HappyJapan HCR3E Series Maintenance Manual
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HappyJapan HCR3E Series Maintenance Manual

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Maintenance Manual for Embroidery Machine
HCR3E SERIES
Version 1.2
HappyJapan Inc.

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  • Page 1 Maintenance Manual for Embroidery Machine HCR3E SERIES Version 1.2 HappyJapan Inc.
  • Page 2 # 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 ......................2 Index ..........................3 Special tool, Measuring equipment, Other .................... 9 1 Placement of key mechanical parts ....................11 2 Setting up the machine 2-1 Machine installation ..................... 13 ....................13 Assemble the thread guide ......................
  • Page 4 Index Page 4-2 Moving head 4-2-1 Assemble and remove moving head (except for 1 head) ....... 40 4-2-2 Assemble and remove moving head (1 Head) ........44 4-2-3 Adjustment of needle position (back and forth) ........49 4-2-4 Adjustment of needle position (left and right) Adjust for 1 head ...

  • Page 5: Table Of Contents

    ndex Page 4-6 Carriage unit 4-6-1 Adjustment of X carriage drive belt tension ............. 90 4-6-2 Adjustment of X carriage timing belt tension ............92 4-6-3 Adjustment of Y carriage drive belt tension ............. 94 4-6-4 Adjustment of Y carriage timing belt tension ............96 4-6-5 Adjustment of carriage timing belt tension .............
  • Page 6 Index Page E1 Placement of key electronic parts --------------------------------------------------------------------108 E2 Exchange and Setting of electric related component E2-1 Exchange and Setting of CONT-R2 Board (Main program Ver.B2.13.0～)----------------------------- ----------------------110 E2-2 Exchange Timing Circuit Board ----------------------------------------------------114 E2-3 Connection of Detection Circuit Board -------------------------------------------116 E2-4 Exchange TC7-8 Circuit Board -----------------------------------------------------117 E2-5...
  • Page 7 Index Page E4 Program update procedure---------------------------------------------------------------------------- 137 E4-1 Preparation for program update ------------------------------------------------------- 138 E4-2 Update the program------ ---------------------------------------------------------------- 139 E4-2-1 Update the main program and the machine program------------------ 139 E4-2-2 Update main program---------------------------------------------------------- 140 E4-2-3 Update machine program----------------------------------------------------- 142 E4-3 Setting of revolution----------------------------------------------------------------------- 144 Re-Initialization of machine system Initializing of machine speed...
  • Page 8 Index Page E7 Electric system diagram E7-1 Pulse motor driver (PMD) wiring----------------------------------------------------------172 E7-2 Pulse motor driver (PMD) setup-----------------------------------------------------------173 E7-3 Inverter wiring--------------------------------------------------------------------------------- 174 E7-4 Electrical connection diagram------------------------------------------------------------ 175 E7-5 List of electrical connection diagram---------------------------------------------------- 178 E7-6 Explanation of function clrcuit board---------------------------------------------------- 180 E8 How to respond for some question (As example step) -------------------------------------------- 187 E9 Trouble shooting E9-1 Electricity doesn’t turn on ------------------------------------------------------------------ 188...
  • Page 9 Special tool, Measuring equipment, Other HSA90030 HSA90131 Keeper positioning gauge (Page 88) 1.2mm thickness gauge (Page 29, 30) HSA90080 HSA90230 Retainer positioning gauge [0.8mm] (Page 74) Tensile gauge (Page 87) HSA90240 HSA90090 Dial-gauge set (Page 55) Positioning pin [φ 4] (Page 27)
  • Page 10 Special tool, Measuring equipment, Other HSA90270 HSA90311 Vernier calliper gauge [200mm] (Page 37) Shell alvania EP Grease 100g (Page 76) HSA90210 HSA90340 0.2mm thickness gauge (Page 63) Shell Grease7 MIL-G-23827B 50g (Page 39) HSA90290 M0404342 Tension gauge 2000Cn(1000g) (Page 92, 94, 97) Needle height gauge (Page 15, 53)
  • Page 11 1 Placement of key mechanical parts Control box Thread tension unit Thread guide pillar Take-up lever Moving head Needle bar change unit Thread stand Thread guide A Neddle plate Rotary hook cover Rotary hook Thread holder...
  • Page 12 1 Placement of key mechanical parts Timing detecting unit Y carriage Upper shaft X carriage Thread cutting driver...
  • Page 13 2-1, 2-2 Setting up the machine 2-1 Machine installation 2-2 Assemble the thread guide Water level Higher Lower Head bed Bolt Tighten the lock nut Lock nut Block base Rubber mount Pipe cover (1) place block base and rubber mount under bolts and adjust bolts so that the machine becomes level.
  • Page 14 2-3, 2-4 Setting up the machine 2-3 Removal of stopper 2-4 Check of needle position Turn power switch ON, and (1) Loosen the screw and remove the red shipping collars that (1). enter user maintenance are equipped on the both side of the guide bar. mode.
  • Page 15 2-5 Setting up the machine 2-5 Check of needle height. (4) Put needle height gauge in rotary hook. (1) Move moving head to the position which 8 needle is active. Remove bobbin case. (2) Bring needle bar down. Refer to [ 5 User maintenance mode ] Check if the needle tip touches to the gauge slightly.
  • Page 16 2-6, 2-7 Setting up the machine 2-6 Check of rotary hook timing (4) Check the clearance between needle and rotary hook should be [ 0.1 ~ 0.2mm (1) Remove needle plate, Move moving head to the position which 8 needle. Turn upper shaft and set to lowest needle position [L] Refer to [ 5 User maintenance mode ] (5) Fix the...
  • Page 17 2-8 Setting up the machine 2-8 Check of thread path (3) Ceramic and rim of take-up lever To keep stable and high quality stitches, please keep a) No burr and crack places where thread contacts in the best condition. <Note> Pleas confirm that there is no burr and crack at the position which thread is passing.
  • Page 18 2-8 Setting up the machine (5) Needle (7) Pressure foot a) Needle tip shouldn't be warped or bent. a) No burr and crack inside hole b) Not bent When you slide needle tip on surface of nail and if the nail gets scratched. needle tip is warped.
  • Page 19 2-8 Setting up the machine (10) Rotary hook retainer a) There is No burr and crack at the position which thread pass through. Rotary hook retainer...
  • Page 20 2-9 Setting up the machine Threading - Upper thread - Bobbin thread Please adjust minor thread tension Bobbin thread tension is depending on adjustment of upper unit that detection rotary is not thead. slipping and turn smoothly. Please note that bobbin will turn to arrow-marked direction <...
  • Page 21 2 Setting up the machine 2-10 Trial sewing (1) Turn thread break detecting switch ON. (2) Please confirm that thread trimming, thread catcher, jumping is functioning. < Important > For a month, please use machine with 70% of maximum speed.
  • Page 22 3-1 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 23 3-2 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 3-3]. <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 24 3-3 Relation between needle and upper 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.
  • Page 25 4-1-1 Exchange of needle bar driver 1. Remove moving head. 2-3. Slide up the Head shaft. Please refer to [ 4-2-1, 4-2-2 Assemble and remove moving head ]. 2. Remove needle bar driver. 2-1. Slide moving head to 8 th needle. And remove the Slide unit.
  • Page 26 4-1-1 Exchange of needle bar driver 3-2. Set head shaft into the needle driver and tight screws. 3-3. Set slide unit. (Hexagon socket set screw : M4-4 2 pcs) (Hexagon socket button head screw : M4-10) < Note > No clearance between head and slide unit. Set bottom head shaft face flat with head face.
  • Page 27 4-1-2 Adjustment of take-up lever timing 1. Move moving-head to the position which 8 needle is 4. Turn upper shaft and insert positioning pin into the hole of active. cam through the positioning hole on machine body. The hole of cam 2.
  • Page 28 4-1-2 Adjustment of take-up lever timing 7. Fix screw. Screw on take up lever cam 8. Pull positioning pin out. 9. Turn brake switch OFF. Turn upper shaft and set angle at [ 270 degrees (C point) 10. Set all covers.
  • Page 29 4-1-3 Check of height of pressure foot 1. Bring needle bar down. 4. If wrong space ( not 1.2mm ), please adjust height of Please refer to [ 5 User maintenance mode ] pressure foot guide bar. Please refer to [ 4-1-4 Adjustment of height of pressure foot ].
  • Page 30 4-1-4 Adjustment of height of pressure foot 1. Bring needle bar down. 4. Insert [ Gauge I.2mm ] between needle plate and pressure Please refer to [ 5 User maintenance mode ] foot. 1.2 mm is standard, But please adjust depends on thickness of material.
  • Page 31 4-1-5 Exchange of pressure foot 1. Loosen fixing screws of front panel (lower) and cord clip. 4. Install good parts. (Fixing screw 2 pcs) Slide front panel (lower) to left or right direction up to the position of pressure foot to be replaced. In case you need to slide front panel (lower) further, please slide front panel (lower) on neighbor head Cord clip...
  • Page 32 4-1-5 Exchange of pressure foot 8. Turn upper shaft and set dial disc to [ 0 degree 10. Tighten fixing screw for pressure foot. Turn brake switch ON. (Fixing screw 1 pcs) At this moment, no gap between gauge and pressure foot or needle plate.
  • Page 33 4-1-6 Adjustment of thread catcher 1. Loosen screw of thread catcher, and push thread catcher Space between hook and pressure foot to direction as below, and temporary fix screw. Space between back side of pressure foot and hook is 0.5 ~ 1mm.
  • Page 34 4-1-6 Adjustment of thread catcher 5. Pull hook completely and return to front for movement of 3 pitches of gear. Gear ar r 6. Loosen screw of photo sensor, and move photo sensor to the position that thread break lamp becomes RED and fix photo sensor.
  • Page 35 4-1-7 Exchange of thread catcher guide 1. Remove guard plate. 4. Please refer to [ 4-1-6 Fixing of thread catcher ], Use the #1 (+) Screw driver install thread catcher to finish. 2. Exchange guide. Fix the guide after moving it to the right. 3.
  • Page 36 4-1-8 Exchange of pressure foot cam 1. Please refer to [ 4-2-1, 4-2-2 Assemble and remove 3. Put on grease to new presser foot cam. moving head ], remove moving head and face plate (right). Also, put on grease to fixing nuts, then insert nuts into hole Moving head of pressure foot cam to prevent drop of the nut.
  • Page 37 4-1-8 Exchange of pressure foot cam In this time, please check distance between upper face 5. Set dial disc to [ L + 0 degrees of presser foot and bottom face of fixed head to [26.1+/-0.2mm]. In this time, please check distance between upper face of presser foot and bottom face of fixed head to [25.5+/-0.2mm].
  • Page 38 4-1-9 Adjustment of fixing of jump solenoid 1. Please refer to [ 4-2-1, 4-2-2 Assemble and remove 3. Install good parts. moving head ], remove moving head and face plate (right). Moving head Please check Jump solenoid position. Turn main shaft till touch plunger of jump solenoid and needle bar driver and check main shaft indicator.
  • Page 39 4-1-10 Disassembling and Cleaning of jump solenoid 1. Disassemble the solenoid nut. 3. Put the designated grease on plunger part. <Grease> Shell Grease7 MIL-G-23827B Use rubber sheet as safeguard. Equivalent brand 4. Assemble the solenoid to the original position. The flat surface of the solenoid nut should come to the front.
  • Page 40 4-2-1 Assemble and remove moving head (except for 1 head) 1. Remove moving head. 1-3. Remove the thread tension bracket. 1-1. Set moving head at position that 15 needle is active. (Pull thread tension bracket to front) Remove the front panel (upper), cord clip and lighting bracket.
  • Page 41 4-2-1 Assemble and remove moving head (except for 1 head) 1-5. Slide moving head to right direction 2. Install moving head. 2-1. Set moving head at position that 15 needle is active. Set all take-up lever to guide bar starting from 1 needle Guide bar After rail goes out from positioning roller, take moving head...
  • Page 42 4-2-1 Assemble and remove moving head (except for 1 head) 2-3. Move moving head to the position that 8 needle is 2-5. Please needle bar of 8 needle down until needle driver active. catches needle bar boss. Then turn upper shaft to needle Tighten 4 screws on moving head.
  • Page 43 4-2-1 Assemble and remove moving head (except for 1 head) 2-7. Install Thread tension bracket. 3. After installation of moving head, please check following (Pan head screw : M4-10 4 pcs) points; 3-1. Check needle height, please check needle height at 1 and 15 needle.
  • Page 44 4-2-2 Assemble and remove moving head (1 Head) < Note > When you need to take all moving head out, 1-3. Remove the thread tension bracket. please take 1 head at last. (Pull thread tension bracket to front) 1. Remove moving head. 1-1.
  • Page 45 4-2-2 Assemble and remove moving head (1 Head) 1-5. Move moving head to the position which 8th needle is 1-7. Slide moving head to the right direction by knob, and active, by knob. take moving head out after the rail going out from roller. Loosen screw on moving head support.
  • Page 46 4-2-2 Assemble and remove moving head (1 Head) Install moving head. 2-2. Set moveing head to 15th needle position and temporally tighten screws. 2-1. When you install moving head, please set the same (Hexagon socket head cap screw : M4-20 6 pcs) position of Needle bar change unit as the position which (Hexagon socket head cap screw : M4-6 2 pcs) you took Moving head out.
  • Page 47 4-2-2 Assemble and remove moving head (1 Head) 2-4. Fix Moving head support to Slide Bar by screws. 2-6. Move moving head to the position that 1 needle is (Hexagon socket head cap screw : M5-15 2 pcs) active. Slide bar Install the needle position plate.
  • Page 48 4-2-2 Assemble and remove moving head (1 Head) 2-9. Please adjust Adjustment of needle position (left and 3. After installation of moving head, please check followindg right) Adjust for 1 head ]. points; Referring to [ 4-2-4 Adjustment of needle position (left and right) Adjust for 1 head ].
  • Page 49 4-2-3 Adjustment of needle position (back and front) 1. Please set Thread break detecting switch to ON for 4. Move the Positioning plate to front and back for adjust adjusting head. Other head, please set to JUMP. needle position against needle hole to center and tight the screw.
  • Page 50 4-2-4 Adjustment of needle position (Left and Right) Adjust for 1 head If you change 1 head position, you need to confirm head position other all head. 1. Remove the cover of Needle bar change unit. Thread detecting board Cover 2.
  • Page 51 4-2-4 Adjustment of needle position (left and right) 5. Please confirm needle position after tight the screw for needle bar change unit inside the beem. 6. Return Thread Detecting Board, detecting cover and needle bar change cover to previous places. 7.
  • Page 52 4-2-5 Adjustment of needle position (left and right) Adjust for 2 to last each head 4. You can move Moving head right and left for position Please set Thread break detecting switch to ON for adjustment by hand. Then tight 4 screws. adjusting head.
  • Page 53 4-2-6 Adjustment of needle height 1. Remove the front panel (upper) and cord clip. 4. Turn upper shaft to set dial disc to [ 10 degrees Slide front panel (lower) to left or right direction up to the position that you can see needle bar to be adjusted. In case you need to slide front panel (lower) further, please slide front panel (lower) on neighbor head.
  • Page 54 4-2-6 Adjustment of needle height 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. 8. Set direction of needle stop as illustrated below. 10.
  • Page 55 4-2-7 Adjustment of needle bar lowest point 1. Take Upper shaft cover. 5. Turn upper shaft to set dial disc to [ 355 degrees ]. Upper shaft cover 6. Turn on the brake switch. 2. Move moving head to the position that 14 needle is active.
  • Page 56 4-2-7 Adjustment of needle bar lowest point 9. Loosen a fixing screw of fasten collar. 11. Check movement of the Dial-gauge with turning fasten collar forward and back ward then, find needle bar lowest point that the movement of the dial-gauge stops. Fasten collar 12.
  • Page 57 4-2-8 Adjustment of needle bar stopper 1. Turn the machine power on. 5.Push “MENU” , and then push “OTHER” 2. Remove thread adjusting unit assembly from a head which requires adjustment. Then, remove two(2) pieces 6.Push Maintenance. of screws indicated with red arrows. Thread Adjusting Unit...
  • Page 58 9. Check an angel on a disk visually, and then loosen a screw of a needle which requires adjustment. If an angel on the disk deviates from a required angle, try to adjust an angle on the disk and tighten the screw when an required angle is secured.
  • Page 59 4-2-9 Exchange of needle bar, needle bar spring, cushion and pressure foot block 1. Refering to [ 4-1-5 Exchange of pressure foot ], remove pressure foot. At this time, remove pressure foot spring (lower), pressure foot block, cushion, pressure foot boss and needle bar boss.
  • Page 60 5. Fix needle bar spring. 6. Fix 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 [ 4-2-6 Adjustment of needle height ].
  • Page 61 4-2-10 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 [ 4-2-1, 4-2-2 Assemble and remove moving head ]. 2. Exchange of needle bar boss check plate. 3.
  • Page 62 4-2-11 Exchange of take-up lever 1. Remove moving head. 4. Please do not miss “Plastic thrust washer” between E-ring Please refer to [ 4-2-1, 4-2-2 Assemble and remove moving and Take up lever. Head ]. Remove plastic thrust washer. (1 pcs) 2.
  • Page 63 4-2-11 Exchange of take-up lever 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 64 4-2-12 Adjustment of tension of thread adjusting spring 1. Remove thread adjusting unit ass’y. (Fixing screw 4 pcs) 2. Block has spring groove to be able to adjust in three steps. Put tip of spring in upper groove. Strongest tension will be obtained in upper groove. 3.
  • Page 65 4-2-13 Adjustment of stroke of thread adjusting spring 1. Loosen screw on adjuster. 2. Move adjuster lower position with small flat-head driver. When you move adjuster upward, stroke will get small. When you move it down, stroke will get large. * The lower position is default setting.
  • Page 66 4-2-14 Adjustment of thread holder 1. Loosen screw to the extent that thread hoIder moves. 3. Thread catcher device should be adjusted if above (Fixing screw 4 pcs) clearance is not keepable. Screw 2. Please putout and withdraw thread catcher by your finger and fix holder position at smoothly moving position.
  • Page 67 4-2-16 Adjustment of clip-type thread holder 1. Loosen screw to the extent that clip-type thread hoIder 3. Thread catcher device should be adjusted if above moves. (Fixing screw 4 pcs) clearance is not keepable. Screw 4. Space between Clip drive and clip should be 1-2mm. 2.
  • Page 68 4-2-17 Adjustment of clip drive unit 1. Move moving head to the position that 1 needle is active. 5. Turn power switch ON, and move moving head to 15 needle. Please confirm space between Clip drive and clip 2. Temporary fix Clip drive unit. is same as space at 1 needle.
  • Page 69 4-3-1 Check / Adjustment of needle bar change unit 1. Remove cover for needle bar change unit. 2-2. Push the Cam to right and push drive shaft to left side and tight Cam screws. Cover Drive shaft Drive Drive 2. Turn the knob to flat position of the cam and push moving head right and left side for confirm should not have a play the Cam.
  • Page 70 4-3-1 Check / Adjustment of needle bar change unit 3-1. For adjustment the sensor and slit position, pleaseloose 4. Turn the knob and move moving head to 15 needle. a screw on the slit. < Note > Please do NOT loose LEFT side screw. 5.
  • Page 71 4-3-1 Check / Adjustment of needle bar change unit 7-2. Turn shaft of Potentiometer and tight screw at middle position on showing [ * ] mark. 7-3. Move Moving head to 1 head and press Position. Confirm indication to [Needle Number 1* ].
  • Page 72 4-4-1 Adjustment of rotary hook timing 1. Move moving head to the position which 8 needle is 4. Turn upper shaft and set dial disc to [ 25 degrees active. < Note > Turn upper shaft anti-clockwise Remove bobbin case and needle plate. Turn brake switch ON.
  • Page 73 4-4-1 Adjustment of rotary hook timing 6. Clearance between needle and rotary hook should be [ 9. For making sure, check position of retainer on bobbin case ~ 0.2mm holder. Please refer to [ 4-4-2 Adjustment of retainer on rotary hook ] 10.
  • Page 74 4-4-2 Adjustment of retainer on rotary hook Loosen screw to the extent that retainer moves. ( 1 pcs ) 0.8mm Needle center position 4. Adjustment has finished. 2. Adjust position back and forth, left and right. Using adjustment gauge and adjust space to be [ 0.8mm for back and forth.
  • Page 75 4-4-3 Exchange of rotary hook shaft 1. Take hook shaft out 1-5. Lossen screws (see below picture) total 4 pcs. 1-1. Take hook retainer out. (Hexagon socket set screw : M4-4 4 pcs) (Hexagon socket button head screw : M3-5) (Plain washer : M3) 1-2.
  • Page 76 4-4-3 Exchange of rotary hook shaft 2. Install new shaft. 2-3. Put gear and fix. Set screw position to flat face of shaft, and tighten screw. (Hexagon socket set screw : M4-4 2 pcs) The parts which has one flat face is for hook side. Center of gear should be center of shaft.
  • Page 77 4-4-3 Exchange of rotary hook shaft 3. Install hook 3-1. Temporary fix hook and hook retainer. (Hexagon socket button head screw : M3-5) (Plain washer : M3) 3-2. Adjust rotary hook timing. Please refer to [ 4-4-1 Adjustment of rotary hook timing ]. 3-3.
  • Page 78 4-5-1 Check of thread cutting driver 1. remove table support cover, cover for thread cutting driver. 3. Check clearance between Driver base and Fasten block for guide [ 18 ~ 19mm ]. Please confirm bulge right side point of "Slide shaft" position likefollowing picture.
  • Page 79 4-5-1 Check of thread cutting driver 6. Check clearance between “Driver base” and “Fasten block for guide” [ 40 ~ 41mm ]. Please confirm bulge left side point of "Slide shaft" position likefollowing picture. Clearance Slide shaft - If you have some error in the step 3. ~ 6, please adjust [ 4-5-2 Adjustment of thread cutting driver ].
  • Page 80 4-5-2 Adjustment of thread cutting driver 1. Remove “Table support cover”, and “Cover for thread 3. Loose Fasten screw and adjust slide shaft position to even cutting driver”. protuberance against face of driver base and tight the screw. Cover for thread cutting driver Slide shaft Fasten screw 4.
  • Page 81 4-5-2 Adjustment of thread cutting driver 5. Adjust Slit right position against sensor. If you off the position, please adjust sensor position by screw on sensor bracket. Sensor Slit 6. After it, please adjust [ 4-5-5 Check / Adjustment of position of moving knife ].
  • Page 82 4-5-3 Exchange of moving knife 1. Remove needle plate. (Fixing screw 2 pcs) 5. Exchange moving knife. 6. Setting drive link hole to moving knife, insert knife drive shaft assembly. 2. Open moving knife. Please refer to [ 5 User maintenance mode ]. 3.
  • Page 83 4-5-4 Exchange of fixed knife 1. Remove needle plate. 4. Tighten fixed knife pushing to forward as full as possible. < Note > In case moving knife and the left side of fixed knife overlaps excessively when closing, adjust the position of 2.
  • Page 84 4-5-5 Check / Adjustment for position of moving knife 1. Remove the Needle plate 4. Loosen screw on Thread cutting link and slide the link to right side for open the moving knife. Screw 2. Please check knife closing position to following drawing. (Point of moving knife same face with fixed knife cutting line) Please refer to [ 5 User maintenance mode ] for easy...
  • Page 85 4-5-5 Check / Adjustment of position of moving knife 6. Keep the Thread cutting link position on “Step 5” and tight Please check opening point. screw. Should open the "Moving knife" to left till "point of Moving Please confirm play the Link plate. knife"...
  • Page 86 4-5-6 Adjustment of moving knife and fixed knife 1. Remove needle plate 2. Check if knife drive shaft has no backlash in up and down 4. Cut thread and check how well it is cut. direction. Use two polyester threads for checking. If backlash is found, adjust it referring to [ 4-5-3 Exchange of moving knife ].
  • Page 87 4-5-7 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 5.
  • Page 88 4-5-8 Adjustment of position of keeper 1. Remove needle plate and bed cover. 4. Insert keeper positioning gauge ( Bobbin ) into rotary hook. Solenoid base 5. Refer to [ E5-1 How to enter maintenance mode ] and 2. Loosen screw on solenoid base. ( Fixing screw 2 pcs ) enter maintenance mode.
  • Page 89 4-5-8 Adjustment of position of keeper 7. Press #4 Keeper Test. < View from right> Keeper positioning gauge About 1.0mm (Bobbin) Keeper Adjust solenoid base where tip of keeper contacts slightly to the gauge then tighten bracket screw. Clearance between bobbin and keepr is [ about 1.0mm 8.

  • Page 90: Adjustment Of X Carriage Drive Belt Tension

    4-6-1 Adjustment of X carriage drive belt tension 1. Remove base cover and drive unit cover. 4. Set tension adjustment screw position 10mm from face of bracket of shaft support. Tighten screw by 1/4 turn. Drive unit cover Base cover 2.
  • Page 91 4-6-1 Adjustment of X carriage drive belt tension 7. Return base cover and drive unit cover to previous places. 8. Please refer to [E5-6 Position- Registration of coordinates for positioning sensor], register embroidery area and finish this adjustment.

  • Page 92: Adjustment Of X Carriage Timing Belt Tension

    4-6-2 Adjustment of X carriage timing belt tension 1. Take drive unit cover and X carriage base cover out. 4. Push belt at center of belt by push gauge with 500gf. Please adjust tension of belt by adjusting nut that belt moves 5-6mm.
  • Page 93 4-6-2 Adjustment of X carriage timing belt tension 7. Return base cover and drive unit cover to previous places. 8. Please refer to [ E5-6 Position- Registration of coordinates for positioning sensor ], register embroidery area and finish this adjustment.

  • Page 94: Adjustment Of Y Carriage Drive Belt Tension

    4-6-3 Adjustment of Y carriage drive belt tension 1. Take middle cover and rear cover out. 4. Loosen screws of Y motor base by half turn. Rear cover Middle cover 5. Push belt by push gauge with 500gf. Belt should hide half of hole for motor fixing screw. 2.
  • Page 95 4-6-3 Adjustment of Y carriage drive belt tension 6. Tighten screws of Y motor base 7. Tighten lock nut of tension adjusting screw Lock nut 8. Set table support cover 9. Set rear cover and middle cover 10. Please register frame position Please refer to [ E5-6 Position- Registration of coordinates for positioning sensor ].

  • Page 96: Adjustment Of Y Carriage Timing Belt Tension

    4-6-4 Adjustment of Y drive timing belt tension The way of adjustment of Y drive timing belt is same right side 3. Loosen lock nut for tension adjusting screw. and left side. <Spanner> 7mm Below explantion is for right side. 1.
  • Page 97 4-6-4 Adjustment of Y drive timing belt tension 5. Push belt by push gauge at a mark position. 7. Tighten lock nut of tension adjusting screw Belt should move 2.5 ~ 3.0mm by 1kgf of push gauge. Please adjust tension by tension adjusting screw Lock nut 8.

  • Page 98: Adjustment Of Center Carriage Timing Belt Tension

    4-6-5 Adjustment of center carriage timing belt tension 1. Take middle cover and rear cover out. 5. Adjust space between tension plate and idler pulley bracket 5mm by tension adjusting screw. Idler pulley bracket Rear cover middle cover Tension plate 2.

  • Page 99: Exchange Of Main Shaft Timing Belt

    4-7-1 Exchange of main shaft timing belt 1. Remove bed cover B. 4. Remove six (6) pieces of screws, and then remove a left cover. Bed Cover B 5. Loosen a nut indicated with a red arrow by using a 7mm 2.
  • Page 100 7. Loosen a screw indicated with a red arrow, and then 10. Tighten two (2) pieces of screws mounted on an upper remove an idler pulley assembly. shaft collar assembly. Screw for tension Idler Pulley 11. Slide a lower shaft, and then remove a lower shaft pulley. adjustment Assembly 8.
  • Page 101 14. Put a lower shaft and a fasten collar A together to make their surfaces flat, and then tighten a screw on the fatsen collar A. Lower Shaft Pulley Lower Shaft Flat Fasten Collar A 15. Put an idler pulley assembly back on. 16.

  • Page 102: Adjustment Of Upper Shaft Timing Belt Tension

    4-7-2 Adjustment of upper shaft timimg belt tension 1. Take mission cover (left) out 4. Adjust space between tension plate and tension plate (lower) 12.5 ~ 13mm by tension adjustingscrew < Note > Please Keep tension plate straight. Mission cover(left) 2.

  • Page 103: Adjustment Of Timing Detecting Unit

    4-7-3 Adjustment of timing detecting unit 1. Remove the Head cover and Detecting cover. 4. Rotate the timing slit clockwise at the view from the disk. Then, tighten the screws when LED4 goes off. (LED4 will go off if the timing slit blocks L point sensor.) L POINT SENSOR LED4 5.
  • Page 104 4-7-3 Adjustment of timing detecting unit 8. Finally, put the cover back on.

  • Page 105: User Maintenance Mode

    5 User maintenance mode User maintenance mode has the items as below. Change jump Change the needle bar’s movement. “JUMP” : Needle Jump, “DRIVE” : Needle Drive Upper shaft turns Upper shaft turns clockwise and counterclockwise. When release button, upper shaft stops. Needle change Move the sewing head to the adjustment needle in the direction of the arrows.

  • Page 106: Machine Movement

    4. Please follow instruction of “5-2 Machine Movement”. 5. In case you press END at above display, return to Menu display. If you press button once more, return to drive mode. 5-2 Machine Movement 1. Refer to [ 5-1 How to enter “User Maintenance Mode” ] 3.
  • Page 108 E1 Placement of key electronic parts Seiral Port Control Box CONT-R2 board Timing detecting board Bobbin Thread Winder Main Switch Jump Unit Brake Release Switch Thread Catcher...
  • Page 109 TC8-7 board Jump SW board Head SW Circuit Board Core module LCD-CE-U board LCD unit Keeper Unit Laser Position Marker Clip Unit Needle Bar Changing Unit Power Supply Box Thread detecting board X Motor Y Motor Sensor Relay Board Keeper Relay Board Servo amp(X) Servo amp(Y) DC fan unit...
  • Page 110 E2 Exchange and Setting of electric related component <note> Please take electric plug, when you exchange electric component. E E 2 2 - - 1 1 E E x x c c h h a a n n g g e e a a n n d d S S e e t t t t i i n n g g o o f f C C O O N N T T - - R R 2 2 B B o o a a r r d d 1.
  • Page 111 10. Select HCR3e 14. Press 15. Press 11. Select your machine model and press 16. Press if you have new program version than current version in the machine. Installation starts after press 12. Press 13. Needed Machine setting items will be displayed brigther. Please set according to your machine specification/options then press ESC after setting is done...
  • Page 112 18. Press 1001001- Center mark position of X axis Center mark position of Y axis 21. When you press START button, registation of X axis direction will start. Frame moves as below. 19.Press 20. Operate following below instructions 22. Then registration of Y axis direction will starat. Frame moves as below.
  • Page 113 23. Below message will be displayed with successful conpletion. - - - - Complete - - - - Retry from step 20, if [Error] occurs. 24. Press OK 「Auto Speed setting」will starts Main shaft will start rotation automatically and adjust speed setting.
  • Page 114 E E 2 2 - - 2 2 E E x x c c h h a a n n g g e e T T i i m m i i n n g g C C i i r r c c u u i i t t B B o o a a r r d d 4.
  • Page 115 7. Turn main shaft and set [0 degree(L point)] These steps are all you have to do. 8. Rotate the timing slit clockwise at the view from the disk. Then, tighten the screws when LED4 goes off. (LED4 will go off if the timing slit blocks L point sensor.) L POINT SENSOR LED4 9.
  • Page 116 E2-3 Connection of Detection Circuit Board CN6 on Detection Circuit Board has different way of connection for each head. Please attention to following information. 1. For Head with emergency stop SW->TC-EMG harness 2. For Head without emergency SW->white loop harness 3.
  • Page 117 E2-4 Exchange TC7-8 Circuit Board 1. Remove the thread tension bracket. Please refer to [ 4 -2-1, 4-2-2 Assemble and remove 5. Remove board by sliding to the left moving head ]. 2. Remove thread tension rear cover. Remove the screws at the tow places below. ＜...
  • Page 118 E E 2 2 - - 5 5 E E x x c c h h a a n n g g e e n n e e e e d d l l e e s s t t o o p p s s e e n n s s o o r r a a n n d d p p o o t t e e n n t t i i o o m m e e t t e e r r 1.
  • Page 119 11. Press Machine Test 14. Set potentiometer and fix <check> 11. Press #1 Needle Adjust and press Position Sensor is located at notch center of slit collar and * mark is shown on creen The position of sensor is not lacated at notch of slit collar, re-adjust again Sensor Slit...
  • Page 120 E2-6 Exchange Thread trimming sensor 5. Turn CAM and set sensor position is out from slit. Power on 1. Take table cover out and press NEXT on control box Sensor Slit 2. Exchange sensor and connect haeness 6. CAM turns and stops at stopping position automatically. Check postion of moving knife Sensor Sensor...
  • Page 121 E2-7 Exchange X-Y Position Sensor 1. Unscrew and take cover out 4. Set cover Y Sensor 5. Set coordintes Refer [E5-6 Position- Registration of coordinates for positioning sensor] X Sensor 2. Unscrew and take Position Sensor Circuit Board. Then take harness out X Sensor Y Sensor 3.
  • Page 122 E2-8 Exchange Brake Unit 1. Remove left rear table. Remove cover left. 2. Take connector out. Unscrew and take brake solenoid. 3. Put 0.1-0.15mm paper between brake solenoid and brake disk, and fix brake solenoid by screw. 4. Take paper out and set cover, set left rear table. End of process.
  • Page 123 E2-9 Exchange Pulse Motor Driver ＜note＞Make sure power plug is disconnected during the process 1. Remove power supply box. 4. Check setting of new driver (same setting for X and Y) Remove the screws at the seven places below. 5. Fix driver by screws and connect harnesses, and put cover. 2.
  • Page 124 E2-10 Exchange of switching power supply and adjustment of output voltage ＜note＞Make sure power plug is disconnected during the process 1. Remove power suplly box cover. 4. Replace swicthing power suplly and fix screw and Remove the screws at the five places below, connector.
  • Page 125 7. Put tester into CN28 of CONT-R2 board. ＜note＞ *Tester(red) to be put into No.1 of CN28. *Tester(black) to be put into No.2 of CN28. 8. Power main switch on, and trun VR(volume) on switching power supply and set [24.0V±0.1V] End of process.
  • Page 126 E2-1 Exchange Cooling Fan ＜note＞Make sure power plug is disconnected during the process 4. Unscrews fan cover (note : nut is reverse side). 1. Remove power supply box cover. Remove the screws at the five places below. 2. Remove filter. 5.
  • Page 127 E2-12 Exchange Inverter ＜note＞Make sure power plug is disconnected during the process 1. Remove power supply box cover. 3. Remove control terminal cover. Remove the screws at the seven places below. Insert fingers in a gap (under the “PULL” indication) on the ‘underside of control terminal cover, and pull the cover ‘toward yourself and remove it.
  • Page 128 E2-13 Setting Inverter In case of spare parts supply, parameter is preset. Please contact HAPPY, when you need to change it. Parameter cannot be set while nachine is running. Pay attention to electric wires as setting is done with power is on. E2-13-1 Parameter release the keep off setting and parameters setting How to release the setting change prohibition.
  • Page 129 7. Select the code you would like to change and press. FUNC/DATA . Parameter of the function is displayed. 8. Change parameter by pressing up of down key. 9. Press FUNC/DATA. After [SAVE] is displayed, the next function code is displayed.
  • Page 130 E2-13-2 Initialize parameter Please note that you are unable to make this setting while the machine is running Whan setting is maistakenly made in mid way, the will return parameter in normal standard in one action. There after please to parameter you want to set. 1.
  • Page 131 E3 Open and remove control box E3-1 Remove control box ＜note＞Make sure power plug is disconnected during the proces 1. Remove cover right . Remove the screws at the six places below. 4. Remove control box. Standard 2. Disconnect a connector(Yellow arrow part). Remove scerws that fix harness 10.4inch 3.
  • Page 132 E3-2 Remove LCD-CE board 1. Remove four setscrews as shown in the figure below 4. Remove core module. and remove rear cover. 2. Remove connectors for SW cable, Box cable, cable for 5. Remove narrow flat cable for LCD unit. LCD inverter (red/white).
  • Page 133 7. Lift LCD-CE board as shown in the figure below. Please reverse procedure when installing LCD-CE board. Remove wide flat cable for LCD unit. Slightly slide to the side and remove cable Adjust clock function by refering to instruction book After power back on.
  • Page 134 E3-2a 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 SW cable Narrow width flat cable 2. Remove the screw of the grounding terminal. 5.
  • Page 135 7. Remove rear cover. Remove thescrews at the four places below. 8. Remove LCD unit. Remove the screws at the four places below. LCD unit Please reverse procedure when installing LCD-CE board. Adjust clock function by refering to instruction book After power back on.
  • Page 136 E3-3 Setting LCD-CE board Memory card Insert our official memory (EPZ012220). Refer to the latest parts list for the parts number. This memory card contains programs and data fo on Enbroidery machine. ＜note＞In case you use SD card in the market, Make sure to use more than 16GB SD card capacity and please ask us for needed data file.
  • Page 137 Program update procedure E E 4 4 ＊The sequence of procedures of program update is described below. If you need more details,please refer to each manual. E4-2-1 Update the main program Prepare USB memory that has updating program. and the machine program Proceed whole program update by selecting [MENU]>>[OTHER]>>[Version] E4-2-2 Update the main profram 2.
  • Page 138 E4-1 Preparation for program update Download latest program file from our Web-page and extracxt it. ***** ***** 2. Copy the extracted file into the USB Memory, You will find program file folder as below image in the PC after extraction. ＜note＞Program folder should be copied to the root directory of USB memory End of process.
  • Page 139 E4-2 Update the program E4-2-1 Update the main program and the machine program E4 2 1 U d t d th 1. Insert USB memory to the machine panel which has Version up program. ＜note＞ ※Do not remove USB memory during installation ※Instllation will take sometime and do not turn off the machine power during Installation In case of writing error and displays 「...
  • Page 140 E4-2-2 Update main program 1. Insert USB memory to the machine panel which has 5. Select following 3items Language 、 Letter 、 Program Version up program. then confirm 3 items are dispayed as ”Update” 6. Press ENTER 2. Turn on machine power Installation will be started 3.
  • Page 141 8. Refer to manual「E4-4 Revolution setting」and proceed 「System initialize」and「Auto speed setting」 That is end of program updates process.
  • Page 142 E4-2-3 Update machine program 5. Select [UpdateFile] 5 S l [U d Fil ] 1. Insert USB memory to the machine panel which has Version up program. 6. Select [MachineInstallDate] 2. Turn on machine power 3. After showing below screen, Keep START/STOP button pressing then press NEXT to enter maintenance mode.
  • Page 143 8. Shut down machine power and Turn on power again. 9. Press NEXT 10. Refer to manual「E4-4 Revolution setting」and proceed 「System initialize」and「Auto speed setting」 That is end of Machine program updates process.
  • Page 144 E4-3 Setting of revolution Re-Initialization of machine system Initializing of machine speed Perform this function only to fix problems with the machine. Setting of revolution of main shaft, which is suitable to the When performed, all settings in the “OPTION” menu are lost. machine is required.
  • Page 145 E E 5 5 M M a a i i n n t t e e n n a a n n c c e e m m o o d d e e Maintenance mode consists of items as shown below.
  • Page 146 E5-2 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. position data #1 Needle Adjust : Input of Needle bar detect Potentiometer You can use this function to check if Frame position data At section of [Setting to detect needle position], this are entered correctly.
  • Page 147 Selected item will be executed. 1. Turn on machine power 2. After showing below screen, Keep START/STOP button # * ********************* # * ********************* pressing then press NEXT to enter maintenance mode. 5. Go back to [MAINTENANCE] screen if press (Not necessary if it backs automatically) 3.
  • Page 148 E E 5 5 - - 3 3 M M e e m m o o r r y y A A l l l l C C l l e e a a r r I I n n i i t t i i a a l l i i z z a a t t i i o o n n o o f f d d e e s s i i g g n n m m e e m m o o r r y y Delete all the design memory.
  • Page 149 E E 5 5 - - 4 4 R R e e c c o o r r d d O O p p e e r r a a t t i i o o n n d d a a t t a a d d i i s s p p l l a a y y You can confirm history of operation.
  • Page 150 E E 5 5 - - 4 4 - - 2 2 R R e e c c o o r r d d o o f f E E r r r r o o r r o o c c c c u u r r r r e e n n c c e e 1.
  • Page 151 E E 5 5 - - 4 4 - - 3 3 N N u u m m b b e e r r o o f f o o c c c c u u r r r r e e n n c c e e i i n n e e a a c c h h e e r r r r o o r r d d i i s s p p l l a a y y 5.
  • Page 152 E E 5 5 - - 4 4 - - 4 4 T T h h r r e e a a d d b b r r e e a a k k h h i i s s t t o o r r y y 1.
  • Page 153 E5-5 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 154 1. Turn on machine power 5. Press ESC button after modifying of setting number. 2. After showing below screen, Keep START/STOP button pressing then press NEXT to enter maintenance mode. 6. The screen returns to drive mode by pressing 3. Press Machine Setting. 7.
  • Page 155 E E 5 5 - - 6 6 P P o o s s i i t t i i o o n n - - R R e e g g i i s s t t r r a a t t i i o o n n o o f f c c o o o o r r d d i i n n a a t t e e s s f f o o r r p p o o s s i i t t i i o o n n i i n n g g s s e e n n s s o o r r This procedure is to memorize embroidery area into the machine.
  • Page 156 5. Press ESC. Center mark position of X axis Center mark position of Y axis 6. Press Frame Position Entry. Operate according to displayed below message. 7. When you press START button, registation of X axis ‘dirextion will start. Frame moves as below. (1).
  • Page 157 9. Below message will be displayed with successful completion. - - - - Complete - - - - Retry from step 6, if [Error] occurs. Frame position registation is finshied. 10. Return to drive mode by pressing ESC and...
  • Page 158 E E 5 5 - - 7 7 M M a a i i n n t t e e n n a a n n c c e e R R e e g g i i s s t t e e r r ― ― R R e e g g i i s s t t r r a a t t ion of machine maintenance date Registration of machine maintenance date When the machine runs more than 2000 hours (default When the machine runs more than 2000 hours (default...
  • Page 159 E E 6 6 - - 1 1 I I n n s s t t a a l l l l a a t t i i o o n n o o f f l l a a s s e e r r p p o o s s i i t t i i o o n n m m a a r r k k e e r r <note>...
  • Page 160 8. Press Machine Setting. 11. Press 12.Adjust angle of pointer unit to point needle position 9. Change [9 LED Needle Pointer No] to LED Needle Pointer Yes] <note> Position may be changed depend on thickness of fabric 10. Prss ESC button. End of process.
  • Page 161 E6-2 Installation of Safety sensor (front) <note>Safety sensor (front) is factory option but sensor is not set on machine. Please install sensor according to this instruction . HCR2-FS2-4 Safety sensor (front)(for 2 and 4 haeds) HCR2-FSX4-6 Safety sensor (front)(for X4 and 6 haeds) 3.
  • Page 162 5. Cut center part of grommet and pass harness through 9. Pass harness through missin (left) and bring to front grommet as photo below. <note> harness should not touch to belt 6. Connect harnessinto CN13 on Drive circuit board 10. Connect harness to extension harness(LS5) at lower part of Y carriage <note>...
  • Page 163 14. Press Machine Setting. 18. Adjust position of sensors. Confirm both LED (green and Orange) is lighting <note> Sencor should be finxed vertical 15. Change [11 N. Safety Sensor N. Safety Sensor Yes] 16. Press ESC button. 17. Press , return to running menu. After these setting, Sencor becomes effective...
  • Page 164 E6-3 Installation of Safety sensor (rear) <note> Safety sensor (rear) is factory option but sensor is not set on machine. Please install sensor according to this instruction HCR2-RS2-4 Safety sensor (rear)(for 2 and 4 haeds) 2. Take mission covers (right and left) out HCR2-RSX4-6 Safety sensor (rear)(for X4 and 6 haeds) HCR2-RSX6-8...
  • Page 165 4. Remove screw of rmission (right), Install Safety Guard on 8. Remove screw of rmission (left), Set Safety Guard (D) on missin (right) mission (left) 5. Remove screw of body, Fix Sencor (C) on body and fix to Sefety Guard(B) by screws(F) 9.
  • Page 166 16. Press ESC button. 11.Set cover <note> harness should not get caught in the cover 12. Turn on machine power 13. After showing below screen, Keep START/STOP button pressing then press NEXT to enter maintenance mode. 17. Press , return to running menu. <note>...
  • Page 167 E6-4 Installation of bobbin thread winder <note> Bobbin thread winder is factory option and installed at factory. In case you need to install later at your side, trained engineer has to install ESHCRU36010 Bobbin thread winder set . 4. Fix winder(A). (Screw M4x8) 5.
  • Page 168 8. Set thread guide (G) with M8 washer and spring washer. 11. Put thread and start to wind bobbin thread. Adjust a position of eyelet on bobbin thread guide to Adjust position bobbin stand and thread tension (E) for a position above of thread standpin (E), and fix nut. winding thread equally.
  • Page 169 E E 6 6 - - 5 5 I I n n s s t t a a l l l l a a t t i i o o n n o o f f U U p p p p e e r r T T h h r r e e a a d d H H o o l l d d e e r r <note>...
  • Page 170 8. Press Machine Setting. 9. Change [12 Clip Holder Device No] to Clip Holder Device Yes]. 10. Press ESC button. 11. Press , return to running menu. After these setting, Upper Thread Holder becomes effective.
  • Page 171 E E 6 6 - - 6 6 A A d d j j u u s s t t m m e e n n t t o o f f C C a a p p d d r r i i v v e e f f r r a a m m e e 1.
  • Page 172 E7 Electric system diagram E7-1 Pulse motor driver (PMD) wiring...
  • Page 173 E7-2 Pulse motor driver (PMD) setup...
  • Page 174 E7-3 Inverter wiring...
  • Page 175 E7-4 Electrical connection diagram...
  • Page 178 E7-5 List of electrical connection diagram...
  • Page 180 E7-6 Explanation of function clrcuit board HCD8122* LCD-CE-MX Board Ass'y...
  • Page 181 HCD8116* TP-SW Circuit Board Ass'y CN No. Function Switch output, LED input...
  • Page 182 HCR8121* CONT-R2 Circuit Board Ass'y...
  • Page 183 HCD8109* TIMING Circuit Board Ass'y CN No. Function Out put of L point, C point, angle sensor HCD8110* POSITION SENSER Circuit Board Ass'y CN No. Function Sensor out put HCR8115* TC7-8 Circuit Board Ass'y CN No. Function Out put to even number sensor Input of even number sensor Detecting board ass'y I/F Jump SW board I/F...
  • Page 184 HCR8108* JUMP SW Circuit Board Ass'y CN No. Function TC7-8 board I/F HCR8109* START/STOP Circuit Board Ass'y CN No. Function TC7-8 board I/F...
  • Page 185 HCR8107* DETEC Circuit Board Ass'y Function Input of relay control signal （to CONT-R2 board) Output of relay control signal （to next detecting board) 24V power source for Thread detecting board 24V power source for Thread detecting board Emergency stop I/F （Connect relay cable when the emergency button is not fixed with head)
  • Page 186 HCR8112* KEEPER RELAY Circuit Board Ass'y CN No. Function Keeper 1 Keeper 2 (next head) Input of keeper relay Output of keeper relay HCR8104* POWER RELAY Circuit Board Ass'y CN No. Function AC power source input AC power source relay (Inverter) (Rev.
  • Page 187 E8 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 serial number Ask contents of question *Circumstance of machine (Windy, Dusty, Floor condition and etc) *Embroidery condition (Frame, Fabric, Thread, Pattern) *Machine creations.
  • Page 188 E9 Trouble shooting E9-1 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. E3-2 2-2 Replace of LCD unit. E3-2 2-3 Replace of CONT-R2 board E2-1...
  • Page 189 E9-2 Thread break Trouble Factor Cause of trouble and measure Page Thread break 1. Is needle drop unstable by vibration? Mechanical 1-1 Reconsider where to install the machine. 1-2 Move the machine to floor fully reinforced. 2. No burr or scratch in thread guide hole? 2-1 Remove burr and scratch.
  • Page 190 Trouble Factor Cause of trouble and measure Page Thread break 11. No problem in rotary hook? Mechanical 11-1 Clean it to remove lints. ( 23-2 ) 11-2 Furbish scratch. 11-3 If backlash of bobbin case holder and outer hook grows bigger, replace them. 11-4 Replace.
  • Page 191 Trouble Factor Cause of trouble and measure Page Thread break 23. Check tip of keeper hit the bobbin case. Mechanical 23-1 Adjust it regularly. 4-5-8 24. ls take-up lever timing proper ? 24-1 Adjust as specified. 4-1-2 25. No problem in timing belt? 25-1 Adjust tension.
  • Page 192 Trouble Factor Cause of trouble and measure Page Thread break Operator 10. Is frame used to suit pattern size? ( 13-1 ) 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 193 Trouble Factor Cause of trouble and measure Page Thread break . Is there something that produce steam, wasted cotton, dust around. Environment the embroidery machine? 4-1 Keep the embroidery machine off those things. 5. Does thread go out of control by taking wind from outside or heater etc.? 5-1 Keep the embroidery machine off such wind.
  • Page 194 E9-3 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. 4-5-2 (E-190) 2. Isn't rubbing of fixed knife and moving knife weak? (E-193) 2-1 Adjust to be able to rub properly. 4-5-6 3.
  • Page 195 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 Replace needle bar cushion. 4-2-9 (E-190) 11-2 Replace needle bar driver. 4-1-1 (E-193) 12. Is position of keeper proper? 12-1 Adjust the fixed position regularly.
  • Page 196 E9-4 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. Is carriage belt tension proper? 4-6-1 2-1 Adjust all belts as specified.
  • Page 197 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-Test Machine movement #11 (Test of timing sensor E5-2 unit) of Maintenance mode, Check timing sensor unit. If trouble found, error number and messages will be displayed. If measure doesn't solve the trouble, replace of timing circuit board or cable.
  • Page 198 Trouble Factor Cause of trouble and measure Page Off-registration Operator 2. Is cloth properly stretched. ( 6-3, 7-6 ) of pattern 2-1 Stretch properly. 3. Is thread tension proper? 3-1 Observing sewing rhythm, set thread tension properly. 4. Was the machine left for a long time in middle of sewing? 4-1 Try to finish sewing as soon as possible.
  • Page 199 E9-5 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. hole 1-3 In case LCD-CE board is in trouble, replace.
  • Page 200 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 solenoid. from needle 12-2 Replace needle bar driver. 4-1-1 hole 11. Is number of revolution proper when sewing started? 13-1 Make automatic speed setting.
  • Page 201 E9-6 Upper thread remains Trouble Factor Cause of trouble and measure Page Upper thread Mechanical Upper thread is difficult to come out of keeper at time of thread cut (bent or warp etc.). remains 1-1 Modify bent or warp. 1-2 Replace keeper. 2. Keeper doesn't return properly at time of thread cut. 2-1 Modify bent of keeper.
  • Page 202 E9-7 Looping Trouble Factor Cause of trouble measure Page Looping 1.Imcorrect Pressure foot height adjustment Mechanical 1-1 Adjust with proper setting 4-1-4 2. Imcorrect Rotary hook timing, Rotary hook clearance, Needle height 4-2-6 , 4-4-1 2-1 Adjust with proper setting Opetator 1.
  • Page 203 E9-8 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. E2-4 (empty 1-3 Clean sensor if dust gets stuck. detection) 1-4 Check if cord doesn't contacts slit disc.
  • Page 204 E9-9 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 205 E9-10 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. Check lint or waste is seized in gap of Moving Cam. (E-022) 2-1 Remove seized lint or waste.
  • Page 206 E9-11 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 4-1-6 1-2 Adjust position of Thread holder. 4-2-14 2. Excessive distance between Hook and tip of Needle. 2-1 Adjust position of Thread catcher.
  • Page 207 E9-12 Others / Mechanical Trouble Factor Cause of trouble and measure Page 1. Check Needle is not bent. Needle Breakage Mechanical 1-1 Replace bent Needle. 2. Check Moving Head set securely. 2-1 Adjust Positioning Roller Shaft. 4-2-3 3. Secure adequate distance between Needle and Rotary Hook. 3-1 Adjust distance properly.
  • Page 208 E9-13 Others / Electric Trouble Factor Cause of trouble and measure Page Frame overrun 1. Interference between censor circuit board and douser. E2-7 Mechanical 1-1 Position adjustment of douser. 1-2 Replace of censor circuit board. 2. Check whether cable has problem or not. E2-7 2-1 Replace in case damage exists.
  • Page 209 E10-1 Startup error and measure 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 Exchanged control When only control box has been exchanged, open...
  • Page 210 E10-2 Error and measure When trouble occurred while the machine is running, error number and error item will be displayed. 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 211 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 212 message Error measure page Position set Failure to read embroidery frame (1) Check if position sensor is dirty. E2-7 sensor signal. (Return) Turn off power source, then turn on again. Position Entry Failure to read embroidery frame (2) Setup mistake of the machine parameter E5-5,-6 sensor signal.
  • Page 213 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. E3-2 Disk error Unable to communicate continuously Turn off power source once and turn it on again. with memory media.
  • Page 214 message Error measure page Error has occurred during update Install data Check an update program. E4-1 program. Frm. drive err Frame movement did not complete (1) Check timing sensor unit and slit. E2-2 (2) Install updated program. during normal movement. (Time over) E4-2 Frm.drive data Frm.drive data...
  • Page 215 E11 Tables for timing / adjustment value Tables for Timing / Adjustment value Machine No. 1001001～ Take-up lever timing 326° Rotary hook timing 25° Needle bar lowest point 10° LED4 light out at 0 degrees (Clockwise) Main shaft timing LED3 light on at 270-284 degrees (Clockwise) Jump solenoid 85°...
  • Page 216 2018 / 9 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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