Happy HCS2-1201-30 User manual

Maintenance Manual for Embroidery Machine
HCS2-1201-30
Version 2. 3
HappyJapan Inc.

2
# For safe adjustment and repair #
In order to conduct adjustment and repair safely and surely,
please b42e sure to abide by what is mentioned in this manual to prevent trouble.
1. When you conduct adjustment and repair of this embroidery machine or handle electric related parts,
you are required to take technical lesson in advance.
2. When you conduct adjustment and repair using this manual, please be sure to use together with instruction
with it in hand.
# Please conduct in accordance 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.
# Please don't touch metal part of circuit board with bare hand as it will short-circuit
and threaten to break circuit boards.
# When you removed circuits boards from the machine or you store or transport them,
please wrap them in static electricity preventive bag and avoid to give shock.

3
Index
page
For safe adjustment and repair 2
Index 3
Special tool, Measuring equipment, Other 8
1 Outline of mechanism
1-1 Placement of key mechanical parts 12
1-2 Placement of key electronic parts 14
2 Outer covers
2-1 Removal of outer covers 15
3 Mechanical mechanism
3-1 Basic maintenance
3-1-1 Maintenance of thread path 19
3-1-2 Fixing of needle 21
3-1-3 Selection of thread 22
3-1-4 Relation between needle and upper thread 23
3-2 Fixed head
3-2-1 Exchange of crank 24
3-2-2 Exchange of rod 28
3-2-3 Adjustment of the lowest needle point 29
3-2-4 Exchange of needle bar driver 30
3-2-5 Adjustment of fixing of jump solenoid 32
3-2-6 Exchange of take-up lever cam 34
3-2-7 Exchange of roller shaft ass’y 36
3-2-8 Adjustment of take-up lever timing 37
3-2-9 Exchange of pressure foot cam 38
3-2-10 Check of height of pressure foot 39
3-2-11 Exchange of pressure foot 40
3-2-12 Adjustment of height of pressure foot guide bar 41
3-2-13 Exchange of pressure foot link and block 42
3-2-14 Exchange of pressure foot drive lever 43
3-2-15 Exchange of pressure foot guide 46
3-2-16 Exchange of pulse motor for pressure foot 48
3-2-17 Adjustment of pressure foot bracket ass’y 50
3-2-18 Exchange of thread catcher 51

4
Index
page
3-2-19 Exchange of thread catcher guide 52
3-2-20 Disassembling and Cleaning of jump solenoid 53
3-2-21 Adjustment of bobbin winder 54
3-3 Moving head
3-3-1 Assemble the upper rail of moving head 56
3-3-2 Adjustment of backlash (back and forth) of moving head 57
3-3-3 Assemble the moving head 58
3-3-4 Adjustment of needle position (back and forth) 62
3-3-5 Check of needle position 63
3-3-6 Adjustment of needle height 64
3-3-7 Exchange of needle bar, needle bar spring and cushion 66
3-3-8 Fixing of needle bar boss guide plate 68
3-3-9 Exchange of take-up lever 69
3-3-10 Exchange of thread adjusting spring 71
3-3-11 Adjustment of tension of thread adjusting spring 73
3-3-12 Adjustment of stroke of thread adjusting spring 74
3-3-13 Adjustment of thread holder 75
3-4 Needle bar change unit
3-4-1 Fixing of needle bar change unit 77
3-4-2 Setting to detect needle position 78
3-5 Rotary hook
3-5-1 Adjustment of rotary hook timing 80
3-5-2 Adjustment of retainer on rotary hook 82

5
Index
page
3-6 Thread cut unit
3-6-1 Assemble the arm ass’y 83
3-6-2 Exchange of thread cutting roller (except for Rev.A) 85
3-6-3 Exchange of thread cutting roller (for Rev.A) 88
3-6-4 Adjustment of thread cutting stopper (except for Rev.A) 91
3-6-5 Adjustment of thread cut timing (except for Rev.A) 92
3-6-6 Exchange of moving knife 95
3-6-7 Exchange of fixed knife 96
3-6-8 Adjustment of moving knife and fixed knife 97
3-6-9 Adjustment of position of moving knife (except for Rev.A) 98
3-6-9b Adjustment of position of moving knife (for Rev.A) 99
3-6-10 Adjustment of bobbin thread holder 101
3-6-11 Exchange of keeper solenoid 102
3-6-12 Adjustment of position of keeper 103
3-7 Carriage unit
3-7-1 Adjustment of X carriage belt tension 104
3-7-2 Exchange of X carriage belt 106
3-7-3 Adjustment of Y carriage belt tension 109
3-7-4 Exchange of Y carriage belt 112
3-8 Transmission unit
3-8-1 Adjustment of timing belt tension 115
3-8-2 Exchange of timing belt 116
3-8-3 Adjustment of motor belt tension 118
3-8-4 Exchange of motor belt 120
4 Electricity
4-1 Circuit board related parts
4-1-1 Remove LCD and LCD-CE board 122
4-1-2 Setting for LCD-CE board 124
4-1-3 Setting for power supply 125
4-2 Sensors
4-2-1 Adjustment of upper shaft timing (C point / L point) 126
4-2-2 Adjustment of TC board 127
4-2-3 Adjustment of stop position of needle bar change unit 127

6
Index
Page
4-3 Inverter
4-3-1 Remove of Inverter 129
4-3-2 Inverter Installation 131
4-3-3 How to set inverter 134
4-3-4 Initialization of parameter 136
4-4 Initialization of system
4-4-1 Program update procedure 137
4-4-2 Preparation for program update 138
4-4-3 Machine program update (Main program 〜Ver.*1.21) 139
4-4-4 Main program update (Main program 〜Ver.*1.21) 141
4-4-4a Machine program and Main program update (Main program Ver.*1.22〜)141a
4-4-5 Setting of revolution 142
4-5 Maintenance mode 143
4-5-1 How to enter maintenance mode 143
4-5-2 Machine Test Machine movement 144
4-5-3 Memory All Clear Initialization of memory 146
4-5-4 Record Opereration data display 147
4-5-4-1 Total number of stitch 147
4-5-4-2 Record of Error occurrence 148
4-5-4-3 Number of occurrence in each error display 149
4-5-4-4 Thread break history 150
4-5-4-5 Setup 151
4-5-4-6 Maintenance Register―Registration of machine maintenance date 152a
4-5-4-7 Machine Setting Navigation after exchanging CONT board (Main program Ver.*1.34~) 152b
5 Electric documents
5-1 Electric system diagram
5-1-1 Electrical connection diagram (except for Rev.A) 153
5-1-2 List of electrical connection diagrams (except for Rev.A) 155
5-1-3 Electrical connection diagram (for Rev.A) 156
5-1-4 List of electrical connection diagrams (for Rev.A) 158
5-2 Inverter
5-2-1 Connection of inverter 100V 159
5-2-2 Connection of inverter 200V 160
5-3 Explanation of function of circuit board 160a

7
Index
Page
6Others
6-1 How to respond for some question ( As example step) 161
6-2 Trouble shooting
6-2-1 Electricity doesn’t turn on 162
6-2-2 Thread break 163
6-2-3 Erraneous thread cut 168
6-2-4 Off-registration of pattern 170
6-2-5 Upper thread comes off from needle hole 172
6-2-6 Upper thread remains 174
6-2-7 Malfunction of thread break detection 175
6-2-8 Suspension of upper shaft 177
6-2-9 Malfunction of needle bar change 178
6-2-10 Defect on thread catcher 179
6-2-11 Others (Mechanical) 180
6-2-12 Others (Electronically) 181
6-3 Error
6-3-1 Startup error and measure (Main program Ver.*1.37~) 181a
6-3-2 Error and measure 182
6-4 Reference date
6-4-1 Tables for timing / adjustment value 186

8
Special tool, Measuring equipment, Other
HSA90010
Needle bar boss positioning gauge [25mm] (Page 65)
HSA90020
2.0mm thickness gauge (Page 102, 103)
HSA90030
Keeper positioning gauge (Page 103)
HSA90051
Bering positioning gauge [4.85mm] (Page 36)
HSA90061
Gauge for adjustment of height of pressure foot bracket
[24.8 - 25.0mm] (Page 50)
HSA90071
Thread hoIder positioning gauge [47.5mm]
(Page 75)

9
HSA90080
Retainer positioning gauge [0.8mm] (Page 82)
HSA90090
Positioning pin (Page 37)
HSA90131
1.2mm thickness gauge (Page 39, 41, 45, 47)
HSA90200
0.03mm thickness gauge (Page 28)
HSA90210
0.2mm thickness gauge (Page 70, 91)
HSA90230
Tensile gauge (Page 55, 101)

10 - 11
HSA90240
Dial-gauge set (Page 29)
HSA90270
Vernier calliper gauge [200mm]
HSA90280
Tension gauge 1000cN (Page 105, 110, 118)
HSA90311
Shell alvania EP Grease 100g
(Page 38, 44)
HSA90340
Shell Grease7 MIL-G-23827B 50g
(Page 53)
HSA90321
11.5mm thickness gauge (Page 27 , 35)
M0404342
Needle height gauge (Page 65)

12
1-1 Placement of key mechanical parts
Thread guide bracket Thread guide pillar Tread stand
Thread tension unit
Moving head
Take-up lever
Control panel
Front cover
X carriage
Thread adjusting spring
Frame base
Thread holder
Needle plate Rotary hook Rotary hook cover
C
g
g

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

14
1-2 Placement of key electronic parts
Pulse motor (Needle bar change unit) CONT-S2 board
TC board
Display board
Emergency stop switch
Fuse
Pulse motor (Pressure foot ) Power swich Noise filter AC power
Power supply
(200V)
Timing detecting board
Inverter
Main motor
Power supply (100V) Pulse motor(Thread catcher)
c
ch
d
)

15
2-1 Removal of outer covers
<Check> Be sure to turn power switch OFF before work.
1. Remove three setscrews of arm E as shown in the figure
below.
2. Disconnect the connectors indicated by the arrows in
the figure below. Remove the screw that fixes cables.
3. Remove three setscrews on arm G as shown in the figure
below.
4. Remove control box.
Please reverse procedure when installing control box.

16
5. Remove thread guide bracket.
6. Loosen a screw of thread guide pillar
7. Remove thread guide pillar and thread stand.
8. Disconnect cable for X carriage.
9. Remove 2 screws, then take the X carriage off.
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10. Remove the thread tension ass’y.

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11. Remove the guide.
12. Take off rubber cap.
13. Remove cover (left). (Remove screw in arrow mark)
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When the cover is fixed by 3 screws as above picture,
please remove these screws.
14. Unlock nail of the cover (left) by pressing an arrow point of
the cover (right).
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15. Remove the cover by pressing an arrow part of
the picture.
(1) Upper part of the cover
(2) Front part of the cover
Nail shape
Male nail shape Female nail shape
x
x

18
When the cover is not fixed by screws, please tilt
the machine slightly to access locking nail easily.
Push down top of the cover and locking nail area as
picture below, then the nail will be released from
the machine base.
Nail shape
16. Remove the screw of an arrow part of the
picture which fixes cover (right).
17. Remove an arrow marked screw which fixes hold arm D.
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18.Remove cover (light). (Remove screw in arrow mark)
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When the cover is fixed by 3 screws as above picture,
please remove these screws.
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19. Remove the cover (right).
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20.By above process, removal of [cover] has finished.
If you need to operate the machine with control box,
please re-assemble the arm and the control box.
x
x
x
x

19
3-1-1 Maintenance of thread path
In a bid to prevent poor sewing finish or thread break, please keep places where thread contacts in the best condition.
1. Thread tension, detecting roller
a) Revolution must be smooth
b) No sticking of lint or dust
2. Holes on thread guide plate
a) No burr and crack
3. Ceramic and rim of take-up lever
a) No burr and crack
4. Thread path in lower side and needle holder.
a) No burr and crack
5. Needle
a) Needle tip shouldn't be warped or bent.
When you slide needle tip on surface of nail and
if the nail gets scratched.
needle tip is warped. Please exchange it with new one.
Please place needle on flat surface and check
clearance (A) from side.
If clearance is not equal, needle is bent.
Please replace it with new one.

20
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 on tip.
10. Thread adjusting spring
a) Should be robust.
Surface
Reverse side

21
3-1-2 Fixing of needle
1. In order of (1)-(4), please remove and fix needle.
(1) Loosen screw holding needle.
(2) Remove needle.
(3) Insert needle till it goes to the end.
(4) Tighten screw holding needle.
Fix needle so that needle groove faces front.
Needle holder
Needle
Front
* Set direction of needle holder as illustrated below.
Check needle holder dose not touch to Needle guard.
About 30 degrees