HappyJapan HCD2-1501-40, Maintenance Manual

Page 1: ...Maintenance Manual for Embroidery Machine HCD2 1501 40 Version 2 3 HappyJapan Inc ...

Page 2: ... with work process in this manual In case there are no specific instructions or explanations in work process please be sure to unplug cord from receptacle When you exchange parts please be sure to use genuine parts designated by us Please never remodel the embroidery machine When you handle circuit boards In order to prevent troubles from static electricity please remove earth from human body Plea...

Page 3: ...3 1 2 Fixing of needle 19 3 1 3 Selection of thread 20 3 1 4 Relation between needle and upper thread 21 3 2 Fixed head 3 2 1 Exchange of crank ass y 22 3 2 2 Exchange of rod 30 3 2 3 Exchange of pressure foot arm ass y 32 3 2 4 Exchange of pressure foot cam 33 3 2 5 Adjustment of the lowest needle point 35 3 2 6 Exchange of needle bar driver 36 3 2 7 Adjustment of fixing of jump device 37 3 2 8 E...

Page 4: ... Exchange of TC8 7 Thread detecting board Rev A 60a 3 4 Needle bar change unit 3 4 1 Fixing of needle bar change unit 61 3 4 2 How to take out needle bar change stop position sensor 62 and needle position sensor potentiometer 3 4 3 Setting to detect needle position 63 3 5 Rotary hook 3 5 1 Exchange and adjustment of rotary hook timing 65 3 5 2 Adjustment of retainer on rotary hook 67 3 6 Thread cu...

Page 5: ...nsion 90 3 8 2 Exchange of timing belt 91 3 8 3 Exchange of main shaft timing board 93 3 8 4 Adjustment of detecting slit and timing slit 94 4 Exchange and Setting of electric related component 4 1 Exchange of fuse 90 4 2 Exchange of CONT D2 board 91 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...

Page 6: ...a Main program update 120 7 4 Setting of revolution 121 Re Initialization of machine system Initializing of machine speed 8 Maintenance mode 122 8 1 How to enter Maintenance mode 122 8 2 Machine Test Machine movement 123 8 3 Memory All Clear Initialization of design memory 125 8 4 Record Opereration data display 126 8 4 1 Total number of stitch 126 8 4 2 Record of Error occurrence 127 8 4 3 Number...

Page 7: ...function of circuit board 151 11 Others 11 1 How to respond for some question As example step 157 11 2 Trouble shooting 11 2 1 Electricity doesn t turn on 158 11 2 2 Thread break 159 11 2 3 Erraneous thread cut 164 11 2 4 Off registration of pattern 166 11 2 5 Upper thread comes off from needle hole 169 11 2 6 Upper thread remains 171 11 2 7 Malfunction of thread break detection 172 11 2 8 Suspens...

Page 8: ...20 2 0mm thickness gauge Page 76 HSA90030 Keeper positioning gauge Page 77 HSA90051 Bering positioning gauge 4 85mm Page 38 HSA90080 Retainer positioning gauge 0 8mm Page 67 HSA90090 Positioning pin Page 39 HSA90131 1 2mm thickness gauge Page 40 42 ...

Page 9: ...2mm thickness gauge Page 58 HSA90220 6mm positioning pin Page 87 HSA90230 Tensile gauge Page 74 HSA90240 Dial gauge set Page 35 HSA90270 Vernier calliper gauge 200mm Page 34 HSA90300 Tension gauge 2000cN Page 78 83 ...

Page 10: ...10 HSA90311 Shell alvania EP Grease2 100g Page 31 33 36 M0404342 Needle height gauge Page 52 ...

Page 11: ... of mechanical mechanism 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: ...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: ...Placement of key electronic parts Pulse motor Needle bar change unit CONT D2 TC board board Emergency stop switch Control box Fuse Power switch AC power Timing board Inverter Main motor Power supply wi itch h ...

Page 14: ...d thread stand 1 Remove all the tube holders from thread tension Tube holders are removed by pulling the tube holder upward 2 Remove 2 fixing screws and thread guide bracket 3 Remove thread guide pillar and thread stand 4 Remove 8 fixing screws and thread stand ...

Page 15: ...ve the cover G ass y Fixing screw 4 pcs 2 Remove the cover E Fixing screw 2 pcs 3 Remove the cover F Fixing screw 2 pcs 4 Remove the cover C Fixing screw 2 pcs 5 Remove the cover H Fixing screw 6 pcs 6 Remove the cover A Fixing screw 2 pcs ...

Page 16: ...in winder Fixing screw 1 pcs Remove the bobbin thread guide Fixing screw 2 pcs 9 Remove the cover B Fixing screw 2 pcs 10 Remove the cover for needle bar change unit Fixing screw 2 pcs 11 Remove the head left side cover Fixing screw 2 pcs 12 By above process removal of cover has finished ...

Page 17: ...ring holes on thread guide plate a No burr and crack 3 Ceramic and rim of take up lever a No burr and crack 4 Thread path in lower side and needle holder a No burr and crack 5 Needle a Needle tip shouldn t be warped or bent When you slide needle tip on surface of nail and if the nail gets scratched needle tip is warped Please exchange it with new one Please place needle on flat surface and check c...

Page 18: ...nd around it 7 Pressure foot a No burr and crack inside hole b Not bent 8 Rotary hook a No burr and crack b Hook point not warped c Backlash between bobbin case holder and outer hook should be less 9 Keeper a No burr and crack on tip Surface Two setscrews ...

Page 19: ... 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: ...Z twisted thread can prevent loosening of twist Z twisted S twisted Left twisted Right twisted 2 Selection of lower thread Basically please use cotton thread 80 120 120 is recommendable Pay attention to the following in selection Thickness should be equal When it is lightly stretched it doesn t break easily In process of time it doesn t get inferior Commercially available paper bobbin can be used ...

Page 21: ... Relation between needle and upper thread will be found below Representative example is shown Needle Size is German 75 in standard accessory If necessary please select in accordance with description of thread and cloth Thread In case needle size is German 75 if thread is rayon 120 is recommendable Relation between needle and upper thread Denier d If needle size and thickness of thread don t match ...

Page 22: ...emove moving head 2 Remove it by holding moving head up Caution Confirm that hook is apart from thread holder 3 Remove thread catcher sensor cable motor cable Remove thread catcher Fixing screw 2 pcs 4 Remove face plate left Fixing screw 2 pcs 5 Remove face plate right Fixing screw 2 pcs ...

Page 23: ...ail Fixing screw 2 pcs 7 Remove head shaft Fixing screw 2 pcs Caution Head shaft should be taken off upward 8 Remove needle bar driver ass y 9 Remove rod ass y Fixing screw 2 pcs Caution Remove crank ass y from guide rail ...

Page 24: ... up lever crank Fixing screw 1 pcs 12 Pull out Take up lever drive shaft and take off the crank ass y 13 Loosen the screw on fasten collar with barrel cam 14 Loosen the screw on upper shaft collar Fixing screw 2 pcs 15 Remove timing detecting board Fixing screw 2 pcs ...

Page 25: ...oosen the screw on slit disc Fixing screw 1 pcs 18 Loosen the screw on timing collar Fixing screw 1 pcs 19 Loosen the screw on upper shaft collar Fixing screw 2 pcs 20 Loosen the screw on drive pulley upper Fixing screw 2 pcs 21 Remove pointer Fixing screw 1 pcs ...

Page 26: ...y and tension block for 6 5mm to 7 0mm 23 Loosen the screw on tension shaft ass y Fixing screw 2 pcs 24 Loose fixing nut of tension block about 60 degrees Spanner 7mm 25 Loosed the adjusting bolt 26 Take off the belt 27 Remove drive pulley upper ...

Page 27: ...till touch to the machine body 29 Turn clank ass y to following picture position Dose not touch clank ass y to machine body at this position 30 Please pull out cxlank Ass y on upper shaft slowly 31 Please slide and off upper shaft collar slit Timing slit and take up lever cam from Clank ass y ...

Page 28: ...verse order For adjusting fixing of each unit please refer to process to adjust fixing of each unit Important Pay attention to following 1 4 1 Position of Upper shaft collar to same face bearing and bearing boss Center bearing Rear bearing 2 Position of upper belt pulley Touch belt pulley to upper collar and fix screw to flat face on upper ...

Page 29: ...er side then fix screw 4 Position of Face plate right close to left side then fix screw 33 Please check and adjust the following timing to finish 1 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 ...

Page 30: ...3 2 1 Exchange of crank ass y remove moving head and thread catcher Moving head Face plate left Needle bar driver ass y 2 Remove Screw on crank pin and take off Rod ass y 3 Take off rod from guide rail 4 Loosen screw on rod Fixing screw 2 pcs ...

Page 31: ... 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 Shell Gudas S2 V220 2 7 Put each unit back to where it was according to manual ...

Page 32: ...ving head face plate left needle bar driver ass y and Rod Moving head Face plate left Needle bar driver ass y Rod 2 Remove pressure foot arm ass y Fixing screw 2 pcs 3 Install good parts Caution Please fix Arm shaft to even stick out from bush 4 Put each unit back to where it was according to manual ...

Page 33: ...and Rod Moving head Face plate left Needle bar driver ass y Rod 2 Remove pressure foot cam Fixing screw 3 pcs 3 fix good parts as temporally tight screw Please check bump 2mm between front of presser foot cam and front face of fixed head Put on grease to presser foot cam Grease Shell alvania EP Grease Equivalent brand Shell Gudas S2 V220 2 2mm ...

Page 34: ...s In this time please check distance between upper face of presser foot and bottom face of fixed head to 25 5 0 2mm 25 5 0 2mm 6 Set dial disc to L 60 degrees In this time please check distance between upper face of presser foot and bottom face of fixed head to 26 1 0 2mm 7 After check item 5 and 6 then tight screw completely for fix take up lever cam 8 Put each unit back to where it was according...

Page 35: ...to 0 degree when dial swings in highest value 3 Please check indicator to 0 degree completely In case of dose not match pointer and 0 degree line please adjust pointer position to just on line 4 Referring to 3 8 4 Adjustment of detecting slit and timing slit check timing nd adjust then finish this process 5 Please check and adjust the following timing to finish 1 Take up lever timing 2 Shuttle hoo...

Page 36: ...ass y Moving head Face plate left Needle bar driver ass y 2 Install good parts At this time put grease to groove of rod shaft Grease Shell alvania EP Grease Equivalent brand Shell Gudas S2 V220 2 3 Put each unit back to where it was according to manual Caution Please fix top of head shaft position lower than ditch of oiling Top of head shaft ...

Page 37: ...t position of Jump shaft of jump device and Needle bar driver as illustrated below Front view Viewing from front Needle bar driver should come to center of Plunger Jump shaft Jump device Needle bar driver View from left This shows a state that plunger and Needle bar driver contacts Jump shaft Needle bar driver 5 Please put parts back in reverse order to finish For adjustment of fixing of each unit...

Page 38: ...ng 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 Bering positioning gauge 4 85mm 4 Return take up lever crank ass y to previous place to finish Should gap between chassis and take up lever crank to 0 03mm Please push to arrow ways Check Please check non gap between rol...

Page 39: ...t positioning pin into pin groove Pin groove 5 Tighten screw Please set position of slit on Fasten collar and Lever barrel cam Important Rotate the Take up lever barrel cam clockwise until pin ditch touches to positioning pin then tighten the screw No gap between take up lever barrel cam and crank Fasten lever barrel cam collar 6 Pull out positioning pin 7 Turn upper shaft and set dial disc to C t...

Page 40: ...rn upper shaft and set dial disc to 0 degree 3 Insert Gauge I 2mm between needle plate and pressure foot No gap between gauge and pressure foot or needle plate will be OK 4 If wrong space not 1 2mm please adjust height of pressure foot guide bar Please refer to 3 2 11 Exchange and Adjustment of pressure foot ...

Page 41: ...nd cushion Caution Please care when remove Needle holder pop down Pressure foot 3 Remove pressure foot Fixing screw 1 pcs 4 Install good parts 5 Please set needle and needle clamp For set needle please reference 3 1 2 Fixing of needle 6 Adjust needle height Please refer to 3 3 6 Adjustment of needle height 7 Bring needle bar down ...

Page 42: ...needle plate and pressure foot 1 2 mm is standard But please adjust depends by thick of material 10 Tighten fixing screw for pressure foot Fixing screw 1 pcs At this moment no gap between gauge and pressure foot or needle plate 11 Return lower front panel to previous places to finish ...

Page 43: ... Machine Test 5 Press Catcher Adjust take thread catcher unit in 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 Fix the sensor with setscrew after adjustment Sensor Hook 6 Tighten the screws securely while pushing thread catcher unit in the direction of the arrows o...

Page 44: ... 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: ...ar cover Fixing screw 4 pcs 3 Remove TC cable and Front LED cable before Rev A Rev A 4 Remove moving head Fixing screw 4 pcs Caution For back on moving head latter please note needle number when youtake off moving head 5 Remove it by holding moving head up Caution Confirm that hook is apart from thread holder ...

Page 46: ...nished 7 Install moving head tentatively Caution Please back on moving head to same needle position when you take off moving head Caution Two type of setscrews Please check length of screw Caution Please put plain washer with hexagon socket head cap screw CAP M4X20 CAP M4X6 ...

Page 47: ...eedle and needle hole of needle plate Needle No 1 8 and 15 Caution Should be check needle No 1 8 and 15 Needle hole of needle plate Needle 10 If not center back and forth please adjust needle position back and forth Refer to 3 3 4 Adjustment of needle position back and forth 11 If OK Please check needle position Refer to 3 3 5 Check of needle position ...

Page 48: ...Fixing 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: ... 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: ...ss y Insert Lower rail to between the two bearing deeply This is for setting of Moving head completely lower rail positioning plate ass y Viewing from side set to center of needle hole Check and adjust with 1st 8th and 15th needle 3 After adjustment please be sure to check and adjust clearance between needle and shuttle hook Please refer to 3 5 1 Adjustment of rotary hook timing ...

Page 51: ...per axis raise a needle bar and unite with C 270 degrees It returns to 300 degrees 230 and unites with 270 degrees after that Note If a top axis is right rotated a needle will enter deeply and needle hole is greatly It becomes Therefore an exact needle position check becomes impossible 6 1st needle and the 15th needles are to 298 degrees 300 degrees about an upper axis by the above mentioned proce...

Page 52: ...e height 1 At this time lower front panel Fixing screw 2 pcs 2 Remove bobbin case 3 Bring needle bar down 5 Turn upper shaft to set dial disc to L 5 degrees 6 Loosen screw on needle bar boss 6 Put needle height gauge in rotary hook ...

Page 53: ...s to the gauge slightly 9 Set direction of needle stop as illustrated below About 30 degrees 9 Tighten the screw of needle bar boss 10 Produce Needle height gauge from hook 11 Back main shaft to 270 degree position 12 Set Lower front panel and bobbin case then end of process ...

Page 54: ...ar boss 3 Take off Needle bar boss At this time remove pressure foot spring lower pressure foot block cushion and needle bar boss 4 Set good parts to needle bar At this time if insert extra needle bar from under you can work more easily Caution Care to insert direction for Pressure foot and Pressure foot boss Pressure foot block Check shape of direction Cushion Needle bar boss ...

Page 55: ...extra needle bar Slide needle bar to lower 6 Fix pressure foot 7 Fix needle needle holder and cushion 8 Adjust needle height Please refer to 3 3 6 Adjustment of needle height 9 Adjust pressure foot height Please refer to 3 2 11 Exchange Adjustment of pressure Foot 10 Put removed parts back to finish ...

Page 56: ...fer 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 Fix positioning needle bar boss check plate 5 Put moving head and other removed parts back to finish ...

Page 57: ...ove moving head 2 Loosen screw on take up lever shaft Fixing screw 2 pcs 3 Remove the E ring 4 Please do not miss Plastic thrust washer between E ring and Take up lever Remove plastic thrust washer 1 pcs 5 Remove the take up lever shaft first then remove the take up lever 6 Remove plastic washer ...

Page 58: ...d 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: ...n at smoothly moving position Caution Please check smoothly moving at 1 st and 12 th needle Positional relationship between hook and holder lower When downing the needle should have gap more than 1 mm between catch hook and presser foot 4 Thread catcher device should be adjusted if above clearance is not keepable 5 Press thread trim key and confirm whole thread trim revolution More than 1 mm ...

Page 60: ...ve holder lower Fixing screw nut 2 pcs 3 Exchange the majic tape Caution Please check screw hole right and left side Also set point line magic tape and holder bracket 4 Assemble holder lower 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: ... relay cord and TC8 7 Board 3 Remove Board bracke exchange of TC8 7 board 4 Put back TC8 7 board Set the cords of Step 2 as showed bellow 5 Slide TC8 7 circuit board for slit position to center of the sensor NOTE Check the position of the board according to the sensor position 6 Return the Tension rear cover Finish of this chapter Tension rear cover TC8 7 Board TC2 cable TC relay cord TC8 7 Board ...

Page 62: ...o positioning pin 2 Bring needle down turn upper shaft to set near to L point 3 Adjust position of unit assembly so that needle comes to center against needle hole on needle plate and fix screws 4 Install parts in reverse order to finish For adjustment of fixing of each unit please refer to process to adjust fixing of each unit ...

Page 63: ...owed as showed bellow 4 Mounting screw and stud a as showed bellow and take out sensor board Mac No 1 10 05 57 70 02 26 6A A 5 Take out potentiometer Remove mounting screws 2 places as showed bellow 6 Loosen a mounting screw as showed bellow Potentiometer can be taken out by pulling to the arrow direction 15 th Needle Mounting Screws 2 places Cover for needle bar change unit Needle bar change cabl...

Page 64: ...2a 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 Finish of procedures Loosen a mounting screw 1 place ...

Page 65: ...ot remove the cable then Mac No 1057026A Slit collar Potentionmeter Remove screws Mac No 1057027A 2 Refer to 9 1 How to enter maintenance mode and enter maintenance mode 3 Press Machine Test 4 Press Needle Adjust Present needle position of potentiometer is indicated The number of needle number on the screen is sometimes not the same as the number of actual needle position 5 Turn knob so that the n...

Page 66: ...e not make a beep once disappears Mac No 1057026A Mac No 1057027A Turning the shaft too much make disappear and turn the shaft back and forth and adjust the position so that continuous beep is made 8 Install potentiometer at the 7 th position while beep is made and fix it with setscrew Mac No 1057026A Slit collar Potentionmeter Fix with screws Mac No 1057027A 9 Press BACK to complete settings nmet...

Page 67: ... on rotary hook adjust retainer on bobbin case holder In case of you do not replace rotary hook do not need remove retainer Just loose three screws on rotary hook 3 Bring needle down 4 Turn upper shaft and set dial disc to 25 degrees Caution Note Please turn shaft and down needle carefulness to needle hit to inner rotary hook Dip point of Inner hook for retainer should upper position Like Picture ...

Page 68: ...hould 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 Please refer to 3 5 2 Adjustment of retainer on rotary hook for adjusting value and follow it 8 Adjustment has finished ...

Page 69: ...tainer on bobbin case 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 Needle center and retainer center should come to same position Space Needle center position 4 Adjustment has finished ...

Page 70: ...y 3 Refer to 9 1 How to enter maintenance mode and enter maintenance mode 4 Press Machine Test 5 Press 7 Cutter Test and then press ESC Moving knife will move and olign with the face of fixed knife closing position Detail Moving knife closing position Same face Fixed knife cutting face and Moving knife point Cover G ass y 2 setscrews 2 2 2 setscrews Cover G ass y ...

Page 71: ...t Note Please fix Sensor position to parallel position with Detecting plate 7 Adjust stopper position Loose stopper screw and adjust clearance 1mm as following picture End of process Image of position for Slit and sensor Detecting plate Sensor Parallel 1mm Stopper Stopper screw Setscrew Knife sensor Se Hide out Come out St ...

Page 72: ... 2 Press Machine Test 3 Press 7 Cutter Test and open moving knife 3 Remove the nut of knife shaft Spanner 7mm 4 Remove the knife shaft 5 Exchange moving knife 6 Fix moving knife with knife shaft and nut 7 Referring to 3 6 4 Adjustment of moving knife and fixed knife check how well thread is cut and adjust then finish this process ...

Page 73: ...as possible Press the fixed knife by off set screw driver Caution 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 5 Referring to 3 6 4 Adjustment of moving knife and fixed knife check how well thread is cut and adjust then finish this process ...

Page 74: ...pper adjustment screw and lower adjustment screw that fix fixed knife Note Rub these screws together to the extent that you don t feel resistance Spanner 5 5mm 3 Cut thread and check how well it is cut Use two polyester threads for checking 4 Check several times and if no mistakes are found finish this process ...

Page 75: ...ife maximum position by finger 4 In this condition Turn link pin till moving knife maximum opened point and fix link pin 5 At this moment please check feel link rod ass y little bits play up and down 0 2mm 0 2mm If you had not feel of play please loose screw on Drive lever and slide up or down for make small play of link rod ass y Caution Motor shaft has flat face for setscrew Drive lever ...

Page 76: ...thread between moving knife and bobbin thread holder 3 Adjust height of bobbin thread holder with adjusting screw 4 Pull bobbin thread toward arrow mark and see that bobbin thread comes off with tensile gauge 20 25g 5 Tighten lock nut Don t move adjusting screw Spanner 5 5mm 6 Check several times and if OK finish this process ...

Page 77: ...of keeper solenoid 1 Remove Bed cover lower Fixing screw 2 pcs 2 Remove connector for keeper solenoid 3 Remove E ring on fulcrum pin 4 Remove Keeper ass y Fixing screw 2 pcs 5 Exchange keeper solenoid Fixing screw 2 pcs ...

Page 78: ...id 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 Put keeper solenoid ass y in previous position then adjustment of position of keeper to finished Refering to 3 6 8 Adjustment of position of keeper ...

Page 79: ...otary hook 3 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 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 5 Adjustment has finished ...

Page 80: ...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 4 Push the belt by tension gauge at 1 5kg and measure distance between connecting plate and top of the belt 0 5kg Wide X carriage Then adjust the distance to 16mm as picture below 17 18mm Wide X carriage 5...

Page 81: ...inally check belt tension then tight lock nut 8 Return things back to previous places in reverse order 9 Please refer to 9 6 Position Registration of coordinates for positioning sensor registry embroidery aria and finish this adjustment ...

Page 82: ...over Fixing screw 6 pcs 12 pcs Wide X carriage 3 Remove detecting plate Fixing screw 2 pcs 4 Loosen fixing screw for tension pulley bracket slightly Fixing screw 2 pcs 4 Loosed the adjusting nut Spanner 7mm 5 Remove belt holding plate Fixing screw 4 pcs ...

Page 83: ...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 When set Detecting plate please tight screw at insert plate to sensor ditch 10 Please refer to 9 6 Position Registration of coordinates for positioning sensor registry embroidery aria and finish this adjustment ...

Page 84: ... belt tension 1 Refering to 2 2 Removal of outer covers remove cover E and cover F 2 Loosen lock nut for tension adjustment screw Spanner 7mm Showing from above 3 Loosen tension screw so as to move tension 4 Move stay to rear end Stay ...

Page 85: ...en screw hole 9 th and 10 th 10 9 Measurement point 10 9 6 Place some straight bar on arm of Y carriage 1 5Kg When press belt 1 5kg should 7mm apace between straight bar and face of belt 7mm Y belt 7 Adjust with screw on Idler bracket Y ...

Page 86: ...hen tighten lock nut Similarly adjust Y carriage right also 10 Put things back in reverse order of respective adjustment 11 Please refer to 9 6 Position Registration of coordinates for positioning sensor registry embroidery aria and finish this adjustment ...

Page 87: ... 1 Refering to 2 2 Removal of outer covers remove cover E and cover F 2 Loosen lock nut for tension adjustment screw Spanner 7mm Showing from top 3 Loosen tension screw so as to move tension 4 Remove belt holding plate Fixing screw 2 pcs ...

Page 88: ...holding plate Insert holding plate with belt to under the carriage stay till setting screw hole come from rear side of stay Then set rear side belt to holding plate And slide back holding plate till setscrew position 8 Fix belt holding plate Caution Please care belt dose not out from belt holding plate ...

Page 89: ...ioning pin gauge to two holes 12 Touch X carriage body to pin gauges Should not have gap between pin and carriage 13 Tighten fixing screw for X carriage ass y 14 Check no gap between pin and carriage then fix screw of drive pulley 15 Return cover to previous places 16 Please refer to 9 6 Position Registration of coordinates for positioning sensor registry embroidery aria and finish this adjustment...

Page 90: ...of Position sensor board will be opposite procedure from Procedure 2 Note Detecting plate should be positioned at the center of sensor of Position sensor board Note 13 6 Coordinate registaration for Positioning sensor should be done at the time of replacement of Positioning sensor Adjustment of Position sensor board for X axis is done Detecting plate Position sensor board Sensor Cable e 2 setscrew...

Page 91: ...ill be opposite procedure from Procedure 2 Note Detecting plate Y should be positioned at the center of sensor of Position sensor board Note 13 6 Coordinate registaration for Positioning sensor should be done at the time of replacement of Positioning sensor Adjustment of Position sensor board is done Detecting plate Y Position sensor board Cover F Remove 2 setscrews Sensor cable S Detecting plate ...

Page 92: ... screw on tension ass y Fixing screw 2 pcs 3 Loose fixing nut of tension block about 60 degrees Spanner 7mm 4 Adjust gaps between Tension ass y and Tension block to 6 5 to 7 0mm by adjusting bolt 5 Fix tension ass y Fixing screw 2 pcs Tighten lock nut on tension block 6 Return cover H to previous places to finish ...

Page 93: ...emoval of outer covers remove cover H 2 Remove pointer Fixing screw 1 pcs 3 Loosen the screw on tension shaft ass y Fixing screw 2 pcs 4 Loose fixing nut of tension block about 60 degrees Spanner 7mm 5 Loosed the adjusting bolt 6 Take off the timing belt ...

Page 94: ...s 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 Check and adjust following timing to finish 1 lowest needle point 2 Rotary hook timing 3 Thread cut timing ...

Page 95: ...and encoder relay cord 3 Take our timing slit board Remover 2 set screws and take out encoder relay cord 4 Put detecting slit board Do the opposite procedure of step 2 NOTE Put detecting slit not to touch sensors 5 Put timing slit board Do the opposite procedure of step 3 NOTE Put timing slit not to touch sensors Finish of procedures Detecting board protective sheet Detecting slit board Timing sli...

Page 96: ...ghten setscrews When detecting slit cover in L point sensor LED4 goes out 4 After main shaft timing board is set turn the main shaft and confirm that LED4 goes out at 0 degree L point 5 Check C point Turn main shaft by hand and confirm turn on the LED 3 between 270 degree to 284 degree 6 Check should not touch sensor and timing slit for L and C Slit disc Setscrew To let detecting slit turn itself ...

Page 97: ...he 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 screw NOTE Be careful not to bend timing slit because it is very thin Finish of procedures Set screw S t To let timing slit turn itself Set screw 0 7 0 2 mm ...

Page 98: ...lathead screwdriver 2 After the fuse holder cap and fuse is pushed out draw them out 3 Remove fuse from fuse cap holder 4 Exchange it to the auxiliary fuse Note Do not use the other fuse than the auxiliary fuse 3SB6A 5 Set fuse in fuse holder cap 6 Set them in fuse holder and close the cover by turning clockwise with a flathead screwdriver End of process Fuse holder 3SB6A 250V V Fuse holder cap ...

Page 99: ...ble which are taken 3 Make adjustment from step 1 to 5 as below or follow the instruction 8 8 Machine Setting Navigation after exchanging CONT board Main program Ver 1 34 then the procedure of Exchange of CONT D2 board is complete 1 8 5 Machine setting 2 7 2 Machine program update 3 7 3 7 3a Main program update 4 8 6 Frame Position Entry Registration of coordinates for positioning sensor 5 7 4 Ini...

Page 100: ...mounting screw as showed bellow 4 Remove the switching power supply cable 2 places 5 Remove Power Supply Cover A Unscrew the mounting screw as showed bellow 6 Remove DC Power Supply cables 2 from Switching Power Supply 2 2 setscrews Cover G ass y C G Cover G ass y 2 setscrews 2 2 Remove a mounting screw Power supply cover B B 36V switching power supply 24V switching power supply switching power su...

Page 101: ...ide And sides where VRs of Switching Power Supply exist shall come to left 10 Procedures are finished after returning Power Switching Power Supply back to previous position wiring and retuning Drive A Circuit Board Unit to previous position Remove screws 2 places Remove screws 2 places 36V switching power supply 24V switching power supply Power switch ass y box ass y b 36V switching V it hi VR VR ...

Page 102: ...er Cover G ass y 3 Remove power supply cover A Remove the mounting screw as showed bellow 4 Set the digital tester range to DC 5 Put the probe of digital tester in an optional power connector under the serial port 6 Turn on the main switch and set 24 6 V 0 1V by turning VR Volume of 24V switching power supply End of process Put back the cover Remove a mounting screw Power supply cover A l A Set to...

Page 103: ... as showed bellow 2 Set the digital tester range to DC 5 Put the probe of digital tester in CN1 the lower part of the circuit board of CONT D2 circuit board NOTE Put RED probe of digital tester in ORANGE of CN1 Put BLACK probe of digital tester in BLACK of CN1 Turn on the main switch and set 36 0V 0 1V by turning VR Volume of 36V switching power supply End of process Put back the cover Remove a mo...

Page 104: ... showed bellow Y pulse motor 1 Remove outer cover right referring to 2 2 How to remove outer cover 2 Remove outer Cover G ass y and Cover C 3 Exchange of cooling fan for pulse motor 4 Remove 2 mounting screws as showed bellow and take out the cooling fan 5 When you put replacement cooling fan turn out the sticker side as showed bellow End of process Return outer covers to previous positions Coolin...

Page 105: ...fixing bracket as shown in the figure below 2 Disconnect the connectors indicated by the arrows in the figure below Remove the screw that fixes cables 2 Remove Clamp filter Remove three setscrews on bracket A as shown in the figure below 4 Remove control box Please reverse procedure when installing control box Clamp filter Standard 10 4 ...

Page 106: ...W cable Box cable Cable for LCD inverter red white 3 Remove set screw and sealed case A 4 Remove core module 5 Remove narrow flat cable for LCD unit Latch Connector When you pull the latch to cord side the cord release When you push the latch to connector side the cord fixed Release Fix 6 Remove two sets screws and two studs Setscrew Stud able cable inver Sealed case A e A ch Co ...

Page 107: ...el off Connector Wide flat cable When you pull the latch to cord side the cord release When you push the latch to connector side the cord fixed Release Latch Fix 8 Remove four setscrews and LCD unit before Rev A Rev A Remove touch panel Please reverse procedure when installing LCD CE board Display LCD unit flat cable Disp t LCD u ck on connec Display p y LCD u LCD u Touch panel ...

Page 108: ...r 2 Remove connectors for SW cable Box cable Box cable Screw for ground 3 Remove set screw and sealed case A 4 Remove connectors LVDS cable ＳＷ cable Narrow flat cable for LCD unit 5 Remove two sets screws and two studs Setscrew Stud 6 Remove sealed case B Sealed case B Sealed case ase B able able ble Na flat cable Set tscrew tscr Stud St ...

Page 109: ...105b 7 Remove set screw and rear cover 8 Remove set screw and LCD unit Please reverse procedure when installing LCD CE board LCD unit it ...

Page 110: ... from local market The necessary information will be provided Coin battery 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 Replace new battery if clock dose not indicate the correct time after setting a clock and turning power switch OFF LCD CE U LCD CE MX Mac No 1...

Page 111: ...ay of inverter is off 1 Remove outer cover Refer to 2 2 How to remove outer cover 2 Remove two screws and inverter with bracket from the machine Be sure not to lose the screws in the machine 3 Remove two screws shown in the following figure and inverter from bracket 4 Remove cable from clip of the bracket Screw Screw Bracket Clip ...

Page 112: ...wdriver for precision instrument and remove 10 cables Cable color ORANGE RED BROWN PURPLE WHITE GREEN BLUE YELLOW BLACK and GLAY 7 Remove main terminal cover Hold both left and right ends of main terminal cover with fingers and slide the cover toward yourself and remove it 8 Remove screws with Phillips screwdriver and remove power cable and motor cable Cable color GLAY WHITE BLACK BLUE and BROWN E...

Page 113: ...on sticker for voltage specifications of the machine 1 Remove control terminal cover Insert a finger in a gap under the PULL indication on the underside of control terminal cover and pull the cover toward yourself and remove it 2 Remove main terminal cover Hold both left and right ends of main terminal cover with fingers and slide the cover toward yourself and remove it Control terminal cover Main...

Page 114: ...er Note Install main terminal cover not to apply stress to the cable If stress is applied to the cable load is applied to the screws for the main terminal and the screws might be loosened 5 Tighten screw and connect 10 cables the following connection diagram Cable color ORANGE RED BROWN PURPLE WHITE GREEN BLUE YELLOW BLACK and GLAY 6 Install control terminal cover Install the cover by inserting th...

Page 115: ...d Be sure not to lose screws in the machine Note Check if voltage specifications of the machine and inverter are matched before installation Sticker on inverter For 110 120V For 200 230V Refer to specification sticker for voltage specifications of the machine 10 Install the outer cover by following reverse procedure of removing the cover Screw Screw Bracket Clip ...

Page 116: ...RG RESET I F _ _ is displayed 2 Press FUNC DATA F 0 0 is displayed 3 Press FUNC DATA again 1 is blinking This means setting change is prohibited 4 Press Up key or Down key while pressing STOP 0 is blinking This means you can change settings 5 Press FUNC DATA After SAVE is indicated F 0 1 is displayed By above process you will be able to set parameters Next change each setting 6 Press Up key and fu...

Page 117: ...Up or Down key to return to setting change prohibition 11 Press FUNC DATA 0 is blinking 12 Press Up key or Down key while pressing STOP 1 is blinking 13 Press FUNC DATA After S A V E is displayed F 0 1 is displayed 14 Press PRG RESET I F _ _ is displayed 15 PRG RESET again Return to normal mode ...

Page 118: ... Enable parameter to be changed by referring 1 to 5 in How to set inverter 2 Press PRG RESET I F _ _ is displayed 3 Select I H _ _ by pressing Down key 3 times 4 Press FUNC DATA H 0 3 is displayed 5 Press FUNC DATA again 0 is displayed 6 Press Up key while pressing STOP 1 is displayed 7 Press FUNC DATA After S A V E is displayed H 0 4 is displayed The settings of inverter become initial settings T...

Page 119: ... machine is booted 2 Enter maintenance mode and update machine program and main program from the menu 3 Replacement of CONT D2 board Register frame position in Maintenance Mode 4 Press MENU button and select System in menu of OTHER for initialization of system 5 Press MENU button and select Speed in menu of OTHER for automatic speed setting 6 Replacement of LCD CE board Calender setting 7 end of p...

Page 120: ...ess 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 UpDateFile NOTE 1 Copy the program to the root folder of USB memory ...

Page 121: ...am Update The screen shows contents of the USB memory 4 Select UpdateFile 5 Select MachineInstallData 6 Select the machine model Installation of program begins After successful installation the display will return to step no 2 NOTE Please do not take out USB memory during installation Please do not turn off the power during installation it will take for a while for completion of installation 7 Tur...

Page 122: ...118 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: ...een show Update on each item 4 Press ENTER Installation of program begins NOTE Please do not take out USB memory during installation Please do not turn off the power during installation it will take for a while for completion of installation Retry updating when the screen shows Error due to writing error Once update id complete the machine will be rebooted automatically 5 Press NEXT button 6 Refer...

Page 124: ...ease do not take out USB memory during installation Please do not turn off the power during installation it will take for a while for completion of installation Retry updating when the screen shows Error due to writing error Once update id complete the machine will be rebooted automatically Press NEXT button 10 Referring to 7 4 Setting of revolution Perform Re Initialization of machine system And ...

Page 125: ...ystems are carried out Indicate HAPPY logo in screen End of process Initializing of machine speed Setting of revolution of main shaft which is suitable to the machine is required If setting is not done the revolution may not speed up 1 Turn on the power After the program start up press MENU and press OTHER 2 Press Speed 3 Press OK Main shaft adjusts its revolution speed automatically Message compl...

Page 126: ... error type Maintenance Register Registration of machine maintenance date Normally not used at maintenance Other Other This item is neither configured nor used License Registration Limited usable period Replaced CONT Board Machine Setting Navigation after exchanging CONT board Main program Ver 1 34 8 1 How to enter maintenance mode 1 Turn on machine 2 Press NEXT while pressing START STOP button at...

Page 127: ...N OFF Use this function to check movement of cooling fan 11 Encoder Check Input test of L point C point timing With turning main shaft you can use this function to check if L point signal C point signal and timing signal are correct or not 12 Position Data Entry Position Data Entry Confirm frame moving sensor This test is used to check action of Frame moving sensor From Main program Ver 1 34 the P...

Page 128: ...s Machine Test 3 Select desired number to be confirmed Page is switched by pressing Selected item will be executed 4 The screen returns to the MACHINE TEST screen by pressing ESC Unnecessary to press ESC if the item completes automatically 5 Return to drive mode by pressing ESC and ESC ...

Page 129: ...place LCD CE board or Core module since the board might be broken NOTE All the internal design memory will be deleted by initialization of design memory You have to be careful when initializing design memory 1 Enter maintenance mode in reference to 8 1 How to enter maintenance mode 2 Press Memory All Clear 3 Confirmation of free area and all delete will be started after pressing OK 4 Return to dri...

Page 130: ...mber of stitch 1 Enter maintenance mode in reference to 8 1 How to enter maintenance mode 2 Press Record 3 Press STITCH The screen shows total number stitches used for embroidery so far 4 Selection menu of Clear Total Stitch will be opened when pressing CLEAR at Procedure 3 Total number of stitch is cleared after pressing OK and the screen shows one in the procedure 3 Total number of stitch is 0 I...

Page 131: ...rd of error occurrence Enable to confirm Occurrence date and error number with button Selection menu of Clear Error Record will be opened when pressing CLEAR Error record is cleared by pressing OK and the screen of the procedure 3 is displayed If you do not prefer to clear it press Cancel and the screen of the procedure 3 is displayed Clear Error Recode Cancel OK ...

Page 132: ...to E 255 will be displayed You can confirm accumulated number for E 000 to E 255 with The screen returns to the previous screen by pressing BACK 5 Selection menu of Clear Error Total Count will be opened when pressing CLEAR and the screen of procedure 4 is displayed Error record is cleared by pressing OK and the screen of the procedure 4 is displayed If you do not prefer to clear it press Cancel a...

Page 133: ...ns to the previous screen by pressing BACK 5 Selection menu of Clear Thread Break Count will be opened when pressing CLEAR at the screen of procedure 3 Thread break history is cleared by pressing OK and the screen of the procedure 3 is displayed If you do not prefer to clear it press Cancel and the screen of the procedure 3 is displayed 6 Head is switched by pressing Clear Thread Break Count Cance...

Page 134: ...O 13 Borer device No Use of Borer device Yes or No 14 Cutter Unit Type PulseMtr Thread cutting unit type 15 X Start base angle 50 20 90 Starting angle of frame movement on X axis 16 Y Start base angle 50 20 90 Starting angle of frame movement on Y axis 17 X Start angle CAP 50 20 90 Starting angle of frame movement on X axis for cap frame 18 Y Start angle CAP 50 20 90 Starting angle of frame moveme...

Page 135: ...ess 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 5 The screen returns to drive mode by pressing 6 Turn off power and on again before use a machine ...

Page 136: ...egistration is done without the cover As frame moves at maximum embroidery area be sure not to have anything around the machine 1 Enter maintenance mode in reference to 9 1 How to enter maintenance mode 2 Press Frame Position Entry Operate according to displayed below message 1 Fix carriage cover 2 Remove cap frame 3 Move frame to center mark position by Refer to below display 4 Press START button...

Page 137: ... the numerical order as shown in the following figure 5 Below message will be displayed with successful completion Retry from procedure 2 if Error occurs Frame position registration is finished 6 Return to drive mode by pressing ESC and 1 2 3 4 Complete ...

Page 138: ...en the machine runs more than 2000 hours default setting or 365 days are passed after last maintenance the machine will display the message to have regular maintenance Registered date Main program Ver 1 34 Pressing the RESET button delete the registered date When the Calender button is pressed you can set calendar of the machine By pressing Days button you can change the number of days for regular...

Page 139: ...tion for program update and prepare latest update programs 1 Insert USB memory that contains data for version up into insertion slot on the control box 2 Refer to 8 1 How to enter Maintenance mode and enter maintenance mode The screen shows below Main program Ver 1 34 3 Press Replaced CONT Board 4 Press OK 5 Press OK Machine setting menu will be opened and all items which are required to set will ...

Page 140: ...of coordinates for positioning sensor begins Refer to 8 6 Position Registration of coordinates for positioning sensor for more details 14 Press ESC 15 Press OK 16 Press OK Initializing of machine speed will be started Refer to Initializing of machine speed of 7 4 Setting of revolution for more details 17 Press OK The screen returns to the maintenance mode End of process 3rd Step Select machine ser...

Page 141: ...me time After removing 1 screw go to the step 2 If 2 screws are removed at the same time position adjustment for holder is required ２ Fix stud bolts to the position where the screws are removed at the step 1 Clamp A 6 pcs Mounting screws 2 places per side Stud bolts both sides All the packing contents Safety sensor optical receiver Left side Safety sensor emission Right side Stud 4 pcs Clamp B 4 p...

Page 142: ...and Clamp B with the screws on both right and left sides NOTE Lace the cord through concave portion of safety sensors 7 Fix safety sensors cord with clamp A on both right and left sides 8 Remove 2 screws and arm upper cover Concave portion Safety sensor emission Right side i i Clamp B Attach clamp A at the same position on the left side of moving head C Attach clamp A at the same position on the l...

Page 143: ...d insert safety sensor emission cord into the large connector 10 Fasten safety sensor cord and TC cable together with spiral tube 11 Fix safety sensor cord and other cord together with clip 12 Fix Arm upper cover End of process Large connector Clip C Small connector Spiral tube ...

Page 144: ... control box after booting the machine 3 Press Machine Setting 4 Select YES on 11 N Safety Sensor Page is switched by pressing 5 After safety sensor setting is complete return to the MAINTENANCE MODE screen by pressing ESC 6 To return to the startup screen press Safety sensor setting procedure is done 次に sensor の adjustment of optical axis を行って下さい ...

Page 145: ... Needle sensor works properly Press OK to release the error then adjustment is completed In some cases you may need to adjust sensibility of the receiver Please note that factory default setting of sensibility volume right side is middle as picture below If the safety sensor detects upper thread the adjustment of receiver is toosensitive In such case slightly turn the volume to min direction If th...

Page 146: ... Guide from Bobbin thread winding motor assembly Remove with hexagonal wrench In order to avoid interference at the time of installation of cover 2 Install Bobbin thread motor assembly as the picture below with attached screws Set of Bobbin winder Bobbin thread tension assembly Thread stand pin Motor assembly Fixing screws 4pcs Winder cover Guide Hexagonal wrench Fix them here ...

Page 147: ... DC motor relay cable from Arm body and 3P connector DC motor cable from Bobbin thread winder assembly 6 Remove Cover J from Cover B 7 Install Cover B to Body Install with attached screws 2 places Motor ass y nstall with att tached screws tach Limit switch cable 2P connector DC motor relay cable witch cable DC t DC motor cable 3P connector DC motor relay cable Cover B Remove screw 1pc Cover J C Fi...

Page 148: ... 11 Install Bobbin thread tension assembly to Thread stand as the picture below Before installment After installment 12 Reinstalle Guide which has been removed at procedure 1 Guide Fix with screws 3pcs Cover D Flat head Screwdriver Thread stand pin Fix with screws 2pcs Cover D Fixing point Thread stand Th d Fix with screws 2pcs Bobbin thread tension assembly thread t ...

Page 149: ...by adjusting position of procedure 13 15 Remove Guide and install attached Winder cover to Cover B Note Clearance around shaft should be kept averagely 16 Install Guide which has been removed on procedure 15 17 Wind the bobbin thread Adjust Position of Guide to adjust volume of thread to be winded Installment of Bobbin thread wider is finished Empty bobbin p Loosen screws 2pcs L Adjust position by...

Page 150: ...143 10 1 Electrical connection diagram before Rev A for LCD CE board 1 3 ...

Page 151: ...144 10 1 Electrical connection diagram before Rev A for LCD CE board 2 3 ...

Page 152: ...145 10 1 Electrical connection diagram before Rev A for LCD CE board 3 3 ...

Page 153: ...146 10 2 Electrical connection diagram before Rev A for LCD CE U LCD CE MX board 1 4 ...

Page 154: ...147 10 2 Electrical connection diagram before Rev A for LCD CE U LCD CE MX board 2 4 ...

Page 155: ...148 10 2 Electrical connection diagram before Rev A for LCD CE U LCD CE MX board 3 4 ...

Page 156: ...149 10 2 Electrical connection diagram before Rev A for LCD CE U LCD CE MX board 4 4 ...

Page 157: ...149a 10 2a Electrical connection diagram Rev A 1 4 ...

Page 158: ...149b 10 2a Electrical connection diagram Rev A 2 4 ...

Page 159: ...149c 10 2a Electrical connection diagram Rev A 3 4 ...

Page 160: ...149d 10 2a Electrical connection diagram Rev A 4 4 ...

Page 161: ...150 10 3 Connection of inverter Inverter set Inverter set ...

Page 162: ...oard Ass y CN No Function X1 Core module I F X2 Core module I F 5 7in LCD I F 5_1 7in touch panel input X5_2 7in LCD backlight output 6_1 USB A connector 1 6_2 USB A connector 2 7 LAN 12 USB B connector 13 AUX 14 SD card X16 TP SW board I F X90 CONT board I F Other CN Reserved ...

Page 163: ...le I F Ｘ5 7in LCD I F Ｘ5_1 7in touch panel input X5_2 10 4in touch panel input X5_3 7in LCD backlight output X5_4 10 4in LCD I F Ｘ6_1 USB A connector 1 Ｘ6_2 USB A connector 2 Ｘ7 LAN Ｘ12 USB B connector Ｘ13 AUX Ｘ14 SD card X16 TP SW board I F X90 CONT board I F OOtherther Other CN Reserved ...

Page 164: ...ule I F X2 Core module I F Ｘ5 7in LCD I F Ｘ5_1 7in touch panel input X5_2 10 4in touch panel input X5_3 7in LCD backlight output X5_4 10 4in LCD I F Ｘ6_1 USB A connector 1 Ｘ6_2 USB A connector 2 Ｘ7 LAN Ｘ12 USB B connector Ｘ14 SD card X16 TP SW board I F X90 CONT board I F ...

Page 165: ...153 HCD8116 TP SW Circuit Board Ass y HCD8124 TC8 7 Circuit Board Ass y Rev A ...

Page 166: ...154 HCD8119 y ...

Page 167: ... Timing detecting board ass y Sensor HCD8109 H Timing detecting board ass y Main CN No Function CN1 AUX CN2 Sensor switching input Sensor output CN3 AUX CN4 Sensor input CN5 Sensor output CN6 Sensor output CN No Function CN1 Out put of L point C point angle sensor CN2 Input of angle sensor CN3 Output of angle sensor ...

Page 168: ... CN1 Switching sensor input Output of present sensor CN2 Input of switch 1 CN3 Input of switch 2 CN4 Input of switch 3 CN5 Input of switch 4 CN10 Input 1 of position sensor CN11 Input 2 of position sensor CN12 Input 3 of position sensor CN13 Input 4 of position sensor CN14 Input 5 of position sensor CN15 Input 6 of position sensor CN No Function CN1 Sensor out put ...

Page 169: ...rame Fabric Thread Pattern Machine creations Create menu Version of machine program Version of Happylinf software About connecting PC etc You may prepare instruction book and parts book by customer Respond for customer s question Advice by Instruction book and Parts book Advice referencing maintenance manual If you can not immediate contact again after more detail check Ask customer s contact numb...

Page 170: ...y 4 3 1 4 Check Volume of the power failure detection fit with CONT D2 board 4 1 Adjust of power failure detection 4 4 4 5 Check of Cable catching causes short circuit 5 1 Please insulate the cable after removing outer cover 5 2 Replace of cable 6 Confirm not getting power supply from same outlet with other embroidery machine or other machines which contains motor 6 1 Preferably only 1 embroidery ...

Page 171: ...rd is unconnected 5 No problem in thread guide unit and thread tension ass y 3 1 1 5 1 Remove burr and scratch if appeared 5 2 Remove lints and clean 6 Does disc on thread tension ass y turn smoothly 3 1 1 6 1 Remove lints and clean 6 2 Replace 7 Is backlash between take up lever and take up crank roller not bigger 7 1 Replace of take up lever 3 3 9 8 No problem in needle holder 8 1 Remove burr an...

Page 172: ...15 No problem in bobbin 15 1 Remove scratch iron bobbin 15 2 If distorted replace it 16 Is needle bar spring not broken 16 1 Replace it 3 3 7 17 Does needle bar make smooth movement 17 1 If bent replace it 3 3 7 18 No backlash in moving head 18 1 Adjust positioning roller shaft 3 3 3 19 Needle doesn t drop in the center of needle hole 19 1 Adjust positioning plate and adjust needle drop back and f...

Page 173: ...k 2 2 Use pattern edited again density_ change 3 Is thread tension properly set 3 1 Upper thread Considering sewing finish set tension 8 1 3 2 Bobbin thread Considering upper thread tension set tension 4 5 4 Is bobbin winding proper 4 1 Adjusting bobbin winding tension wind with proper strength 4 4 5 Is bobbin put in bobbin case properly 5 1 Viewing from front of bobbin case set so that bobbin tur...

Page 174: ...se thread with knot or uneven size 3 Is thread properly wound aginst cone 3 1 Use thread to be wound smoothly 4 Isn t tip of cone warped or isn t thread caught in scratch 4 1 Remove warp and scratch 5 Don t use thread left for a long period inferior thread 5 1 Don t buy thread more than you use 5 2 Tell not to store thread for a long period 5 3 Tell how to store direct sunshine humidity dust etc 6...

Page 175: ...Move the embroidery machine to proper place Pattern 1 Does thread break occur repeatedly at same place in design 1 1 Check pattern to modify punching 2 Is it too narrow between stitches 2 1 Check pattern to modify punching 2 2 Setting of Reading menu Stitch sweeper 14 4 3 Too many empty stitches 3 1 Make Reading setting Skip null stitches 14 4 Others 1 Using spray paste adhesive material 1 1 Clean...

Page 176: ...No backlash in up and down direction of knife drive shaft 3 6 2 6 1 Check no loosening of screw on moving knife 6 2 Check no loosening of screw on knife drive shaft 7 No backlash in fixed knife 3 6 4 7 1 Check no loosening of screw on fixed knife 8 Does thread cut pulse motor work properly 8 1 Check cable 8 2 If trouble found in LCD CE board or CONT D2 board replace 4 2 8 3 If trouble found in thr...

Page 177: ... 13 1 Readjust if it is not smooth 3 6 7 Operator 1 No negligence in cleaning thread cut device 23 2 1 1 Tell to clean regularly It s desirable to prepare brush with soft hair and air gun 2 Is timing of thread tension proper 2 1 Upper thread Considering sewing finish set tension 8 1 2 2 Bobbin thread Considering upper thread tension set tension 4 5 Environment 1 Are power and voltage rated and sta...

Page 178: ...just positioning roller shaft to remove backlash back and forth 3 3 3 7 Is height of pressure foot proper 7 1 Adjust as specified 3 2 10 8 No problem in motion of pulse motor 8 1 Check wiring If screw got loosened tighten more 8 2 After 9 1 still problem then replace 9 No problem in motion of CONT D2 board 9 1 Check wiring If screw got loosened tighten more 9 2 After 10 1 still problem then replac...

Page 179: ...lve the trouble replace of timing circuit board or cable 3 8 3 E 18 Problem in detecting angle of main shaft Check timing slit Adjust timing slit 3 8 4 Turn main shaft once by hand If LED4 L point lights two times or more Adjust detecting slit E 51 L point sensor doesn t detect E 52 C point sensor doesn t detect Clean dust attached to sensor Check detecting slit If trouble found Adjust detecting s...

Page 180: ...ansformer 2 3 Use stabilizer 3 Is there no place where noise is generated near the machine 3 1 Don t use the machine near where noise is generated 4 Doesn t drive frame hit obstacle 4 1 Remove obstacle 4 2 When useing cap frame see not to hit table 7 2 Thread 1 Not using shrinkable cloth 4 3 cloth 1 1 Use backing paper consider number of sheets to use 2 Isn t breakable cloth is used by thread tigh...

Page 181: ... when contacting moving knife 3 6 6 5 2 In case bobbin thread holder is in trouble replace 5 3 Clean bobbin thread holder 6 No error in thread cut 2 threads cut 6 1 Check and adjust thread cut timing 3 6 1 6 2 Position moving knife as specified 3 6 5 6 3 Check and polish burr or scratch on moving knife 6 4 In case moving knife is in trouble replace 3 6 2 7 Are clearance between needle and rotary p...

Page 182: ...rly 3 Is setting of bobbin thread proper 4 5 3 1 Pass thread on bobbin thread guide surely 4 Is bobbin thread properly wound 4 4 4 5 4 1 Adjust tensile strength of bobbin winder and check holding plate 4 2 Pull out bobbin thread to check if it comes out smoothly 5 Is upper thread properly passed 4 6 4 7 5 1 Pass properly again 6 Does thread cone stand properly 4 6 6 1 Keep thread from hitting felt...

Page 183: ...ad holder 3 1 Insert something Thickness 0 1 0 2mm into holder then move it right and left to put magic tape in order 3 2 Replacement of magic tape 3 3 11 4 Doesn t thread catch hook cut upper thread 4 1 Polish burr on hook 4 2 In case hook is in trouble replace 5 Isn t rubbing of fixed knife and moving knife weak 5 1 Adjust to be able to rub properly 3 6 4 Operator 1 Setting of thread tension is ...

Page 184: ...3 3 Clean and overhaul of Jump device 3 2 14 3 4 Replace of Jump device Operator 1 No thread is passed through detecting roller 1 1 Pass thread properly 4 7 2 Is thread tension proper 2 1 Observing sewing rhythm adjust thread tension properly 4 5 8 1 3 Is proper detection sensitivity of thread cut selected 3 1 Select detection sensitivity according to sewing condition of thread and cloth etc 5 1 E...

Page 185: ...3 Replace of CONT D2 board 4 2 not detected Operator 1 Is thread tension proper slow detected 1 1 Observing sewing rhythm adjust to proper thread tension 4 5 8 1 Adjust it little bits stronger 2 Is proper detecting sensitivity of thread cut selected 5 1 2 1 Please check TRD break detect in setting menu to except Off 2 2 Select detection sensitivity of thread cut according to sewing condition of th...

Page 186: ...ace of LCD CE board 5 2 Replace of Timing Board 3 8 3 5 3 Replace of inverter 5 4 Replace of CONT D2 board 4 2 6 Trouble of software in LCD CE board 7 1 6 1 Initialize then make automatic speed setting 7 4 7 Trouble in control of number of revolution 7 1 Make automatic speed setting 7 4 Operator 1 Isn t foreign stuff such as thread or cloth caught in where revolution is driven 1 1 Get rid of forei...

Page 187: ... by breakage of parts 3 1 Repair broken place 4 No problem in CONT D2 board 4 1 Replace of CONT D2 board 4 3 Operator 1 Check Stopper of Moving Head is removed 1 1 Remove Stopper Uncontrollable Mechanical 1 No problem in sensor circuit board Move 1 1 Clean dust attached to sensor E 024 1 2 Replace sensor circuit board 3 8 3 E 025 2 Trouble in potentiometer 2 1 Replace 3 4 2 3 Needle number is not ...

Page 188: ...e Hook 2 Check position of Thread catcher is proper 2 1 Adjust 3 2 12 3 Check position of Thread holder is proper 3 1 Adjust 3 3 12 4 Check Thread catcher 4 1 Check cable is securely connected 4 2 Replace Pulse Motor with trouble 5 No damage in electric parts 5 1 Replace LCD CE board 5 2 Replace of CONT D2 board 4 2 Hook hits or Mechanical 1 Check Hook is bent or not catches Needle 1 1 Repair bent...

Page 189: ...t movement 1 1 Adjust installment position of thread catch holder 3 3 10 1 2 In case pressure foot is fixed at an angle fix it vertically again 3 2 11 Abnormal noise Mechanical 1 By defect of cover installation Pressure foot drive Carriage etc 1 1 Take care of insert condition clearance etc and fix again 2 By lack of oil inside rotary hook 2 1 Refuel 23 1 2 2 Replace of rotary hook 3 5 1 Big noise...

Page 190: ...o poor cable bundling can not be pressed circuit board being pushed from inside down and returned 1 1 Bundle cable again 5 2 Defect of LCD Mechanical 1 Check LCD 1 1 Replace of LCD 5 2 2 Inadequate condition of cable insertion 2 1 Insert to the back firmly 5 2 3 Check whether LCD CE board is out of order or not 3 1 Replace of LCD CE board Defect of data Mechanical 1 Check whether PC has problem or...

Page 191: ...x or CONT board does not match for the installed data of Machine setting When only control box has been exchanged open the menu of 8 5 Setup Machine setting and just close without any amendment When CONT board has been exchanged follow the procedure of 8 8 Machine Setting Navigation after exchanging CONT board Installed frame drive data in the machine does not match Check setting contents of Machi...

Page 192: ...to set to rated voltage 016 Alarm X unit X motor related trouble i e x motor 1 Power off machine test pantograph overload short circuit problem with movement manually Check for any motor drive unit abnormality throughout full range of motion 017 Alarm X unit Y motor related trouble i e y motor If none found power on again overload short circuit problem with 2 Check related harnes 3 Replace drive A...

Page 193: ... timing circuit board board stained photo sensor poor adjustment of slit disc 052 C sensor Damage in color change point sensor on timing circuit board Damage in timing detecting circuit board stained photo sensor poor adjustment of slit disc 060 X limit Drive frame went beyond limits in X direction 1 Move drive frame back to limits with move key 061 Y limit Drive frame went beyond limits in Y dire...

Page 194: ...nctions 2 Check and modify the design data if there is wrong 106 No function Interval between start read time and Read pattern data again from the first 5 6 time of reception of actual pattern data 108 Improper read While reading pattern data there Read pattern data again from the first 5 6 accrued error in internal processing 110 Memory full While reading pattern data memory 1 Delete unnecessary ...

Page 195: ...dable with 5 5 the machine Prepare readable memory media for the machine 142 Disk full Memory media is full to capacity Clear unnecessary patterns or use a different memory media 143 Multi name Another pattern with same name has Change name use a different memory media been detected while attempting to or overwrite existing pattern write to memory media 190 Cut blade Thread cut knife is not at sto...

Page 196: ...ovement Time over 2 Update program 7 2 7 3a 217 Frm drive data Frm drive data Update program 7 2 7 3a 255 Default Error During embroidery frame movement Re initialize machine speed setting 7 4 did not complete until main shaft reach Check adjustment of upper shaft timing Lowest needle position C point L point Reference instruction book ...

Page 197: ...stment value Tables for Timing Adjustment value Take up lever timing 0 degrees Rotary hook timing 23 degrees Needle height 5 degrees Main shaft timing L LED4 light out at 0 degrees Clockwise C 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 ...