HappyJapan HCR3-1502 Maintenance Manual Download

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Maintenance Manual for Embroidery Machine

HCR3E SERIES

Version 1.

HappyJapan Inc.

Summary of Contents for HCR3-1502

Page 1: ... Maintenance Manual for Embroidery Machine HCR3E SERIES Version 1 2 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: ...g 21 3 Basic maintenance 3 1 Fixing of needle 22 3 2 Selection of thread 23 3 3 Relation between needle and upper thread 24 4 Exchange and Setting of mechanical related component 4 1 Fixed head 4 1 1 Exchange of needle bar driver 25 4 1 2 Adjustment of take up lever timing 27 4 1 3 Check of height of pressure foot 29 4 1 4 Adjustment of height of pressure foot 30 4 1 5 Exchange of pressure foot 31...

Page 4: ...p lever 62 4 2 12 Adjustment of tension of thread adjusting spring 64 4 2 13 Adjustment of stroke of thread adjusting spring 65 4 2 14 Adjustment of thread holder 66 4 2 15 Adjustment of clip type thread holder 67 4 2 16 Adjustment of clip drive unit 68 4 3 Needle bar change unit 4 3 1 Check Adjustment of needle bar change unit 70 4 4 Rotary hook 4 4 1 Adjustment of rotary hook timing 72 4 4 2 Adj...

Page 5: ...ension 94 4 6 4 Adjustment of Y carriage timing belt tension 96 4 6 5 Adjustment of center carriage timing belt tension 98 4 7 Transmission unit 4 7 1 Exchange of main shaft timing belt 99 4 7 2 Adjustment of upper shaft timing belt tension 102 4 7 3 Adjustment of timing detecting unit 103 5 User maintenance mode 5 1 How to enter user maintenance mode 105 5 2 Machine movement 106 ...

Page 6: ...hread trimming sensor 120 E2 7 Exchange X Y Position Sensor 121 E2 8 Exchange Breake Unit 122 E2 9 Exchange Pulse Motor Driver 123 E2 10 Exchange of switching power supply and adjustment of output voltage 124 E2 11 Exchange Cooling Fan 126 E2 12 Exchange Inverter 127 E2 13 Setting Inverter E2 13 1 Parameter release the keep off setting parameter setting 128 E2 13 2 Initialize parameter 130 E3 Part...

Page 7: ... 148 E5 4 Record Operation data display 149 E5 4 1 Total number of stitch 149 E5 4 2 Record of Error occurrence 150 E5 4 3 Number of occurrence in each error display 151 E5 4 4 Thread break history 152 E5 5 Machine setting 153 E5 6 Frame Position Entry Registration of coordinates for positioning sensor 155 E5 7 Maintenance Register Registration of machine maintenance date 158 E6 Installment and se...

Page 8: ...187 E9 Trouble shooting E9 1 Electricity doesn t turn on 188 E9 2 Thread break 189 E9 3 Erroneous thread cut 194 E9 4 Off registration of pattern 196 E9 5 Upper thread comes off from needle hole 199 E9 6 Upper thread remains 201 E9 7 Looping 202 E9 8 Malfunction of thread break detection 203 E9 9 Suspension of upper shaft 204 E9 10 Malfunction of needle bar change 205 E9 11 Defect on thread catche...

Page 9: ...ther HSA90030 Keeper positioning gauge Page 88 HSA90080 Retainer positioning gauge 0 8mm Page 74 HSA90090 Positioning pin φ 4 Page 27 HSA90131 1 2mm thickness gauge Page 29 30 HSA90230 Tensile gauge Page 87 HSA90240 Dial gauge set Page 55 ...

Page 10: ...er calliper gauge 200mm Page 37 HSA90210 0 2mm thickness gauge Page 63 HSA90290 Tension gauge 2000Cn 1000g Page 92 94 97 HSA90311 Shell alvania EP Grease 100g Page 76 HSA90340 Shell Grease7 MIL G 23827B 50g Page 39 M0404342 Needle height gauge Page 15 53 ...

Page 11: ...ent of key mechanical parts Thread tension unit Take up lever Moving head Control box Thread guide pillar Needle bar change unit Thread guide A Thread stand Thread holder Rotary hook Rotary hook cover Neddle plate ...

Page 12: ...12 1 Placement of key mechanical parts Upper shaft Timing detecting unit Y carriage X carriage Thread cutting driver ...

Page 13: ...s moment get caster slightly risen from the floor As shown in Fig levelers should be placed on both sides of head bed with upper cover removed 2 Fix the lock nut 3 Fix the pipe cover 2 2 Assemble the thread guide 1 Turn the thread guide pillar front long rear short clockwise with a spanner until tight Fix rear thread guide pillar with a washer and a nut M8 Spanner 10mm 13mm 2 Install the thread gu...

Page 14: ...del Head stopper 2 4 Check of needle position 1 Turn power switch ON and enter user maintenance mode Refer to 5 User maintenance mode 2 Remove bobbin case 3 With help of user maintenance mode please move needle bar down and confirm needle position is center of needle hole on needle plate Note Please move needle bar slowly Note Please check position of 8 th needle then check 1 st and 15 th needle N...

Page 15: ...is active Remove bobbin case 2 Bring needle bar down Refer to 5 User maintenance mode 3 Turn upper shaft anti clockwise and set dial disc to L 10 degrees Turn brake switch ON 4 Put needle height gauge in rotary hook 5 Check if the needle tip touches to the gauge slightly 6 Take Needle height gauge out from hook ...

Page 16: ...ser maintenance mode 2 Turn upper shaft anti clockwise and set dial disc to 25 degrees Turn brake switch ON 3 Check the position of needle and tip of hook as below 4 Check the clearance between needle and rotary hook should be 0 1 0 2mm 5 Fix the needle plate 2 7 Oiling Lubricate the specified oil locations Oil 10 Sewing machine oil 1 Rotary hook Between the outer and inner rotary hook 2 Needle ba...

Page 17: ...s confirm that there is no burr and crack at the position which thread is passing 1 Thread tension Thread guide Rectifier a Revolution must be smooth b No sticking of lint or dust 2 Thread Adjusting Spring a No burr and crack b Spring move smoothly 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 ...

Page 18: ...urface and check clearance A from side If clearance is not equal needle is bent Please replace it with new one 6 Needle plate a No burr and crack in needle hole and 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 in needle h...

Page 19: ...19 2 8 Setting up the machine 10 Rotary hook retainer a There is No burr and crack at the position which thread pass through Rotary hook retainer ...

Page 20: ...hread slip on rotary Detecting rotary Please check thread is not disturbed by spring Upper thread tension should be adjusted depending on type of thread needle and fabric etc Standard 100 150Cn gf Bobbin thread Bobbin thread tension is depending on adjustment of upper thead Please note that bobbin will turn to arrow marked direction when you pull bobbin thread Standard 25 35cN gf Note Please check...

Page 21: ...up the machine 2 10 Trial sewing 1 Turn thread break detecting switch ON 2 Please confirm that thread trimming thread catcher jumping is functioning Important For a month please use machine with 70 of maximum speed ...

Page 22: ...order of 1 4 please remove and fix needle 1 Loosen screw holding needle 2 Remove needle 3 Insert needle till it goes to the end 4 Tighten screw holding needle Fix needle so that needle groove faces front Needle holder Needle Front ...

Page 23: ...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 bu...

Page 24: ... 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 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...

Page 25: ...ove the Slide unit Hexagon socket set screw M4 10 2 pcs 2 screws are inside of the position with arrow mark on above picture Oiling pipe Remove Oiling pipe 2 2 Loose screws for head shaft Hexagon socket set screw M4 4 2 pcs 2 3 Slide up the Head shaft Take off the broken needle driver 3 Set the new needle bar driver Assemble reverse step with step no 2 3 1 Set needle bar driver to block pin ...

Page 26: ... shaft face flat with head face 3 3 Set slide unit Hexagon socket button head screw M4 10 Note No clearance between head and slide unit Oiling pipe Keeping cut face front and insert oiling pipe into hole 4 Install moving head Please refer to 4 2 1 4 2 2 Assemble and remove moving head 5 Check needle height Please refer to 2 5 Check of needle height ...

Page 27: ...te right and Head cover bracket Face plate right 4 Turn upper shaft and insert positioning pin into the hole of cam through the positioning hole on machine body The hole of cam The positioning hole on machine body Please note that moving head is removed on the picture below just for taking photograph 5 Loosen screw on take up lever cam Screw on take up lever cam The positioning pin 6 Turn upper sh...

Page 28: ... 4 1 2 Adjustment of take up lever timing 7 Fix screw Screw on take up lever cam 8 Pull positioning pin out 9 Turn brake switch OFF Turn upper shaft and set angle at 270 degrees C point 10 Set all covers ...

Page 29: ...d set dial disc to 0 degree Turn brake switch ON 3 Insert Gauge I 2mm between needle plate and pressure foot Please confirm that there is no gap between gauge and pressure foot and needle plate 4 If wrong space not 1 2mm please adjust height of pressure foot guide bar Please refer to 4 1 4 Adjustment of height of pressure foot ...

Page 30: ...to 0 degree Turn brake switch ON 3 Loosen fixing screw of pressure foot Fixing screw 1 pcs 4 Insert Gauge I 2mm between needle plate and pressure foot 1 2 mm is standard But please adjust depends on thickness of material 5 Tighten fixing screw for pressure foot Fixing screw 1 pcs At this moment no gap between gauge and pressure foot or needle plate ...

Page 31: ...rther please slide front panel lower on neighbor head Cord clip 2 Remove needle needle holder and cushion Note When needle holder is removed pressure foot move down quickly 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 Fixing of Needle 6 Adjust needle height Please refer to 4 2 6 Adjustment of needle height 7...

Page 32: ...m between needle plate and pressure foot Please confirm that there is no gap betwen gauge and pressure foot and needle plate 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 front panel lower and cord clip to previous places to finish ...

Page 33: ...er Move hook in and out by hand and confirm that hook is moving smoothly Note Please check at 1 st needled and 15 th needle Space between hook and pressure foot Space between back side of pressure foot and hook is 0 5 1mm Space If space is OK fix thread catcher 3 In case space is not within allowance re adjust position of thread catcher 4 Turn thread break detecting switch ON ace ...

Page 34: ... 3 pitches of gear Gear 6 Loosen screw of photo sensor and move photo sensor to the position that thread break lamp becomes RED and fix photo sensor Screw of photo sensor 7 Pull hook completely and return to front for movement of 3 pitches of gear and confirm that thread break lamp becomes RED ar r ...

Page 35: ...d catcher guide 1 Remove guard plate Use the 1 Screw driver 2 Exchange guide Fix the guide after moving it to the right 3 Install the guard plate 4 Please refer to 4 1 6 Fixing of thread catcher install thread catcher to finish ...

Page 36: ...pcs 3 Put on grease to new presser foot cam Also put on grease to fixing nuts then insert nuts into hole of pressure foot cam to prevent drop of the nut Grease Shell alvania EP Grease Shell Gudas S2 V220 2 4 Fix good part as temporally by fixing screw and nut Make sure to cover fixing hole with finger to prevent drop of the nut Please check bump 2mm between front of presser foot cam and front face...

Page 37: ...r foot and bottom face of fixed head to 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 to manual ...

Page 38: ...lenoid and needle bar driver and check main shaft indicator Should be between 83 to 87 degrees Just touched to plunger Dubble check Please double check Jump solenoid position by following test Continually fillip needle bar driver to arrow direction while main shaft turning and hearing plunger touch ing noise Should change noise between 83 to 87 degrees shaft position 4 Please put parts back in rev...

Page 39: ...ger part Grease 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 Front face 5 Confirm the movement of the plunger is smooth enough 6 Procedure is done after assembling the Jump solenoid Referring to 4 1 9 Adjustment of fixing of jump solenoid ...

Page 40: ... bracket 1 2 Loosen screw on thread tension bracket Pan head screw M4 10 4 pcs 1 3 Remove the thread tension bracket Pull thread tension bracket to front Put thread tension bracket and lighting bracket on head upper cover 1 4 Remove the set screw A Hexagon socket head cap screw M4 20 6 pcs B Hexagon socket head cap screw M4 6 2 pcs C Hexagon socket head cap screw M4 18 4 pcs Hexagon socket head ca...

Page 41: ...ing head at position that 15 th needle is active Set all take up lever to guide bar starting from 1 st needle Guide bar Take up lever Insert rail into positioning roller Positioning roller Rail 2 2 Temporally tighten screws A Hexagon socket head cap screw M4 20 6 pcs B Hexagon socket head cap screw M4 6 2 pcs C Hexagon socket head cap screw M4 18 4 pcs Please put plain washer with hexagon socket h...

Page 42: ...er to lever crank 2 5 Please needle bar of 8 th needle down until needle driver catches needle bar boss Then turn upper shaft to needle down and check that needle is center of needle hole on needle plate If needle position is not center of needle hole please move moving head right or left to fit needle position Please refer to 4 2 5 Adjustment of needle position left and right 2 6 Tighten 8 screws...

Page 43: ...please check following points 3 1 Check needle height please check needle height at 1 st 8 th and 15 th needle Please refer to 2 5 Check of needle height In case needle height is not same for each needle installation of moving head was wrong Please check step 2 3 again 3 2 Check of rotary hook timing please check hook timing by 8 th needle Please refer to 2 6 Check of rotary hook timing In case ho...

Page 44: ... bracket Truss head screw M4 6 6 pcs Upper shaft cover Cord clip Lighting bracket 1 2 Loosen screw on Thread tension bracket Pan head screw M4 8 4 pcs 1 3 Remove the thread tension bracket Pull thread tension bracket to front Put thread tension bracket and lighting bracket on head upper cover Needle bar change cover 1 4 Remove the Needle bar change cover and needle position plate Needle position p...

Page 45: ...exagon socket head cap screw M5 15 2pcs 1 6 Remove set screw Hexagon socket head cap screw M4 20 6 pcs Hexagon socket head cap screw M4 6 2 pcs Hexagon socket head cap screw is a set with plain washer Please keep as a set 1 7 Slide moving head to the right direction by knob and take moving head out after the rail going out from roller Positioning roller Rail ...

Page 46: ...r setting to 15th needle please move slightly to the right by knob of Needle bar change unit Guide bar Cam follower With turning knob set the rail into Positioning Rollers Positioning roller Rail 2 2 Set moveing head to 15th needle position and temporally tighten screws Hexagon socket head cap screw M4 20 6 pcs Hexagon socket head cap screw M4 6 2 pcs Please put plain washer with hexagon socket he...

Page 47: ...crew on moving shaft Note Please confirm Fasten block position to make clearance about 2 5mm against Moving head Moving head Fasten block 2 6 Move moving head to the position that 1 th needle is active Install the needle position plate Needle position plate 2 7 Install Thread tension bracket Pan head screw M4 10 4pcs 2 8 Set the front panel upper cord clip and lighting bracket Truss head screw M4 ...

Page 48: ...lease check needle positon for all other head too 3 After installation of moving head please check followindg points 3 1 Check needle height please check needle hight at 1 st 8 th and 15 th needle Please refer to 2 5 Check of needle height In case needle height is not same for each needle installation of moving head was wrong Please check step 2 3 again 3 2 Check of rotary hook timing please check...

Page 49: ...eedle plate Please refer to 5 User maintenance mode 4 Move the Positioning plate to front and back for adjust needle position against needle hole to center and tight the screw Note Insert Lower rail to between the two bearing deeply Positioning plate Needle Needle hole of needle plate 5 After adjustment confirm the position by 1 st and 15 th needle also If you have big different the needle positio...

Page 50: ...eedle bar change unit Cam 3 Move the head to 8th needle and remove Detecting Cover and Thread Detecting Board of 1st head and loose screw for needle bar change unit Note Please turn off machine power Detecting cover Thread detecting board Screw for needle bar change unit inside the beem 4 Turn the knob and stop at a needle stop position Then down needle till needle point to needle plate face You c...

Page 51: ... previous places 7 Turn on the machine and confirm the position at 8th needle position If the needle position is not at center of needle hole please refer to 4 3 1 Check Adjustment of needle bar change unit 8 Please confirm 1 st and 15 th needle also 9 After adjustment the positon for 1 st head please adjust 2nd head to last head Please refer to 4 2 5 Adjustment of needle position left and right A...

Page 52: ...below 3 Down needle till point of neeld with face of the needle plate Please refer to 5 User maintenance mode 4 You can move Moving head right and left for position adjustment by hand Then tight 4 screws 5 Please confirm 1 st and 15 th needle also after 8 th needle If the needle position is not at center of needle hole please replace 6 After adjustment Please confirm needle height and rotary hook ...

Page 53: ... that you can see needle bar to be adjusted In case you need to slide front panel lower further please slide front panel lower on neighbor head 2 Remove bobbin case 3 Bring needle bar down Please refer to 5 User maintenance mode 4 Turn upper shaft to set dial disc to 10 degrees 5 Loosen screw on needle bar boss 6 Put needle height gauge in rotary hook ...

Page 54: ...uches to the gauge slightly 8 Set direction of needle stop as illustrated below About 30 degrees 9 Tighten the screw of needle bar boss 10 Take Needle height gauge out from Hook 11 Back main shaft to 270 degrees C point position 12 Set front panel lower and cord clip set bobbin case then end of process ...

Page 55: ...3 Turn off the brake switch Turn upper shaft to set dial disc to C point 270 degrees 4 Bring needle bar down 5 Turn upper shaft to set dial disc to 355 degrees 6 Turn on the brake switch 7 Fix Dial gauge set on left side of bed 8 Set lever of the Dial gauge at lower surface of needle holder then adjust position of the Dial gauge so as to move pointer of the Dial gauge around 1mm ...

Page 56: ... can not be moved again Fasten collar 11 Check movement of the Dial gauge with turning fasten collar forward and back ward then find needle bar lowest point that the movement of the dial gauge stops 12 Tighten fixing screw of fasten collar Fasten collar 13 Turn brake switch off 14 Turn upper shaft to set dial disc to 355 degrees Turn main shaft forward and back ward with checking the Dial gauge mo...

Page 57: ...dicated with red arrows 3 Loosen a screw of a needle which requires adjustment 4 Put down needle bar assembly of a neelde manually which requires adjustment down 5 Push MENU and then push OTHER 6 Push Maintenance 7 Push and then change to Drive from Jump at Main Shaft Turns 8 Push Angle and then rotate a main shaft by 180 degrees 180 Thread Adjusting Unit Assembly Needle Bar Assembly ...

Page 58: ...e above step No 9 deactivate thread detection and then check if a needle bar works correctly with a machine activated Note If a needle bar does not work correctly go back to the above step No 8 and lower an angle by every two 2 degrees as appeared at Example below Tighten a screw of a needle which requires adjustment when an appropriate angle is secured Then go back to the above step No 10 Example...

Page 59: ...eedle bar boss At this time remove pressure foot spring lower pressure foot block cushion pressure foot boss 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 Note Care to insert direction for Pressure foot and Pressure foot boss Pressure foot block Check shape of direction Pressure foot boss Should hole to under side ...

Page 60: ...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 4 2 6 Adjustment of needle height 9 Adjust pressure foot height Please refer to 4 1 4 Adjustment of height of pressure foot 10 Put removed parts back to finish ...

Page 61: ...4 2 1 4 2 2 Assemble and remove moving head 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 62: ...remove 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 63: ...er 7 Install good take up lever assembly with plastic thrust washer plastic washer E ring 8 Leave space of 0 2mm between take up lever and moving head Tight screw for Take up lever shaft 9 Put moving head in previous position to finish ...

Page 64: ...spring 1 Remove thread adjusting unit ass y Fixing screw 4 pcs 2 Block has spring groove to be able to adjust in three steps Put tip of spring in upper groove Strongest tension will be obtained in upper groove 3 Fix thread adjusting unit ass y to finish ...

Page 65: ... Loosen screw on adjuster 2 Move adjuster lower position with small flat head driver When you move adjuster upward stroke will get small When you move it down stroke will get large The lower position is default setting 3 After adjustment tighten screw to finish ...

Page 66: ...position at smoothly moving position Note Please check smoothly moving at 1 st and 15 th needle Positional relationship between pressure foot and holder lower When downing the needle should have gap more than 1 mm between holder and presser foot Gap 3 Thread catcher device should be adjusted if above clearance is not keepable 4 Press thread trim key and confirm whole thread trim revolution ...

Page 67: ...g at 1 st and 15 th needle Positional relationship between pressure foot and holder lower When downing the needle should have gap more than 1 mm between holder and presser foot When is hook pull out space between hook and bottom of pressure foot should be more than 1mm 3 Thread catcher device should be adjusted if above clearance is not keepable 4 Space between Clip drive and clip should be 1 2mm ...

Page 68: ...holder Clip drive Clip 5 Turn power switch ON and move moving head to 15 th needle Please confirm space between Clip drive and clip is same as space at 1 st needle 6 If case above space at 1 st needle and at 15 th needle is not same position of clip holder may be incorrect Please check position of Clip holder and Clip drive unit 7 Refer to E5 1 How to enter maintenance mode and enter maintenance m...

Page 69: ...has 2 pcs of set screw Inner set screw is Cup Point type and outer set screw is Flat Point type 2 2 Push the Cam to right and push drive shaft to left side and tight Cam screws Cam Drive shaft 2 3 Check the cam should not have play After this adjustment please check and adjust the needle position Please refer to 4 2 4 Adjustment of needle position left and right 3 Turn the knob and stop at needle ...

Page 70: ...f sensor and slit When needle selection cam is position on flat angle of slit against sensor should be even like below drawing 4 Turn the knob and move moving head to 15 th needle 5 Enter maintenance mode referring to E5 1 How to enter maintenance mode 6 Press Machine Test 7 Press 1 Needle Adjust and press Position Should showing Needle Number 15 and has beep sound 7 1 If your machine showing diff...

Page 71: ...Moving head to 1 st head and press Position Confirm indication to Needle Number 1 7 3 Move Moving head to 1 st head and press Position 7 4 Press BACK to complete settings 8 Please check needle position to needle plate and back on cover Note Piositioning image for needle selection Cam Slit Sensor Center Imagine figure of position sensor and cam ...

Page 72: ...osen screw on rotary hook 3 places Note Please do not loose screws too much 3 Bring needle down up to the needle lowest position Refer to 5 User maintenance mode Note Please do not loose screws too much 4 Turn upper shaft and set dial disc to 25 degrees Note Turn upper shaft anti clockwise Turn brake switch ON 5 Set the position of needle and tip of hook as below ...

Page 73: ... with 1st 8th and 15th needle 8 Tighten screws on rotary hook 9 For making sure check position of retainer on bobbin case holder Please refer to 4 4 2 Adjustment of retainer on rotary hook 10 Set needle plate keeping needle position is center of needle hole on needle plate Needle Needle hole of needle plate 11 Adjustment has finished ...

Page 74: ...ck and forth left and right Using adjustment gauge and adjust space to be 0 8mm for back and forth insert gauge between retainer and inner hook The position for right and left is center of the needle Gauge Center of needle and center of retainer to be adjusted Gauge 0 8mm Needle center position 4 Adjustment has finished ...

Page 75: ...osen screw and take hook out 1 3 Loosen screw of collar Hexagon socket set screw M4 4 2 pcs Please loose screw enough because shaft has flat face 1 4 Take cover of bed Screw for needle plate 2 pcs 1 5 Lossen screws see below picture total 4 pcs Hexagon socket set screw M4 4 4 pcs 1 6 Take gear out 1 7 Pull shaft out Take hook shaft out has finished ...

Page 76: ...5mm out from collar Please fix screw Hexagon socket set screw M4 4 2 pcs 2 3 Put gear and fix Set screw position to flat face of shaft and tighten screw Hexagon socket set screw M4 4 2 pcs Center of gear should be center of shaft please adjust position of gear 2 4 Please put grease on gear Grease Shell alvania EP Grease Note Put grease equally 3 5 Put cover of bed Screw for needle plate 2 pcs ...

Page 77: ...ok and hook retainer Hexagon socket button head screw M3 5 Plain washer M3 3 2 Adjust rotary hook timing Please refer to 4 4 1 Adjustment of rotary hook timing 3 3 Adjust retainer on rotary hook Please refer to 4 4 2 Adjustment of retainer on rotary hook Exchange has finished ...

Page 78: ...e to closing Please refer to 5 User maintenance mode 3 Check clearance between Driver base and Fasten block for guide 18 19mm Please confirm bulge right side point of Slide shaft position likefollowing picture Clearance Slide shaft 4 Turn the Cam till stop end And confirm a ditch of Cam has allowance 5 Keep Moving knife to opening Please refer to 5 User maintenance mode ...

Page 79: ...ease confirm bulge left side point of Slide shaft position likefollowing picture Clearance Slide shaft If you have some error in the step 3 6 please adjust 4 5 2 Adjustment of thread cutting driver 7 Please keep Moving knife to closing Please refer to 5 User maintenance mode Return cover to previous places to finish ...

Page 80: ...over 2 Turn the Thread cutting cam and move Fasten block guide to center area of the bracket 3 Loose Fasten screw and adjust slide shaft position to even protuberance against face of driver base and tight the screw Slide shaft Fasten screw 4 Turn the Thread cutting cam till end position Please see picture bellow Please keep this position for next adjustment ...

Page 81: ...or If you off the position please adjust sensor position by screw on sensor bracket Sensor Slit 6 After it please adjust 4 5 5 Check Adjustment of position of moving knife 7 Confirm Moving knife position to CLOSE Please refer to 5 User maintenance mode Back on covers to previous position ...

Page 82: ...g drive link hole to moving knife insert knife drive shaft assembly 7 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 upward and downward direction 8 Close moving knife Please refer to 5 User maintenance mode 9 Referring to 4 5 6 Adjustment of moving knife and fixed knife check how well thread is...

Page 83: ...shing to forward as full as possible Note In case moving knife and the left side of fixed knife overlaps excessively when closing adjust the position of fixed knife slightly to the right direction 5 Referring to 4 5 6 Adjustment of moving knife and fixed knife check how well thread is cut and adjust then finish this process ...

Page 84: ...maintenance mode for easy adjustment for this progress You can open and close the knife manually Same face 3 For this adjustment remove Table support cover on front and go to next step 4 Loosen screw on Thread cutting link and slide the link to right side for open the moving knife Screw 5 Slide the Thread cutting link to left side for close Moving knife and stop at right position of knife closed p...

Page 85: ...tly 7 Check Moving knife closing point If the closing position is not right please back Set 5 and 6 Please check opening point Should open the Moving knife to left till point of Moving knife overfrom Rotary hook retainer Point of Moving knife Rotary hook retainer If the position is not right please check Thread cutting driver Referring to 4 5 1 Check of thread cutting driver 8 After confirm please...

Page 86: ...referring to 4 5 3 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 t feel resistance 4 Cut thread and check how well it is cut Use two polyester threads for checking 5 Check several times and if no mistakes are found finish this process ...

Page 87: ...bobbin 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 6 Check several times and if OK finish this process ...

Page 88: ... and bed cover Solenoid base 2 Loosen screw on solenoid base Fixing screw 2 pcs 3 Loosen screw for stopper 1 pcs 4 Insert keeper positioning gauge Bobbin into rotary hook 5 Refer to E5 1 How to enter maintenance mode and enter maintenance mode 6 Press Machine Test ...

Page 89: ...f 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 8 Adjust position of stopper This is the position where tip of keeper contacts to gauge 9 Adjustment has finished ...

Page 90: ...it cover Base cover 2 Loosen the adjusting lock nut Spanner 7mm 3 Loosen screw of Pulse motor bracket half turn 3 pcs 4 Set tension adjustment screw position 10mm from face of bracket of shaft support Tighten screw by 1 4 turn 5 Tighten screw for the pulse motor bracket 6 Tighten the adjusting lock nut ...

Page 91: ...X carriage drive belt tension 7 Return base cover and drive unit cover to previous places 8 Please refer to E5 6 Position Registration of coordinates for positioning sensor register embroidery area and finish this adjustment ...

Page 92: ...osen lock nut for tension adjusting nut Spanner 7mm Lock nut Adjusting nut 3 Loosen screws of tension plate half turn 2 screws 4 Push belt at center of belt by push gauge with 500gf Please adjust tension of belt by adjusting nut that belt moves 5 6mm 5 6mm 5 Tighten the screws of tension plate 6 Tighten the lock nut for tension adjusting nut Lock Nut ...

Page 93: ... carriage timing belt tension 7 Return base cover and drive unit cover to previous places 8 Please refer to E5 6 Position Registration of coordinates for positioning sensor register embroidery area and finish this adjustment ...

Page 94: ... lock nut of tension adjusting screw you can find this screw under table Spanner 7mm 4 Loosen screws of Y motor base by half turn 5 Push belt by push gauge with 500gf Belt should hide half of hole for motor fixing screw Please adjust tension by tension adjusting screw Note Push gauge should touch belt with 90 degrees and be close to table edge Hole for motor fixing screw Tension adjusting screw Lo...

Page 95: ...ghten screws of Y motor base 7 Tighten lock nut of tension adjusting screw Lock nut 8 Set table support cover 9 Set rear cover and middle cover 10 Please register frame position Please refer to E5 6 Position Registration of coordinates for positioning sensor ...

Page 96: ...nd left side Below explantion is for right side 1 Take Y cover bracket and Y cover out Y cover bracket Y cover 2 Move X carriage 150mm from center of idler pulley and put a mark at 75mm 150mm A mark 3 Loosen lock nut for tension adjusting screw Spanner 7mm Lock nut 4 Loosen screw for idlerpulley bracketby half turn ...

Page 97: ... of push gauge Please adjust tension by tension adjusting screw Tension adjusting screw 6 Tighten screws of idler pulley bracket 7 Tighten lock nut of tension adjusting screw Lock nut 8 Set Y cover and Y cover bracket 9 Please register frame position Please refer to E5 6 Position Registration of coordinates for positioning sensor ...

Page 98: ...ut 3 Loosen screws for idler bracket by half turn 2 pcs 5 Adjust space between tension plate and idler pulley bracket 5mm by tension adjusting screw Idler pulley bracket Tension plate 6 Tighten lock nut for tension adjusting screw Lock nut 7 Set middle cover and rear cover 8 Please register frame position Please refer to E5 6 Position Registration of coordinates for positioning sensor ...

Page 99: ...s of screws indicated with red arrows 4 Remove six 6 pieces of screws and then remove a left cover 5 Loosen a nut indicated with a red arrow by using a 7mm spanner 6 Rotate two 2 pieces of screws mounted on a tension plate by approximate 180 degrees to loosen them Bed Cover B Nut for tension adjustment Tension Plate ...

Page 100: ...unted on an upper shaft collar assembly 11 Slide a lower shaft and then remove a lower shaft pulley 12 Remove a timing belt 13 Put a timing belt on a lower shaft pulley and then put a lower shaft back in After this loosen screws on an upper shaft collar assembly and then fix a lower shaft pulley Screw for tension adjustment Idler Pulley Assembly Rear Left Cover Lower Shaft Lower Shaft Pulley ...

Page 101: ... screws Note As appeared in the picture below screws should be tightened so that they will come face up 17 Go to 4 7 2 Adjustment of upper shaft timing belt Tension for more information on timing belt adjustment 18 Put rear left cover left cover and bed cover B back on 19 Adjust a rotary hook timing referring to 4 4 1 Adjustment of rotary hook timing Steps complete Flat Fasten Collar A Lower Shaft...

Page 102: ...ews for tension plate by half turn Note Please do not turn main shaft when screws for tension plate is loosen Timing may be changed 4 Adjust space between tension plate and tension plate lower 12 5 13mm by tension adjustingscrew Note Please Keep tension plate straight 5 Tighten screws for tension plate 6 Tighten lock nut of tension adjusting screw 7 Set mission cover left ...

Page 103: ...isk Then tighten the screws when LED4 goes off LED4 will go off if the timing slit blocks L point sensor 5 After tightening the screws rotate the upper shaft to reach 0 degree L Point at the disk and confirm that LED4 goes off 6 Rotate the main shaft in the right direction and confirm that LED3 goes on in the range between 270 through 284 degrees C Point 7 Make sure that the timing slit does not c...

Page 104: ...105 4 7 3 Adjustment of timing detecting unit 8 Finally put the cover back on ...

Page 105: ...t is not at C point Thread cut blade is not at stop position Thread Catcher is open position this key work for back to standby position automatically Indicates point which sensors are active L point sensor The point that indicator becomes RED is L point when main shaft is turned C point sensor The point that indicator becomes RED is C point when main shaft is turned Needle sensor The point that in...

Page 106: ...Mode 2 Press oen of button on control panel and check machine movement Note The machine moves quickly please be carefull that all head move at once machine show following message when you press key C point Upper shaft is not at C point Cut blade Thread cut blade is not at standby position Thread Catcher Thread Catcher is open position Please press for back to standby potion and repeat step 2 again...

Page 107: ...107 ...

Page 108: ...108 E1 Placement of key electronic parts Timing detecting board Seiral Port CONT R2 board Bobbin Thread Winder Control Box Main Switch Brake Release Switch Thread Catcher Jump Unit ...

Page 109: ...er Supply Box Laser Position Marker Keeper Relay Board Needle Bar Changing Unit X Motor Y Motor Thread detecting board Sensor Relay Board TC8 7 board Servo amp Main shaft Servo amp Y Servo amp X Magnetic contactor Noise filter Switching power supply No fuse breaker Power relay circuit board DC fan unit ...

Page 110: ...emove the screws at the six places below 2 Remove all the Harness and 4screws and exchange to a new CONT R2 board 3 Connect all the harness back to the board 4 Refer to E4 1 Preparation for program update and prepare update program 5 Inser USB Memory stick to the machinee that contain update program 6 Turn machine power on 7 After showing below scree Keep START STOP button pressing then press NEXT...

Page 111: ...layed brigther Please set according to your machine specification options then press ESC after setting is done 14 Press OK 15 Press OK 16 Press OK if you have new program version than current version in the machine Installation starts after press OK Press Cancel in case current program version is latest 17 Press OK ...

Page 112: ... position by Refer to below display 4 Press START button Press ESC button in case of cancellation 21 When you press START button registation of X axis direction will start Frame moves as below 22 Then registration of Y axis direction will starat Frame moves as below Center mark position of X axis Center mark position of Y axis 1 2 3 4 1 2 3 4 ...

Page 113: ...h successful conpletion Retry from step 20 if Error occurs 24 Press OK Auto Speed setting will starts Main shaft will start rotation automatically and adjust speed setting 25 Press OK Back to Maitenance mode menu window End of process Complete ...

Page 114: ... C and the removed harness as shown with D back on and tighten the screws note Make sure that the slits go further into the slots of the sensors 5 Put the part as shown with B back on Then tighten the screws note Make sure that the flat portion on the shaft of the part encoder as shown as B matches the location of the screw as appeared in the picture note Check visually if the upper shaft and the ...

Page 115: ...nt sensor 9 After fixing timing detecting board rotate the upper shaft to reach 0 degree L Point at the disk and confirm that LED4 goes off 10 Rotate the main shaft in the right direction and confirm that LED3 goes on in the range between 270 through 284 degrees C Point 11 Contorl that slit does not touch sensor These steps are all you have to do SENSOR SLIT LED4 L POINT SENSOR C POINT SENSOR LED3...

Page 116: ...s different way of connection for each head Please attention to following information 1 For Head with emergency stop SW TC EMG harness 2 For Head without emergency SW white loop harness 3 For last Head Red loop harness After connect all please check if emergency SW works correctly ...

Page 117: ... at the bottom four places 5 Remove board by sliding to the left Note Confirm Slit is not in the Sensor groove befor removing the Board Sensor might get damaged if you pull it by force 6 Adust the position of Board bracket and Shaft of Detecting thread tension ass y then slide the board to fix the position 7 Make sure Sensor and Slit are not interfering 8 Put Thread tension cover back and install ...

Page 118: ...llow arrow part 4 Remove screw and exchange Sensor board then connect to a connector back 5 Loosen screw and pull potentiometer out 6 Loosen slit collar fixing screw and make slit collar free to turn 7 Adjust notch position of slit collar to be sensor and cam position where moving head does not move 8 Connect harness of potentiometer 9 Turn on machine power 10 After showing below screen Keep START...

Page 119: ...4 Set potentiometer and fix check Sensor is located at notch center of slit collar and mark is shown on creen The position of sensor is not lacated at notch of slit collar re adjust again 15 Turn knob and move head to 1 st needle position check mark appears when notch center of slit collar comes sensor position If position is not matching please re adjust again Sensor Slit Center ...

Page 120: ...d confirm that shaft is not moving 5 Turn CAM and set sensor position is out from slit Power on and press NEXT on control box 6 CAM turns and stops at stopping position automatically Check postion of moving knife Position of Moving knife and fixed knife 7 Fix Cap screw Set cover Sensor Slit Sensor Slit Sensor CAM stopping position Relation of CAM and Knife SENSOR SLIT KNIFE ASS Y ...

Page 121: ...r Circuit Board Then take harness out 3 Replace Board and set harness and fix by screw note Adjust postion of detecting plate to be center of sensor 4 Set cover 5 Set coordintes Refer E5 6 Position Registration of coordinates for positioning sensor X Sensor X Sensor Y Sensor Y Sensor X Sensor Y Sensor ...

Page 122: ...eft rear table Remove cover left 2 Take connector out Unscrew and take brake solenoid 3 Put 0 1 0 15mm paper between brake solenoid and brake disk and fix brake solenoid by screw 4 Take paper out and set cover set left rear table End of process ...

Page 123: ...ox Remove the screws at the seven places below 2 Take harnesses out from driver 3 Unscrew 4 screws on base plate 4 Check setting of new driver same setting for X and Y 5 Fix driver by screws and connect harnesses and put cover Detail information about harnesses connection is mentioned in E7 1 Pulse motor driver PMD wiring ...

Page 124: ...e screws at the five places below 2 Take AC100V connector out Unscrew 4 screws on base plate 3 Switching power suplly locates under base Unscrew and take connector out 4 Replace swicthing power suplly and fix screw and connector note Harness should not get caught 5 Remove cover right Remove the screws at the six places below 6 Set DC of degital tester 0V DIGITAL MULTIMETE R DC AC ...

Page 125: ...er into CN28 of CONT R2 board note Tester red to be put into No 1 of CN28 Tester black to be put into No 2 of CN28 8 Power main switch on and trun VR volume on switching power supply and set 24 0V 0 1V End of process ...

Page 126: ...over Remove the screws at the five places below 2 Remove filter 3 Unscrew fan cover note nut is on reverse side 4 Unscrews fan cover note nut is reverse side 5 Proceed in revese order and exchange to a new Fan note1 Arrow mark side should come to a left side note2 Make sure fan is not interfering harness End of process ...

Page 127: ...r the PULL indication on the underside of control terminal cover and pull the cover toward yourself and remove it 4 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 5 Set new inverter and connect harness and fix pefer E7 2 Inverter wiring for detail information of harness connection 6 Put cover 7 Referrin...

Page 128: ...ng 6 Press up key and function code is displayed Select the function code whose parameter you would to change Press down key and the function code returns to the previous code The following table shows function codes setting details and factory default setting Function other than described below are initial setting of inverter Refer to the next clause for the method of initial setting Code Functio...

Page 129: ...played This means change of the function code is made How to set the prohibition setting 10 After each setting is done select F 0 0 by pressing Up of 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 SAVE is displayed F 0 1 is displayed 14 Press PRG RESET I F _ _ is displayed 15 PRG RESET aga...

Page 130: ...ed by referring in E2 13 1 Parameters relase the keep setting and parameters settin 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 0 00 is displayed The settings of inverter become initial se...

Page 131: ... cover right Remove the screws at the six places below 2 Disconnect a connector Yellow arrow part Remove scerws that fix harness 3 Remove Clamp filter Remove three sets screws on bracket A as shown in the figure below 4 Remove control box Please reverse procedure when installing control box bracket A Clamp filter Standard 10 4inch ...

Page 132: ... connectors for SW cable Box cable cable for LCD inverter red white SW cable Box cable Cable for LCD inverter red white 3 Remove sealed case A 4 Remove core module 5 Remove narrow flat cable for LCD unit Make slight slide and remove the cable 6 Remove two sets screws and two studs Sealed case A Sets screws Studs ...

Page 133: ...de to the side and remove cable 8 Remove display bracket and LCD unit Remove 4 screws Red arrow part 9 Remove touch panel Please reverse procedure when installing LCD CE board Adjust clock function by refering to instruction book After power back on Wide flat cable LCD unit Display bracket Touch panel ...

Page 134: ... 2 Remove the screw of the grounding terminal Remove connectors for Box cable 3 Remove sealed case A Remove the screws at the tow places below 4 Remove connectors 5 Remove two setsscrews and two studs Setscrew Stud 6 Remove sealed case B Box cable Ground terminal screw Sealed case A LVDS cable SW cable Narrow width flat cable Sealed case B ...

Page 135: ...thescrews at the four places below 8 Remove LCD unit Remove the screws at the four places below Please reverse procedure when installing LCD CE board Adjust clock function by refering to instruction book After power back on LCD unit ...

Page 136: ...mory EPZ012220 Refer to the latest parts list for the parts number This memory card contains programs and data fo on Enbroidery machine note In case you use SD card in the market Make sure to use more than 16GB SD card capacity and please ask us for needed data file ...

Page 137: ...pdate by Menu of Maintenance mode 4 Replacement of CONT R2 board Register frmae position in Maintenance Mode 5 Press MENU button and select System in menu of OTHER for initialization of system 6 Press MENU button and select speed in menu of OTHER for automatic speed setting 7 Replacement of LCD CE board Calender setting 8 End of process E4 2 3 Update the machine progra E4 2 2 Update the main profr...

Page 138: ...t program file from our Web page and extracxt it 2 Copy the extracted file into the USB Memory You will find program file folder as below image in the PC after extraction note Program folder should be copied to the root directory of USB memory End of process ...

Page 139: ...ote Do not remove USB memory during installation Instllation will take sometime and do not turn off the machine power during Installation In case of writing error and displays Error please try to install again Monitor will be reboot automatically when updates is finished 5 Press NEXT 6 Refer to manual E4 4 Revolution setting and proceed System initialize and Auto speed setting That is end of progr...

Page 140: ...in Program Update 5 Select following 3items Language Letter Program then confirm 3 items are dispayed as Update 6 Press ENTER Installation will be started note Do not remove USB memory during installation Instllation will take sometime and do not turn off the machine power during Installation In case of writing error and displays Error please try to install again Monitor will be reboot automatical...

Page 141: ...141 8 Refer to manual E4 4 Revolution setting and proceed System initialize and Auto speed setting That is end of program updates process ...

Page 142: ...ance mode 4 Press Machine Program Update Contents in the USB memory will be displayed 5 Select UpdateFile 6 Select MachineInstallDate 7 Select your machin model Installation will be started and back to Maintenance mode menu screen once installation is completed properly Note Do not remove USB memory during installation Instllation will take sometime and do not turn off the machine power during Ins...

Page 143: ...8 Shut down machine power and Turn on power again 9 Press NEXT 10 Refer to manual E4 4 Revolution setting and proceed System initialize and Auto speed setting That is end of Machine program updates process ...

Page 144: ...em 3 Press OK Formatting of the machines systems 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 re...

Page 145: ... 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 E E5 5 1 1 H Ho ow w t to o e en nt te er r m ma ai in nt te en na an nc ce e m mo od de e 1 Turn on...

Page 146: ...ling 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 Pulse motor will be un locked when you activate t...

Page 147: ... press NEXT to enter maintenance mode 3 Press Machine Test 4 Select desired number to be confirmed Page is switching by pressing Selected item will be executed 5 Go back to MAINTENANCE screen if press ESC Not necessary if it backs automatically 6 Press ESC and then back to Drive mode screen ESC ESC ...

Page 148: ... 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 Turn on machine power 2 After showing below screen Keep START STOP button pressing then press NEXT to enter maintenance mode 3 Press Memory All Clear 4 Return to drive mode by pressing ESC and 4 Memory activation che...

Page 149: ...by needle bar E E5 5 4 4 1 1 T To ot ta al l n nu um mb be er r o of f s st ti it tc ch h 1 Turn on machine power 2 After showing below screen Keep START STOP button pressing then press NEXT to enter maintenance mode 3 Press Record 4 Press STITCH The screen shows total stitches used for embroidery so far 5 Total Stitch clear selection screen will be appear by press CLEAR 6 Total number of stitch i...

Page 150: ...intenance mode 3 Press Record 4 Press ERROR Enable to confirm Record 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 5 Error record is cleared by pressing OK and the screen of the Error Record is displayed If you do not prefer to clear it press CANCEL and the screen of the Error Record is dis...

Page 151: ...onfirm record of error occurrence 5 Press COUNT You can confirm total number of occurrence in each error E 000 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 6 Error Record Clear select screen will appear by press CLEAR 7 Error record is cleared by pressing OK and the screen of the Error Record is dis...

Page 152: ...rd 4 Press THREAD You can confirm thread break history by needle bar The screen returns to the previous screen by pressing BACK Head is switched by pressing 5 Thread break count Clear select screen will appear by press CLEAR 6 Thread break history is cleared by pressing OK and the screen of the Record THREAD is displayed If you do not prefer to clear it press Cancel and the screen of the Record TH...

Page 153: ...orer Device No Use of Borer device Yes or No 14 Cutter Unit Type PulseMtr Thread cutting unit type 15 X Start Base Angle 60 20 90 Starting angle of frame movement on X axis 16 Y Start Base Angle 60 20 90 Starting angle of frame movement on Y axis 17 X Start Angle CAP 40 20 90 Starting angle of frame movement on X axis for cap frame 18 Y Start Angle CAP 40 20 90 Starting angle of frame movement on ...

Page 154: ...nter maintenance mode 3 Press Machine Setting 4 Select desired number and modify setting Setting values become default by pressing Page is switched by pressing 5 Press ESC button after modifying of setting number 6 The screen returns to drive mode by pressing 7 Turn off power and on again before use a machine ...

Page 155: ...ximum embroidery area be surenot to have anything around the machine 1 Turn on machine power 2 After showing below screen Keep START STOP button pressing then press NEXT to enter maintenance mode 3 Press Machine Setting 4 Please check below items are correctly set by model 5 Machine Eria X HCR3 1502 5000 HCR3 1504 3600 HCR3 X1504 5000 HCR3 1506 3600 HCR3 X1506 5000 HCR3 1508 3600 HCR3 X1508 5000 H...

Page 156: ...center mark positon by Refer to below display 4 Press START button Press ESC button in case of cancellation 7 When you press START button registation of X axis dirextion will start Frame moves as below 8 Then registration of Y axis direction will start Frame moves as below Center mark position of X axis Center mark position of Y axis 1 2 3 4 1 2 3 4 ...

Page 157: ...157 9 Below message will be displayed with successful completion Retry from step 6 if Error occurs Frame position registation is finshied 10 Return to drive mode by pressing ESC and Complete ...

Page 158: ...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 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 maintenance 1 3 650 dsys By pressing Hours button yo...

Page 159: ...ined engineer has to install ESHCRU28010 Laser position marker set 1 Set bandage B with stud A on right side of moving head 2 Bind harness of pointer unit C with bandage B 3 Set pointer unit C on stud A 4 Pass harness through hole at left side of moving head 5 Put harness to CN11 on detection circuit board 6 Turn on machine power 7 After showing below screen Keep START STOP button pressing then pr...

Page 160: ...D Needle Pointer No to 9 LED Needle Pointer Yes 10 Prss ESC button 11 Press return to running menu 11 Press and 12 Adjust angle of pointer unit to point needle position note Position may be changed depend on thickness of fabric End of process ...

Page 161: ...er safety sensor separately please check the machine if harness A is already installed or not For some high demand countries harness A is installed beforehand at factory In this case you need to order only Safety sensor front without Harness A B Sensor emission part C Sencer receiving part 1 Take cover out at behind of machine 2 Take mission covers right and left out 3 Connect harness note Harness...

Page 162: ...eft and bring to front note harness should not touch to belt 10 Connect harness to extension harness LS5 at lower part of Y carriage note put cable in order for avoiding to touch to shaft 11 Set cover note harness should not get caught in the cover 12 Turn on machine power 13 After showing below screen Keep START STOP button pressing then press NEXT to enter maintenance mode note This setting is d...

Page 163: ...fety Sensor No 11 N Safety Sensor Yes 16 Press ESC button 17 Press return to running menu After these setting Sencor becomes effective 18 Adjust position of sensors Confirm both LED green and Orange is lighting note Sencor should be finxed vertical ...

Page 164: ...arately please check the machine if harness A is already installed or not For some high demand countries harness A is installed beforehand at factory In this case you need to order only Safety sensor rear without Harness A B Safety Guard right C Sensor receiving part D Safety Guard left E Sencer emission part F M3X6 screws 6 pcs 1 Take cover out at behind of machine 2 Take mission covers right and...

Page 165: ...nessinto CN14 on Drive circuit board RS4 CN14 RS4 RS3 CN14 RS3 RS2 CN14 RS2 RS1 CN14 RS1 RS5 CN13 RS5 8 Remove screw of rmission left Set Safety Guard D on mission left 9 Remove screw of body Fix Sencor E on body and fix to Sefety Guard D by screws F 10 Connect harness to extension harness LS at side of Y carriage note put cable in order for avoiding to touch to shaft LS1 LS1 LS2 LS2 LS3 LS3 LS4 L...

Page 166: ...with machine You can skip this step 14 Press Machine Setting 15 Change 10 Safety Sensor No to 10 Safety Sensor Yes 16 Press ESC button 17 Press return to running menu After these setting Sencor becomes effective 18 In case error occurs during operation Please adjust position of sensor where both LED green and Orange light stable by screws below note Please do not press sensor when you need to move...

Page 167: ...toinstall ESHCRU36010 Bobbin thread winder set 1 Take mission cover right out 2 Set stud H with M4 washer Spanner 7mm 3 Connect harness C to harness of motor A with limit switch and put harness into mission 4 Fix winder A Screw M4x8 5 Connect harness C into CN10 on CONT R2 board 6 Set Thread tension device D on Body Screw M4x8 7 Set thread stand E with M4 washer B C D E F G H A CN10 ...

Page 168: ... nut 9 Set stop switch F 10 Set cover and power on 11 Put thread and start to wind bobbin thread Adjust position bobbin stand and thread tension E for winding thread equally Thread tension D 12 Take stop switch F out and put cover B 13 Set stop switch F and adjust position where stop switch F will open when bobbin wilnd thread full NG OK Therad stand pin E ...

Page 169: ...Clip drive unit B with bandage C by screw D at right side of moving head bandage is common used for laser pointer and thread holder 4 Connect harness to connector 2P at left side of moving head and bind cable with bandage note Cable should not touch to any moving part 5 Adjust space around 1 2mm between clip dirve unit B and thread holder 6 Turn on machine power 7 After showing below screen Keep S...

Page 170: ...170 8 Press Machine Setting 9 Change 12 Clip Holder Device No to 12 Clip Holder Device Yes 10 Press ESC button 11 Press return to running menu After these setting Upper Thread Holder becomes effective ...

Page 171: ...hat gap between rotary cylinder and needle plate comes to gap shown in fig The Drive frame is set exactly at the factory Normally you do not need to adjust If it is not as shown in the figure adjust it in next step 3 Loosen four screws slightly shown by the arrow mark move the Rotary cylinder and adjust it so that it becomes the same gp as in step 2 Fix the four screws securely after adjustment ...

Page 172: ...172 E7 Electric system diagram E7 1 Pulse motor driver PMD wiring ...

Page 173: ...173 E7 2 Pulse motor driver PMD setup ...

Page 174: ...174 E7 3 Inverter wiring ...

Page 175: ...175 E7 4 Electrical connection diagram ...

Page 176: ...176 ...

Page 177: ...177 ...

Page 178: ...178 E7 5 List of electrical connection diagram ...

Page 179: ...179 ...

Page 180: ...180 E7 6 Explanation of function clrcuit board HCD8122 LCD CE MX Board Ass y ...

Page 181: ...181 HCD8116 TP SW Circuit Board Ass y CN No Function CN1 Switch output LED input ...

Page 182: ...182 HCR8121 CONT R2 Circuit Board Ass y ...

Page 183: ...t angle sensor HCD8110 POSITION SENSER Circuit Board Ass y HCR8115 TC7 8 Circuit Board Ass y CN No Function CN1 Sensor out put CN No Function CN1 Out put to even number sensor CN2 Input of even number sensor CN3 Detecting board ass y I F CN4 Jump SW board I F CN5 Start Stop board I F ...

Page 184: ...184 HCR8108 JUMP SW Circuit Board Ass y CN No Function CN1 TC7 8 board I F HCR8109 START STOP Circuit Board Ass y CN No Function CN1 TC7 8 board I F ...

Page 185: ... of relay control signal to next detecting board CN3 24V power source for Thread detecting board CN4 24V power source for Thread detecting board CN6 Emergency stop I F Connect relay cable when the emergency button is not fixed with head CN7 TC7 8 board I F CN8 Output of Thread catch motor Jump solenoid Clip solenoid CN9 Option I F CN10 Unused CN11 Laser pointer output CNE Reserved for factory ...

Page 186: ...f keeper relay HCR8104 POWER RELAY Circuit Board Ass y CN No Function CN1 AC power source input CN2 AC power source relay Inverter Rev A XY PM driver CN3 AC power source relay for Optionr CN4 AC power source relay Switching power supply CN6 Transformer input Rev A Unconnected AC200V Changing of tap for transformer AC220V AC230V AC240V ...

Page 187: ...abric 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 number Pho...

Page 188: ...d adjust the correct voltage E2 10 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 supply from same outlet with other embroidery machine or other machines which contains motor 5 1 Preferably only 1 embroidery machine should be connected with 1 outlet Maximum 2 3m...

Page 189: ...d guide unit and thread tension ass y 2 8 5 1 Remove burr and scratch if appeared 5 2 Remove lints and clean 6 Does disc on thread tension ass y turn smoothly 2 8 6 1 Remove lints and clean 6 2 Replace 7 Is backlash between take up lever and take up crank roller not bigger 4 2 11 7 1 Replace of take up lever 8 No problem in needle holder 8 1 Remove burr and scratch 8 2 Make proper fixing direction...

Page 190: ... is off replace 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 4 2 9 17 Does needle bar make smooth movement 17 1 If bent replace it 4 2 9 18 Needle doesn t drop in the center of needle hole 18 1 Adjust positioning plate and adjust needle drop back and forth 4 2 3 18 2 Adjust position of needle selection un...

Page 191: ...ed again density_ change 3 Is thread tension properly set 3 1 Upper thread Considering sewing finish set tension 2 9 3 2 Bobbin thread Considering upper thread tension set tension 2 9 4 Is bobbin winding proper 4 1 Adjusting bobbin winding tension wind with proper strength E6 4 5 Is bobbin put in bobbin case properly 5 1 Viewing from front of bobbin case set so that bobbin turns left wise 2 9 6 Do...

Page 192: ...d 2 4 Don t use 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 humidi...

Page 193: ...ry 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 10 3 3 Too many empty stitches 3 1 Make Reading setting Skip null stitches 10 3 Others 1 Using spray paste adhesive material 1 1 Clean around rotary ho...

Page 194: ...in up and down direction of knife drive shaft 4 5 3 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 4 5 6 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 R2 board replace E3 2 E2 1 8 3 If trouble found in thread cu...

Page 195: ...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 9 2 1 Upper thread Considering sewing finish set tension 2 2 Bobbin thread Considering upper thread tension set tension Environment 1 Are power and voltage rated and stable 1 1 Supply rated voltage 23 1 Thread 1 Is...

Page 196: ...shaft to remove backlash back and forth 4 2 3 7 Is height of pressure foot proper 7 1 Adjust as specified 4 1 4 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 PMD 9 1 Check wiring If screw got loosened tighten more 9 2 After 10 1 still problem then replace E2 9 10 Does t other frame than H...

Page 197: ...ace of timing circuit board or cable E 18 Problem in detecting angle of main shaft Check timing slit Adjust timing slit 4 7 3 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 slit 4 7 3 Operator 1 Is se...

Page 198: ...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 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 tightening 4 3 2 1 Use backing paper consider number of sheets to use 3 I...

Page 199: ...ving knife 4 5 7 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 4 5 2 6 2 Position moving knife as specified 4 5 5 6 3 Check and polish burr or scratch on moving knife 6 4 In case moving knife is in trouble replace 4 5 3 7 Are clearance between needle and rotary point and needle hei...

Page 200: ...sile strength of bobbin winder and check holding plate 4 4 4 2 Pull out bobbin thread to check if it comes out smoothly 2 9 5 Is upper thread properly passed 4 6 4 7 5 1 Pass properly again 2 9 6 Does thread cone stand properly 4 6 6 1 Keep thread from hitting felt 6 2 Stand vertically 7 Is Machine settings properly set 15 1 7 1 Select setting of length of TRD Cut Long 7 2 Select setting of Quick ...

Page 201: ... order 3 2 Replacement of magic tape 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 tension is weak 1 1 Strengthen so as not to cause trouble in sewing rhythm 2 9 2 Is Machine settings properly set 15 1 2 1 Select setting of length of TRD cut Normal Thread 1 Using hard cloth make thread difficult to go throug...

Page 202: ...Bobbin thread winding 3 1 Adjust tension of bobbin thread winder 4 4 3 2 Check bobbin thread can be pulled out smoothly by hand 2 9 4 Weak upper thread tension 4 1 Adjust tension slightly stronger 2 9 5 Weak Bobbin thread tension 5 1 Adjust tension slightly stronger Thread 1 Weak Bobbin thread tension cloth 1 1 Try to use same kind of thread as cloth 2 Using thread might be not proper for the desi...

Page 203: ...erator 1 No thread is passed through detecting roller 1 1 Pass thread properly 2 9 2 Is thread tension proper 2 1 Observing sewing rhythm adjust thread tension properly 2 9 3 Is proper detection sensitivity of thread cut selected 15 1 3 1 Select detection sensitivity according to sewing condition of thread and cloth etc 3 2 Please check TRD break detect in setting menu to except Off 4 Is thread te...

Page 204: ... Replace of Timing Board E2 2 5 3 Replace of inverter E2 12 5 4 Replace of CONT R2 board E2 1 6 Trouble of software in LCD CE circuit board 6 1 Initialize then make automatic speed setting E4 3 7 Trouble in control of number of revolution 7 1 Make automatic speed setting E4 3 Operator 1 Isn t foreign stuff such as thread or cloth caught in where revolution is driven 1 1 Get rid of foreign stuff 1 ...

Page 205: ...e of parts 3 1 Repair broken place 4 No problem in CONT R2 board 4 1 Replace of CONT R2 board E2 1 Operator 1 Check Stopper of Moving Head is removed 1 1 Remove Stopper 2 3 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 E2 5 E 025 2 Trouble in potentiometer 2 1 Replace E2 5 3 Needle number is not exactly ...

Page 206: ...d catcher is proper 2 1 Adjust 4 1 6 3 Check position of Thread holder is proper 3 1 Adjust 4 2 14 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 E3 2 5 2 Replace of CONT R2 board E2 1 5 3 Replace of Detection board E2 3 Hook hits or Mechanical 1 Check Hook is bent or not catches Needle 1 1 Re...

Page 207: ... thread catcher holder touch each other or not foot movement 1 1 Adjust installment position of thread catch holder 4 2 14 1 2 In case pressure foot is fixed at an angle fix it vertically again 4 1 4 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 Refue...

Page 208: ...1 1 Replace of LCD E3 2 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 board E3 2 No response of Mechanical 1 Check it touch panel bites foreign object or any damage on the touch panel Touch panel 1 1 Exchange touch panel E3 2 Desing can t be Mechanical 1 Check if stock design is over 999 read 1 1 Tr...

Page 209: ...d does not match for the installed data of Machine setting When only control box has been exchanged open the menu of E5 5 Setup Machine setting and just close without any amendment When CONT board has been exchanged follow the procedure of E5 8 Machine Setting Navigation after exchanging CONT board Installed frame drive data in the machine does not match Check setting contents of Machine setting b...

Page 210: ...rouble i e x motor 1 Power off machine test pantograph overload short circuit problem with movement manually Check for any motor drive unit voltage drop abnormality throughout full range of motion momentary If none found power on again 017 Alarm X unit Y motor related trouble i e y motor 2 Check related harnes overload short circuit problem with 3 Replace of PMD E2 9 10 motor drive unit voltage dr...

Page 211: ...aft 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 d...

Page 212: ...tions 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 5 time of reception of actual pattern data 108 Improper read While reading pattern data there Read pattern data again from the first 5 5 accrued error in internal processing 110 Memory full While reading pattern data memory 1 Delete unnecessary pa...

Page 213: ... 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 stop position 1 Resto...

Page 214: ... sensor unit and slit E2 2 during normal movement Time over 2 Install updated program E4 2 217 Frm drive data Frm drive data Install updated program E4 2 255 Default Error During embroidery frame movement Re initialize machine speed setting E4 3 did not complete until main shaft reach Check adjustment of upper shaft timing Lowest needle position C point L point Reference instruction book ...

Page 215: ...ables for Timing Adjustment value Machine No 1001001 Take up lever timing 326 Rotary hook timing 25 Needle bar lowest point 10 LED4 light out at 0 degrees Clockwise LED3 light on at 270 284 degrees Clockwise Jump solenoid 85 Main shaft timing L C ...

Page 216: ...2018 9 HappyJapan Inc 9 5 TAITO 2 CHOME TAITO KU TOKYO JAPAN TEL 81 3 3834 0711 FAX 81 3 3835 8917 ...

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HappyJapan HCR3-1502, Maintenance Manual

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