possible to achieve perfect thread position while
sewing.

If thread breaks or thread movement occurs, turn the

needle slightly to the right. This helps to form a
good loop as the very slight angle can help the point
of the hook catch the thread with greater ease during
the formation of the stitch.

Hook Point Hook Point

Cotton Loop

Synthetic Loop

As we have learned, when a stitch is formed, it makes a loop. The loop size may vary depending on the
thread selection. Cotton forms a much tighter loop then synthetic thread. Loop formation can compromise the
quality of your embroidery. The synthetic threads are polyester and rayon. Polyester has a greater elongation
factor than rayon or cotton, meaning that it can be stretched more before returning to its original position and
so creates a larger loop. Tightening the top tension when using polyester thread can eliminate the looping.

34
 RELATIONSHIP BETWEEN TAKE-UP LEVER AND HOOK

The following pictures show the location of hook when the take-up lever starts to move up from the lower
dead stop (main shaft rotation angle: 295°).

In case of fast hook timing When the hook timing falls in the A range (see
illustration below) the loop will be too small. Stitch
formation will take place faster than the upward
movement of the take-up lever. The thread will be
too loose and looping and skipped stitches will
occur.

Too
small

In case of slow hook timing If the hook timing falls in the B range (see below),
the hook point will catch the thread when the loop is
too big. This will cause thread breaks since the
upward movement of the take-up lever is faster then
the rate at which the thread comes off the hook.

Too
Large

When the hook timing is correct, the

hook should move within the C range.
CAUTION
(B)

(C)
(A)

35
 THREAD –BREAK DETECTING UNIT
The thread-break detecting unit contains rollers which sense the smooth rotation of the thread which
determines if there has been a break in the upper or lower thread. Any dust, thread remnants, etc. will
interfere with the roller’s rotation and prevent detection of broken thread. Therefore, It is important to
always keep the rollers and bush bearings clean and free of dust and dirt.

To clean the thread-break detecting unit, remove the cover of the thread tension adjusting plate, separate the
cables and unscrew the roller base joint screw.

Use a soft brush of canned air to clean the rollers and bush bearings and then reassemble the unit.

Film

Bush Bearing
Roller Base Screw
Roller Base
Thread Detecting
Roller

Be sure to place the thread detecting board in the correct position or the unit will
not operate.
NOTICE

36
 CHAPTER 8
MAINTENANCE AND INSPECTION

CHECK POINTS FOR REGULAR INSPECTIONS

Observe the machine safety and electrical rules during inspections.

Before inspecting or cleaning, turn the machine power off.
Use a compressor to clean each part.
CAUTION

1) Clean, oil and grease the recommended points and parts on a regular basis.
2) Inspect the tension of each drive belt.
3) The following problems can occur if the machine is not inspected regularly.
* Corrosion of P/C circuit board
* Damage on semi-conductor of the P/C circuit board
* Abnormal operation of the floppy disk drive.
* Defective connecter contacts.
* Insufficient oil and grease can cause abnormal wear on machine parts.

CLEANING
Use a compressor to clean the machine.

Clean around the hook every day.

Hook

37
 Sun Star is not responsible for machine damages or malfunctions caused by
insufficient or irregular cleaning or oiling.
CAUTION

Turn OFF the main power before inspecting or cleaning of the following parts.
Adjust your cleaning cycle to the environment and conditions of your machine.
CAUTION

Guide rail for thread take-up lever. Clean once a

week.

② Guide Rail
for Thread
Take-Up Lever

Movable and fixed blades. Clean once or twice a

week. To clean, remove the needle plate and then
pull the movable blade forward as shown. Clean,
and then reassemble. Take note of the order the
parts are removed so you can replace correctly.

Fixed
Blade

Movable Blade

38
 OIL SUPPLY

Turn OFF the machine when oiling.

CAUTION

Sun Star is not responsible for machine damages or wear-outs caused by

insufficient oiling.
CAUTION

The main power should be off while oiling the machine.

Excessive oil can stain thread and fabrics.
After oiling, run the machine without stitching for 2 or 3 minutes.
CAUTION Avoid excess oil in the hook as this will cause trimming problems.

WHERE TO OIL
Use sewing machine oil(Spindle Oil) or VG18 of ISO.

Oil Tank
Once every two weeks or when the oil falls below
the red line of the oil tank window. ①

Needle Bar and Needle Bar Drive Shaft.

①
Oil once a week. ②

39
 Three Oil Holes in Bed Cover
Oil once every three days. ③
③

RACEWAY
Place a small amount of oil on the raceway of the
hook assemble after removing the bobbin case. ④
Race Part
④ Oiling cycle: once after 3-4 hours of operation

Hook
Bobbin Case

Blades
Oil the juncture of the movable blade and the fixed
blade in the trimming area. ⑤

Oiling cycle: once every 2-3 weeks

40
2) Oiling the Arm

Use the oiling device to oil each part of the arm. Do not overfill the tank.

• upper shaft bushing • presser foot drive lever shaft

• needle bar crank rod • needle bar lever
• needle bar and controller • presser foot shaft
• take-up lever drive lever shaft

Oil hole

41
 GREASE SUPPLY

The main power should be off while greasing the machine.

Use lithium grease made of high quality mineral oil.
Greasing the machine decreases noise and prevents wear.
CAUTION

Inside of the arm, the take-up lever drive cam, the main part of the take-up lever, the needle bar reciprocator,
the presser foot drive shaft, the color change cam, and the blade cam (①, ②, ③, ④, ⑤, ⑥) should be
cleaned and greased once every three months.

②
⑤
④

①
③

42
 The main power should be off while greasing the machine.
Be sure to apply the grease only to the parts indicated.
Use lithium-type grease (JIS No.2) Albania No.2.
CAUTION

X-axis LM Guide. Grease once a month.

Y-axis Rail Guide (2 on left and 2 on right). Grease

once a month.
①

Head Drive-LM Guide. Grease once a month.

43
 CHAPTER 9
MACHINE ADJUSTMENTS

Turn the power to the machine off before adjusting the machine.
After an automatic or manual thread cutting signal, the movable blade, started
by the thread cutting cam, approaches at a set angle.
WARNING

Blade Lever
ADJUSTING THE TRIMMERS
Stopper Screw
To check the position of the thread cutting lever
Blade Lever Stopper
stopper, insert the roller into the blade cam with the
thread cutting solenoid manual handle at the 100
degree position. Make sure the thread cutting lever
is close to the blade cutting stopper. Unfasten the
screw and change the position.

Blade Lever
Solenoid Manual
Handle

ADJUSTING THE MOVABLE BLADE

Blade Driving Lever
(Upper)
To adjust the approach angle of the movable blade,
M4×P0.7
Tap
first check its position. The cutting point should be
about 1mm inside the tip of the fixed blade. If the
movable blade is not adjusted correctly, upper thread
breaks or incorrect cuts can occur. If the position of
the movable blade is incorrect, loosen the upper screw
on the thread cutting drive lever and adjust the blade
Cutting Point manually. When the blade is adjusted correctly, tighen
Fixed Blade the upper screw firmly on the thread cutting drive
Movable Blade
lever. Check that the upper and lower thread cutting
drive lever can move easily with no movement of the
thread cutting lever shaft bracket.

44
 ADJUSTING THE ANGLE OF THE MOV-
ABLE BLADE
Blade Cam Screw
To adjust the entrance angle of the movable blade,
Blade Cam
unfasten the two blade screws to set the upper shaft
rotary angle at 295 degrees using the hand pulley.
Insert a roller into the blade cam by turning the
trimming solenoid manual. Then turn the mes cam.
Blade Cam When the roller aligns with the curving line of the
Roller
cam, tighten the blade cam bolts. Make sure the
movable blade enters at operates at an angle of 295
Solenoid Knob degrees.

ADJUSTING THE TENSION OF THE FIXED

AND MOVABLE BLADE
Movable Blade
After changing or repairing the movable and fixed
blade, check the tension of the blades as they cross
by moving the blade manually. Cut the upper thread
and check the thread. To adjust, use the tension
Tension adjusting bolt of the fixed blade. Move the movable
Adjusting
Screw blade manually until it is parallel with the cutting
line of the fixed blade from the entering point to the
returning position.

Fixed Blade

Make sure that the tension of the movable blade is correct. If it is too tight, the
trimmers will not operate correctly and this incorrect tension will wear the
blade. Be sure to clean this area of the machine often since thread trimmings
CAUTION accumulate.

45
 ADJUSTING THE TRIMMER RETURN
SPRING
Thread Return Spring
The Trimming Return Spring helps the movable
blade to return to its original position after
Spring Shaft Screw trimming. If the machine is operated with the
movable blade in an incorrect position the movable
blade or the needle may be damaged.

To adjust the trimming return spring, unfasten the

spring shaft screw so that the gap between where the
bolt is attached to the surface and the center of the
Nut spring is 12mm. Turn the spring holder to adjust the
tension of the spring and then refasten the screw. Turn
the spring holder clockwise to increase the tension and
counter-clockwise to decrease the tension.

PICKER ADJUSTMENT
If the position or the starting height of the picker is incorrect, the machine may not be able to separate the
upper and the lower thread and cut them both, resulting in short upper thread.

1) Adjusting the picker position

Manually move the picker so it touches the bobbin. Using the picker screws, adjust so the tip of the
picker is in the correct position as in [Fig.11-5].

correct position
of the picker

Picker

Picker screw
Bobbin case

46
2) Adjusting the starting height
Loosen the screw for the picker stopper and adjust the picker to be 0.2~0.5mm apart from the bobbin
when the picker is pressed. Make left and right adjustments for the picker stopper. When all the
adjustments are done, tighten the screw for the picker stopper.

Picker

Picker stopper

3) Adjusting picker standby position

Unfasten the screws on the picker solenoid cover. Adjust the position of the solenoid cover so that the tip
of the picker is around 20mm away from the bobbin.

After adjusting the picker standby position, check if the bobbin case moves
smoothly.
CAUTION

Screws on the picker solenoid cover

Picker solenoid

47
 Screw on the base of the
upper thread holder

Motor shaft link lever Screw on the upper

thread holder base

Screw on the upper thread

holder bracket

Upper thread holder bracket

Upper thread holder

UPPER THREAD TENSION ADJUSTING PLATE

Press the Motor shaft link lever by hand, unscrew the holding screw of the upper thread pick up base and
then adjust the upper thread base where the hook passes the center of the needle. Unfasten the bracket joint
screw and refasten it so that the upper thread is picked up smoothly. Use the color change function to check
each needle bar, assuring that the thread pick up action is smooth on each one.

48
 When adjusting the small driving lever, be sure there is no movement at the axis
where the driving lever and the arm attach.
CAUTION

ADJUSTING THE PRESSER FOOT FOR MINIMAL NOISE

1) Unscrew all the jointed screws of the presser foot driving cam and the small driving lever. Turn the hand
wheel until the needle bar is at the lowest point(180 degrees/white bolt). Turn the cam and when the
roller is located at the outer part of the arm, refasten the joint screw of the small driving lever snugly.

Cam ① Screw Driving Lever(Small) Screw Driving Lever(Small)

Cam

Roller

Cam
Roller

Cam ② Screw
Arm

2) Turn the hand wheel to 100 degrees(black bolt).

Presser Foot Stopper Presser Foot Holder
Turn the cam until the presser foot holder is on
Presser Foot
Reciprocator Bracket the rubber of the presser foot stopper, and then
fasten the joint screw of the cam tightly.

Presser Foot Reciprocator

49
 ADJUSTING THE HEIGHT OF THE PRESSER
FOOT

Presser Foot Holder Use the hand wheel to check what the relation
between the presser foot and the needle will be
when embroidering. Set the needle bar to 180
Screw
degrees. Remove the plate on the sides and loosen
the joint screw of the presser foot. Adjust the space
Washer
between the bottom of the presser foot and the upper
part of the needle plate to accomodate the material
being embroidered (K). Refasten the joint screw
snugly. Repeat for each presser foot.
Presser Foot

Needle

Standard Setting Value

Needle plate for cap = 1.5mm
Needle plate for flats(tubular) = 1mm

50
RELATIONSHIP BETWEEN PRESSER FOOT AND NEEDLE

The presser foot should be touching the material

being embroidered before the needle enters it. This
gives a stable target for the needle and the upper
thread. It also ensures that if the needle comes out
the fabric for any reason the pressure foot and the
Presser Foot
Needle Needle needle location are aligned with the needle insertion
Deviate Insert
point.
Embroidery
Material

Needle
Plate

If the presser foot is too high, the needle will

penetrate what is essentially an unstable target,
causing flagging (movement of the fabric against the
throat plate)which can result in broken thread and
birdnesting(the term used to describe the collection
of unwanted thread beneath the throat plate.)
Needle
Insert

If the presser foot does not touch the fabric, it can

be lifted by the exit motion of the needle, creating a
space between the fabric and the needle plate. This
can cause thread breaks, skipped stitches and other
problems.

Needle
Deviate

51
 Color changes must be done when the upper shaft angle is at 100 degrees. If the
needle is not in the center of the needle hole after adjustment, contact your
machine distributor for repair.
CAUTION

Color Change Adjustment

When the machine changes needles (color change) the needle should be in the center of the needle hole. If it
is not, manually adjust the cam so that the roller is located on the right center of the straight line of the cam.
Open the cover of the half turn sensor and adjust so that the center is lined up with the center of the half-turn
film.

Half-Turn Sensor
Half-Turn Film

Half-Turn Sensor

Color Change Cam

52
ENCODER ADJUSTMENT

If the needle bar gets stuck, adjust the encoder position. For a fine adjustment, unfasten the two screws of
the encoder coupling. Turn the hand wheel manually to 98 degrees. If the stop position light is red after this
adjustment, refasten the two screws snugly.

If the encoder coupling can’t be moved, loosen the two encoder screws and turn the hand wheel to 98
degrees. Adjust the encoder according to the illustration below. When the stop position light on the operation
box is red, refasten the encoder screws snugly.

Hand Wheel

Screw of Encoder
Screw of Encorder Coupling

53
JUMP SOLENOID ADJUSTMENT

If the jump solenoid is not functioning correctly or

Nut needs to be replaced, release the solenoid nut with
wrench included in the accessories kit. The
Needle Bar measurement between the bracket projection to the
Reciprocator
solenoid should be 3.5mm.

If the solenoid projects too far, the needle bar will

not move or it will catch. If it does not project far
Jump
Solenoid enough the needle bar reciprocator will not move
correctly.

Bracket

When assembling the bracket, solenoid and base

Jump Solenoid plate, adjust the distance of the arm to the bracket
section to 1mm. Fasten with the bracket joint screw.

Arm If the installation position is incorrect and the needle

Section
bar reciprocator touches the needle bar when
Bracket
jumping, bend the needle bar slightly to adjust.
1mm

Screw of Bracket

54
ADJUSTMENT OF DRIVE BELT TENSION

The main power should be off when adjusting drive belt tensions.
When drive belt tension adjustments are needed, contact your service technician
as the loss of tension will adversely affect the quality of embroidery as well as the
CAUTION operation of the machine.

Tension Adjustment Specifications

Model Name : U-305 Series – Standard
Phonometry Belt Tester
Manufacturer : UNITTA

TIMING BELT OF Y-AXIS

Check the belt with a sound wave tension meter. Pluck the end of the X drive at the center of the belt with a
finger or tool and then adjust the Y-axis belt to 30~32 kgf. The input data should be :

Weight : 003.8gf/m
Width : 015.0mm/#R
Span : 0540mm

Release the tension base fixing bolts and turn the tension adjusting bolt to achieve the proper tension.
Turning the bolt clockwise increases the belt tension. Turning it counter-clockwise decreases the tension.

X-Drive
Tension Drive Pulley
Adjusting Bolt Driven Pulley

Tension Base Bolt

55
TIMING BELT OF X-AXIS

Move the frame fixing plate on the right side to the end, then use the phonometry belt tension tester. Pluck
the center of the X drive belt with a finger or tool and then adjust the X-axis belt to 10~11kgf. The input data
should be :

Weight : 003.8gf/m
Width : 015.0mm/#R
Span : 0577mm

Release the tension base fixing bolts and turn the tension adjusting bolt to achieve the proper tension.
Turning the bolt clockwise increases the belt tension. Turning it countercolckwise decreases the tension.

Tension Adjusting Nut

Tension Adjusting Bolt

Adjusting Nut X-Frame Fixing Plate

56
 CHAPTER 10
TROUBLESHOOTING

PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Machine fails to Decrease of tension on belt. Adjust the tension or

operate correctly. replace the belt.

Main power shortage. Check the F1 fuse on the Confirm correct fuse size
controller box and replace if and voltage.
necessary.

Machine fails to sense Change needle bar manually

needle position. check the color change by
turning on the signal light
on the normal needle
position, then adjust the
half-turn film.

The frame moved out of X Correct start point of

or Y limits (limit set). embroidery (manually move
the frame so the design
comes into the limit).

Bad connection of power Check and firmly plug the

supply box. connector.

Machine stops with Decrease in tension on main Adjust belt tension.

needle in incorrect drive belt.
position.
Incorrect encoder position Adjust position of encoder
or bad encoder. or replace it.

Incorrect color change. Machine stops with needle Manually change the needle After moving the shaft
in incorrect position. bar position. manually to clean, check
and repair, turn the main
shaft angle back to the
normal position (100
degrees).

57
 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Incorrect color change. Machine does not sense Perform the color change
one-time turning signal of manually then readjust the
needle position. half-turn film.

Incorrect needle for Adjust the needle bar.

position.

Incorrect take-up lever Adjust the take-up lever so Loosen the screw of the
position. it is even with the other take-up lever drive and
levers at the stopping adjust its position so it is
position(main rotary shaft even with the other levers
angle is 100 degrees). on the take-up lever guide
rail, then refasten the screw.

Loose connection or the Replace the F3 fuse in the Confirm correct fuse size
color change motor fuse has power board. Check for and voltage.
blown. loose connections.

Upper thread not Defective rotation of thread Disassemble thread

detected. detecting roller. detecting roller, clean the
gauge and bush bearing.

Poor connection on the Verify that the connection

thread tension adjusting on the tension plate is
plate. working. If not, replace the
circuit board.

58
 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Bad jump Short circuit in fuse of Replace F3 fuse on the Confirm correct fuse size
jumping circuit. power board. and voltage.

Failure of or short circuit in Correct short circuit on

the solenoid wiring. wiring or replace the
solenoid.

Loose connection. Check connection.

Switch failure on thread Replace switch and circuit

tension adjusting plate and board.
circuit board.

Poor stitching quality. Poorly digitized design. Digitize design correctly.

Incorrect X or Y belt tension. Adjust tension.

Foreign substance on X or Clean the rail.

Y rail.

Failure of X/Y circuit board. Replace circuit board.

Embroidery frame/materials Lower the machine speed.

are unusually heavy.

Frequent thread Stitches are too short. Edit design to eliminate

breaks. short stitches.

Thread breaks at the same Digitize the design again

place in the design. and correct the problem
area.

Needle too small or large Use proper needle for the

for the thread selected. thread.

Needle is damaged, bent, Replace the needle.

worn or the eye has a nick
or burr.

Needle is installed Reinstall needle.

incorrectly(height or
orientation).

Needle is dirty from Clean the needle and hook Use minimum adhesive.
adhesive or sticky backing. assembly or replace the
needle.

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 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Frequent thread Poor quality or old thread Use good quality thread. Choose quality thread and
breaks. (uneven poorly twisted, or store it away from sunlight
poorly wound.) and dust.

Using S-twisted thread. Use Z-twisted thread.

The rotary hook rotates
counterclockwise so Z-
twisted thread prevents the
upper thread from
unraveling.

Z-twisted thread(twisted to
the left)
S-twisted thread(twisted to
the right)

Z-twist prevents unraveling

of thread in the
counterclockwise rotation
of the hook

Upper thread tension is too Adjust tension.

tight.

Upper and lower thread not Adjust tension.

adjusted correctly in
relationship to each other.

Spring tension is too tight or Adjust spring tension and

take-up lever is not adjusted take-up lever.
correctly.

Damaged hook or bobbin Use crocus cloth to remove Check rotary hook.
case. any nicks and scratches or
replace the damaged part(s).

Distance between the hook Adjust the distance. * Correct distance for smooth
and the groove of the passing of upper thread is
needles is too narrow. 0.5~0.7mm.
m
7m
.5~0.
0

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 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Frequent thread Not enough oil in the hook. Oil the raceway of the hook
breaks. assembly.

Timing between the needle Adjust the timing.

and the hook is incorrect.

Incorrect lower dead stop Readjust lower dead stop on

on the needle bar. the needle bar.

Thread is damaged on its Check the presser foot

way through the thread where the thread passes, the
path. needle hole on the throat
plate, the thread guides on
the sewing head and the
tension discs for nicks and
burrs.

Too much movement in the Correct hooped material so

material in the embroidery it is held taut for stitching.
hoop.

Incorrect presser foot Adjust the height of the

height. presser foot.

Skipped stitches. The needle is bent. Change the needle.

Incorrect needle size for Change the needle or use a

thread. different thread.

The needle is installed Install needle correctly.

incorrectly.

Timing between the needle Readjust the timing between

and the hook is incorrect. the needle and hook.

Too much distance between Adjust the distance between

the groove of the needle and the needle and the hook
the point of the hook. point.

Incorrect lower dead stop Readjust the lower dead

on needle. stop on the needle.

Damage to the point of the Use crocus cloth to smooth

hook. out the point of the hook or
replace the hook.

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 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Skipped stitches. Frequent stops in the supply Readjust the upper and
of the upper and lower lower thread tension.
thread.
If the problem is only on the
lower thread. Replace the
bobbin or the bobbin case.

The thread is too thick or Select the proper thread for

has too much stretch. the job.

Take-up spring is adjusted Adjust the take-up spring

incorrectly resulting in stroke and tension.
tension that is too tight.

Fabric moves in the hoop Replace the tension spring

when the needle enters or on the presser foot.
exits because the tension of
the presser foot is too weak
or the tension spring on the
presser foot is damaged.

Stitches pull out of Upper thread tension is too Adjust upper thread tension.
material. loose.

Upper thread is dirty which Clean discs of the pre-

is affecting the tension. and main tensioners.

Lower thread tension is too Adjust bobbin thread

loose. tension.

Uneven bobbin tension. Clean the bobbin case,

being careful to clean any
lint from under the
adjustment spring.

Thread is too thick. Use good quality thread.

Incorrect timing between Adjust the timing.

the needle and the hook.

Not enough oil in the Oil the raceway of the hook

raceway of the hook. assembly.

Needle Breaks. Needle is bent. Replace the needle.

Needle is poor quality. Buy good needle.

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 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Needle Breaks. Tip of the needle is dull, Replace the needle.

worn or damaged.

Needle is wrong size for the Use proper needle size.

thread.

Needle and hook point are Adjust the distance between

touching. the hook point and the
needle.

Needle is installed Install the needle correctly.

incorrectly.

Needle is striking the throat Make sure the screws on the

plate. needle plate are snug.
Check the position of the
needle bar to be sure that
the needle is centered in the
hole of the plate.

Puckering. Upper and lower thread Adjust the tensions. The size of the needle hole
tension is too tight. in the throat plate is 2.0mm
and the standard needle and
Presser foot is not adjusted Loosen tension of presser thread is :
correctly. foot spring. Cotton thread : #50-70
Silk thread : #75-120
Needle is damaged, dull or Change the needle. Needle DB×K5#9-14
the wrong size. Rayon thread : #30-60
Polyester thread : #40
Hole in the throat plate is Use the proper size needle.
too small for the size of the
needle.

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 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Short upper thread Short circuit of fuse on the Replace the F2 fuse on the Confirm correct fuse size
after trimming due to cutting circuit. power board first. Then the and voltage.
separation failure. F3.

Failed connection on Replace the connection on

terminal or solenoid. the cutting solenoid.

Solenoid failure. Replace the solenoid.

Broken TR cutting driver. Replace the power board.

Thread pulls out When the upper thread is Adjust the upper thread
before it is cut. too short, check the tension. tension.

Check for damage on the Remove the damage on the

movable blade. movable blade using fine
sandpaper or crocus cloth.

If the lower (bobbin) thread Adjust or replace the

is too short, check that the tension spring of the bobbin Area to check for damage.
thread is coming off the case. Remove any dirt or
bobbin easily. Use quality foreign materials in the
bobbins to ensure the thread thread guide of the bobbin
is not too weak or does not case. Change the bobbin.
stretch too much.

If the lower thread is too

short when the trim is made,
the first stitch after the trim
will not form.

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 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Upper thread comes Upper thread has been Check upper thread tension. The default tail length is
out of the eye of the trimmed too short. Medium.
needle after the trim.
Upper thread tail is above Set the length of the thread
the throat plate after cutting. tails to Long or Medium on
the control panel.

Remove any foreign

substance in the Velcro strip
that may be causing the
thread to break.

Tread is not cutting The movable and fixed Check the fastening screw
on one of the heads. blades are not working. of the movable blade, the
crank of the movable blade,
the driving clamp and the
connection of fastening
screw.

The cross tension of the Adjust the tension of the

movable blade and the fixed fixed screw.
blade is too loose.

The movable blade is Replace the movable blade.

broken.

The movable blade does not Adjust the position of the

return to its correct position. movable blade.

No solenoid Short circuit of the fuse. Replace F4 fuse in the Confirm correct fuse size
operation of the (when all heads operate power board if required. and voltage.
upper thread catcher. incorrectly)

Malfunction of the solenoid Check solenoid terminal

wiring or the solenoid itself. connection and/or replace
the solenoid.

Malfunction of circuit disc. Replace thread sensor disc

on pre-tensioner (thread
sub-controller).

Bad connection Check connection

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 PROBLEM PROBABLE CAUSE REMEDY TIP or PAGE

Upper thread catcher Upper thread catcher stroke Adjust reach of upper
malfunction. is too short. thread catcher.

Upper thread catcher is Remove the reason for the

overloaded. overload.

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 CHAPTER 11
NEEDLE CHART

FABRIC NEEDLE SIZE POINT

Fine Knitwear 75/11 BALL

Woven Fabrics 70/10 SHARP

Denim-light/medium 75/11 SHARP

Terry 75/11 SHARP

Densely Woven 80/12 SHARP

Silk 65/9 SHARP

Coated Fabrics/Cordura 80/12 SHARP

Vinyl 75/11 SHARP

Leather 75/11 SHARP

Caps-Woven, Corduroy 75/11 or 80/12 SHARP

Fleece 75/11 or 80/12 BALL

Knitwear/ Jersey 75/11 BALL

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 CHAPTER 12
BACKING

Backings fall into three categories: tearaway, cutaway and specialty.

Tearaway is a logical choice for many jobs and does not require scissors for removal-a safety feature for
beginning embroiderers. Tearaways range in weight from one to three ounces per yard. A good tearaway is
stable enough to stand up to multiple needle penetrations as well as tear well both directions.Tearaways that
can be torn in only one direction can result in distortion of the embroidered design and unsightly remnants of
the backing, which then must be cut away. Having to cut a tearaway negates one of the benefits of using the
product. Delicate fabrics and designs demand a quality tearaway as longer stitches and fragile textiles should
not be pulled roughly. Tear the backing away from the stitches as closely as possible; if you use two layers
of tearaway, tear them away one at a time to avoid distortion. On delicate and stretch knit fabrics, use
tearaway with caution-but on swimsuits and socks, tearaway should be used. The two layer trick works well
on these stretchy items but pull it away a layer at a time.

Cutaways are required to provide a stable base for knits and other stretchy fabrics. Cutaway weights
range from 1.5 to 3.5 ounces per yard. While the article is stitching, the backing can prevent the fabric from
disappearing into the hole of the throat plate and, after the stitching is completed, the cutaway helps keep the
fabric in shape through launderings. When trimming cutaways be sure to keep the shirt in view at all times.
Place the shirt closest to you and hold the backing up in the air. With the shirt hanging down and the backing
in hand, trim the backing with sharp scissors, preferably with blunt ends. Use a gliding motion instead of
sawing with the blades, as this will help you avoid cuts in the fabric. Quality stable cutaways tolerate
multiple needle penetrations; wash well maintaining the shape of the design, and trim easily. Although soft
backings are desirable, it is often necessary to choose a more stable and therefore stiffer backing to achieve a
crisp embroidered design.

Fusible backings can be bonded permanently to garments and fabrics. They lend stability to stretchy
fabrics, which can also be difficult fabrics to hoop. Fusible backings can also be used as a final application
on the reverse surface of completed embroidery projects to cover scratchy metallic for wearing comfort, or
permanently fuse designs to enhance durability. Ensure that the fabric can be ironed before using fusible
backings. You can use spray adhesive to affix regular cutaways and tearaways to garments and other
embroiderable product.

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 CHAPTER 13
HOOPING AND TENSIONS

The tension of the fabric in your hoop is just as important as the tension on the threads of your machine.
Many a stitching problem can be traced to poor hooping. Proper hooping is one of the most important factors
in producing quality stitching.

Make sure that your fabric is straight in the hoop. Use a hooping device or mark with disappearing ink or
tailor’s chalk. Hoop the chosen backing with the garment and press the inner hoop down. The idea is to get
the fabric taut in the hoop so the material doesn’t shift, and close enough to the throat plate so the hooped
fabric doesn’t bounce against the throat plate. This is called flagging and can cause poor quality, skipped
stitches and can compromise your design registration. Sliding an extra piece of backing under the hooped
garment can often help if you experience skipped stitches as this fills any gap between the garment and the
throat plate. The needle and hook have the best change of forming a good stitch when the material is stable
and tight against the machine.

You should not stretch the fabric after hooping it. You should avoid tightening the thumbscrews of the
hoop after the hooping is completed. You could unintentionally tighten too much which can cause bruising
or breaking of the fibers. The exception would be with very heavy fabrics.

Hooping caps should be approached the same way. You want the material to be as close to the throat plate
as possible. Caps are a challenge because they are curved. You should research and find the caps that fit your
machine the best.

When hooping, pull the cap down tight against the cap hooping device, using the closure in the back.
Then fasten the hoop against the front of the cap, snug down on the seam of the crown and the bill of the
cap. Be aware that your cap frames are adjustable, so you can make them tighter or looser when required.

Closing the gap between the cap and the throat plate is most important when stitching caps. Hoop a piece
of backing with the cap even if it already has fused buckram or other backing. You will find that your design
registration and stitch quality is best when the cap is as snug and immovable as possible. Sliding another
piece of backing under the cap before you begin to stitch can help.

The tension of your machine is important to stitch quality, too. The upper and lower thread should pull
out smoothly. Be careful, especially if you wind your own bobbins, that there is not too much thread on the
bobbin. Overwound bobbins can cause stitching troubles as the thread does not come off the bobbin
smoothly and evenly.

69
 Before you being, check for damage to the bobbin, its case and the cone or spool of thread you are using
for stitching.

Make sure that your machine is threaded correctly before you begin to check the tensions. Your upper
thread should run through the pretensioners ( sub-controllers) and the main tensioner as well as the take-up
lever and all the eyes and guides on the way to the needle.

The bobbin should be threaded correctly and the thread should be under the adjustment plate and through
the pigtail,

When checking the bobbin tension, perform a “ drop test” Put a new bobbin in the case but do not pass
thread through the pigtail. Hold the bobbin by the thread and let it drop into the palm of your hand, which
You should hold about 8-12 inches under the bobbin. If it drops a few inches and stops, the bobbin tension is
correct. If it doesn’t move, it is too tight. If it drops into your hand, it is too loose. Turn the screw on the
bobbin to the right to tighten and to the left to loosen the tension. Once the bobbin tension is set correctly,
leave it alone. Adjust the top thread to fine tune the thread on each needle.

The top tension begins with the pre-tensioners, the discs that first meet the thread as it comes off the
cones and through the thread rack guides. Loosen the main tension knob so there is no tension on the thread
at the tension spring and remove the thread from the needle eye. Hold the main tension disc to prevent
turning and pull the trand. If it stops when it is around the main tension disc, the pre-tensioner is doing its
job. If is does not, tighten the pre-tensioner until the thread stops. Your pre-tensioner has too much tension
on it if the main tension discs fail to turn when they are not being held. If the thread does not stay on the
main tension disc, you have too little tension at the pre-tensioner.

Once the pre-tensioners are adjusted, back off the main tension knob until there is no tension at all and
then tighten it down about 7or 8 turns. Sew a block, about 2 or 3 inches square. The reverse of the
embroidery should show 1/3 bobbin and 2/3 upper thread. If there is more bobbin thread, you need to loosen
the main tension. If there is more upper thread, you need to tighten the main tension.

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