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If the error goes when you remove the embroidery unit is is likely to be a positioning error when the machine is lost to where the needle is in position to the frame.
The error code means you have a problem with your feed step motor. I have included a link to the owner's manual. Page 31 shows what the error is. On Page 37 it shows you the electrical connections to the main circuit board. Before you go inside, be sure to unplug the machine. Look for the plugs that deal with the feed step motor and ensure they are plugged in properly. Check for dust as well. After that you need to take it to a repair shop. http://videos.jennys-sewing-studio.com/main.php?g2_view=core.DownloadItem&g2_itemId=16556
No, there's no secret to putting it on, but occasionally, you can get a bad hoop. You see, the hoops for every machine are not made by the same people that make the machine. Often, for instance, the center markings are slightly off.
If your machine is under warranty, just email Singer with a copy of the receipt, and they'll send you a replacement. If it isn't under warranty, you can easily find one on Amazon or ebay. By the way, if it fits the XL-400, any SEQS machine, or an XL-420 or -480, it will fit yours, too, and they're not expensive.
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