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HappyJapan HCD2-1501-40 Maintenance Manual

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Maintenance Manual for Embroidery Machine
HCD2-1501-40
Version 2.3
HappyJapan Inc.

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Summary of Contents for HappyJapan HCD2-1501-40

  • Page 1 Maintenance Manual for Embroidery Machine HCD2-1501-40 Version 2.3 HappyJapan Inc.

  • Page 2: For Safe Adjustment And Repair

    # For safe adjustment and repair # In order to conduct adjustment and repair safely and surely, please be sure to abide by what is mentioned in this manual to prevent trouble. 1. When you conduct adjustment and repair of this embroidery machine or handle electric related parts, you are required to take technical lesson in advance.
  • Page 3 Index page For safe adjustment and repair Index Special tool, Measuring equipment, Other 1 Outline of mechanism 1-1 Outline of mechanical mechanism. 1-2 Placement of key electronic parts 2 Outer covers 2-1 Removal of thread guide ass’y, thread guide pillar and thread stand. 2-2 Removal of outer covers.
  • Page 4 Index page 3-3 Moving head. 3-3-1 Assemble and remove moving head. 3-3-2 Fixing of upper rail. 3-3-3 Adjustment of backlash (back and forth) of moving head. 3-3-4 Adjustment of needle position (back and forth). 3-3-5 Check of needle position. 3-3-6 Adjustment of needle height. 3-3-7 Exchange of needle bar, needle bar spring, cushion and pressure foot block.
  • Page 5 Index page 3-7 Carriage unit 3-7-1 Adjustment of X carriage belt tension 3-7-2 Exchange of X carriage belt 3-7-3 Adjustment of Y carriage belt tension 3-7-4 Exchange of Y carriage belt 3-7-5 X carriage limit sensor replacement and adjustment 3-7-6 Y carriage limit sensor replacement and adjustment 3-8 Transmission unit 3-8-1 Adjustment of timing belt tension 3-8-2 Exchange of timing belt...
  • Page 6 Index Page 5 Parts Replacement in control box and setting 5-1-1 Remove control box 5-1-2 Remove LCD-CE board 5-1-2a 10.4” Remove LCD-CE board 105a 5-1-3 Setting for LCD-CE board 6 Exchange and setting of Inverter 6-1 Exchange Inverter 6-1-1 Remove Inverter 6-1-2 Inverter Installation 6-2 Setting of inverter 6-2-1 How to set inverter...
  • Page 7 Index Page 9 Installment and setting of option unit 9-1 Installment, setting and adjustment of needle sensor 9-1-1 Installment of safety sensor 9-1-2 Setting procedure. 9-1-3 Adjustment of optical axis. 9-2 Installment of Bobbin winder 10 Electric system diagram 10-1 Electrical connection diagram (before Rev. A) (for LCD-CE board) 10-2 Electrical connection diagram (before Rev.
  • Page 8 Special tool, Measuring equipment, Other HSA90020 HSA90080 2.0mm thickness gauge (Page 76) Retainer positioning gauge [0.8mm] (Page 67) HSA90030 HSA90090 Keeper positioning gauge (Page 77) Positioning pin (Page 39) HSA90051 HSA90131 Bering positioning gauge [4.85mm] (Page 38) 1.2mm thickness gauge (Page 40, 42)
  • Page 9 HSA90210 HSA90240 0.2mm thickness gauge (Page 58) Dial-gauge set (Page 35) HSA90220 HSA90270 6mm positioning pin (Page 87) Vernier calliper gauge [200mm] (Page 34) HSA90230 HSA90300 Tensile gauge (Page 74) Tension gauge 2000cN (Page 78, 83)
  • Page 10 HSA90311 Shell alvania EP Grease2 100g (Page 31, 33, 36) M0404342 Needle height gauge (Page 52)

  • Page 11: O Utline Of Mechanical Mechanism

    utline of mechanical mechanism 1-1 O Thread guide bracket Thread guide pillar Tread stand Thread tension unit Moving head Take-up lever Control panel X carriage Frame base Thread holder Needle plate Rotary hook Rotary hook cover...
  • Page 12 Needle bar change unit Thread cutting driver Needle bar driver unit Thread holder Y carriage Upper shaft Take-up lever cam Thread cacher...
  • Page 13 acement of key electronic parts 1-2 Pl Pulse motor (Needle bar change unit) CONT-D2 TC board board Emergency stop switch wi itch Control box Fuse Power switch AC power Timing board Inverter Main motor Power supply...
  • Page 14 2-1 Removal of thread guide ass’y, thread guide pillar and thread stand 1. Remove all the tube holders from thread tension. 4. Remove 8 fixing screws and thread stand. Tube holders are removed by pulling the tube holder upward. 2. Remove 2 fixing screws and thread guide bracket. 3.
  • Page 15 2-2 Removal of outer covers 1. Remove the cover G ass'y. (Fixing screw 4 pcs) 4. Remove the cover C. (Fixing screw 2 pcs) 5. Remove the cover H. (Fixing screw 6 pcs) 2. Remove the cover E. (Fixing screw 2 pcs) 6.
  • Page 16 7. Remove the cover D. (Fixing screw 2 pcs) 9. Remove the cover B. (Fixing screw 2 pcs) 8. Guide should be removed if there is a bobbin winder. 10. Remove the cover for needle bar change unit. (Fixing screw 1 pcs) (Fixing screw 2 pcs) Remove the bobbin thread guide.

  • Page 17: Maintenance Of Thread Path

    3-1-1 Maintenance of thread path In a bid to prevent poor sewing finish or thread break, please keep places where thread contacts in the best condition. 1. Thread tension, detecting roller, thread adjusting spring 4. Thread path in lower side and needle holder. a) Revolution must be smooth a) No burr and crack b) No sticking of lint or dust...
  • Page 18 6. Needle plate 8. Rotary hook a) No burr and crack in needle hole and around it. a) No burr and crack. b) Hook point not warped. c) Backlash between bobbin case holder and outer hook should be less. Surface Two setscrews 9.

  • Page 19: Fixing Of Needle

    3-1-2 Fixing of needle 1. In order of (1)-(4), please remove and fix needle. (1) Loosen screw holding needle. (2) Remove needle. (3) Insert needle till it goes to the end. (4) Tighten screw holding needle. Fix needle so that needle groove faces front. Needle holder Needle Front...

  • Page 20: Selection Of Thread

    3-1-3 Selection of thread 1. Selection of upper thread. <Description> Please select considering cloth, design of pattern and flavor etc. <Thickness> Please refer to [Relation between needle and upper thread 3-1-4]. <Twist> Z twisted thread is to be used. (As rotary hook turns left- wise, Z twisted thread can prevent loosening of twist) Z-twisted S-twisted (Left - twisted)
  • Page 21 3-1-4 Selection of thread 1. Description of needle Basically please use [DB X K5] in standard accessory. If description or thickness of cloth doesn't suit needle size, poor sewing finish / thread break / skipping will occur. Therefore careful attention is required in selecting needle. 2.
  • Page 22 3-2-1 Exchange of crank ass’y 4. Remove face plate (left). (Fixing screw 2 pcs) Assemble and remove moving 1. Refering to [3-3-1 head ], remove moving head. 2. Remove it by holding moving head up. <Caution> Confirm that hook is apart from thread holder. 5.
  • Page 23 6. Remove upper rail. (Fixing screw 2 pcs) 8. Remove needle bar driver ass'y. 7. Remove head shaft. (Fixing screw 2 pcs) 9. Remove rod ass'y. (Fixing screw 2 pcs) <Caution>Head shaft should be taken off upward. <Caution> Remove crank ass’y from guide rail.
  • Page 24 10. Take off setscrew for bearing. (setscrew 2 pcs) Loosen the screw on fasten collar with barrel cam. 11. Remove take-up lever crank. (Fixing screw 1 pcs) Loosen the screw on upper shaft collar. (Fixing screw 2 pcs) 15. Remove timing detecting board. (Fixing screw 2 pcs) 12.
  • Page 25 Loosen the screw on upper shaft collar. 16. Remove detecting board bracket. (Fixing screw 2 pcs) (Fixing screw 2 pcs) Loosen the screw on 20. Loosen the screw on drive pulley (upper). slit disc. (Fixing screw 1 pcs) (Fixing screw 2 pcs) 21.
  • Page 26 22. Check clearances between tension ass’y and tension 25. Loosed the adjusting bolt. block for 6.5mm to 7.0mm. 26. Take off the belt. 23. Loosen the screw on tension shaft ass'y. (Fixing screw 2 pcs) 27. Remove drive pulley (upper). 24.
  • Page 27 28. Slide clank ass'y in upper shaft to front side of machine. 30. Please pull out cxlank Ass'y on upper shaft slowly. <Caution> Slide clank ass'y till touch to the machine body. 31. Please slide and off upper shaft collar, slit, Timing slit and take up lever cam from Clank ass'y 29.
  • Page 28 <Important> Pay attention to following (1) - (4) (1) Position of Upper shaft collar to same face bearing and <Caution> Please care for some damage. because Timing bearing boss. slit is very thin and weak. Center bearing Rear bearing 32. Remove crank ass’y. (2) Position of upper belt pulley.
  • Page 29 <Caution> Fix and tight setscrew to flat face on upper 33. Please check and adjust the following timing to shaft. finish. lowest needle point (Adjusting of pointer) (2)upper shaft timing (L point, C point) (3)Take-up lever timing (4)Shuttle hook timing (5)Thread cut timing (6) Fixing of jump solenoid (3) Position of “Face plate (left)”...

  • Page 30: Exchange Of Rod

    3-2-2 Exchange of rod Exchange of crank ass’y 1. Refering to [3-2-1 ], remove 2. Remove “Screw on crank pin” and take off "Rod ass'y”. moving head and thread catcher. Moving head Face plate (left) 3. Take off rod from guide rail. Needle bar driver ass'y 4.
  • Page 31 5. Remove rod. 7. Put each unit back to where it was according to manual. <Caution> The plastic thrust washer in crank ass'y. Please care dose not lose. Plastic thrust washer 6. Install good parts. At this time, put grease to bering of rod. <Grease>Shell alvania EP Grease Equivalent brand.
  • Page 32 3-2-3 Ex change of pressure foot arm ass'y 1. Refering to [3-2-1 Exchange of crank ass’y], remove moving head, face plate (left), needle bar driver ass'y and. Rod. Moving head 2. Remove pressure foot arm ass'y. (Fixing screw 2 pcs) Face plate (left) 3.
  • Page 33 3-2-4 Exch ange of pressure foot cam 1. Refering to [3-2-1 Exchange of crank ass’y], remove moving head, face plate (left), needle bar driver ass'y and. Rod. Moving head 2. Remove pressure foot cam. (Fixing screw 3 pcs) Face plate (left) 3.
  • Page 34 4. Install rod ass’y. Should not have gap between a rod ass’y and washer. 6. Set dial disc to [ L + 60 degrees Also rod should work smoothly. Not have gap In this time, please check distance between upper face of presser foot and bottom face of fixed head to In case has gap between a rod and washer, machine makes noise.

  • Page 35: Adjustment Of The Lowest Needle Point

    3-2-5 Adjustment of the lowest needle point 1. Turn upper shaft so that needle bar driver ass’y comes 3. Please check indicator to degree] completely. in the bottom. In case of dose not match pointer and [0 degree line], please adjust pointer position to just on line. In case there is moving head, bring needle bar to lowest point.

  • Page 36: Exchange Of Needle Bar Driver

    3-2-6 Exchange of needle bar driver 1. Refering to [3-2-1 Exchange of crank ass’y], remove 2. Install good parts. moving head, face plate (left) and needle bar driver ass'y. At this time, put grease to groove of rod shaft. <Grease>Shell alvania EP Grease Equivalent brand.
  • Page 37 3-2-7 Adjustment of fixing of jump device Assemble and remove moving 1. Refering to [3-3-1 4. Set upper shaft to degrees] to adjust position of Jump head ], remove moving head. shaft of jump device and Needle bar driver as illustrated below.

  • Page 38: Exchange Of Roller Shaft Ass'y

    3-2-8 Exchange of roller shaft ass’y 1. Remove take-up lever crank ass’y. 3. Insert bering positioning gauge [4.85mm] between bering and bering , and then tighten roller shaft ass’y. Please adjust roller shaft for machine rear side ways. This roller shaft ass’y is eccentricity. Turn lean screw and just touch roller to gauge.
  • Page 39 3-2-9 Adj ustment of take-up lever timing 1. Loosen screw on take up lever barrel cam. 4. Turn take up lever barrel cam slowly and insert positioning pin into pin groove. Pin groove 2. Set dial disc to [ 0 degrees 5.
  • Page 40 3-2-10 Ch eck of height of pressure foot 1. Bring needle bar down. 4. If wrong space (not 1.2mm), please adjust height Pick needle holder and down hardly. of pressure foot guide bar. Please refer to [3-2-11 Exchange and Adjustment of pressure foot].
  • Page 41 3-2-11 Excha Adjustment of nge and pressure foot 1. Remove lower front panel. (Fixing screw 2 pcs) 4. Install good parts. 2. Remove needle, needle holder and cushion. 5. Please set needle and needle clamp. <Caution> Please care when remove Needle holder, pop For set needle, please reference [3-1-2 Fixing of down Pressure foot.
  • Page 42 8. Turn upper shaft and set dial disc to [ 0 degree 11. Return lower front panel to previous places to finish. 9. Insert [Gauge I.2mm] between needle plate and pressure foot. 1.2 mm is standard, But please adjust depends by thick of material.
  • Page 43 3-2-12 Fixi ng of thread catcher 1. Install thread catcher tentatively by tightening Press , take thread catcher unit in Catcher Adjust screws. and out, and move and adjust the sensor shown in the direction of the arrow so that the dimension in the following figure meets the value in the following figure when hook goes back.
  • Page 44 7. Continue to “Adjustment of thread holder”. When you adjust thread holder, you might need to adjust thread catcher unit again. Follow the procedure in “3-3-10 Adjustment of thread holder.”...
  • Page 45 3-3-1 Assemble and remove moving head 1.. Remove Take-up lever cover. (Fixing screw 2 pcs) 4.. Remove moving head. (Fixing screw 4 pcs) <Caution> For back on moving head latter, please note needle number when youtake off moving head. 2. Remove Tension rear cover. (Fixing screw 4 pcs) 3.
  • Page 46 Install moving head tentatively. 6. place a moving head on the thread guide. <Caution> Please back on moving head to same needle position when you take off moving head. .Moving head removing has finished. <Caution> Two type of setscrews. Please check length of screw <Caution>...
  • Page 47 8. Please check NO gap between “Moving head” and “Rail support”. You can check from side of moving head 9. Check center (right and left)(back and forth) of needle and needle hole of needle plate.(Needle No.1 ,8 and 15.) <Caution> Should be check needle No.1 ,8 and 15.
  • Page 48 3-3-2 Fix ing of upper rail 1. Slide “Rail support” on “Upper rail ass’y” to center of fixed head and tight back screws. <Caution> Please push and close rail to following narrow direction then tight screws. 2. Fixing has finished.

  • Page 49: Ad Justment Of Backlash (Back And Forth) Of Moving Head

    3-3-3 Ad justment of backlash (back and forth) of moving head 1. Adjust positioning roller shaft so as to put moving rail (lower) between bearings. Move moving head back and forth so as not to cause backlash. 2. After adjustment, check and adjust needle drop to finish Please refer to [3-3-4 Adjustment of needle position (back and forth) ].

  • Page 50: Adjustment Of Needle Position (Back And Forth)

    3-3-4 Adjustment of needle position (back and forth) 1. Bring needle bar down. Viewing from side, set to center of needle hole. #Check and adjust with 1st, 8th and 15th needle. 2. Turn upper shaft and set needle near to the lowest needle position [L] to adjust positioning plate ass’y.

  • Page 51: Check Of Needle Position

    3-3-5 Check of needle position 1. Slide moving head to 8 needle. 5. Reverse-rotate an upper axis, raise a needle bar, and unite with C [270 degrees]. 2. Stick a seal on needle hole of a needle plate. (It returns to 300 degrees-> 230", and unites with 270 degrees after that.) <Note>...
  • Page 52 3-3-6 Adj ustment of needle height 1. At this time, lower front panel. (Fixing screw 2 pcs) 5. Turn upper shaft to set dial disc to [ L + 5 degrees]. 2. Remove bobbin case. 6. Loosen screw on needle bar boss. 3.
  • Page 53 7. Adjust the needle bar height up and down till the needle tip 9. Tighten the screw of needle bar boss. touches to the gauge slightly. 9. Set direction of needle stop as illustrated below. 10. Produce “Needle height gauge” from hook. 11.
  • Page 54 3-3-7 Exchange of needle bar, needle bar spring, cushion and pressure foot block pressure foot At this time, remove pressure foot spring (lower), 1. Refering to [3-2-11 Exchange of remove pressure foot. pressure foot block, cushion and needle bar boss. 4.
  • Page 55 needle bar spring. pressure foot. Finally, push upper needle bar and string all parts then pull out lower extra needle bar. 7. Fix needle, needle holder and cushion. Slide needle bar to lower. 8. Adjust needle height. Please refer to [3-3-6 Adjustment of needle height]. 9.
  • Page 56 3-3-8 Fixing of needle bar boss check plate 1. Remove moving head. 5. Put moving head and other removed parts back to finish. Please refer to [3-2-1 Exchange of crank ass’y]. 2. Exchange of needle bar boss check plate. 3. Temporarily, use the pan head screw to center the needle bar boss check plate then fix the screw 4.

  • Page 57: Exchange Of Take-Up Lever

    3-3-9 Exchange of take-up lever 1. Remove moving head. 4. Please do not miss “Plastic thrust washer” between E-ring Assemble and remove moving Please refer to [3-3-1 and Take up lever. head Remove plastic thrust washer. (1 pcs) 2. Loosen screw on take-up lever shaft. (Fixing screw 2 pcs) 5.
  • Page 58 7. Install good take-up lever assembly with plastic thrust washer, plastic washer, E-ring. 8. Leave space of [0.2mm] between take-up lever and moving head . Tight screw for “Take up lever shaft” 9. Put moving head in previous position to finish.

  • Page 59: Adjustment Of Thread Holder

    3-3-10 Adjustment of thread holder 1. Loosen screw to the extent that thread hoIder moves. 4. Thread catcher device should be adjusted if above clearance is not keepable. (Fixing screw 4 pcs) 2. Please putout and withdraw thread catcher by your finger 5.

  • Page 60: Exchange Of Majic-Tape On Thread Holder

    3-3-11 Exchange of majic-tape on thread holder 1. Remove thread holder ass’y. (Fixing screw 4 pcs) 4. Assemble holder (lower). 2. Remove holder (lower). (Fixing screw, nut 2 pcs) 5. Install holder ass’y to moving head in reverse order to finish. Please refer to [3-3-10 Adjustment of thread holder].
  • Page 61 3-3-12 Exchange of TC8-7 Thread detecting board (Rev. A) <Note> 4. Put back TC8-7 board. Set the cords of Step 2 as showed (Please disconnect machine inlet from the wall) bellow. 1. Remove Tension rear cover by following 4 set screws. Tension rear cover 5.

  • Page 62: Fixing Of Needle Bar Change Unit

    3-4-1 Fixing of needle bar change unit 1. Place needle bar change unit assembly. 3. Adjust position of unit assembly so that needle comes to please set positioning hole on unit assembly to center against needle hole on needle plate and fix screws. positioning pin.
  • Page 63 3-4-2 How to take out needle bar change stop position sensor and needle position sensor (potentiometer) <Note> Disconnect the plug during the work. 4. Mounting screw and stud a as showed bellow and take out sensor board 1. Move the head to 15 needle by turning a knob by hand.
  • Page 64 Mac. No. 1057027A〜 5. Take out potentiometer. Loosen a mounting screw as showed bellow. Potentiometer can be taken out by pulling to the arrow direction. Loosen a mounting screw (1 place) Finish of procedures...
  • Page 65 3-4-3 Sett ing to detect needle position It is necessary to memorize the value of needle selection 3. Press Machine Test . sensor along the needle positions. Lateral motion of the machine may not be done normally without the settings. 1.
  • Page 66 7. Turn the shaft of potentiometer to reach the 7 needle and 8. Install potentiometer at the 7 position while beep is made continue to turn until *(asterisk) is indicated on the right of and fix it with setscrew. the needle number on the screen. The machine make a beep once * indicates.
  • Page 67 3-5-1 Exchange and adjustment of rotary hook timing 1. Remove needle plate. (Fixing screw 2 pcs) 3. Bring needle down. 4. Turn upper shaft and set dial disc to degrees]. 2. In case of you would like to replace rotary hook to new one, <Caution>...
  • Page 68 At this moment, clearance between needle and rotary 8. Adjustment has finished. hook should be [ 0.1 - 0.2mm Check and adjust with 1st, 8th and 15th needle. Clearance 6. For making sure, check position of retainer on bobbin case holder.

  • Page 69: Adjustment Of Retainer On Rotary Hook

    3-5-2 Adjustment of retainer on rotary hook 1. Loosen screw to the extent that retainer on bobbin case 4. Adjustment has finished. holder moves. ( 2 pcs) 2. Adjust position back and forth, left and right. Space has to be [0.8mm] and the position right and left is center of the needle.
  • Page 70 3-6-1 Adj ust for Thread trim sensor and stopper 3. Refer to “9-1 How to enter maintenance mode” and enter <Note> maintenance mode. Please disconnect power inlet from the wall. 4. Press Machine Test . 1. Remove needle plate. (Fixing screw 2 pcs) 5., Press # 7 Cutter Test and then press ESC .
  • Page 71 6. Loose Setscrew for adjusting knife sensor position. 7. Adjust stopper position. Fix sensor position by sliding knife sensor to [Hide out] or Loose stopper screw and adjust clearance 1mm as [Come out]. following picture. Setscrew Hide out Stopper Knife sensor Stopper screw Come out End of process.

  • Page 72: Exchange Of Moving Knife

    3-6-2 Exchange of moving knife 1. Remove needle plate. 4. Remove the knife shaft. 5. Exchange moving knife 2. (1) Refer to “9-1 How to enter maintenance mode” and enter maintenance mode. (2) Press Machine Test . nut. 6. Fix moving knife with knife shaft and (3) Press # 7 Cutter Test and open moving knife.

  • Page 73: Exchange Of Fixed Knife

    3-6-3 Exchange of fixed knife 1. Remove needle plate. 4. Tighten fixed knife pushing to forward as full as possible. Press the fixed knife by off set screw driver. <Caution> 2. Remove fixed knife. In case moving knife and the left side of fixed knife overlaps excessively when closing, adjust the position of fixed knife slightly to the right direction.

  • Page 74: Adjustment Of Moving Knife And Fixed Knife

    3-6-4 Adjustment of moving knife and fixed knife 1. Remove needle plate 3. Cut thread and check how well it is cut. Use two polyester threads for checking. 2. Adjust slant of fixed knife with [upper adjustment screw] and [lower adjustment screw] that fix fixed knife. <Note>...

  • Page 75: Adjustment Of Position Of Moving Knife

    3-6-5 Adjustment of position of moving knife 1. Remove needle plate. (Fixing screw 2 pcs) 4. In this condition, Turn link pin till moving knife maximum Confirm that the moving knife has closed. opened point and fix link pin. Loosen screw on link pin. (Fixing screw 1 pcs) 5.

  • Page 76: Adjustment Of Bobbin Thread Holder

    3-6-6 Adjustment of bobbin thread holder 1. Remove needle plate. (Fixing screw 2 pcs) 4. Pull bobbin thread toward arrow mark and see that bobbin thread comes off with tensile gauge [20-25g]. 2. Close moving knife like putting bobbin thread between Tighten lock nut.

  • Page 77: Exchange Of Keeper Solenoid

    3-6-7 Exchange of keeper solenoid 1. Remove Bed cover (lower). (Fixing screw 2 pcs) 3. Remove E-ring on fulcrum pin. 4. Remove Keeper ass'y. (Fixing screw 2 pcs) 2. Remove connector for keeper solenoid. 5. Exchange keeper solenoid. (Fixing screw 2 pcs)
  • Page 78 6. Install good parts. <Caution> Pushing keeper solenoid to solenoid base. Insert 2.0mm thickness gauge between solenoid base to polyslider. 2.0mm thickness gauge <Front view> Keeper plunger Solenoid base Clearance between keeper plunger and solenoid base should be kept as much as equally. 7.

  • Page 79: Adjustment Of Position Of Keeper

    3-6-8 Adjustment of position of keeper 1. Loosen screw on solenoid base. (Fixing screw 2 pcs) 3. Insert keeper positioning gauge (Bobbin) into rotary hook. <View from right> Keeper positioning gauge About 1.0mm (Bobbin) Keeper 4. Adjust position of stopper. This is the position where tip of keeper contacts to gauge 3.

  • Page 80: Adjustment Of X Carriage Belt Tension

    3-7-1 Adjustment of X carriage belt tension 3. Adjust belt tension. 1. Remove base cover. (Fixing screw 6 pcs [12 pcs Wide X-carriage]) Use push and pull gauge. Scaling position should center between two position sensor boards. (Please scale it for Wide X-carriage model at center of between first and second position sensor board from right side.) 3.
  • Page 81 6. Fix tension pulley bracket. 7. Finally check belt tension then tight lock nut. 8. Return things back to previous places in reverse order. Please refer to [ 9-6 Position Registration of coordinates for positioning sensor ], registry embroidery aria and finish this adjustment.

  • Page 82: Exchange Of X Carriage Belt

    3-7-2 Exchange of X carriage belt 1. Remove base cover. 4. Loosed the adjusting nut. (Fixing screw 6 pcs [12 pcs Wide X-carriage]) <Spanner> 7mm 3. Remove detecting plate. (Fixing screw 2 pcs) 5. Remove belt holding plate. (Fixing screw 4 pcs) 4.
  • Page 83 Exchange belt to good one. 8. Referring to [3-7-1 Adjustment of X carriage belt tension], adjust tension of belt. 9. Return case cover and frame base to previous places. <Caution> Please do not fit tooth of belt to inside ditch. <Caution>...

  • Page 84: Adjustment Of Y Carriage Belt Tension

    3-7-3 Adjustment of Y carriage belt tension 1. Refering to [2-2 Removal of outer covers], remove cover E Showing from above and cover F. 3. Loosen tension screw so as to move tension. 2. Loosen lock nut for tension adjustment screw. 4.
  • Page 85 5. Measure belt tension at between screw hole 9 and 10 6. Place some straight bar on arm of Y carriage. 1.5Kg 10 9 When press belt 1.5kg, should [7mm] apace between straight bar and face of belt. Measurement point Y belt 7.
  • Page 86 8. Fix Idler bracket Y. 9. Check belt tension again then tighten lock nut. Similarly, adjust Y carriage right also. 10. Put things back in reverse order of respective adjustment. Please refer to [ 9-6 Position Registration of coordinates for positioning sensor ], registry embroidery aria and finish this adjustment.

  • Page 87: Exchange Of Y Carriage Belt

    3-7-4 Exchange of Y carriage belt 1. Refering to [2-2 Removal of outer covers], remove cover E and cover F. Showing from top. 3. Loosen tension screw so as to move tension. 2. Loosen lock nut for tension adjustment screw. 4.
  • Page 88 5. Loosen screw on drive pulley. (Fixing screw 2 pcs) Then set rear side belt to “holding plate. And slide back “holding plate” till setscrew position. 6. Exchange belt. 8. Fix belt holding plate. <Caution> Please care belt dose not out from “belt holding plate”.
  • Page 89 9. Referring to [3-7-3 Adjustment of Y carriage belt tension], 12. Touch X carriage body to pin gauges. adjust tension of Y belt. 10. Loosen fixing screw for X carriage ass’y. (Fixing screw 4 pcs) Should not have gap between pin and carriage. 13.
  • Page 90 3-7-5 X c arriage limit sensor replacement and adjustment <Note> Please turn off machine power. 3. Installment of Position sensor board will be opposite procedure from Procedure 2. 1. Remove base cover. <Note> (Fixing screw 6 pcs [12 pcs Wide X-carriage]) Detecting plate should be positioned at the center of sensor of Position sensor board.
  • Page 91 3-7-6 Y carri age limit sensor replacement and adjustment <Note> 3.Installment of Position sensor board will be opposite Please turn off machine power. procedure from Procedure 2. <Note> 1. Remove Cover F Detecting plate Y should be positioned at the center of sensor of Position sensor board.

  • Page 92: Adjustment Of Timing Belt Tension

    3-8-1 Adjustment of timing belt tension Removal of outer covers 4. Adjust gaps between “Tension ass’y” and “Tension block” 1. Refering to [2-2 ], remove cover H. to [6.5 to 7.0mm] by adjusting bolt. 2. Loosen the screw on tension ass’y. (Fixing screw 2 pcs) 5.

  • Page 93: Exchange Of Timing Belt

    3-8-2 Exchange of timing belt Removal of outer covers 4. Loose fixing nut of tension block about 60 degrees. 1. Refering to [2-2 ], remove cover H. <Spanner> 7mm 2. Remove pointer. (Fixing screw 1 pcs) 5. Loosed the adjusting bolt. 3.
  • Page 94 7. Take off the timing belt from motor pulley. 8. Exchange belt to good one. 9. Install each parts in reverse order. For installation and adjustment of each part, please refer to respective manuals. Referring to [3-8-1 Adjustment of timing belt tension], adjust tensile strength of timing belt.
  • Page 95 3-8-3 Exch ange of main shaft timing board 1. Exchange main shaft timing board by the bellow process. 4. Put detecting slit board. Do the opposite procedure of step Main shaft timing board consists of detecting slit board and timing slit board as showed bellow. <NOTE>...
  • Page 96 3-8-4 Adj ustment of detecting slit and timing slit 1. Loosen the setscrew fixing detecting slit showed as bellow 4. After main shaft timing board is set, turn the main shaft and so that detecting slit can turn itself. confirm that LED4 goes out at 0 degree (L point). 5.
  • Page 97 7. Loosen the setscrew fixing timing slit showed as bellow so that timing slit can turn itself. To let timing slit turn itself Set screw 8. Adjust the distance between timing slit and timing board. As showed bellow, adjust the distance between timing slit and timing board to [ 0.7 + / - 0.2mm ] and tighten the...
  • Page 98 4-1 E xchange of fuse <Check> auxiliary fuse. Make sure that power switch is off before this work. 4. Exchange it to the <Note> <Note> Do not use the other fuse than the auxiliary fuse(3SB6A) Disconnect the plug during the work. 1.
  • Page 99 4-2 Exchange of CONT-D2 board <Note> Disconnect the plug during the work. * Remove outer cover (right), referring to [ 2-2 How to remove outer cover ] 1. Take all connector out and exchange CONT-D2 board. 2. Fix screws and connect all cable which are taken. 3.
  • Page 100 4-3 Exchange of switching power supply and adjustment of power voltage output and of power failure detection 4-3-1 Exchange of switching power supply 1. Remove Drive A Circuit Board Unit, referring to [ 4-3 How 4. Remove the switching power supply cable. (2 places) to remove Drive A Circuit Board Unit ] 36V switching 2.
  • Page 101 7. Remove Power switch assy box 9. Check if Power switch assy box is not set upside down. Remove 4 screws as shown bellow. Sides where corners are cut shall come to downside. And sides where VRs of Switching Power Supply exist shall come to left.
  • Page 102 4-4-2 Adjustment voltage output of 24V switching power supply 5. Put the probe of digital tester in an optional power (Please use digital Tester for this work.) connector under the serial port. <Check> Make sure that power switch is off before this work. 1.
  • Page 103 4-4-3 Adjustment voltage output of 36V switching power supply 5. Put the probe of digital tester in CN1 (the lower part of (Please use digital Tester for this work.) the circuit board) of CONT-D2 circuit board. <Check> Make sure that power switch is off before this work. 1.
  • Page 104 4-4 Exchange of cooling fan <Note>Disconnect the plug during the work. Y pulse motor 1. Remove outer cover (right), referring to [ 2-2 How to CONT-D2 circuit board remove outer cover ] 1. Remove outer cover (right), referring to [ 2-2 How to remove outer cover ] 2.
  • Page 105 5 Open and remove control box 5-1 Remove control box <Check> Be sure to turn power switch OFF before work. 4. Remove control box. 1. Remove three setscrews of fixing bracket as shown in Standard the figure below. 10.4” 2. Disconnect the connectors indicated by the arrows in the figure below.
  • Page 106 5-2 Remove LCD-CE board 1. Remove four setscrews as shown in the figure 4. Remove core module. below and remove rear cover. 5. Remove narrow flat cable for LCD unit. 2. Remove connectors for SW cable, Box cable, cable for LCD inverter (red/white).
  • Page 107 7. Lift LCD-CE board as shown in the figure below. 8. Remove four setscrews and LCD unit. Remove wide flat cable for LCD unit. before Rev. A before Rev. A Wide flat cable flat cable Rev. A LCD unit LCD u LCD u LCD u Display...
  • Page 108 5-2a 10.4” Remove LCD-CE board 1. Remove emergency stop blacket. 4. Remove connectors. Remove four setscrews as shown in the figure below and remove rear cover. LVDS cable able Narrow flat cable for LCD unit flat cable ＳＷ cable 5. Remove two sets screws and two studs. 2. Remove connectors for SW cable, Box cable.
  • Page 109 7. Remove set screw and rear cover. 8. Remove set screw and LCD unit. LCD unit it Please reverse procedure when installing LCD-CE board. 105b...
  • Page 110 5-3 Setting for LCD-CE board DIP switch (LCD-CE-U) Coin battery Switch to OFF on all the settings for DIP switch. Insert our official coin battery (EPZ01190). Refer to the latest parts list for the parts number. The battery is used for back-up power source of real-time clock on an embroidery machine.
  • Page 111 6-1-1 Remove Inverter <Notice> Please disconnect machine inlet from the wall. 3. Remove two screws shown in the following figure and <Check> inverter from bracket. Before you start to work, make sure the display of inverter is Screw off. 1. Remove outer cover. Refer to [2-2 How to remove outer cover].
  • Page 112 Remove control terminal cover. 7. Remove main terminal cover Insert fingers in a gap (under the “PULL” indication) on the Hold both left and right ends of main terminal cover with underside of control terminal cover, and pull the cover fingers and slide the cover toward yourself and remove it.
  • Page 113 verter Installation 6-1-2 In <Note> Check if voltage specifications of the machine and inverter Refer to specification sticker for voltage specifications of are matched before installation. the machine. Remove control terminal cover. Sticker on inverter Insert a finger in a gap (under the “PULL” indication) Inverter for 110 - 120V on the underside of control terminal cover, and pull the cover toward yourself and remove it.
  • Page 114 3. Tighten screws with screwdriver to install power cable and 5. Tighten screw and connect 10 cables the following motor cable per the following connection diagram. connection diagram. (Cable color: ORANGE, RED, (Cable color: GLAY, WHITE BLACK, BLUE, and BROWN) BROWN, PURPLE, WHITE, GREEN, BLUE, YELLOW, BLACK, and GLAY) main terminal cover...
  • Page 115 7. Mount bracket in inverter with two screws tightened. 9. Install inverter in the machine with two screws tightened. (2 places) (Be sure not to lose screws in the machine.) Screw Screw <Note> Check if voltage specifications of the machine and inverter are matched before installation.

  • Page 116: How To Set Inverter

    6-2-1 How to set inverter In case of spare parts supply, parameter is preset. Please contact HAPPY, when you need to change it. Parameter cannot be set while machine is running . Pay attention to electric wires as setting is done with power is on. Next, change each setting.
  • Page 117 How to set the prohibition setting 10. After each setting is done, select [ F 0 0 ] by pressing Up or Down key to return to setting change prohibition. 11. Press FUNC/DATA. 0 ] is blinking. Press Up key or Down key while pressing STOP. 1 ] is blinking.
  • Page 118 6-2-2 Initialization of parameter Please note that you are unable to make this setting while the machine is running. When setting is mistakenly made in mid way, the setting will return to parameter in normal standard in one action. Thereafter please change to parameter you want to set. 1.
  • Page 119 7 Program update procedure * The sequence of procedures of program update is described below.. If you need more details, please refer to each manual. 1. Insert the updated program downloaded USB memory to the USB port of the machine with its power turned “OFF”.
  • Page 120 7-1 Preparation for program update * Download updated program file and decompress the file. Program for HCD2, HCS2, HCH, HCR2 " "MainProgramA**** " *Copy the decompressed file(s) or the folder that contains decompressed file to USB memory. File names on your PC are shown below: Program for HCD2, HCS2, HCH, HCR2 "...
  • Page 121 7-2 Machine program update 1. Insert USB memory that contains data for 4. Select [UpdateFile]. version up into insertion slot on the control box. 5. Select [MachineInstallData]. 2. Refer to [ E5-1 How to enter maintenance mode] and enter maintenance mode. The screen shows below: 6.
  • Page 122 8. Press NEXT. 9. Referring to [7-4 Setting of revolution], Perform [Re-Initialization of machine system] And [Initializing of machine speed]. ・* End of process.
  • Page 123 7-3 Main program update (Main program 〜Ver.*1.21) 1. Insert USB memory that contains data for version up into <NOTE> insertion slot on the control box. * Please do not take out USB memory during installation. * Please do not turn off the power during installation (it will 2.
  • Page 124 7-3a Main program update (Main program Ver.*1.22〜) 1. Insert USB memory that contains data for <NOTE> version up into insertion slot on the control box. * Please do not take out USB memory during installation. * Please do not turn off the power during installation (it will 2.
  • Page 125 7-4 Setting of revolution Re-Initialization of machine system Initializing of machine speed Perform this function only to fix problems with the Setting of revolution of main shaft, which is suitable machine. to the machine is required. When performed, all settings in the “OPTION” menu If setting is not done, the revolution may not speed are lost.

  • Page 126: How To Enter Maintenance Mode

    8 Maintenance mode Maintenance mode consists of items as shown below. Machine Test Movement test, maintenance, and adjustment Machine Setting Machine control setting Memory All Clear Initialization of design memory. Main Program Update Update of operation program and language data Machine Program Update Update of control program and frame move data Frame Position Entry...
  • Page 127 8-2 Machine Test Machine movement Below operation will be moved solely. In some operations, actuator of motor will be moved, Keep hands and face away during movement for your own safety. #13 Position Data Entry : Confirm registration of frame #1 Needle Adjust : Input of Needle bar detect Potentiometer position data At section of [Setting to detect needle position], this...
  • Page 128 1. Enter maintenance mode in reference to [8-1 How to enter 5. Return to drive mode by pressing ESC and maintenance mode] 2. Press Machine Test . 3. Select desired number to be confirmed. Page is switched by pressing Selected item will be executed. # * *************** 4.
  • Page 129 8-3 Memory All Clear Initialization of design memory Delete all the design memory. Execute this function when occurring design breakage or impossibility of design input. If abnormality is found after deleting all the data, replace LCD-CE board (or Core module) since the board might be broken.
  • Page 130 8-4 Record Operation data display You can confirm history of operation. Total number of stitch : Total number of stitch used for embroidery so far Error occurrence record : Type of errors and its occurrence date Occurrence record by error type : Accumulated number of each error occurrence Thread break history : The number of thread break by needle bar...
  • Page 131 8-4-2 Record of Error occurrence 1. Enter maintenance mode in reference to [ 8-1 How * Error record is cleared by pressing OK and to enter maintenance mode ] the screen of the procedure 3 is displayed. 2. Press Record . * If you do not prefer to clear it, press Cancel and the screen of the procedure 3 is displayed..
  • Page 132 8-4-3 Number of occurrence in each error display 1. Enter maintenance mode in reference to [ 8-1 How * You can confirm accumulated number for E-000 to to enter maintenance mode ] E-255 with 2. Press Record . * The screen returns to the previous screen by pressing BACK.
  • Page 133 8-4-4 Thread break history ・ 5. Selection menu of Clear Thread Break Count will 1. Enter maintenance mode in reference to [ 8-1 be opened when pressing CLEAR at the screen of How to enter maintenance mode ] procedure 3. 2.
  • Page 134 8-5 Setup Machine setting <NOTE> ( *: Setting is for each indivisual machine, so prohibit to change setting. When you need to chage it, please contact us in advance) ( $ : Setting is different for each model type. Please check before changing data) ( # : Setting is depending on options installed.
  • Page 135 1. Enter maintenance mode in reference to [ 9-1 How to enter maintenance mode ]. Press Machine Setting. 3. Select desired number and modify setting. ・ Setting values become default by pressing ・Page is switched by pressing 4. Press ESC button after modifying of setting number.
  • Page 136 8-6 Position Registration of coordinates for positioning sensor This procedure is to memorize embroidery area into the machine. This procedure has to be done after exchange of CONT-S2 board, position sensor board etc. (Machine will display error [ E-67 Position data ] without the registration of coordinate of Position sensor. <NOTE>...
  • Page 137 4. Then register Y axis direction. Frame moves in the numerical order as shown in the following figure. 5. Below message will be displayed with successful completion. - - - - Complete - - - - * Retry from procedure 2 if [Error] occurs. Frame position registration is finished.
  • Page 138 8-7 Maintenance Register―Registration of machine maintenance date Registration of machine maintenance date When last maintenance date is registered, next regular ・ By pressing Days button, you can change the number of maintenance date will be set automatically. days for regular maintenance. (1 ~ 3,650 dsys) ・ By pressing Hours button, you can change the number of 1.
  • Page 139 8-8 Machine Setting Navigation after exchanging CONT board (Main program Ver.*1.34~) After exchange CONT board, please activate [Machine 5．Press Setting Navigation after exchanging CONT board] function. Machine setting menu will be opened and all items which Then you can set necessary machine setting with one are required to set will be highlighted.
  • Page 140 Press 9. When the current machine program is older than latest START . version, press OK . [Position Registration of coordinates for positioning begins. The installation will be started. sensor] Refer to [8-6 Position Registration of coordinates for positioning sensor] for more details. Press ESC.
  • Page 141 9-1 Installment, setting and adjustment of safety sensor All the packing contents Safety sensor Safety sensor emission optical receiver (Right side) (Left side) Clamp A Clamp B Spiral tube Stud (6 pcs) (4 pcs) (1 pcs) (4 pcs) 9-1-1 Installment of safety sensor For your own safety make sure to unplug cord from receptacle.
  • Page 142 6. Remove screws fixed on needle bar boss check Fix safety sensor optical receiver to the stud on plate and fix the safety sensors’ cord and the left side with the mounting screws removed Clamp B with the screws on both right and left sides.
  • Page 143 9. Insert safety sensor optical receiver cord into 12. Fix Arm upper cover. the small connector and insert safety sensor emission cord into the large connector. Small connector Large connector Fasten safety sensor cord and TC cable together End of process with spiral tube.

  • Page 144: Setting Procedure

    9-1-2 Setting procedure Turn on machine. 5. After safety sensor setting is complete, return to the [MAINTENANCE MODE] screen by pressing ESC. To access maintenance mode, press NEXT while pressing START/STOP button at the startup screen of the control box after booting the machine. .
  • Page 145 9-1-3 Adjustment of Optical axis 1. Loosen screws that are fixing 4. Confirm of operation check. Safety sensor optical receiver Block Optical axis of Needle sensor at drive mode (Use (Left side). screwdriver or something) Loosen slightly ghtly Loosen screw until Safety sensor can move slightly Optical axis 5.
  • Page 146 9-2 Installment of Bobbin winder *. Install Bobbin winder Remove outer cover left. Refer to [ 2-2 How to remove Outer cover left ] * Confirm all the necessary items are ready. Set of Bobbin winder Bobbin thread tension assembly Thread stand pin Motor assembly Fixing screws...
  • Page 147 3.After installment 5. Connect 3P connector (DC motor relay cable) from Arm body and 3P connector (DC motor cable) from Bobbin thread winder assembly. DC motor cable Motor ass’y (3P connector) Install with attached screws nstall with att tached screws tach (2 places) * Make sure with mounting direction...
  • Page 148 as the picture below. 8. Install Cover B with screws. ( Before installment ) Fix with screws Thread stand Fixing point (3pcs) (After installment) 9. Remove screw from Cover D and Install Thread stand pin to Cover D. Use Flat head screwdriver. Flat head Screwdriver Fix with screws...
  • Page 149 13. Adjust position of Guide. 15. Remove Guide and install attached Winder cover to Put Empty bobbin into Thread winding shaft and adjust Cover B. position of Guide to be center of Empty bobbin. <Note> Clearance around shaft should be kept averagely. Empty bobbin Winder Cover Fix with Screw...

  • Page 150: Electrical Connection Diagram

    10-1 Electrical connection diagram (for LCD-CE board) 1/3 (before Rev. A)
  • Page 151 10-1 Electrical connection diagram (for LCD-CE board) 2/3 (before Rev. A)
  • Page 152 10-1 Electrical connection diagram (for LCD-CE board) 3/3 (before Rev. A)
  • Page 153 10-2 Electrical connection diagram (before Rev. A) (for LCD-CE-U, LCD-CE-MX board)
  • Page 154 10-2 2/4 Electrical connection diagram (before Rev. A) (for LCD-CE-U, LCD-CE-MX board)
  • Page 155 10-2 Electrical connection diagram (before Rev. A) (for LCD-CE-U, LCD-CE-MX board)
  • Page 156 10-2 Electrical connection diagram (before Rev. A) (for LCD-CE-U, LCD-CE-MX board) 4/4...
  • Page 157 Electrical conne 10-2a ction diagram (Rev. A) 1/4 149a...
  • Page 158 Electrical connection diagram 10-2a (Rev. A) 2/4 149b...
  • Page 159 Electrical connection diagram 10-2a (Rev. A) 3/4 149c...
  • Page 160 Electrical connection diagram 10-2a (Rev. A) 4/4 149d...
  • Page 161 10-3 Connection of inverter...
  • Page 162 10-4 Explanation of function of circuit board HCD8121* LCD-CE-U Circuit Board Ass'y CN No. Function Core module I/F Core module I/F 7in LCD I/F 7in touch panel input X5_2 7in LCD backlight output USB-A connector 1 USB-A connector 2 USB-B connector SD card TP-SW board I/F CONT-** board I/F...
  • Page 163 HCD8122 LCD-CE-MX Circuit Board Ass'y CN No. Function Core module I/F Core module I/F 7in LCD I/F Ｘ5 7in touch panel input Ｘ5_1 X5_2 10.4in touch panel input X5_3 7in LCD backlight output X5_4 10.4in LCD I/F USB-A connector 1 Ｘ6_1 USB-A connector 2 Ｘ6_2...
  • Page 164 HCD81222 LCD-CE-MX Circuit board Ass'y CN No. Function Core module I/F Core module I/F 7in LCD I/F Ｘ5 7in touch panel input Ｘ5_1 10.4in touch panel X5_2 input 7in LCD backlight X5_3 output X5_4 10.4in LCD I/F USB-A connector 1 Ｘ6_1 USB-A connector 2 Ｘ6_2...
  • Page 165 HCD8116* TP-SW Circuit Board Ass'y HCD8124* TC8-7 Circuit Board Ass'y (Rev. A)
  • Page 166 HCD8119*...
  • Page 167 HCD8117*S TC sensor board ass'y (Sensor) (before Rev. A) HCD8117*H TC sensor board ass'y (Relay) (before Rev. A) CN No. Function Sensor switching input, Sensor output Sensor input Sensor output Sensor output HCD8109*S Timing detecting board ass'y (Sensor) HCD8109*H Timing detecting board ass'y (Main) Function Out put of L point, C point, angle sensor...
  • Page 168 HCD8111* Sensor relay board ass'y CN No. Function Switching sensor input, Output of present sensor Input of switch 1 Input of switch 2 Input of switch 3 Input of switch 4 CN10 Input 1 of position sensor CN11 Input 2 of position sensor CN12 Input 3 of position sensor CN13...

  • Page 169: How To Respond For Some Question (As Example Step)

    11-1 How to respond for some question (As example step) *When you receive some question from customer, please use this step for sold problem as sample. Receive contact from customer Ask machine model and serial number Ask contents of question *Circumstance of machine (Windy, Dusty, Floor condition and etc) *Embroidery condition (Frame, Fabric, Thread, Pattern) *Machine creations.
  • Page 170 11-2-1 Trouble shooting (Electricity doesn’t turn on) Trouble Factor Cause of trouble and measure Page Electricity 1. Did fuse blow? Mechanical doesn't turn on 1-1 If it did, replace it. 2. Check of defect on board. 2-1 Replace of LCD-CE board. 2-2 Replace of LCD unit.
  • Page 171 11-2-2 Trouble shooting (Thread break) Trouble Factor Cause of trouble and measure Page Thread break 1. Is needle drop unstable by vibration? (2-2) Mechanical 1-1 Reconsider where to install the machine. 1-2 Move the machine to floor fully reinforced. 1-3 Use strong table to be able to endure vibration. 2.
  • Page 172 11-2-2 Trouble shooting (Thread break) Trouble Factor Cause of trouble and measure Page Thread break 11. No problem in rotary hook? 3-1-1 Mechanical 11-1 Clean it to remove lints. 11-2 Furbish scratch. 11-3 If backlash of bobbin case holder and outer hook grows bigger, replace them. 11-4 Replace.
  • Page 173 11-2-2 Trouble shooting (Thread break) Trouble Factor Cause of trouble and measure Page Thread break 24. Check tip of keeper hit the bobbin case. Mechanical 24-1 Adjust it regularly. 3-6-8 25. ls take-up lever timing proper ? 25-1 Adjust as specified. 3-2-9 26.
  • Page 174 11-2-2 Trouble shooting (Thread break) Trouble Factor Cause of trouble and measure Page Thread break Operator 10. Is frame used to suit pattern size? (20-1) 10-1 Use frame to suit pattern size. 11. When you dispose of thread (thread remains around rotary hook), didn't you damage rotary hook, needle plate with scissors? 11-1 Tell to dispose of thread carefully.
  • Page 175 11-2-2 Trouble shooting (Thread break) Trouble Factor Cause of trouble and measure Page Thread break . Is there something that produce steam, wasted cotton, dust around. Environment the embroidery machine? 5-1 Keep the embroidery machine off those things. 5. Does thread go out of control by taking wind from outside or heater etc.? 6-1 Keep the embroidery machine off such wind.
  • Page 176 11-2-3 Trouble shooting (Erroneous thread cut) Trouble Factor Cause of trouble and measure Page Erroneous 1. Is thread cut timing proper? Mechanical thread cut 1-1 Set timing to specified value. 3-6-1 (E-190) 2. Isn't rubbing of fixed knife and moving knife weak? (E-193) 2-1 Adjust to be able to rub properly.
  • Page 177 11-2-3 Trouble shooting (Erroneous thread cut) Trouble Factor Cause of trouble and measure Page Erroneous 11. Check the needle bar moves up and down during thread cut. Mechanical thread cut 11-1 Adjust position of jump device. 3-2-7 (E-190) 11-2 Replace needle bar cushion. 3-3-7 (E-193) 11-3 Replace needle bar driver.
  • Page 178 11-2-4 Trouble shooting (Off-registration of pattern) Trouble Factor Cause of trouble and measure Page Off-registration 1. Does frame move smoothly? Mechanical of pattern 1-1 Avoid curling of thread and cloth. 1-2 Reinstall of outer cover in case of touch with outer cover. 2.
  • Page 179 11-2-4 Trouble shooting (Off-registration of pattern) Trouble Factor Cause of trouble and measure Page Off-registration Mechanical 14. No problem in timing sensor unit? of pattern 14-1 Test the Machine-Machine movement #11 (Test of timing sensor unit) of Maintenance mode, Check timing sensor unit. If trouble found, error number and messages will be displayed.
  • Page 180 11-2-4 Tro uble shooting (Off-registration of pattern) Trouble Factor Cause of trouble and measure Page Off-registration Operator 2. Is cloth properly stretched. (6-2) (7-5) of pattern 2-1 Stretch properly. 3. Is thread tension proper? (4-5) (8-1) 3-1 Observing sewing rhythm, set thread tension properly. 4.
  • Page 181 11-2-5 Trouble shooting (Upper thread comes off from needle hole) Trouble Factor Cause of trouble and measure Page Upper thread 1. Is keeper in motion? Mechanical comes off 1-1 Check if cable was cut or there is something unusual. from needle 1-2 In case solenoid is in trouble, replace.
  • Page 182 11-2-5 Trouble shooting (Upper thread comes off from needle hole) Trouble Factor Cause of trouble and measure Page Upper thread 10.Check the needle bar moves when start sewing. Mechanical comes off 12-1 Adjust position to fix jump device. 3-2-5 from needle 12-2 Replace needle bar driver.
  • Page 183 11-2-6 Trouble shooting (Upper thread remains) Trouble Factor Cause of trouble and measure Page 1. Does wind let thread go beyond control? (outside wind, heater, and fan etc.) Environment 1-1 Keep the embroidery machine off from wind. 2. Is voltage of power as rated and stable? 2-1 Supply rated voltage.
  • Page 184 11-2-7 shooting (Malfunction of thread break detection) Trouble Factor Cause of trouble and measure Page Malfunction 1. Trouble in turning detection roller. Mechanical thread break 1-1 Clean roller shaft holder. detection 1-2 Check if slit disc doesn't contacts sensor. (empty 1-3 Clean sensor if dust gets stuck.
  • Page 185 11-2-7 Trouble shooting (Malfunction of thread break detection) Trouble Factor Cause of trouble and measure Page Malfunction 1. Check circuit board. Mechanical thread break 1-1 Replace of LCD-CE board. detection 1-2 Replace of TC 12 board. 1-3 Replace of CONT-D2 board. (not detected) Operator 1.
  • Page 186 11-2-8 Trouble shooting (Suspension of upper shaft) Trouble Factor Cause of trouble and measure Page Suspension 1. Upper thread twine round rotary hook or rotary hook retainer. Mechanical of main shaft 1-1 Get rid of it. (23-2) (E-18) 2. Check return of keeper goes smooth. (when start sewing, thread cutting. (E-51) 2-1Adjust it regularly.
  • Page 187 11-2-9 Trouble shooting (Malfunction of needle bar change) Trouble Factor Cause of trouble and measure Page Head does not 1. Check lint or cloth is seized between Lower Moving rail and Bearing. Mechanical move 1-1 Remove seized lint or cloth. (E-021) 2.
  • Page 188 11-2-10 Trouble shooting (Defect on Thread catcher) Trouble Factor Cause of trouble and measure Page does not catch 1. Thead catcher does not extend hook sufficiently. Mechanical thread 1-1 Adjust position of Thread catcher 3-2-12. 1-2 Adjust position of Thread holder. 3-3-10 2.
  • Page 189 11-2-11 Trouble shooting (Others / Mechanical) Trouble Factor Cause of trouble and measure Page 1. Check Needle is not bent. Needle Breakage Mechanical 1-1 Replace bent Needle. 3-1-2 2. Check Moving Head set securely. 2-1 Adjust Positioning Roller Shaft. 3-3-3 3.
  • Page 190 12-2-12 Trouble shooting ( Others / Electric Trouble Factor Cause of trouble and measure Page Frame overrun 1. Interference between censor circuit board and douser. Mechanical 1-1 Position adjustment of douser. 1-2 Replace of censor circuit board. 2. Check whether cable has problem or not. 2-1 Replace in case damage exists.
  • Page 191 11-3-1 Startup error and measure (Main program Ver.*1.37~) Error message will be displayed if error occurs during machine startup. After confirming contents, press button [OK] on control box to release error, then restore in accordance with measure in this list. Message Error Measure...
  • Page 192 11-3- Error and measure When trouble occurred while the machine is running, error number and error item will be displayed. After confirming contents, press button [SET] on control box to release error, then restore in accordance with measure in this list. Message Error Measure...
  • Page 193 message Error measure page Needle center Stop position of needle bar is off center (1)Turn needle selection cam by hand to set to regular position. (2)If trouble occurs repeatedly, fix mechanical trouble in needle selection & its vicinity. Needle over Specified needle number went beyond Adjust position of needle selection cam (poten- needle number of the machine.
  • Page 194 message Error measure page Position set Failure to read embroidery frame (1)Check if position sensor is dirty. 3-7-5 sensor signal. (Return) Turn off power source, then turn on again. 3-7-6 Position Entry Failure to read embroidery frame (2) Setup mistake of the machine parameter sensor signal.
  • Page 195 message Error measure page Memory error It became impossible to retain contents (1) Turn power off once and turn on again. of memory. (2) If problem recurs frequently, replace LCD-CE board. Disk error Unable to communicate continuously (1)Turn off power source once and turn it on with memory media.
  • Page 196 message Error measure page Frm. drive err Frame movement did not complete (1) Check timing sensor unit and slit. (2) Update program 7-2, 7-3a during normal movement. (Time over) Frm.drive data Frm.drive data Update program. 7-2, 7-3a 255 Default Error During embroidery, frame movement Re-initialize machine speed setting.
  • Page 197 11-4-1 Tables for timing / adjustment value Tables for Timing/Adjustment value Take-up lever timing 0 degrees Rotary hook timing 23 degrees Needle height 5 degrees LED4 light out at 0 degrees(Clockwise) Main shaft timing LED3 light on at 270-284 degrees(Clockwise)
  • Page 198 2017 / 8 HappyJapan Inc. 9-5. TAITO 2-CHOME,TAITO-KU,TOKYO,JAPAN TEL +81-3-3834-0711 FAX +81-3-3835-8917...

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