Related Manuals for SunStar SWF Series
Summary of Contents for SunStar SWF Series
- Page 1 USER ’ ’ S MANUAL FOUR-HEAD AUTOMATIC EMBROIDERY MACHINE WITH FLAT SIX-HEAD AUTOMATIC EMBROIDERY MACHINE WITH FLAT SWF/E- Series S S u u n n S S t t a a r r C C O O . . , , L L T T D D . . M M M M E E - - 0 0 9 9 0 0 9 9 2 2 9 9...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SAFETY RULES …………………………………………………………………… CHAPTER 1 1-1) MACHINE DELIVERY ……………………………………………………………… 1-2) MACHINE INSTALLATION ………………………………………………………… 1-3) MACHINE OPERATION …………………………………………………………… 1-4) REPAIR ……………………………………………………………………………… 1-5) PLACEMENT OF WARNING STICKERS ………………………………………… 1-6) CONTENTS OF WARNING STICKERS …………………………………………… ………………………………… CHAPTER 2 INSTALLATION AND MACHINE ASSEMBLY ……………………………………………………………………... - Page 4 MACHINE ADJUSTMENTS ……………………………………………………… CHAPTER 7 7-1) ADJUSTING THE TRIMMERS ……………………………………………………… 7-2) ADJUSTING THE TRIMMER RETURN SPRING ………………………………… …………………………………………………………… 7-3) PICKER ADJUSTMENT 7-4) ADJUSTING UPPER THREAD HOLDER ………………………………………… ……………………………………… 7-5) ADJUSTING HEIGHT OF PRESSER FOOT 7-6) CORRECT POSITION OF NEEDLE ………………………………………………… ………………………...
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Page 5: Chapter 1 Safety Rules
CHAPTER SAFETY RULES The following set of safety rules categorized as DANGER, WARNING, and CAUTION indicates possibilities of physical or property damages if not fully observed. : These safety instructions MUST be observed to be safe from danger when installing, delivering, or DANGER repairing the machine. -
Page 6: 1-2) Machine Installation
2) Using a Forklift Make sure that size and weight of the forklift is sufficient to support the machine. Use the pallet to place the machine so that its center is on the forklift arm (see [Fig.1-2]). Lift the machine carefully so that the machine does not tilt to either side. -
Page 7: 1-3) Machine Operation
1-3) MACHINE The SWF Automatic Embroidery Machine is designed for applying OPERATION embroidery to fabric and other similar materials. Pay careful attention to the stickers on certain WARNING CAUTION parts of the machine. Make sure to observe the following when operating the machine: 01) Read thoroughly and fully understand the manual before operating the WARNING... -
Page 8: 1-5) Placement Of Warning Stickers
Observe the directions on ALL warning stickers placed on the machine as 1-5) PLACEMENT OF reminders for your safety. WARNING STICKERS 1) Location of Warning Stickers Fire or death may be caused by high voltage electric shock. Don’t open the cover except for service man assigned by SWF. -
Page 9: 1-6) Contents Of Warning Stickers
1-6) CONTENTS OF 1) Warning WARNING STICKERS Injury may be caused by winding. Be sure to turn off the power before cleaning, lubricating, adjusting or repairing. [ Notice ] Cover in the “WARNING” means all covers near operating part of the machine. Injury may be caused by moving needle. -
Page 10: Chapter 2 Installation And Machine Assembly
CHAPTER INSTALLATION AND MACHINE ASSEMBLY Install your machine in an appropriate environment and with adequate electrical supply. Failure to follow the directions may result in machine malfunction. 2-1) ENVIRONMENT 1) Temperature: ① 0 ∼ 40℃ (32 ∼ 104°F) when the machine is in operation ②... -
Page 11: 2-3) Leveling The Machine
2-3) LEVELING THE MACHINE The machine must be accurately leveled (especially front and back) to prevent the needle from moving out of position. 1) Use the adjusting bolts installed at the four stands to level the machine (front, rear, left, and right). Use a level gauge. -
Page 12: 2-4) Assembly Of Peripheral Devices
2-4) ASSEMBLY OF PERIPHERAL DEVICES 1) Assembling Upper Thread Stand Spool plate Support Thread holder [Fig.2-4] 2) Assembling Operation Box Operation box Power Cable FDD Cable [Fig.2-6] [Fig.2-5]... -
Page 13: Parts Of The Machine
CHAPTER PARTS OF THE MACHINE [Fig.3-1] ① Machine Body ⑩ Head ⒖ Encoder ② Table ⑪ Thread tension adjustment board ⒗ Main power switch ③ Upper thread stand ⑫ Sub-controller (21) Lamp ④ Main shaft drive motor ⑬ X-axis driving system (22) Supporting bolt ⑤... - Page 14 CHAPTER FEATURES AND SPECIFICATIONS 1) EXPANDED MEMORY SIZE The machine can store a maximum of 100 designs. The basic memory size is 2 million stitches. 2) MIRROR IMAGE CONVERSION AND DESIGN DIRECTION You can turn the design from 0°to 359°in the increments of 1°and also reverse the design in the X direction (mirror image).
- Page 15 12) AUTOMATIC DETECTION OF UPPER AND LOWER THREAD BREAKS The machine detects when the upper thread breaks or the lower thread is out of the needle and automatically stops the machine. 13) AUTOMATIC RETURN TO STOP POINT IN UNEXPECTED BLACKOUT When the power fails unexpectedly, the frame moves back to the exact point where the stitching stopped.
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Page 16: Chapter 5 Functions For Basic Machine Operation
CHAPTER FUNCTIONS FOR BASIC MACHINE OPERATION 5-1) EMERGENCY POWER AND START/STOP/BAR SWITCH 5-1-1) Emergency Power Switch Starting the machine in the initial stage ① Turn on the main power ([Fig.5-1]). ② Press the emergency power switch (green color). ③ Emergency power switch will not turn on if the main power is off. Emergency power switch [Fig.5-1] [NOTE]... - Page 17 ① START/STOP for starting embroidery and stopping the machine BUTTON OPERATION MACHINE OPERATION Machine starts and embroidery work begins. Press START Machine inches (see Note1) until you release the button. Hold START Machine stops. Press STOP [NOTE 1] You cannot perform non-stitching (floating) at the start of the embroidery because the function is not in the start menu.
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Page 18: 5-2) Emergency Stop
5-2) EMERGENCY STOP Press EMERGENCY STOP if you have to stop the machine immediately, i.e. machine error. [Fig.5-3] ① EMERGENCY STOP will turn off the machine. ② To restart the machine, rotate the main shaft to 100° . ③ Turn the EMERGENCY STOP button off and then on again. [Fig.5-4]... -
Page 19: 5-3) Lamp On Thread Tension Adjustment Board
5-3) LAMP ON THREAD TENSION ADJUSTMENT BOARD 1) Switch ① For normal operation, turn the toggle switch on to turn on the indicator lamp. ② If the machine stopped after detecting a thread break, move the frame back to the location of the thread break using STOP button and restart the machine to pick up stitching (design edit). -
Page 20: 5-4) Needle Stop Clutch
5-4) NEEDLE STOP CLUTCH The needle bar moves when the red signal on the clutch is facing the operator ([Fig.5-6]). Turn the clutch 90°in the direction of the arrow to stop the needle bar. Clutch [Fig.5-6] The trimmer and the take-up lever continue to move even when the needle bar is stopped by the clutch. -
Page 21: 5-5) Upper Threading And Tension Adjustment
5-5) UPPER THREADING AND TENSION ADJUSTMENT 1) Upper Threading Upper thread stand Upper thread (from the upper thread stand) Sub thread adjuster Thread tension adjustment board Thread detecting roller Thread detecting board Take-up lever spring Rotary tension disk Main thread tension adjuster Upper thread guide... - Page 22 Threading the sub Threading the thread Threading the main Threading around the tension adjuster detector roller tension adjuster needle Thread holder Thread guide Thread Sensing spring (lower) Roller One and One turn Thread Guide Disk half turn (Pass through the Rotary Tension Disk middle of shaft) Fix the upper thread...
- Page 23 3) Take-Up Spring CORRECT WRONG Connect between the take-up spring and the stopper. Take-up spring unable to connect with the stopper (due to dust or foreign substances in the stopper.) stopper Take-up spring [Fig.5-10] ① Take-up Spring Functions Difference in the length of the upper thread pulled by the take-up lever and pulled by the hook creates tension or looping.
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Page 24: 5-6) Lower (Bobbin) Threading And Tension Adjustment
5-6) LOWER (BOBBIN) THREADING AND TENSION ADJUSTMENT 1) Lower Threading ① Use cotton yarn (#80-#120) for your lower thread. ② Threading the bobbin: • Insert the threaded bobbin into the bobbin case with the thread coming out from the case slot. Pull the thread through the thread guide. -
Page 25: 5-7) Thread Winder
5-7) THREAD WINDER 1) Lower thread winding ① Insert the bobbin into the thread winder shaft as in [Fig. 5-14]. Wind the bobbin 5-6 times by hand in the thread winding direction. Then press the start button, and the thread winding begins. Knob Thread tension adjusting nut Tension adjusting holder... - Page 26 3) Adjustment of bobbin thread status ① 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 Thread tension adjustment.
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Page 27: 5-8) Precautions In Using Floppy Disks Or Usb Memory Sticks
5-8) PRECAUTIONS IN USING FLOPPY DISKS OR USB MEMORY STICKS Make sure to meet the following conditions when using the above devices. 1) You can use pre-formatted disks, but be sure to use disks of recognized quality. 2) You can use USB memory sticks of FAT 16 (file system). The machine does not accommodate FAT 32. -
Page 28: 5-9) Inserting Floppy Disks And Usb Memory Sticks
5-9) INSERTING FLOPPY DISKS AND USB MEMORY STICKS – Inserting floppy disks Insert the disk in the indicated direction. – Inserting USB memory sticks Insert the USB memory into the USB port. Floppy disk USB memory [Fig.5-19] 5-10) DELETING FLOPPY DISKS AND USB MEMORY STICK –... -
Page 29: 5-13) Needle-Hook Timing Control
5-13) NEEDLE-HOOK TIMING CONTROL 1) Needle ① It is very important to select the right needle for the type of thread and fabric used. ② Inappropriate needle may cause bad embroidery, thread breaks, skipped stitches, etc. ③ For normal embroidery, use a DB×K5 needle. [CAUTION] DB K5 needle has an eye twice larger than that of DB1 (used for normal sewing). - Page 30 ② When inserting the needle, make sure that the groove Needle insert hole of the needle is facing front. Shaft of the needle should be inserted completely into the needle bar. Needle groove (front) [Fig.5-21] [CAUTION 1] For special threads such as artificial silk, turn the needle slightly to the right to prevent thread breaks (see [Fig.5-22]).
- Page 31 4) Relationship between Needle and Hook ① Adjusting Timing between Needle and Hook Default timing of the needle and the hook is set by the main shaft angle of 201° and varies as below. Hook Top edge of Top edge of the Hook point point needle eye...
- Page 32 [CAUTION] Functions by Needle Shape ① Size of the hole and groove differs by needle. • Front groove: protects the thread from the heat of the Front groove sewing friction (which may cause thread breaks). • Back groove: helps regulate the hook timing and prevents looping.
- Page 33 5) Relationship between the Take-up Lever and the Hook Hook point timing is directly related to thread tension and thread breaks. The following pictures show the location of hook when the take-up lever starts to move up from the lower dead stop (main shaft rotation angle: 292° ). Fast Hook Timing Groove of the hook is in the (A) range.
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Page 34: 5-14) Assembly And Functions Of Thread Detector
5-14) ASSEMBLY AND FUNCTIONS OF THREAD DETECTOR 5-14-1) Functions of Thread Detector Detection of the breaks of upper or lower threads prevents ill quality embroidery. The thread- break detector unit contains rollers that sense the smooth feeding of the thread. Any dust, thread remnants, etc. will interfere the rollers’... -
Page 35: Chapter 6 Maintenance And Inspection
CHAPTER MAINTENANCE AND INSPECTION 6-1) CHECK POINTS FOR REGULAR INSPECTION Safety rules must be observed during the inspection. CAUTION 1) Clean, oil, and grease the set parts of the machine on a regular basis. 2) Inspect tension of each driver belt. 3) Failure to perform regular inspections may cause the following: •... - Page 36 Hook Guide rail to the take-up lever Trimming cam box Movable blade Lower thread holder Fixed blade [Fig.6-1]...
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Page 37: 6-3) Oil Supply
6-3) OIL SUPPLY Make sure to turn the power OFF during oil supply. CAUTION Sun Star is not responsible for machine damages or wear-outs caused by insufficient oiling. CAUTION 1) Oil supply Use the SWF sewing machine oil (Spindle Oil) or ISO-standard VG18. 2) Manual oil supply Oiling cycle Ref. - Page 38 3) Semi-Automatic Greasing from Oil Tank ① Greasing Cycle: once in 2-3 days [Fig.6-3] [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.
- Page 39 ② Grease supply Make sure to turn OFF the main power during the grease supply. CAUTION Use high-quality mineral-based lithium grease. Where to Grease Greasing cycle Reference Fig. Inside the arm Take-up lever drive cam Needle bar drive cam Once in 3 months Needle bar controller Take-up lever drive roller Driving plate for the upper thread holder...
- Page 40 Turn OFF the main power during the grease supply. CAUTION Use lithium-type grease (JIS No.2) - Albania No.2. Where to Grease Greasing cycle Reference Fig. Head drive LM guide Once a month [CATUION] Do NOT grease the parts not indicated (needle bar, hook, etc.) ①...
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Page 41: 6-4) Drive Belt Tension
6-4) DRIVE BELT TENSION Turn OFF the main power when inspecting drive belt tension. CAUTION Too weak or too tight tension on the drive belt may cause machine malfunction or damages (abnormal wear-out of drive unit). Inspect the driver belt on a regular basis. Location for inspection Inspection cycle Inspection... -
Page 42: Chapter 7 Machine Adjustments
CHAPTER MACHINE ADJUSTMENTS Turn OFF the main power when adjusting the machine. WARNING 7-1) ADJUSTING THE TRIMMERS 7-1-1) Adjusting the Position of the Trimming Cam (Insert Angle of Movable Blade) The movable blade is started by the trimmer cam in the angle it is inserted. As one of the basic trimming functions, it arranges the upper thread tails in the needle after trimming. - Page 43 7-1-2) Adjusting Space between Movable Blade and Hook To adjust a space between the movable blade and the hook, remove or insert a spacer (t 0.1) between the blade base and the hook base. In the case of spacer removal, make sure to check if the hook does not interfere with the movable blade.
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Page 44: 7-2) Adjusting The Trimmer Return Spring
7-1-4) Adjusting Tension on Lower Thread Holder By holding the thread coming from the bobbin case after trimming, the lower thread holder forms starting stitches after trimming. ① Unscrew the movable blade crank. Cut the lower thread with the movable blade and check the cross-section of the thread. -
Page 45: 7-3) Picker Adjustment
7-3) 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 Correct position Manually move the picker so it touches the... - Page 46 ② If the wiper does not move well, unscrew the driver link and adjust the wiper lever up and down. Unfasten the bracket screw so there is lesser overload from upper thread holder bracket. Adjust and fasten the bracket back at the point where the wiper moves well.
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Page 47: 7-5) Adjusting Height Of Presser Foot
7-5) ADJUSTING HEIGHT OF PRESSER FOOT 1) Relationship between Presser Foot and Needle/ Embroidery Material Presser foot For stable stitching, the presser foot must be pressing Needle Needle the embroidery material before the needle pierces into the material. The same is true for when the needle Embroidery comes out of the material. -
Page 48: 7-6) Correct Position Of Needle
7-6) CORRECT POSITION OF NEEDLE ① Make sure to check the position of the needle - it may change during machine delivery or leveling. First check if the needle is bent. Then turn the main shaft lever 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. -
Page 49: 7-7) Adjusting Half-Turn Film For Color Change
7-7) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE Adjust the half-turn film as below to align the needle to the center of the needle hole on the plate for automatic color change. ① Turn the hand lever for color change and align the roller at the center of the straight line of the cam (see [Fig.7- 17]). -
Page 50: 7-9) Jump Solenoid Adjustment
7-9) JUMP SOLENOID ADJUSTMENT Adjust the position of the jump solenoid if the solenoid has been replaced or it malfunctions. 1) Adjusting the Standby Position (assembling the solenoid and the bracket) Screw ① Use the spanner for jump solenoid adjustment 3.5mm (included in the SWF basic kit) to unfasten the solenoid. -
Page 51: Chapter 8 Troubleshooting
CHAPTER TROUBLESHOOTING DANGER CAUTION Inspect/repair the machine by the guideline when in machine failures. Error Type Cause Inspection & Repair Reference Operation failure Loose belt tension / belt Adjust belt tension / change belt damage Power failure or short-circuit Check fuse in main shaft motor of fuse and change fuse Failure to sense signals for... - Page 52 Error Type Cause Inspection & Repair Reference Bad Color Incorrect position of needle Refer to user s manual Set main shaft angle back at Change stop 100 , if you manually moved it for cleaning, inspection or repair. Failure to sense signals for Run manual color change and needle position or 1 rotation check if signal lamps (needle...
- Page 53 Error Type Cause Inspection & Repair Reference Poor detection Failure of thread detecting Disassemble the roller and clean of upper thread roller the roller and bush bearing. Poor connection & quality Check the plate connection and of tension adjusting plate change the circuit board Bad jump Short-circuit of fuse for...
- Page 54 Error Type Cause Inspection & Repair Reference Thread breaks Stitch is too small/dense Re-punch design tape Check design for thread Frequent thread break in Re-punch after checking the same spot design Correct the stitches on operation box Inadequate needle size Change needle for thread Needle damage (bent,...
- Page 55 Error Type Cause Inspection & Repair Reference Bad thread (weak, Change thread Check the thread used uneven thickness, poorly twisted, old) How to select thread Select soft thread with even thickness Choose left-twisted thread Right-twisted thread Change to left-twisted thread Z-direction: left twist S-direction: right twist left-twist prevents...
- Page 56 Error Type Cause Inspection & Repair Reference Dent on thread path on Remove dent or change the case hook and bobbin case Narrow space between Adjust space Set it at 0.5-0.7mm for hook holder and groove smooth feeding of upper for hook holder (on hook) thread Hook...
- Page 57 Error Type Cause Inspection & Repair Reference Skipped Bent needle Stitches Inadequate needle size for Change needle thread Incorrect installation of Adjust installation needle Poor timing of needle and Adjust timing hook Large gap between needle groove and hook point Incorrect lower dead stop Adjust the lower dead stop Damaged hook point...
- Page 58 Error Type Cause Inspection & Repair Reference Poor stitch Weak upper thread tension Adjust tension tension Uneven upper thread Clean main and sub tension tension due to foreign adjusters in the thread tension substances adjusting plate Weak lower thread tension Adjust tension Uneven lower thread Clean bobbin case and check...
- Page 59 Error Type Cause Inspection & Repair Reference Puckering Excessive thread tension Adjust tension Excessive pressure of Change presser foot spring presser foot Needle failure - Change needle worn out/damaged needle needle is too large for thread Needle hole is too large for Use adequate size of needle SWF/ needle holes...
- Page 60 Error Type Cause Inspection & Repair Reference Trimmer return Poor connection of sensor Check connection failure Bad circuit board Change circuit board Bad sensor or sensor change sensor position. clean around the sensor Dirty area around the adjust location of the sensor sensor.
- Page 61 Error Type Cause Inspection & Repair Reference Short upper Upper thread is trimmed check upper thread tension The default is MEDIUM thread after too short and comes LONG MEDIUM trimming unthreaded length of trimmed thread in data set-up Upper thread is trimmed MEDIUM SHORT too long and thread tail...