Happy HCS2-1201-30 Maintenance Manual Download Page 14

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2-1 Removal of outer covers

<Check>

Be sure to turn power switch OFF before work.

1. Remove three setscrews of arm E as shown in the figure
below.

2. Disconnect the connectors indicated by the arrows in
the figure below. Remove the screw that fixes cables.

3. Remove three setscrews on arm G as shown in the figure
below.

4. Remove control box.

Please reverse procedure when installing control box.

Summary of Contents for HCS2-1201-30

Page 1: ...Maintenance Manual for Embroidery Machine HCS2 1201 30 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...

Page 3: ...djustment of the lowest needle point 29 3 2 4 Exchange of needle bar driver 30 3 2 5 Adjustment of fixing of jump solenoid 32 3 2 6 Exchange of take up lever cam 34 3 2 7 Exchange of roller shaft ass...

Page 4: ...3 6 Adjustment of needle height 64 3 3 7 Exchange of needle bar needle bar spring and cushion 66 3 3 8 Fixing of needle bar boss guide plate 68 3 3 9 Exchange of take up lever 69 3 3 10 Exchange of t...

Page 5: ...lder 101 3 6 11 Exchange of keeper solenoid 102 3 6 12 Adjustment of position of keeper 103 3 7 Carriage unit 3 7 1 Adjustment of X carriage belt tension 104 3 7 2 Exchange of X carriage belt 106 3 7...

Page 6: ...memory 146 4 5 4 Record Opereration data display 147 4 5 4 1 Total number of stitch 147 4 5 4 2 Record of Error occurrence 148 4 5 4 3 Number of occurrence in each error display 149 4 5 4 4 Thread br...

Page 7: ...comes off from needle hole 172 6 2 6 Upper thread remains 174 6 2 7 Malfunction of thread break detection 175 6 2 8 Suspension of upper shaft 177 6 2 9 Malfunction of needle bar change 178 6 2 10 Def...

Page 8: ...m Page 65 HSA90020 2 0mm thickness gauge Page 102 103 HSA90030 Keeper positioning gauge Page 103 HSA90051 Bering positioning gauge 4 85mm Page 36 HSA90061 Gauge for adjustment of height of pressure fo...

Page 9: ...ioning gauge 0 8mm Page 82 HSA90090 Positioning pin Page 37 HSA90131 1 2mm thickness gauge Page 39 41 45 47 HSA90200 0 03mm thickness gauge Page 28 HSA90210 0 2mm thickness gauge Page 70 91 HSA90230 T...

Page 10: ...nier calliper gauge 200mm HSA90280 Tension gauge 1000cN Page 105 110 118 HSA90311 Shell alvania EP Grease 100g Page 38 44 HSA90340 Shell Grease7 MIL G 23827B 50g Page 53 HSA90321 11 5mm thickness gaug...

Page 11: ...rts Thread guide bracket Thread guide pillar Tread stand Thread tension unit Moving head Take up lever Control panel Front cover X carriage Thread adjusting spring Frame base Thread holder Needle plat...

Page 12: ...13 Needle bar driver unit Y carriage Thread cutting driver Upper shaft Take up lever cam Thread cacher Needle bar change unit Pressure foot driver unit Thread holder...

Page 13: ...dle bar change unit CONT S2 board TC board Display board Emergency stop switch Fuse Pulse motor Pressure foot Power swich Noise filter AC power Power supply 200V Timing detecting board Inverter Main m...

Page 14: ...ee setscrews of arm E as shown in the figure below 2 Disconnect the connectors indicated by the arrows in the figure below Remove the screw that fixes cables 3 Remove three setscrews on arm G as shown...

Page 15: ...d guide bracket 6 Loosen a screw of thread guide pillar 7 Remove thread guide pillar and thread stand 8 Disconnect cable for X carriage 9 Remove 2 screws then take the X carriage off 10 Remove the thr...

Page 16: ...r is fixed by 3 screws as above picture please remove these screws 14 Unlock nail of the cover left by pressing an arrow point of the cover right 15 Remove the cover by pressing an arrow part of the p...

Page 17: ...emove the screw of an arrow part of the picture which fixes cover right 17 Remove an arrow marked screw which fixes hold arm D 18 Remove cover light Remove screw in arrow mark When the cover is fixed...

Page 18: ...e 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 W...

Page 19: ...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 cr...

Page 20: ...ding 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 Set direction of needle holde...

Page 21: ...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 t...

Page 22: ...needle 2 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 desc...

Page 23: ...nge of crank 1 Remove rear cover 2 Disconnect TC cable and limit switch cable 3 Remove front cover on front panel 4 Referring to 3 3 3 Assemble the moving head remove moving head Caution Do not lost s...

Page 24: ...er 6 Remove face plate on the left Installation position should be up and back side As shown an arrow 7 Referring to 3 2 4 Exchange of needle bar driver remove needle bar driver ass y 8 Remove circuit...

Page 25: ...ower supply 10 Loosen screw on upper shaft collar upper pulley drive pulley 11 Loosen collar screw on take up lever cam 12 Loosen screw on crank 13 Pull out upper shaft To the extent that crank comes...

Page 26: ...y 3 Position of upper pulley is 2mm from upper shaft collar 3 Position of upper pulley is space from upper shaft collar Type of small collar Thickness gauge 11 5mm 4 Confirm that belt is not interfere...

Page 27: ...ass y Caution Do not lost simm material 2 Referring to 3 2 4 Exchange of needle bar driver remove needle bar driver ass y 3 Loosen screw on rod pin to remove rod 4 Install good parts Important Leave...

Page 28: ...hen dial disc reads 0 degree fix detecting disk 4 Work will finish by checking and adjusting timing mentioned below 4 2 1 Upper shaft timing L point C point 3 2 8 Take up lever timing 3 5 1 Rotary hoo...

Page 29: ...Exchange of needle bar driver 1 Refering to 3 2 1 Exchange of crank moving head and face plate left ass y Caution Do not lost simm material 2 Loosen screw on main shaft in head 3 Pull out main shaft...

Page 30: ...ant Make sure that Needle bar driver ass y rotate smoothly and no clearance between rod and arm 7 Put each unit back according to manual 8 After exchange please be sure to adjust needle height Please...

Page 31: ...32 3 2 5 Adjustment of fixing of jump solenoid 1 Remove rear cover 2 Disconnect TC cable and LED cable 3 Remove front cover on front panel 4 Remove moving head Caution Do not lost simm material...

Page 32: ...come to center of Plunger Plunger Jump solenoid ass y Jump body View from left This shows a state that plunger and jump body contacts Plunger Jump body 7 Adjust upper shaft to be 180 degrees and tip o...

Page 33: ...supply 2 Remove timing detecting board ass y 3 Loosen screws on upper shaft collar upper pulley and drive pulley 4 Loosen screw on fasten collar for take up lever cam 5 Loosen screw on crank 6 Pull ou...

Page 34: ...ut space from machine body except upper pulley 3 Position of upper pulley is space from upper shaft collar Type of small collar Thickness gauge 11 5mm 4 Confirm that belt is not interfere the pulley f...

Page 35: ...m 8mm 3 Insert bering positioning gauge 4 85mm between bering and bering and then tighten roller shaft ass y Please adjust roller shaft for machine front side ways This roller shaft ass y is eccentric...

Page 36: ...from right side 4 Turn take up lever cam slowly and insert positioning pin into pin groove pin groove 5 Loosen screw Important Rotate the Take up lever cam clockwise until pin ditch touches to positio...

Page 37: ...Exchange of pressure foot cam 1 Remove screw on pressure foot cam 2 Exchange pressure foot cam 3 Put on grease to pressure foot cam Grease Shell alvania EP Grease2 Shell Gadus S2 V220 2 4 Exchange has...

Page 38: ...finger 2 Bring needle down 3 Turn upper shaft and set dial disc to 0 degree 4 Insert Gauge I 2mm between needle plate and pressure foot No gap between gauge and pressure foot or needle plate will be O...

Page 39: ...40 3 2 11 Exchange of pressure foot 1 Remove pressure foot 2 Install good pressure foot 3 Adjust height of pressure foot to finish Please refer to 3 2 10 Check of height of pressure foot...

Page 40: ...tate the upper shaft to be lowest point 0 degrees 4 Push down block ass y 5 Adjust the center between needle hole of needle plate and hole of pressure foot 6 Insert thickness gauge 1 2mm between needl...

Page 41: ...t link A then remove block ass y 4 If you remove the pressure foot link B ass y first remove the pressure foot cam collar and pressure foot drive cam 5 Remove pressure foot link B ass y 6 Assemble the...

Page 42: ...ver 1 Remove face plate 2 Remove upper rail 3 Remove pressure foot and pressure foot guide bar After remove pressure foot spring 2 remove pressure foot guide bar to up side 4 Remove sensor board ass y...

Page 43: ...se Shell alvania EP Grease2 Shell Gadus S2 V220 2 Oil insert bush 7 Put on grease to fulcrum shaft Caution Do not put on grease to a part of screw 8 Assemble pressure foot drive lever ass y 9 Assemble...

Page 44: ...the height of pressure foot guide bar Please refer to 3 2 12 Adjustment of height of pressure foot guide bar 13 Assemble the upper rail of moving head Please refer to 3 3 1 Assemble the upper rail of...

Page 45: ...oosen the screw which fixes guide bar boss 3 Remove pressure guide bar After remove pressure foot spring 2 remove pressure foot guide bar to up side 4 Remove E ring E 4 which fixes guide bar boss 5 Ex...

Page 46: ...47 7 Adjust the height of pressure foot guide bar to finish Please refer to 3 2 12 Adjustment of height of pressure foot guide bar...

Page 47: ...sconnect cable from Pulse motor and Sensor board ass y 2 Down the Pressure foot 3 Remove bracket ass y 4 Remove drive gear A 5 Exchange the pulse motor Fix it temporarily 6 Assemble the drive gear A T...

Page 48: ...n of pulse motor then fix it Keep slightly backlash between drive geer A and gear Every point 8 Continue to conduct Adjust the pressure foot bracket ass y Please refer to 3 2 17 Adjustment of pressure...

Page 49: ...e space between needle plate and pressure foot should be 24 8 25 0mm Gauge for adjustment of height of pressure foot bracket 4 Adjust position of pressure foot guide plate B ass y Caution Make sure th...

Page 50: ...er tentatively 2 Tighten thread catcher pushing it upward and forward As shown an arrow 3 Continue to conduct Adjustment of thread holder When you adjustment of thread holder in case of adjust again t...

Page 51: ...e of thread catcher guide 1 Remove guard plate 2 Exchange guide Fix the guide after moving it to the right 3 Install the guard plate 4 Please refer to 3 2 18 Exchange of thread catcher install thread...

Page 52: ...Shell Grease7 MIL G 23827B Equivalent brand 4 Assemble the solenoid to the original position The flat surface of the solenoid nut should come to the front Solenoid cable should come to the back side F...

Page 53: ...th keeping the space between shaft and the cover hole 3 Assemble thread tension ass y The marked position by arrow should come to the center 4 Assemble guide as tentatively 5 Confirm that the shaft do...

Page 54: ...ion gauge 7 Rewind the bobbin thread 8 Adjust the inclination of Winder bracket ass y in accordance with thread winding condition 9 Adjust the height of Guide to adjust volume of thread to be winded 1...

Page 55: ...1 Assemble the upper rail of moving head 1 Tighten right and left LM guide base Follow in picture keep push to allow way each LM guide base Notice Should be front side which letter on side of LM guid...

Page 56: ...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 Pl...

Page 57: ...come out from LM guide side 3 Put in SIMM 0 05mm between a moving head and LM guide Don t tighten a screw only by inserting SIMM here Please give Caution Do not lost simm material View of behind Posit...

Page 58: ...ew from LM guide Please fasten 5 Put in SIMM 0 05mm between a moving head and LM guide View of behind To puts in central position between screws Moving head SIMM Middle SIMM Left LM guide Veiw of left...

Page 59: ...head is pushed from the front and it is LM guide It is made for there to be no crevice 7 An outside screw arrow portion in a figure is tightened 8 Turn the drive shaft B screw for manual operation and...

Page 60: ...eedle plate Needle No 1 6 and 12 Caution Should be check needle No 1 6 and 12 Needle hole of needle plate Needle 12 If not center back and forth please adjust needle position back and forth Refer to 3...

Page 61: ...west needle position L to adjust positioning plate ass 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 fr...

Page 62: ...bar and unite with C 275 degrees It returns to 303 degrees 220 and unites with 275 degrees after that Note If a top axis is right rotated a needle will enter deeply and needle hole is greatly It becom...

Page 63: ...ve bobbin case 3 Bring pressure foot down Either way mentioned below 1 press key on control box 2 Turn gear with finger 4 Bring needle down 5 Turn upper shaft to set dial disc to 5 degrees 6 Loosen ne...

Page 64: ...needle holder as illustrated below About 30 degrees Check needle holder dose not touch to Needle guard 10 Tighten the screw of needle bar boss 11 Tighten the screw of needle bar boss B When tightenin...

Page 65: ...bar needle bar spring and cushion 1 Remove rear cover 2 Disconnect TC cable and limit switch cable 3 Remove front cover of front panel 4 Remove thread tension bracket 5 Remove lower front paneI 6 Remo...

Page 66: ...needle bar At this moment remove needle bar boss needle bar bossB needle bar spring and cushion 9 While pressing needle bar spring insert good needle bar 10 Fix needle and needle holder 11 Adjust need...

Page 67: ...er to 3 3 9 Exchange of take up lever 2 Exchange of needle bar boss guide plate Temporarily use the pan head screw to center the needle bar boss guide plate then fix the screw 3 Fix positioning needle...

Page 68: ...69 3 3 9 Exchange of take up lever 1 Remove rear cover 2 Disconnect TC cable and limit switch cable 3 Remove front cover on front panel 4 Remove thread tension bracket 5 Remove moving head...

Page 69: ...take up lever shaft first then remove the take up lever 9 Install good take up lever assembly with plastic washer E ring 10 Leave space of 0 2mm between take up lever and moving head Tight screw for T...

Page 70: ...ring 1 Remove lower front panel 2 Remove adjuster base 3 Remove thread adjusting spring ass y 4 Remove thread adjusting spring and spring holder 5 Exchange thread adjusting spring 6 Assemble the threa...

Page 71: ...72 Set the thread adjusting spring to Middle position as Picture below E ring Washer 7 Put removed parts back in reverse order Middle Strong Weak...

Page 72: ...thread adjusting spring 1 Remove lower front panel 2 Block has spring groove to be able to adjust in three steps Put tip of spring in desired position Strongest tension will be obtained in upper groov...

Page 73: ...ring 1 Loosen screw on adjuster 2 Move adjuster position up and down with small frat head driver to change stroke When you move adjuster upward stroke will get small When you move it down stroke will...

Page 74: ...0 1mm between lower part of moving head and holder upper and mount it vertical 4 Hold down the pressurefoot and take the hook in and out by finger to check movement of hook goes smoothly Check this at...

Page 75: ...76 6 Check up with thread trimmer function 7 Assemble lower front panel to terminate this procedure...

Page 76: ...sure foot down Either way mentioned below 1 press key on control box 2 Turn gear with finger 3 Bring needle down turn upper shaft to set near to L point 4 Adjust position of unit assembly so that need...

Page 77: ...1056034A Slit collar Potentionmeter Remove screws Mac No 1057001A Slit collar Potentionmeter 2 Refer to 4 5 1 How to enter maintenance mode and enter maintenance mode 3 Press Machine Test 4 Press Nee...

Page 78: ...not make a beep once disappears Mac No 1056034A Mac No 1057001A Turning the shaft too much make disappear and turn the shaft back and forth and adjust the position so that continuous beep is made 7 I...

Page 79: ...g 1 Remove needle plate 2 Bring pressure foot down Either way mentioned below 1 press key on control box 2 Turn gear with finger 3 Tighten screw on rotary hook 3 places 4 Bring needle down 5 Turn uppe...

Page 80: ...cessory At this moment clearance between needle and rotary hook should be 0 1 0 2mm Check and adjust with 1st 6th and 12th needle 7 For making sure check position of retainer on bobbin case holder Ple...

Page 81: ...avoid interfere of screw and Rotary hook retainer during installing Needle plate 3 Adjust position back and forth left and right Space has to be 0 8mm and the position right and left is center of the...

Page 82: ...screw Caution Make sure that there is clearance between arm and body 3 Hold the left side of arm to body and tighten screw 4 Hold the right side of arm to arrow pointed direction at below picture and...

Page 83: ...cting plate and sensor or connector of sensor board A part of sensor Sensor Detecting plate Conector A part or conector 7 Adjust by bending detecting plate by hand if you find any interference with se...

Page 84: ...6 2 Exchange of thread cutting roller except for Rev A 1 Remove bobbin winder and power supply 2 Remove arm 3 Loosen the screw for coupling of the Y carriage 4 Remove the screw of Y carriage bracket...

Page 85: ...86 Remove the Y carriage 5 Remove E ring 6 Remove spring 7 Remove drive link ass y from thread cutting driver ass y 8 Remove thread cutting driver ass y 9 Remove thread cutting roller...

Page 86: ...spring and E ring 14 Fix Y carriage bracket left to the machine Fix the base with state of pushing it down Tighten drive shaft with screw 15 Connect cable from sensor board Place parts back in accord...

Page 87: ...of thread cutting roller for Rev A 1 Remove bobbin winder and power supply 2 Remove arm 3 Disconnect cable from sensor board Loosen the screw for coupling of the Y carriage 4 Remove the screw of Y car...

Page 88: ...move the Y carriage 5 Remove thread cutting driver 6 Disconnect cable 7 Remove Pulse motor 8 Remove Drive gear 9 Install Drive gear on good Pulse motor Position of Drive gear is space from Pulse motor...

Page 89: ...90 10 Place parts back in accordance with manual 11 Check and adjust position of moving knife to finish Please refer to respective adjustment...

Page 90: ...k to C 275 degrees 3 Keep the lever down 4 Insert 0 2mm thickness gauge between cam and roller and adjust the clearance 0 2mm between cam and roller by adjusting screw To be sure that cam and roller a...

Page 91: ...screw on thread cut cam 3 Set dial disc to 116 degrees 4 Turn thread cut cam clock wise while pushing release lever down Important Push thread cut cam against rotary hook shaft collar A so as not to...

Page 92: ...93 94 6 With release lever being pushed down turn upper shaft to open and close moving knife repeatedly 7 On Checking that the knife began to open at 116 degrees 0 2degrees work has finished...

Page 93: ...oving knife insert knife drive shaft assembly 6 Pushing down moving knife and knife drive shaft retainer like putting them together fix knife drive shaft retainer Fix so that there is no backlash in u...

Page 94: ...ing to forward as full as possible Notice 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 R...

Page 95: ...g to 3 6 6 Exchange of moving knife 3 Adjust slant of fixed knife with upper adjustment screw and lower adjustment screw that fix fixed knife Note Rub these screws together to the extent that you don...

Page 96: ...ink pin 2 Turn link pin to adjust position of moving knife Adjustment of clearance between moving knife and fixed knife is where both tip of then are attached 3 If necessary please refer to 3 6 8 Adju...

Page 97: ...Machine Test 4 Press 2 Cutter Adjust 5 Press Separate then the Moving knife will be opened Please confirm that the tip of Moving knife is located at center of Rotary hook retainer Tip of moving knife...

Page 98: ...ce between moving knife and fixed knife is where both tip of then are attached 8 Press Separate and Origin by turns to confirm that t he Moving knife is closed in the right position Press ESC to finis...

Page 99: ...read 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...

Page 100: ...ntion Pushing keeper solenoid to solenoid base Insert 2 0mm thickness gauge between solenoid base to polyslider 2 0mm thickness gauge Front view Keeper plunger Solenoid base Clearance between keeper p...

Page 101: ...lenoid base and slider then pull in keeper solenoid and keeper rod 4 Adjust solenoid base where tip of keeper contacts slightly to the gauge then tighten bracket screw Clearance between bobbin and kee...

Page 102: ...nt of X carriage belt tension 1 Remove frame base 2 Disconnect X carriage cable 3 Remove X carriage 4 Remove X carriage cover 5 Remove sensor bracket 6 Loosen fixing screw for tension pulley bracket s...

Page 103: ...ide connecting plate to right as full as possible Gauge in the middle of idler pulley and tension pulley Measurement point Idler pulley Tension pulley Adjustment tighten fixing screw for tension pulle...

Page 104: ...106 3 7 2 Exchange of X carriage belt 1 Remove frame base 2 Disconnect X carriage cable 3 Remove X carriage 4 Remove X carriage cover 5 Remove sensor bracket 6 Loosen screw for tension...

Page 105: ...e extent that tension bracket moves 9 Remove belt from motor pulley 10 Remove connecting plate 11 Exchange belt to good one Important Exchange it so as not to break groove and belt tooth on belt of co...

Page 106: ...osition of belt Space between edge of X base and belt is 10mm 13 Referring to 3 7 1 Adjustment of X carriage belt tension adjust tension of belt 14 Return X carriage assembly and frame base to previou...

Page 107: ...109 3 7 3 Adjustment of Y carriage belt tension 1 Remove frame base 2 Disconnect X carriage cable 3 Remove X carriage 4 Remove arm...

Page 108: ...tension to use belt tension gauge Use push and pull gauge Adjustment value Adjusted to be 200g at state that Belt attaches to Rail Push belt holding plate backward as full as possible Gauge in the mi...

Page 109: ...111 9 Tighten lock nut for tension adjustment screw 10 Return arm X carriage assembly and frame base to previous places to finish...

Page 110: ...112 3 7 4 Exchange of Y carriage belt 1 Remove frame base 2 Disconnect X carriage cable 3 Remove X carriage 4 Remove arm...

Page 111: ...ew so as to move tension 7 Loosen screw for tension 8 Remove belt holding plate 9 Exchange belt 10 Set belt to belt groove of guide frame base Important Exchange it so as not to break belt tooth and c...

Page 112: ...114 11 Fix belt holding plate 12 Referring to 3 7 3 Adjustment of Y carriage belt tension adjust tension of Y belt 13 Return arm X carriage ass y and frame base to previous places to finish...

Page 113: ...wer supply 2 Adjust tension of timing belt Important Tension shaft ass y to be set at the center against screw hole of the body No need to adjust tension Please move tension shaft ass y upward and dow...

Page 114: ...er and power supply 2 Remove timing detecting board ass y Remove support roller ass y 3 Loosen screws on upper shaft collar upper pulley and drive pulley 4 Loosen screw on fasten collar for take up le...

Page 115: ...rew 2 Make sure that pulleys and collars are attached without space from machine body except upper pulley 3 Position of upper pulley is space from upper shaft collar Type of small collar Thickness gau...

Page 116: ...nder and power supply 2 Remove inverter 3 Loosen screw on motor bracket 4 Adjust motor belt tension Use push and pull gauge Adjustment value 320 330 g 3mm Gauge in the near center between drive pulley...

Page 117: ...320 330g at belt is pressed 3mm Belt is pressed 3mm Move main motor upward and downward to adjust 5 Tighten screw on motor bracket 6 Return power supply bracket power supply bobbin winder and inverte...

Page 118: ...e bobbin winder and power supply 2 Remove timing detecting board ass y 3 Loosen screws on upper shaft collar upper pulley and drive pulley 4 Loosen screw on fasten collar for take up lever cam 5 Loose...

Page 119: ...rew 2 Make sure that pulleys and collars are attached without space from machine body except upper pulley 3 Position of upper pulley is space from upper shaft collar Type of small collar Thickness gau...

Page 120: ...te SW 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...

Page 121: ...peel 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...

Page 122: ...card 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 ba...

Page 123: ...ork 1 Turn the machine on and put tester against terminal plate or connector then turn V ADJ to adjust to 24 6V 0 1V for 100V V ADJ For 200V V ADJ Notice 1 Be sure to put cover on power supply termina...

Page 124: ...board 3 Set upper shaft to 0 degree 4 Move circuit board up and down and set to position where LED 2 disappears at 0 degree then fix with screw 5 With this state turn to C point and check if LED1 Iig...

Page 125: ...of needle bar change unit 1 Remove potentiometer ass y Mac No 1056034A Mac No 1057001A 2 Set position where sensor on sensor board and slit don t cross to area where moving head doesn t move when turn...

Page 126: ...e cover toward yourself and remove it If screw is provided on the cover remove it 3 Remove main terminal cover Hold both left and right ends of main terminal cover with fingers and slide the cover tow...

Page 127: ...129 7 Remove two screws shown in the following figure and inverter End of process Inverter for 110 120V Inverter for 200 230V Screw Screw...

Page 128: ...rminal 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...

Page 129: ...tor cable per the following connection diagram Cable color GLAY WHITE BLACK BLUE BROWN 11 4 FR S510W 5 Tighten screw and connect 9 cables the following connection diagram Cable color ORANGE BROWN PURP...

Page 130: ...s applied to the screws for the main terminal and the screws might be loosened 8 Install control terminal cover Install the cover by inserting the nail on top of the cover to the ditch of the inverter...

Page 131: ...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 bli...

Page 132: ...sing Up or Down key to return to setting change prohibition 11 Press FUNC DATA 0 is blinking 12 Press Up key while pressing STOP 1 is blinking 13 Press FUNC DATA After S A V E is displayed F 0 1 is di...

Page 133: ...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...

Page 134: ...tton of the control box at tne screen after the machine is booted 2 Enter maintenance mode and update machine program and main program from the menu 3 Press MENU button and select System in menu of OT...

Page 135: ...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...

Page 136: ...ogram Update The screen shows contents of the USB memory 4 Select UpdateFile 5 Select MachineInstallData 6 Select the machine model 7 Select the file Installation of program begins After successful in...

Page 137: ...140 9 Press NEXT 10 Referring to 4 4 5 Setting of revolution Perform Re Initialization of machine system And Initializing of machine speed End of process...

Page 138: ...n 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...

Page 139: ...s 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...

Page 140: ...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 don...

Page 141: ...pe 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 Replac...

Page 142: ...action of Laser pointer 10 Fan Drive Test Action test of cooling fan ON OFF Not used in HCS2 11 Encoder Check Input test of L point C point timing With turning main shaft you can use this function to...

Page 143: ...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...

Page 144: ...lace LCD CE board or Memory card 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...

Page 145: ...1 Total number of stitch 1 Enter maintenance mode in reference to 4 5 1 How to enter maintenance mode 2 Press Record 3 Press STITCH The screen shows total number stitches used for embroidery so far 4...

Page 146: ...ror occurrence Enable to confirm Occurrence date and error number of last 32 cases with button Selection menu of Clear Error Record will be opened when pressing CLEAR Error record is cleared by pressi...

Page 147: ...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 op...

Page 148: ...The screen returns 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...

Page 149: ...vice No Use of Borer device Yes or No 14 Cutter Unit Type PulseMtr Solenoid 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...

Page 150: ...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...

Page 151: ...When 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 V...

Page 152: ...d prepare latest update programs 1 Insert USB memory that contains data for version up into insertion slot on the control box 2 Refer to 4 5 1 How to enter Maintenance mode and enter maintenance mode...

Page 153: ...ss OK 11 Enter the corresponding machine number 12 Press OK 13 Press OK Initializing of machine speed will be started Refer to Initializing of machine speed of 4 4 5 Setting of revolution for more det...

Page 154: ...153 5 1 1 Electrical connection diagram except for Rev A...

Page 155: ...154 5 1 1 Electrical connection diagram except for Rev A...

Page 156: ...155 5 1 2 List of electrical connection diagrams except for Rev A...

Page 157: ...156 5 1 3 Electrical connection diagram for Rev A...

Page 158: ...157 5 1 3 Electrical connection diagram for Rev A...

Page 159: ...158 5 1 4 List of electrical connection diagrams for Rev A...

Page 160: ...159 5 2 1 Connection of inverter 100V Inverter set...

Page 161: ...160 5 2 2 Connection of inverter 200V Inverter set...

Page 162: ...y CN No Function X1 Core module I F X2 Core module I F D5 7in LCD I F D5_1 7in touch panel input X5_2 7in LCD backlight output D6_1 USB A connector 1 D6_2 USB A connector 2 D7 LAN D12 USB B connector...

Page 163: ...le I F 5 7in LCD I F 5_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 6_1 USB A connector 1 6_2 USB A connector 2 7 LAN 12 USB B connector 13 A...

Page 164: ...le I F X2 Core module I F 5 7in LCD I F 5_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 6_1 USB A connector 1 6_2 USB A connector 2 7 LAN 12 U...

Page 165: ...160c HCD8116 TP switch board ass y 6 5 265 2 1 6 7 257...

Page 166: ...1 8 3 8 1 50 18 250 6820 9 5968 3 8 1 50 76 592654 8 9 5968 5 8 8 6 25 25 8 46 68 6 7 327 963 562 6 7 9 8 7625 8 6 7 865 6 7 5 5 7 8 963 562 6 7 18 250 963 562 6 7 25 9 2 1 8 46 6 7 57 6 7625 7625 25...

Page 167: ...160e HCB8105 TC12 board ass y HCD8109 Timing detecting board ass y 6 5 265 5968 6 7 5 3 5968 257 5 3 6 8 6 5 265 7 6 7625 7625 503 9 5968...

Page 168: ...NS0R Circuit Board Ass y HCD8110 POSITION SENSOR Circuit Board Ass y HCB8116 FRONT LED Circuit Board Ass y CN No Function CN1 24V power source input CN No Function CN Sensor output CN No Function CN1...

Page 169: ...achine 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 bo...

Page 170: ...age 4 1 3 3 2 Try to replace power supply 4 Check of Cable catching causes short circuit 4 1 Please insulate the cable after removing outer cover 4 2 Replace of cable 5 Confirm not getting power suppl...

Page 171: ...ard 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...

Page 172: ...it 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 r...

Page 173: ...1 Adjust size so as to produce less thread break 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 th...

Page 174: ...ead 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...

Page 175: ...he 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...

Page 176: ...drive shaft 3 6 8 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 8 7 1 Check no loosening of screw on fixed knife...

Page 177: ...s not smooth 3 6 12 Operator 1 No negligence in cleaning thread cut device 1 1 Tell to clean regularly 23 2 It s desirable to prepare brush with soft hair and air gun 2 Is drive greased 2 1 Apply grea...

Page 178: ...7 1 Adjust positioning roller shaft to remove backlash back and forth 3 3 2 8 Is height of pressure foot proper 8 1 Adjust as specified 3 2 12 9 No problem in motion of pulse motor 9 1 Check wiring If...

Page 179: ...e 2 2 Use transformer 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 2 4 4...

Page 180: ...1 Check and adjust thread cut timing 3 6 5 5 2 Position moving knife as specified 3 6 9 5 3 Check and polish burr or scratch on moving knife 5 4 In case moving knife is in trouble replace 3 6 6 6 Are...

Page 181: ...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 pa...

Page 182: ...order 3 2 Replacement of Guard holder upper ass y 3 3 14 4 Doesn t thread catch hook cut upper thread 4 1 Polish burr on hook 4 2 In case hook is in trouble replace Operator 1 Setting of thread tensi...

Page 183: ...enoid 3 2 20 3 5 Replace of Jump solenoid Operator 1 No thread is passed through detecting roller 1 1 Pass thread properly 4 6 4 7 2 Is thread tension proper 2 1 Observing sewing rhythm adjust thread...

Page 184: ...board 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 sensitivit...

Page 185: ...by sand paper 5 2 Replace of pressure foot block ass y and link ass y 3 2 13 6 Effect by breakage of parts 6 1 Repair broken place 7 No damage in electric parts 7 1 Replace of CONT board 7 2 Replace...

Page 186: ...seized lint or waste 3 Effect by breakage of parts 3 1 Repair broken place Operator 1 Check Stopper of Moving Head is removed 1 1 Remove Stopper Uncontrollable Mechanical 1 No problem in sensor circui...

Page 187: ...Hook extend 1 2 Replace Hook 2 Check position of Thread catcher is proper 2 1 Adjust 3 2 18 3 Check position of Thread holder is proper 3 1 Adjust 3 3 13 4 Check Thread catcher 4 1 Check cable is secu...

Page 188: ...foot is fixed at an angle fix it vertically again 2 Defect of censor circuit board 2 1 Replace of censor circuit board Abnormal noise Mechanical 1 Check whether needle clamp touch needle guard or not...

Page 189: ...ct of LCD Mechanical 1 Check LCD 1 1 Replace of LCD 2 Inadequate condition of cable insertion 2 1 Insert to the back firmly 3 Check whether LCD CE board is out of order or not 3 1 Replace of LCD CE bo...

Page 190: ...T board does not match for the installed data of Machine setting When only control box has been exchanged open the menu of 4 5 4 5 Setup Machine setting and just close without any amendment When CONT...

Page 191: ...4 3 4 Check if voltage high or not If high check origin of power source of factory Or use stabilizer transformer to set to rated voltage 018 Main shaft Suspension of main shaft in mid way 1 Check if...

Page 192: ...on doesn t come replace LCD CE board below 100rpm 050 C point Main shaft stops off its position 1 Turn main shaft to plus direction to set to C point 24 4 051 L sensor Poor lowest needle position sens...

Page 193: ...While reading pattern data memory 1 Delete unnecessary patterns and read from 5 B exceeded its capacity the outset 111 Change over While reading pattern data the 1 Modify pattern data and reduce frequ...

Page 194: ...media been detected while attempting to or overwrite existing pattern write to memory media 190 Cut blade Thread cut knife is not at stop position 1 Restore the moving knife to stop position 24 5 2 Ch...

Page 195: ...ake up lever timing 10 degrees Rotary hook timing 25 degrees Needle height 5 degrees Thread cut timing except for Rev A 116 degrees 0 2degrees Main shaft timing L LED2 light out at 0 degrees C LED1 li...

Page 196: ...2017 8 HAPPYJAPAN Inc 9 5 TAITO 2 CHOME TAITO KU TOKYO JAPAN TEL 81 3 3834 0711 FAX 81 3 3835 8917...

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