Machine troubleshooter

SWF troubleshooting

SWF embroidery error codes 100-954 explained - 102 overload, 103 trim return, 200-203 frame limits, 650 USB, 900 CAN errors - plus fixes and oiling.

  • Commercial
  • Made in South Korea (SunStar)
  • Files: DST (Tajima T-code), SST (SWF native); panels also report ZSK and Barudan data errors

Control panel: Older machines: LED alphanumeric or LCD panel with an SWF M-Setting key; E-series and later: OP box with screen, USB port and Error Information log

Short answer

On SWF machines most stops come back to three things: the main shaft not parked at 100 degrees, thread wrapped in the hook (which throws 102 overload), and trimmer knives that did not return (103). Park the shaft on the red 100 mark, clear the hook and knives, and power-cycle. Frame limit codes 200-203 just mean the design ran past the set limit, and 650 means the USB stick is not FAT16-friendly.

SWF model families

Find your machine to see what it's known for, then jump to its error codes and fixes.

E-T single-head (E-T1501C, E-T1201C, compact and full size)

Type
Commercial single-head, 12 or 15 needles
Years
E-series era to present
Field
see the E-T manual for your frame set
Max speed
1,200 rpm default maximum (compact, bridge and regular single-head E-series)
Panel
OP box with screen and USB
Formats
DST, SST

The most common SWF in small shops. Error codes follow the standard SWF table (100s main shaft, 200s frame, 600s media, 700s memory, 900s communication). Typical failures are birdnests causing 102, trim knives not returning (103) and USB sticks not recognised (650).

single-head15-needle12-needlecaptubular

E-T full-size single-head

Type
Commercial single-head, 15 needles
Years
E-series era to present
Field
see the full-size manual
Max speed
1,200 rpm default maximum
Panel
OP box with screen
Formats
DST, SST

Same control logic as the compact with a larger field. The manual's troubleshooting chapter is symptom-based (bad color change, thread breaks, skipped stitches, trimming failure) and is the best guide for mechanical faults.

single-head15-needlecap

E Dual Function

Type
Multi-head with two head types (e.g. embroidery plus cording/sequin)
Years
E-series era
Field
see the dual function manual
Max speed
per machine parameter
Panel
OP box with 10-entry error log
Formats
DST, SST

Uses the same error numbering as the single-heads, including valve (107) and air pressure (108) errors for the pneumatic devices.

multi-headcordingsequin

E-series multi-head (2, 4, 6, 8 heads; compact 6-head)

Type
Commercial multi-head
Years
E-series era
Field
see the E-series multi-head manual
Max speed
per machine parameter
Panel
OP box
Formats
DST, SST

All heads share one trim linkage and one trim sensor, so a birdnest on one head gives error 103 for the whole machine. The trim plunger collecting grease is a classic multi-head fault.

multi-head15-needlecap

MAS-12 and MAS-15

Type
Compact single-head, 12 (MAS-12) or 15 (MAS-15) needles
Years
recent
Field
MAS-12: 360 x 230 mm tubular; wide cap frame 360 x 75 mm; semi-wide cap 180 x 83 mm
Max speed
MAS-12: 1,000 rpm
Panel
OP box with USB memory stick input
Formats
DST, SST

Brushless main motor and stepper frame motors. Uses the same code table as larger SWFs; in this manual 109 is listed as an AC line (power) error.

single-head12-needle15-needlecapcompact

SB series and K / KS / KX multi-heads

Type
Commercial multi-head (also covers DM, K-series and multi-head E on the same manual)
Years
various
Field
see the SB series manual
Max speed
per machine parameter
Panel
OP box with USB and network
Formats
DST, SST

Largest published SWF code table (main shaft, frame, color change, encoder, media, network, USB, memory, sequin and CAN communication codes).

multi-headnetworksequin

MA-6 and other compact/older lines (MAN-12, A, B, C, HC, UI)

Type
Compact single-heads and older series
Years
various
Field
see model manual
Max speed
MA-6: 1,000 rpm default maximum
Panel
varies by generation
Formats
DST, SST

The MA-6 shares the E-series parameter set with lower speed limits (jump speed default 650 rpm). Older series have their own manuals in the Stitch It library.

single-head6-needleolder

SWF error codes 53

Type the code or words from the screen. Codes vary by model and software version — when in doubt, your machine's own manual wins.

CodeMessageWhat it meansWhat to doModelsSource
100Main shaft motor stop position errorThe machine stopped with the main shaft somewhere other than 100 degrees.Turn the shaft with the lever or wheel until the red 100 mark lines up, then power-cycle.All E-series, MAS, SBSB series manual; MAS-12 manual; E-T compact manual
101Main shaft motor driver errorThe main motor driver reported a fault. Dealer experience: usually thread jammed in the hook.Clear any thread from the hook, then switch the main power off and on. Repeated 101 needs a technician to check the driver.AllSB series manual; Stitch It "Errors 102 & 103"
102Main shaft motor overloadThe main shaft could not turn freely: thread wrapped in the hook, a bad needle bar drive, or thread tangled during a trim.Cut away the nest under the needle plate, pull and clean the bobbin case, reset bobbin tension, check the hook on every head, then power-cycle. Reset top pre-tension and main tension before sewing.AllSB series manual; MAS-12 manual; Stitch It "Errors 102 & 103"
103No trimming system recovery / Trimming returnThe trim sensor did not see the knives return after a trim. Usually thread under the fixed knife or grease on the trim plunger.Pull the needle plates, swing the moving knife out and clear thread under the fixed knife. Check the under-thread presser is not bent up. Wipe grease off the trim plunger and cam groove, oil the plunger, then run the trim solenoid test until you hear two clicks.All, especially multi-headsStitch It "Errors 102 & 103"; SB series manual
104Start switch errorThe start button was held or stuck when the machine powered on.Release the button and check it is not shorted at its connector.AllSB series manual; MAS-12 manual
105Stop switch errorThe stop button was held or stuck at power-on.Release it and check its connector.AllSB series manual; MAS-12 manual
107Valve errorA pneumatic valve is open.Check the valve and air device (sequin/boring).Machines with air devicesSB series manual
108Air pressure errorSupply air pressure is below the required level for the sequin device.Check the compressor, regulator and hoses.Sequin-equippedSB series manual
109Pulley ratio error (AC line error on MAS-12)The set pulley ratio does not match the machine; on MAS-12 the same number is a power supply or power measuring circuit fault.Have a technician check the pulley ratio setting, or on MAS-12 the incoming power and circuit.SB, E-T compact; MAS-12SB series manual; MAS-12 manual
110AC line errorA fault on the joint board.Technician to replace the joint board.SB, E-T compactSB series manual
200(+X) frame limitThe frame hit the +X limit.Jog the frame in the -X direction and re-centre the design.AllSB series manual; MAS-12 manual
201(-X) frame limitThe frame hit the -X limit.Jog the frame in the +X direction.AllSB series manual; MAS-12 manual
202(+Y) frame limitThe frame hit the +Y limit.Jog the frame in the -Y direction.AllSB series manual; MAS-12 manual
203(-Y) frame limitThe frame hit the -Y limit.Jog the frame in the +Y direction.AllSB series manual; MAS-12 manual
204X-axis driver errorThe X drive reported a fault.Power-cycle. If it returns, a technician should test the X driver board and motor.AllSB series manual; MAS-12 manual
205Y-axis driver errorThe Y drive reported a fault.Power-cycle; repeat errors need the Y driver and motor checked.AllSB series manual; MAS-12 manual
206Wiper return errorThe wiper did not return.Free or repair the wiper mechanism.AllSB series manual; MAS-12 manual
207Trimmer return errorThe trimmer motor or solenoid did not return.Clear thread from the knives and repair the trimmer mechanism.AllSB series manual; MAS-12 manual
300Needle bar stop position errorAfter a color change the needle bar did not land in position.Turn the needle bar by hand, feel for a tight spot, and set it on a needle position.AllSB series manual; MAS-12 manual
400Main shaft encoder A errorSignal problem on encoder channel A.Check the encoder cable and power-cycle.AllSB series manual; MAS-12 manual
401Main shaft encoder Z errorSignal problem on encoder channel Z (the once-per-turn signal).Check the encoder cable and power-cycle.AllSB series manual; MAS-12 manual
501Repeat work setting errorThe X count times Y count in repeat work is over 99.Lower the repeat counts so their product is under 99.AllSB series manual; MAS-12 manual
600No disketteNo floppy disk in the drive.Insert a disk.Floppy-drive machinesSB series manual
601No sectors on the disketteThe disk is unformatted or in another format.Format or swap the disk.Floppy-drive machinesSB series manual
602No design data in the disketteNo embroidery design on the disk.Use a disk with designs saved in a machine format.Floppy-drive machinesSB series manual
603Remove the write protect tabThe disk is write-protected during a copy.Slide the write-protect tab off.Floppy-drive machinesSB series manual
604Diskette damagedThe disk is damaged.Format or replace it.Floppy-drive machinesSB series manual
605Insufficient memory capacity (disk)Not enough free space on the disk for the copy.Use a new disk.Floppy-drive machinesSB series manual
606Diskette removed from FDDThe disk was pulled out mid-operation.Reinsert it and restart the job.Floppy-drive machinesSB series manual
607Bad sector during readingBad sector on read.Format or replace the disk.Floppy-drive machinesSB series manual
608Bad sector during writingBad sector on write.Format or replace the disk.Floppy-drive machinesSB series manual
609Diskette error, unknown causeUnexplained disk error.Format or replace the disk.Floppy-drive machinesSB series manual
610Diskette errorGeneral disk error.Format or replace the disk.Floppy-drive machinesSB series manual
611ZSK design errorProblem reading a ZSK-format design.Re-save the design in DST or SWF format and reload.AllSB series manual; Dual Function manual
612BARUDAN design errorProblem reading a Barudan-format design.Re-save in DST or SWF format and reload.AllSB series manual; Dual Function manual
613Bad sector errorMedia sector error.Replace or reformat the media.AllSB series manual
614Operating program install errorThe program file to install is missing or misnamed.Check the program file name matches what the machine expects (the Dual Function manual names it swf_tb.bin).AllSB series manual; Dual Function manual
630Error found in the read dataData read through the tape reader is corrupt.Re-read the tape.Tape-reader machinesSB series manual
640Network device errorNetwork devices are not connected.Check the network cable and device status.Networked machinesSB series manual
650USB errorThe USB driver is not ready or the stick's file system is not supported.Reformat the stick as FAT16 (FAT), plug it straight into the OP box (no hub or extension), and try a major-brand stick.All USB machinesSB series manual; E-T compact manual
700No embroidery data in memoryThe memory has no design.Load a design from USB or disk.AllSB series manual; MAS-12 manual
701Insufficient memory capacityNot enough memory to copy the design in.Delete unneeded designs.AllSB series manual; MAS-12 manual
702100 memory rooms are fullAll design slots are used.Delete unneeded designs.AllSB series manual; MAS-12 manual
703Error in design memory systemA copy or delete between memories failed.Press Reset or power-cycle.AllSB series manual; MAS-12 manual
704Bad memory batteryThe backup battery ran flat while powered off, so stitch count and frame position were not kept.Have the dealer replace the battery; if it keeps happening the CPU board may need replacing.AllSB series manual; Dual Function manual
801Sequin design errorThe sequin design has an error.Fix the design's sequin commands.Sequin-equippedSB series manual
900Communication error 0CAN bus messages between boards are not arriving regularly.Check the cables and power-cycle.MAS-12, Dual FunctionMAS-12 manual; Dual Function manual
901MC1 communications error / Comm. error 1CAN communication fault.Check cables and power-cycle.AllSB series manual; MAS-12 manual
902MC2 communications error / Comm. error 2CAN communication fault.Check cables and power-cycle.AllSB series manual; MAS-12 manual
903-915Comm. error 3 to 15CAN communication faults on other board addresses.Power-cycle; if a number repeats, have a technician trace that board's cable.MAS-12, Dual FunctionMAS-12 manual; Dual Function manual
952Unsupported disk format or I/O errorThe USB file system is not supported (lettering).Reformat the stick as FAT16.E-T single-headsE-T compact manual
953Key disk should be initializedThe USB lock key for lettering is not inserted.Insert the correct USB lock key.E-T single-headsE-T compact manual
954Wrong key valueThe USB lock key does not match this model.Use the lock key issued for this machine.E-T single-headsE-T compact manual

SWF problems and fixes

Fixes are in order — cheapest and most likely first. Filter by symptom or type what you see.

Error 102 overload after a birdnestBirdnestMotorsBobbin

Likely causes: thread wrapped in the hook, bobbin seated wrong, dirty bobbin case, wrong bobbin tension

  1. Power off and cut the nest out from under the needle plate.
  2. Remove the bobbin case, take out the bobbin and clean lint from the case.
  3. Reinsert the bobbin correctly and reset bobbin tension.
  4. Reset top pre-tension, then main tension.
  5. Turn the shaft back to the red 100 mark and power on.

Call a technician if: 102 returns with a clean hook (needle bar drive or driver fault), or the driveline was knocked off its factory marks.

Why birdnests happen. What a nest is, the usual causes in order, and how to clear one safely.
Error 103 / thread not trimmingTrimmerBirdnestSensors

Likely causes: thread under the fixed knife, bent under-thread presser, grease on the trim plunger, worn fixed knife, failed trim solenoid, blown fuse

  1. Remove the needle plates and swing the moving knife out. Clear thread and lint from under the fixed (SWF-engraved) knife.
  2. Check the thin under-thread presser is not bent up.
  3. On multi-heads, move the knife shaft under the table fully left then back right and confirm the trim sensor flag lines up and its LED lights.
  4. Wipe grease off the plunger and the cam groove, oil the plunger and its lever.
  5. Run Machine Test > Trim Sol. Test and listen for two clicks each time (fire, then drop back).
  6. Turn heads off and run a few manual trims while watching the knives.

Call a technician if: the solenoid does not fire, the fixed knife is nicked, or fuses F1/F3 on the joint board keep blowing.

Upper thread path. Every guide from the cone to the needle eye — the fix for most breaks and nests.
Upper thread breakingThread breaksNeedleTension

Likely causes: wrong or damaged needle, needle in wrong, dense stitching, poor or right-twist thread, tension too high, burr in the thread path, dry hook, timing

  1. Change the needle and install it correctly; use a size that suits the thread.
  2. Use quality left-twist (Z) embroidery thread; right-twist thread unravels on SWF hooks.
  3. Lower top tension and balance it against the bobbin.
  4. Check for burrs at the presser foot, needle plate hole, head guides and tension discs.
  5. Oil the hook raceway.
  6. If it breaks in the same spot every time, fix the stitch density in the design.

Call a technician if: breaks continue after the above (hook timing, lower dead point, hook clearance 0.5-0.7 mm).

Upper thread path. Every guide from the cone to the needle eye — the fix for most breaks and nests.
Skipped stitchesNeedleHook timingTension

Likely causes: bent or wrong needle, timing off, damaged hook point, weak presser foot spring, fabric flagging

  1. Replace the needle and check it is in straight.
  2. Check top thread feeds freely and take-up spring stroke is not excessive.
  3. Make sure the presser foot holds the fabric down.

Call a technician if: the hook point is damaged or needle-hook timing is off.

The I-test for tension. Read the back of a satin column to balance top and bobbin tension.
Loose or uneven stitch tensionTensionLoopsBobbin

Likely causes: dirt in the tension discs, weak bobbin tension, dirty bobbin case spring, poor thread, dry hook

  1. Clean the main and sub tension discs on the tension plate.
  2. Clean the bobbin case and spring and reset bobbin tension.
  3. Oil the hook raceway.
  4. Change to better thread.

Call a technician if: tension still varies with clean parts (timing).

Upper thread path. Every guide from the cone to the needle eye — the fix for most breaks and nests.
Needle breaksNeedleHook timing

Likely causes: bent or poor needle, needle too small, needle touching hook point or needle plate hole

  1. Replace with a quality DBxK5 needle sized for the fabric.
  2. Check the needle plate is screwed down tight.
  3. Make sure the needle is fully seated and facing correctly.

Call a technician if: the needle strikes the hook or the needle bar position needs adjusting.

Needle orientation. Long groove to the front, scarf to the hook, pushed fully up.
PuckeringPuckeringTensionHoop

Likely causes: tension too high, presser foot pressing too hard, needle too large for the thread

  1. Lower top tension.
  2. Fit a lighter presser foot spring if fitted with a heavy one.
  3. Match needle to thread (SWF needle holes suit about #9-#14 DBxK5).
  4. Hoop firmly with the right backing.

Call a technician if: puckering stays with balanced tension and a fresh needle.

The I-test for tension. Read the back of a satin column to balance top and bobbin tension.
Bad color change / error 300Colour changeMotors

Likely causes: shaft not at 100, take-up lever out of line, needle position signal not sensed, blown color change fuse

  1. Set the main shaft back to 100 degrees.
  2. Run a manual color change and check the panel shows a normal needle position.
  3. Look along the take-up levers; a lever out of line needs adjusting to match the others.
  4. Turn the needle bar by hand and feel for binding.

Call a technician if: fuse F3 on the joint board blows or the color change motor does not move.

Thread pulls out after trims / long tailsTrimmerThread breaks

Likely causes: trimmed thread length setting, upper thread holder dirty or solenoid failed, picker position, too-short bobbin tail

  1. Set the trimmed thread length to Medium (default) or Long if threads pull out; Short if tails show.
  2. Clean the Velcro strip in the upper thread holder.
  3. Check bobbin thread unwinds smoothly and the bobbin case spring is not too tight.

Call a technician if: the holder solenoid or picker does not fire (check fuse F3).

Upper thread path. Every guide from the cone to the needle eye — the fix for most breaks and nests.
Upper thread break not detectedSensorsThread breaks

Likely causes: dirty detector roller, poor tension plate connection, sensor setting at 0

  1. Clean the thread detector roller and its bushing.
  2. Run the Thread Sensing Test and watch each head's lamp.
  3. Check the thread break sensor setting is not 0.

Call a technician if: the tension plate circuit board fails the test.

Upper thread path. Every guide from the cone to the needle eye — the fix for most breaks and nests.
Frame limit errors 200-203Frame / pantographHoop

Likely causes: design start point too close to the edge, design larger than the set limit, wrong frame type selected

  1. Jog the frame back inside the limit.
  2. Use the design trace; any red section of the outline means it will hit a limit.
  3. Move the start point or choose a bigger frame.
  4. Check the frame setting is Cap when sewing caps (it auto-rotates designs 180 degrees).

Call a technician if: the limits trip in the middle of the field (frame origin lost).

Hooping layers. Firm, flat and square — the root of most puckering and registration faults.
USB stick not recognised (650 / 952)USBDesign files

Likely causes: wrong file system, extension cable or hub, worn port, off-brand stick

  1. Format the stick FAT16 and copy only designs to it.
  2. Plug directly into the OP box port and check its LED lights.
  3. Try a major-brand stick.
  4. Save designs as DST or SWF format.

Call a technician if: no stick is ever recognised (port or board).

Machine will not run at allPowerMotors

Likely causes: emergency stop pressed, blown fuse, loose main belt, shaft not at 100, frame outside limit, loose connector

  1. Check the emergency stop is released.
  2. Set the shaft to 100 degrees.
  3. Check the power fuses (control box front) and the main motor fuse.
  4. Check the main drive belt is tight and reseat connectors.

Call a technician if: fuses blow again on power-up.

Diagrams and photos

Tap any picture to enlarge it. Diagrams are generic — your machine's threading chart and manual take priority.

Maintenance schedule

IntervalTaskNotes
Every 3-4 hours of runningPut a small amount of oil on the hook racewayRemove the bobbin case first. Too much oil in the hook causes trim faults and thread breaks.
DailyBlow lint out around the hook with compressed airPower off first.
Daily (E-T full size)Fill the oil funnelMAS-12 tank: fill when below the red line, about every 2 weeks.
Every 3 daysOil the needle plate lubrication holes / bed cover holesThree holes on the E-T bed cover.
WeeklyOil the take-up lever guide rail
Every 2-3 weeksOil the joint between moving and fixed trim knives
PeriodicallyGrease the take-up lever cam and drive parts; check drive belt tensionBelt tension checked with a sound-wave tension gauge on E-T.
After oilingRun 2-3 minutes without stitchingStops oil staining thread and fabric.
Oil typeSWF spindle oil or ISO VG18SWF does not cover damage from poor oiling.

Settings that cause stitch problems

  • Thread break sensor (stitches): default 3 stitches. Setting it to 0 turns detection off, so a broken thread can sew empty for a whole color.
  • Thread break method (sensitivity): Low, Medium or High. Too high gives false stops on slick or thin threads.
  • Trimmed thread length: default Medium. Short causes thread to pull out of the needle after trims; Long leaves tails on the front.
  • Trimming by jump frequency / jump length: controls when a run of jump codes in a DST becomes a trim. Set wrong, the machine either trims constantly or drags long jumps across the work.
  • Start/end filter: default 0.0 mm. Raising it (up to 0.5 mm) filters tiny first and last stitches that cause thread breaks at start points.
  • Inching speed and inching stitches: the slow start after a trim (default 180 rpm, 2 stitches). Too fast and the thread pulls out before it locks.
  • Max speed / embroidery speed: single-heads default to 800 rpm working speed with a 1,200 rpm ceiling (MA-6: 1,000). Caps and dense designs need lower speed. "Speed switching data" drops speed 30-50 rpm for heavy items.
  • Frame setting: must be Cap for caps; it rotates designs 180 degrees. Leaving it on Flat makes cap designs sew upside down and hit limits.
  • Frame start angle (A/B area): default 240 degrees; changing it alters when the frame moves relative to the needle and can cause registration or needle-deflection problems.
  • Power-on auto origin: if enabled with a wrong origin, the machine can reset settings; set the frame origin correctly first.

Frequently asked questions

What does SWF error 102 mean?

It is a main shaft overload: the shaft could not turn freely. The SWF distributor says the usual cause is thread wrapped in the hook from a birdnest. Cut the nest out, clean and reseat the bobbin case, reset tensions, set the shaft to 100 and power-cycle.

How do I fix SWF error 103?

The trim knives did not return to their home position, so the trim sensor never reset. Pull the needle plates, clear thread from under the fixed knife, then clean grease off the trim plunger and oil it. Use the trim solenoid test to confirm it fires and drops back.

What do SWF errors 200, 201, 202 and 203 mean?

They are frame limit stops in +X, -X, +Y and -Y. Jog the frame back the opposite way, then trace the design and move it or use a larger frame before restarting.

What are SWF errors 204 and 205?

X-axis and Y-axis driver faults. Power-cycle first; if they come back, a technician needs to test the driver boards and frame motors.

Why won't my SWF read my USB stick?

SWF panels expect a FAT16 file system and a direct connection to the OP box. Reformat a small major-brand stick, avoid hubs and extension cables, and save designs as DST or SWF format.

What file format does an SWF embroidery machine use?

SWF machines read Tajima DST and save in either SWF format (.SST) or Tajima format (.DST). They also recognise ZSK and Barudan data and show error 611 or 612 if those files are bad.

How often should I oil an SWF embroidery machine?

Oil the hook raceway every 3-4 hours of running, the needle plate holes every three days, the take-up lever rail weekly and the trim knives every two to three weeks. Use SWF spindle oil or ISO VG18 and run the machine empty for a few minutes afterwards.

Machine's fine — but the design still sews badly?

Density, underlay, pull compensation and stitch order cause more "machine problems" than machines do. EasyDigitizer builds production-ready files for SWF in your browser.

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