HappyJapan HCR3E Series Maintenance Manual Download Page 1

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Maintenance Manual for Embroidery Machine

HCR3E SERIES

Version 1.

HappyJapan Inc.

Summary of Contents for HCR3E Series

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...

Page 3: ...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 E...

Page 4: ...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 thre...

Page 5: ...nsion 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 Adjust...

Page 6: ...read 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 volt...

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...

Page 8: ...87 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...

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

Page 10: ...r 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 23827...

Page 11: ...nt 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...

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

Page 13: ...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 t...

Page 14: ...el 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 mo...

Page 15: ...s 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...

Page 16: ...er 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...

Page 17: ...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 Sp...

Page 18: ...rface 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...

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: ...read 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 Bobb...

Page 21: ...p 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...

Page 22: ...rder 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 fro...

Page 23: ...wisted 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...

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 descr...

Page 25: ...ve 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 socke...

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 ho...

Page 27: ...e 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...

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 cove...

Page 29: ...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 wr...

Page 30: ...o 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 th...

Page 31: ...ther 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 Fixin...

Page 32: ...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...

Page 33: ...r 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...

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 ret...

Page 35: ...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 instal...

Page 36: ...cs 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 V2...

Page 37: ...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 Af...

Page 38: ...enoid 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 Continua...

Page 39: ...er 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...

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...

Page 41: ...ng 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 Tem...

Page 42: ...r 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 pla...

Page 43: ...lease 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 need...

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...

Page 45: ...xagon 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...

Page 46: ...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 S...

Page 47: ...rew 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...

Page 48: ...ease 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 Plea...

Page 49: ...edle 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...

Page 50: ...edle 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 D...

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...

Page 52: ...elow 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 scre...

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...

Page 54: ...ches 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 2...

Page 55: ...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 gau...

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...

Page 57: ...icated 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...

Page 58: ...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 low...

Page 59: ...edle 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 f...

Page 60: ...xtra 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 hei...

Page 61: ...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...

Page 62: ...emove 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...

Page 63: ...r 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 h...

Page 64: ...pring 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 uppe...

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 i...

Page 66: ...osition 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 mo...

Page 67: ...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 sp...

Page 68: ...older 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...

Page 69: ...as 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 Chec...

Page 70: ...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 m...

Page 71: ...oving 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...

Page 72: ...sen 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 muc...

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 needl...

Page 74: ...k 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 G...

Page 75: ...sen 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...

Page 76: ...mm 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 ge...

Page 77: ...k 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...

Page 78: ...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...

Page 79: ...ase 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 P...

Page 80: ...ver 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 ti...

Page 81: ...r 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 positi...

Page 82: ...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 ther...

Page 83: ...hing 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 Re...

Page 84: ...aintenance 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 o...

Page 85: ...ly 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 R...

Page 86: ...eferring 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 y...

Page 87: ...obbin 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...

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 m...

Page 89: ...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...

Page 90: ...t 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...

Page 91: ...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...

Page 92: ...sen 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 tensi...

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...

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...

Page 95: ...hten 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 Po...

Page 96: ...d 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...

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...

Page 98: ...t 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 nu...

Page 99: ...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 mount...

Page 100: ...nted 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...

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...

Page 102: ...ws 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 13m...

Page 103: ...sk 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 c...

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

Page 105: ...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 se...

Page 106: ...ode 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 p...

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: ...r 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 Magnet...

Page 110: ...move 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 upd...

Page 111: ...ayed 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 i...

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...

Page 113: ...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 Maitenanc...

Page 114: ...th 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 t...

Page 115: ...t 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 t...

Page 116: ...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...

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 posi...

Page 118: ...low 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...

Page 119: ...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...

Page 120: ...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 m...

Page 121: ...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 Reg...

Page 122: ...ft 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 s...

Page 123: ...x 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 connec...

Page 124: ...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...

Page 125: ...r 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...

Page 126: ...ver 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...

Page 127: ...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...

Page 128: ...g 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...

Page 129: ...layed 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...

Page 130: ...d 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 displ...

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...

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 un...

Page 133: ...e 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...

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...

Page 135: ...hescrews 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 bo...

Page 136: ...ory 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...

Page 137: ...date 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...

Page 138: ...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...

Page 139: ...te 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 insta...

Page 140: ...n 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 installat...

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: ...nce 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...

Page 143: ...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 pro...

Page 144: ...m 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...

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 perio...

Page 146: ...ing 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 Positi...

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...

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 p...

Page 149: ...y 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 m...

Page 150: ...ntenance 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 open...

Page 151: ...nfirm 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...

Page 152: ...d 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 wil...

Page 153: ...rer 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...

Page 154: ...ter 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 set...

Page 155: ...imum 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 Pre...

Page 156: ...enter 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...

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: ...uns 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...

Page 159: ...ned 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...

Page 160: ...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 dep...

Page 161: ...r 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...

Page 162: ...ft 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...

Page 163: ...ety 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...

Page 164: ...rately 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 r...

Page 165: ...essinto 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 Senco...

Page 166: ...ith 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...

Page 167: ...oinstall 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 mi...

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 st...

Page 169: ...lip 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 bin...

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: ...at 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...

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: ...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...

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 emer...

Page 186: ...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...

Page 187: ...bric 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 f...

Page 188: ...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...

Page 189: ...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...

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...

Page 191: ...d 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 windi...

Page 192: ...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 a...

Page 193: ...y 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 punc...

Page 194: ...n 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...

Page 195: ...perator 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 thr...

Page 196: ...haft 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...

Page 197: ...ce 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 Adjus...

Page 198: ...tabilizer 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 usin...

Page 199: ...ing 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 m...

Page 200: ...ile 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...

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 Strengt...

Page 202: ...obbin 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...

Page 203: ...rator 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 sensit...

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 Troub...

Page 205: ...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...

Page 206: ...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...

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 A...

Page 208: ...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 Mecha...

Page 209: ...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...

Page 210: ...ouble 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 mome...

Page 211: ...ft 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 staine...

Page 212: ...ions 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 I...

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...

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 movem...

Page 215: ...bles 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 Clo...

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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