HCS3-MaintenanceManual1 0

Maintenance Manual for Embroidery Machine
HCS3-1201-30
Version 1.0
HappyJapan Inc.
# For safe adjustment and repair #
In order to conduct adjustment and repair safely and surely,

please be 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.
2
Index
page
For safe adjustment and repair 2
Index 3
Special tool, Measuring equipment, Other 7
1 Outline of mechanism
1-1 Outline of mechanical mechanism 10
1-2 Placement of key electronic parts 12
2 Outer covers
2-1 Removal of outer covers 13
3 Mechanical mechanism
3-1 Basic maintenance
3-1-1 Maintenance of thread path 18
3-1-2 Fixing of needle 20
3-1-3 Selection of thread 21
3-1-4 Relation between needle and upper thread 22
3-2 Fixed head

3-2-1 Exchange of crank 23
3-2-2 Exchange of rod 27
3-2-3 Adjustment of the lowest needle point 28
3-2-4 Exchange of needle bar driver 29
3-2-5 Adjustment of fixing of jump device 31
3-2-6 Exchange of take-up lever cam 33
3-2-7 Exchange of roller shaft ass’y 34
3-2-8 Adjustment of take-up lever timing 35
3-2-9 Exchange of pressure foot cam 36
3-2-10 Check of height of pressure foot 37
3-2-11 Exchange of pressure foot 38
3-2-12 Adjustment of height of pressure foot guide bar 39
3-2-13 Exchange of pressure foot link and block 40
3-2-14 Exchange of pressure foot drive lever 41
3-2-15 Exchange of pressure foot guide 44
3-2-16 Exchange of pulse motor for pressure foot 45
3-2-17 Adjustment of pressure foot bracket ass’y 47
3
Index
page
3-2-18 Exchange of thread catcher 48

3-2-21 Adjustment of bobbin winder 50
3-3 Moving head

3-3-1 Assemble the upper rail of moving head 52
3-3-2 Adjustment of backlash (back and forth) of moving head 53
3-3-3 Assemble the moving head 54
3-3-4 Adjustment of needle position (back and forth) 58
3-3-5 Check of needle position 59
3-3-6 Adjustment of needle height 60
3-3-7 Exchange of needle bar and needle bar spring 62
3-3-8 Fixing of needle bar boss guide plate 64
3-3-9 Exchange of take-up lever 66
3-3-10 Exchange of thread adjusting spring 67
3-3-11 Adjustment of tension of thread adjusting spring 68
3-3-12 Adjustment of laser pointer 69
3-3-13 Adjustment of thread holder 70
3-3-14 Exchange of majic-tape on thread holder 72
3-4 Needle bar change unit

3-4-1 Fixing of needle bar change unit 73
3-5 Rotary hook

3-5-1 Adjustment of rotary hook timing 75
3-5-2 Adjustment of retainer on rotary hook 77
3-6 Thread cut unit

3-6-1 Assemble the arm ass’y 78
3-6-2 Exchange of pulse motor for thread cutting driver 80
3-6-3 Exchange of bobbin thread holder 8D
3-6-6 Exchange of moving knife 82
3-6-7 Exchange of fixed knife 83
3-6-8 Adjustment of moving knife and fixed knife 84
3-6-9 Adjustment of position of moving knife 85
3-6-10 Adjustment of bobbin thread holder 87
3-6-11 Exchange of keeper solenoid 88
3-6-12 Adjustment of position of keeper 89

Index
page
3-7 Carriage unit
3-7-1 Adjustment of X carriage belt tension 90
3-7-2 Exchange of X carriage belt 92
3-7-3 Adjustment of Y carriage belt tension 95
3-7-4 Exchange of Y carriage belt 97
3-8 Transmission unit

3-8-1 Adjustment of timing belt tension 99
3-8-2 Exchange of timing belt 100
3-8-3 Adjustment of motor belt tension 102
3-8-4 Exchange of motor and motor belt 104
4 Electricity
4-1 Circuit board related parts
4-1-1 Remove LCD and LCD-T board 106
4-1-2 Setting for LCD-T board 108
4-1-3 Setting for power supply 109
4-2 Sensors
4-2-1 Adjustment of upper shaft timing (C point / L point) 110
4-2-2 Adjustment of TC board 111
4-2-3 Adjustment of stop position of needle bar change unit 111
4-3 Inverter
4-3-1 Remove of Inverter 112
4-3-2 Inverter Installation 114
4-3-3 How to set inverter 117
4-3-4 Initialization of parameter 119
4-4 Initialization of system

4-4-1 Program update procedure 120
4-4-2 Preparation for program update 121
4-4-3 Program update 122
4-4-4 Initialization / Initialize of machine speed 123
4-5 Maintenance mode.

4-5-1 How to enter maintenance mode 124
5
Index
Page
4-5-2 Machine Test Machine movement 125
4-5-3 Memory All Clear Initialization of memory 127
4-5-4 Record Opereration data display 128
4-5-4-1 Total number of stitch 128
4-5-4-2 Record of Error occurrence 129
4-5-4-3 Number of occurrence in each error display 130
4-5-4-4 Thread break history 131
4-5-4-5 Machine setting 132
4-5-4-6 Maintenance Register―Registration of machine maintenance date 133
4-5-4-7 Machine Setting Navigation after exchanging CONT board 134
5 Electrical connection diagram 136
6 Explanation of function of circuit board 141
7 Others
7-1 How to respond for some question ( As example step) 147
7-2 Trouble shooting
7-2-1 Electricity doesn’t turn on 148
7-2-2 Thread break 149
7-2-3 Erraneous thread cut 154
7-2-4 Off-registration of pattern 156
7-2-5 Upper thread comes off from needle hole 158
7-2-6 Upper thread remains 160
7-2-7 Malfunction of thread break detection 161
7-2-8 Suspension of upper shaft 163
7-2-9 Malfunction of needle bar change 164
7-2-10 Defect on thread catcher 165
7-2-11 Others (Mechanical) 166
7-2-12 Others (Electronically) 167
7-3 Error
7-3-1 Startup error and measure 158
7-3-2 Error and measure 169
7-4 Reference date
7-4-1 Tables for timing / adjustment value 172
7-4-２ Use TAJIMA made tubular frame 173
6
Special tool, Measuring equipment, Other
EJIG-R40 HSA90050
Keeper positioning jig ) Bering positioning gauge [4.85mm]
7
HSA90080 HSA90200
Retainer positioning gauge [0.8mm] 0.03mm thickness gauge
HSA90090 HSA90230
Positioning pin Tensile gauge
HSA90131
1.2mm thickness gauge
8
HSA90311
HSA90240 Shell alvania EP Grease 100g
Dial-gauge set
HSA90270
Vernier calliper gauge [200mm] M0404342
Needle height gauge
HSA90280
Tension gauge 1000cN
9
Outline of mechanical mechanism 1-1
Thread guide bracket Thread guide pillar Tread stand
Thread tension
unit
Moving head
Take-up lever
Control panel
Front cover
over
X carriage
Thread adjusting
spring
Frame base
Thread holder
Needle plate Rotary hook Rotary hook cover
10
Outline of mechanical mechanism 1-1
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
11
Placement of key electronic parts 1-2
Pulse motor (Needle bar change unit) CONT-S3 board
TC board
Display board
Fuse
Pulse motor (Pressure foot ) Power swich Noise filter AC power
Timing detecting board
Main motor
Power supply Pulse motor (Thread catcher)
12
Removal of outer covers (THREAD STAND) 2-1
1. Remove thread guide bracket.
2. Loosen a screw of thread guide pillar
3. Remove thread guide pillar and thread stand.

Removal of outer covers (CONTROL BOX) 2-1
<Check> Be sure to turn power switch OFF before

work. 4. Remove control box.
1. Remove three setscrews of arm E as shown in the figure
below.
Please reverse procedure when installing control box.
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.

Removal of outer covers 2-1
5. Disconnect cable for X carriage. 8. Take off rubber cap.
6. Remove 2 screws, then take the X carriage off. 9. Remove cover (left). (Remove screw in arrow mark)
x x x
7. Remove the guide.
10. Unlock nail of the cover (left) by pressing an arrow point of
the cover (right).
7
11. Remove the cover by pressing an arrow part of 12. Remove the screw of an arrow part of the
the picture. picture which fixes cover (right).
(1) Upper part of the cover
(2) Front part of the cover
Nail shape 13. Remove an arrow marked screw which fixes hold arm D.
Male nail shape Female nail shape
16
14. Remove cover (light). (Remove screw in arrow mark)
x x x
15. Remove the cover (right).
16. 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.
17
Maintenance of thread path 3-1-1
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
4. Needle
2. Ceramic and rim of take-up lever a) Needle tip shouldn't be warped or bent.
a) No burr and crack
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.
3. Thread path in lower side and needle holder.
a) No burr and crack 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.
18
Maintenance of thread path 3-1-1
5. Needle plate 7. Rotary hook
a) No burr and crack in needle hole and around it. a) No burr and crack.
b) Hook point not warped.
c) Backlash between bobbin case holder and outer hook
should be less.
Surface
8. Keeper
a) No burr and crack on tip.
Reverse side
6. Pressure foot
a) No burr and crack inside hole
b) Not bent
19
Fixing of needle 3-1-2
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
① ④
③ ②
Needle
Front
20
Selection of thread 3-1-3
1. Selection of upper thread.
<Description>
Please select considering cloth, design of pattern and flavour etc.
<Thickness>
Please refer to [Relation between needle and upper thread 3-1-4].
<Twist>
Z twisted thread is to be used.
(As rotary hook turns left- wise, Z twisted thread can prevent loosening of twist)
Z-twisted S-twisted
(Left - twisted) (Right - twisted)
2. Selection of lower thread.
Basically please use cotton thread (#80-120), #120 is recommendable.
Pay attention to the following in selection.
# Thickness should be equal.
# When it is lightly stretched. it doesn't break easily.
# In process of time, it doesn't get inferior.
Commercially available paper bobbin can be used, but please select thread with
thickness corresponding to cotton thread (#80-120).
When you prefer to use paper bobbin, please remove spring which is located inside the bobbin case.
21
Relation between needle and upper thread 3-1-4
1. Description of needle
Basically please use [DB X K5] in standard accessory.
If description or thickness of cloth doesn't suit needle size, poor sewing finish / thread break / skipping will occur.
Therefore careful attention is required in selecting 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't match, following problem will be likely to occur.
- Thread break
- Skipping
- Poor sewing finish
22
Exchange of crank 3-2-1
5. Loosen screws located at right and left side, then take front
1. Referring to [2-1 Removal of outer covers], cover off.
remove outer covers.
2. Remove the Rear cover.
6. Change needle bar to no.1 and no.7 with turning the gear
by finger and remove all arrow marked screws, then
remove the moving head.
3. Disconnect TC cable, Laser pointer cable and Front lighting
cable.
4. Remove the thread tension bracket.
Thread tension bracket
<Caution> Do not lost simm material.
23
9. Referring to [3-2-4 Exchange of needle bar driver],
7. Remove thread catcher ass’y remove needle bar driver ass’y.
10. Remove circuit board assembly for timing detecting
board. Cable 1 pcs, Screw 2 pcs
8. Remove face plate on the left.
11. Remove Bobbin winder, power supply.
Screw 4 pcs
Bobbin winder
Power supply
24
12. Loosen screw on upper shaft collar, upper pulley, 16. Remove Needle bar boss stopper.
drive pulley.
17. Loosen fixing screws and pull down pressure foot guide
bar and guide shaft.
13. Loosen collar screw on take-up lever cam.
Pressure foot
guide bar
Guide shaft
14. Loosen screw on crank. 18. Remove bearing retainer.
15. Pull out upper shaft. (To the extent that crank comes out) 19. Remove crank ass’y.
25
20. Put parts once removed back in reverse order 21. Please check and adjust timing mentioned below to finish.
For adjusting fixing of each unit, please refer to process (1)Upper shaft timing (L point, C point)
to adjust fixing of each unit. (2)Take-up lever timing
(3)Rotary hook timing
<Important> Pay attention to following (1) - (4). (4)Jump device
(5)Needle height
(1)Please fix upper shaft collar, upper pulley, drive pulley
on flat surface of upper shaft with screw tightly.
(2)Make sure that pulleys and collars are attached
without space from machine body except upper pulley.
(3)Position of upper pulley is [2mm] from upper shaft collar.
(3)Position of upper pulley is space from upper
shaft collar.
Type of small
collar
Thickness gauge [11.5mm]
(4)Confirm that belt is not interfere the pulley flange and
not come out from pulley groove.
Adjustment will be done with following pulley.
Timing belt has to be adjusted with upper pulley position.
Motor belt has to be adjusted with motor pulley position.
26
Exchange of rod 3-2-2
1. Referring to [3-2-1 Exchange of crank], 2. Referring to [3-2-4 Exchange of needle bar driver],
board ass’y, face plate (left) ass’y and moving head. remove needle bar driver ass’y.
3. Loosen screw on rod pin to remove rod.
4. Install good parts.
Please confirm that the number is printed on one side of
the crank and this side should be located front.
<Important> Leave space of [0.03mm] between
crank and rod.
5. Put each unit back to where it was according to manual.
27
Adjustment of the lowest needle point 3-2-3
1. . Loosen screw on detecting disk. 3. When dial disc reads [0 degree], fix detecting disk.
2. Turn upper shaft so that needle bar driver ass’y comes 4. Work will finish by checking and adjusting timing
in the bottom. mentioned below.
(1)upper shaft timing (L point, C point)
(2)Take-up lever timing
(3)Shuttle hook timing
(4)Jump device
(5)Needle height
Please use dial gauge for strict checking.
Please see that timing on dial disc comes to [0 degree]
when dial swings in highest value.
In case there is moving head, bring needle bar down.
Needle holder
Dial-gauge
28
Exchange of needle bar driver 3-2-4
1. Referring to [3-2-1 Exchange of crank], 2. Loosen screw on main shaft in head.
Remove board ass’y, face plate (left) ass’y and moving
head.
<Caution> Do not lost simm material. 3. Pull out main shaft in head.
29
Exchange of needle bar driver 3-2-4
4. Loosen screw on lower part of needle bar driver ass’y. 7. Put each unit back according to manual.
8. After exchange, please be sure to adjust needle height.
Please refer to [3-3-6 Adjustment of needle height].
<Attention>
Head shaft should be positioned slightly lower than
ditch for oil.
5. Remove needle bar driver ass’y.
6. Install good parts.
<Important>
Make sure that Needle bar driver ass’y rotate
smoothly and no clearance between rod and arm.
30
Adjustment of fixing of jump device 3-2-5
1. Referring to [3-2-1 Exchange of crank], 4. Install good parts.
Remove moving head. Set upper shaft to [80 degrees] to adjust position of Jump
shaft of jump device and Needle bar driver as illustrated
below.
2. Move the rod of thre dcat cher nd Remove jump device.
<Front view>
Viewing from front, Needle bar driver should come to
center of Plunger.
Jump shaft
Jump device
3. Install good parts. Needle bar driver
<View from left>
This shows a state that plunger and Needle bar driver
contacts.
Jump shaft Needle bar driver
Front side
31
Adjustment of fixing of jump device 3-2-5
5. Set upper shaft to [180 degrees] and confirm that the tip of
the body is located at right side of the Head shaft center
line.
6. Please put parts back in reverse order to finish.
For adjustment of fixing of each unit, please refer to
process to adjust fixing of each unit.
32
Exchange of take-up lever cam 3-2-6
１. Referring to [3-2-1 Exchange of crank], (2)Make sure that pulleys and collars are attached
pull out upper shaft without space from machine body except upper pulley.
２. Remove take up lever cam.
(3)Position of upper pulley is space from upper
shaft collar.
Type of small
collar
3. Remove fasten collar.
Timing belt has to be adjusted with upper pulley position.
Motor belt has to be adjusted with motor pulley position.
(5) Please insert the Barrel cam into the Fasten collar first,
then assemble it to the Upper shaft.
4. Put good parts back in reverse order. 5. Please check and adjust the following timing to finish.
For adjustment of fixing of each unit, please refer to (1) lowest needle point
process to adjust fixing of each unit. (2) upper shaft timing (L point, C point)
(3)Take-up lever timing
<Important> Pay attention to following (1) - (5) (4)Shuttle hook timing
(5)Jump device
(6)Needle height (7) pressure foot

(1)Please fix upper pulley, crank ass’y
on flat surface of upper shaft with screw tightly.
33
Exchange of roller shaft ass’y 3-2-7
1. Remove take-up lever crank. 3. Insert bering positioning gauge [4.85mm] between bering
and bering , and then tighten roller shaft ass’y.
Please adjust roller shaft for machine front side ways.
This roller shaft ass’y is eccentricity.
Turn lean screw and just touch roller to gauge.
Bering positioning gauge [4.85mm]
Push take-up lever shaft

haft
h ft b l d shaft.
by slender 4. Return take-up lever crank ass’y to previous place to
(Hexagon wrench etc.) finish.
Shaftt Plain
a washer (M6) Take-up lever crank
<Attention>
Machine number ~1047001 is having a Plain washer Please push to arrow ways until stop.
(M6) between Shaft and Take-up lever crank. <Attention>
2. Exchange roller shaft ass’y. Although the Take-up lever crank is assembled to
<Spanner> 7mm, 8mm the left side, but it is correct.
0.5mm 2.5mm
34
Adjustment of take-up lever timing 3-2-8
1. . Loosen screw on fasten collar for take-up lever cam. 4. Turn take up lever cam slowly and insert positioning pin
into pin groove.
pin groove
2. Set dial disc to [10 degrees].
5. Loosen screw.
<Important>
Rotate the Take up lever cam clockwise until pin
ditch touches to positioning pin then tighten the screw.
(No gap between take-up lever cam and crank)
3. Insert positioning pin from right side.
6. Pull out positioning pin.
7. Turn upper shaft and set dial disc to [C] to finish.
35
Exchange of pressure foot cam 3-2-9
1. Remove screw on pressure foot cam. 4. Exchange has finished.
2. Exchange pressure foot cam.
3. Put on grease to pressure foot cam.
<Grease>
Shell alvania EP Grease2
(Shell Gudas S2 V220 2)
36
Check of height of pressure foot 3-2-10
1. Bring pressure foot down. (Either way mentioned below) 3. Turn upper shaft and set dial disc to [0 degree].
(1)press P_FOOT key on control box.
4. Insert [Gauge I.2mm] between needle plate and pressure
foot.
No gap between gauge and pressure foot or needle plate,
will be OK.
(2)Turn gear with finger.
In case the space is not 1.2mm, loosen the fixing screw
and adjust height of pressure foot as following picture.
2. Bring needle bar down by finger.
Also you can move down the needle bar by maintenance
mode through menu of control box.
After adjustment, when pressing pressure foot to bottom
with hand, confirm whether pressure foot turns back by
spring.
37
Exchange of pressure foot 3-2-11
1. Referring to [3-2-1 Exchange of crank], remove Front
coverand Thread tension.
2. The needle which you insist to exchange pressure foot
should be located at offset position from bed. 3. Remove pressure foot.
(1) Press key on control box.
4. Install good pressure foot.
(2) Turn gear with finger.
5. Adjust height of pressure foot to finish.
Please refer to [3-2-10 Check of height of pressure foot].
38
Adjustment of height of pressure foot guide bar 3-2-12
1. Rotate the upper shaft to be lowest point [0 degrees]. 4. In case the lenght of pressure foot gide bar is not 37 mm,
loosen the screw which fixes guide bar block and adjust it
as 37mm.
2. Turn gear by finger, then bring pressure foot guide bar
down.
3. Please confirm that the lenght of pressure foot gide bar
should be 37 mm.
Also confirm that the pressure foot guide bar should not
touch the LM guide, when the bar goes up to top
position.
39
Exchange of pressure foot link and block 3-2-13
4. If you remove the pressure foot link B ass’y, first remove
1. Referring to [3-2-4 Exchange of needle bar driver], the pressure foot cam collar and pressure foot drive cam.
remove the Head shaft and remove the Needle bar
driver ass'y.
2. Loosen the screw which fixes guide shaft 5. Remove pressure foot link B ass’y.
then move the guide shaft lower.
6. Assemble the parts by opposite procedure to terminate
this exchange.
When assembling each unit, please refer to each
3. If you exchange block ass’y, loosen the screw which fixes procedure Instruction for assemble adjustment.
pressure foot link A then remove block ass’y. <Attention>
Position of guide shaft is attached to lowest and the side
of Head.
40
Exchange of pressure foot drive lever 3-2-14
1. Referring to [3-2-1 Exchange of crank], remove face 5. Remove pressure foot drive lever ass’y
plate.
2. Remove upper rail.
3. Loosen fixing screw of guide bar boss and bring
pressure foot guide bar down.
6. Exchange pressure foot drive lever ass’y.
4. After remove pressure foot spring, remove pressure
foot guide bar to up side.
41
7. Put on grease to bady and oil bush of pressure foot lever 10. Assemble pressure foot guide.
ass’y.
<Grease>
Shell alvania EP Grease2
(Shell Gudas S2 V220 2)
Oil insert bush
8. Put on grease to fulcrum shaft.
<Caution> Do not put on grease to a part of screw.
9. Assemble pressure foot drive lever ass’y.
42
11. Adjust position of pressure foot guide plate A ass’y. 14. Assemble the Needle bar boss stopper.
<Caution>
Make sure that pressure foot guide plate A ass’y is mount
perpendicular and parallel to the body.
<Spanner> 7mm
90 degrees
12. Adjust the height of pressure foot guide bar. 15. Assemble the face plate.
Please refer to [3-2-12 Adjustment of height of pressure
foot guide bar].
13. Assemble the upper rail of moving head.
Please refer to [3-3-1 Assemble the upper rail of moving 16. Install parts in reverse order to finish.
head]. For adjustment of fixing of each unit, please refer to
43
Exchange of pressure foot guide 3-2-15
1. Referring to [3-2-1 Exchange of crank], Remove face 4. Exchange guide.
plate (left) ass’y and moving head.
Loosen the screw and move the Guide bar boss B lower.
5. Assemble the pressure foot gude bar and Pressure foot
2. Remove pressure guide bar. spring.
After remove pressure foot spring, remove pressure
foot guide bar to up side.
6. Adjust the height of pressure foot guide bar to finish.
Please refer to [3-2-12 Adjustment of height of pressure
3. Remove E-ring (E-4) which fixes guide bar boss. foot guide bar.]
44
Exchange of pulse motor for pressure foot 3-2-16
1. Change needle bar to no. 0 and disconnect cable from 4. Remove drive gear A.
pulse motor.
5. Exchange the pulse motor.
Fix it temporarily.
2. Down the Pressure foot.
3. Disconnect cable from Sensor board ass’y and Remove 6. Assemble the drive gear A.
bracket ass’y. The position should come to the middle of the gear range.
Cable from Sensor board ass’y
45
Exchange of pulse motor for pressure foot 3-2-16
7. Adjust position of pulse motor then fix it.
Keep slightly backlash between drive geer A and gear.
(Every point.)
Remove clamp filter from original motor, then re-set to new
motor.
8. Continue to conduct [Adjust the pressure foot bracket
ass’y].
Please refer to [3-2-17 Adjustment of pressure foot bracket
ass’y].
46
Adjustment of pressure foot bracket ass’y 3-2-17
1. Fix pressure foot bracket ass’y tentatively. 4. Adjust position of pressure foot guide plate B ass’y.
<Caution>
Make sure that pressure foot guide plate B ass’y is mount
perpendicular and parallel to the body.
90 degrees
2. Lift up pressure foot.
5. Procedure is done after confirming the pressure foot
movement by pressing the on control box.
3. Pull pressure foot bracket ass’y downward, then fix it.
47
Exchange of thread catcher 3-2-18
5. Press Catcher Adjust , take thread catcher unit in
1. Tighten the screws securely while pushing thread and out, and move and adjust the sensor shown in
catcher unit in the direction of the arrows of the the direction of the arrow so that the dimension in
following figure to fix the unit. the following figure meets the value in the
following figure when hook goes back.
Fix the sensor with setscrew after adjustment.
Sensor
2. Loose screw of sensor for thread catcher unit

a little bit.
Sensor
10mm
Hook
3. Refer to “5-6-11 How to enter maintenance mode” and

enter maintenance mode.
4. Press Machine Test .
48
Exchange of thread catcher 3-2-18
6. Continue to “Adjustment of thread holder”.

When you adjust thread holder, you might need to
adjust thread catcher unit again.
Follow the procedure in “3-3-13 Adjustment of
thread holder.”
49
Adjustment of bobbin winder 3-2-21
# Adjust if the thread is leans to one side. 4. Assemble guide as tentatively.
1. Assemble the winder bracket ass’y tentatively.
5. Confirm that the shaft does not touch the cover
by turning motor.
2. Assemble the left cover with keeping the space (Set the empty bobbin and down the Guide.)
between shaft and the cover hole.
If the guide touches the bobbin adjust position
3. Assemble thread tension ass’y. of the winder bracket ass’y.
The marked position by arrow
should come to the center.
50
Adjustment of bobbin winder 3-2-21
6. Adjust bobbin thread tension [30g] by tension gauge. 9.Adjust the height of Guide to adjust volume of thread
to be winded.
7. Rewind the bobbin thread.
10. Reinstall the parts which has been removed.
8. Adjust the inclination of Winder bracket ass’y
in accordance with thread winding condition.
51
Assemble the upper rail of moving head 3-3-1
1. Tighten right and left LM guide base.
Follow in picture, keep push to allow way each LM guide
base.
<Notice>
Should be front side which letter on side of LM guide base.
52
Adjustment of backlash (back and forth) of moving head 3-3-2
1. Adjust positioning roller shaft so as to put moving rail
(lower) between bearings.
Move moving head back and forth so as not to cause
backlash.
2. After adjustment, check and adjust needle drop to finish
Please refer to [3-3-4 Adjustment of needle position
(back and forth) ].
53
Assemble the moving head 3-3-3
1. Please confirm that the position of needle bar change 3. Put in SIMM [0.05mm] between a moving head and
unit is set at 12 th
needle. LM guide.
* Don't tighten a screw only by inserting SIMM here.
Please give
2. moving head を 12th needles の位置で、Install moving head
tentatively.
<View of behind>
Position which SIMM puts in screws
Moving head (central position between)
<Caution>
Screw head not to come out from LM guide side.
LM guide SIMM (Right)
<View of right side>
Moving head
Front
LM guide SIMM (Three places)
Position (it puts in to the back) which SIMM puts in
54
4. Turn the drive shaft B screw for manual operation, <Veiw of left side>
and make it the 1st needle. Moving head
* When a moving head is caught on the way and does not
carry out horizontal movement.
The screw tightened tentatively in "the work procedure 1"
has come out from LM guide.
A screw from LM guide. Please fasten.
LM guide SIMM (Three places)
Position (it puts in to the back) which SIMM puts in.
5. Put in SIMM [0.05mm] between a moving head and * Don't put in SIMM but push up a moving head lightly a case.
LM guide. <important>
Please do not lower LM guide by any means.
There is a possibility that LM guide may bend.
<View of behind>
To puts in (central position between screws)
Moving head
ead
SIMM (Middle)
Middle
Middle SIMM (Left)
SIMM LM guide
55
6. Tighten an inside screw (arrow portion in a figure). 7. An outside screw (arrow portion in a figure) is tightened.
<important>
Please perform a screw bundle in order of "inside to
outside."
8. Turn the drive shaft B screw for manual operation,
and make it the 12th needles.
At this time, a moving head is pushed from the front and it
is LM guide.
It is made for there to be no crevice.
9. Tighten an inside screw (arrow portion in a figure).
<important>
Please perform a screw bundle in order of "inside to
outside."
56
At this time, a moving head is pushed from the front and it is 11. Check center (right and left)(back and forth) of needle and
LM guide. needle hole of needle plate.(Needle No.1 ,6 and 12.)
It is made for there to be no crevice.
<Caution>
Should be check needle No.1 ,6 and 12.
Needle hole of needle plate Needle
12. If not center (back and forth),please adjust needle position
(back and forth).
Refer to [3-3-4 Adjustment of needle position (back and
forth)].
10. Tighten an outside screw (arrow portion in a figure). 13. If not center (right and left), please adjust again
procedure 6-10.
14. If “OK”. Please check [needle position].
Refer to [3-3-5 Check of needle position].
If “NG” this process, adjust again procedure 12-13.
57
Adjustment of needle position (back and forth) 3-3-4
1. Bring pressure foot down. (Either way mentioned below) 3. Turn upper shaft and set needle near to the lowest needle
position [L] to adjust positioning plate ass’y.
(1)press key on control box.
(2)Turn gear with finger. * Insert Lower rail to between the two bearing deeply.
(This is for setting of Moving head completely.)
lower rail
positioning plate ass’y
Viewing from side, set to center of needle hole.
#Check and adjust with 1st, 4th and 7th needle.
mode through menu of control box.
4. After adjustment, please be sure to check and adjust
clearance between needle and shuttle hook.
Please refer to [3-5-1 Adjustment of rotary hook timing].
58
Check of needle position 3-3-5
1. A main switch is turned on. Also you can move down the needle bar by maintenance
The is pressed and it changes into an mode through menu of control box.
operation state.
2. Press and make it the 4th needles.
3. Stick a seal on needle hole of a needle plate.
6. Turn an upper axis up to [302 degrees - 303 "], and it is the
needle mark to a seal. A hole is made.
<Note> Needle point will become large if the angle of a dial
disc is made into 304 degrees or more.
An exact needle position check becomes impossible.
4. Bring pressure foot down. (Either way mentioned below)
7. Reverse-rotate an upper axis, raise a needle bar, and
(1)press P_FOOT key on control box. unite with C [275 degrees].
(It returns to 303 degrees-> 220", and unites with 275
degrees after that.)
<Note> If a top axis is right-rotated, a needle will enter
deeply, and needle hole is greatly.
It becomes. Therefore, an exact needle position check
becomes impossible.
8. 1st needle and the 7th needles are to 302 degrees - 303
degrees about an upper axis by the above-mentioned
(2)Turn gear with finger. procedure. It turns, a needle is lowered and a needle
position is checked.
It will be O.K. if the needle point goes into the seal hole
made by the 4th needles at this time.
* If “NG”. Please adjust again, follow to [3-3-3 Asemble
the moving head] of procedure 6-10.
* 303°→ Diameter of φ0.2mm、310°→Diameter of φ0.5mm
The order which the screw which is fixing the move head
fastens -- from an inner side. If it does not carry out
correctly outside, a needle position will shift -- it is –
9. Un-stick a seal on needle plate to finish.
59
Adjustment of needle height 3-3-6
1. Referring to [3-2-1 Exchange of crank], remove lower
front panel. 4. Bring needle down.
2. Remove bobbin case.
5. Turn upper shaft to set dial disc to [5 degrees].
(1)press P_FOOT key on control box.
6. Loosen needle bar boss and needle bar boss B.
Needle bar boss B
Needle bar boss
60
Adjustment of needle height 3-3-6
7. Put needle height gauge in rotary hook.
About 30 degrees
10. Tighten the screw of needle bar boss.
8. Adjust the needle bar height up and down till the needle tip
touches to the gauge slightly.
11. Bring pressure foot down and Turn upper shaft to set dial
disc to [270 degrees]..
12. Tighten the screw of needle bar boss B.
When tightening needle bar boss B, please insert
9. Set direction of needle stop as illustrated below. Calliper (pre-set as 25.3mm) in-between.
* Check the movement of needle bar goes smoothly.
13. Put things back in reverse order of 1-2 to finish.
61
Exchange of needle bar and needle bar spring 3-3-7
1. Referring to [3-2-1 Exchange of crank], remove lower
front panel.
2. The needle which you insist to exchange needle bar should
be located at offset position from bed. 3. Remove needle, needle holder and pressure foot.
(1) Press key on control box.
(2) Turn gear with finger. 4. Loosen needle bar boss and needle bar boss B.
Needle bar boss B
Needle bar boss
62
Exchange of needle bar and needle bar spring 3-3-7
5. Pull out needle bar.
At this moment, remove needle bar boss, 8. Adjust needle height.
needle bar bossB, Needle bar spring H, Pressure foot Please refer to [3-3-6 Adjustment of needle height].
block B, Pressure foot spring, Cushion and Plain washer
(M6). 9. Put removed parts back to finish.
6. While pressing needle bar spring, insert good needle bar
with needle bar boss, needle bar boss B, Pressure foot
block B, Cushion, Plain washer (M6), Needle bar spring H
and Pressure foot spring.
7. Fix needle , needle holder and pressure foot.
63
Fixing of needle bar boss guide plate 3-3-8
1. Referring to [3-2-1 Exchange of crank], remove 3. Remove boss screw.
moving head. Please note that you need hexagonal driver for front screw
and spanner (4mm for rear nut as photo below.
2. Remove Clamp of laser pointer cable.
4. Exchange of needle bar boss guide plate and fix it.
Push needle bar boss check plate to arrow marked
direction and keep the length of both sides equally
as photo below, then fix screws.
8mm
64
Fixing of needle bar boss guide plate 3-3-8
5. Fix boss screw again.
6. Fix Clamp of laser pointer cable temporary.
7. Referring to [3-3-3 Assemble the moving head],
Put moving head and other removed parts
8. Adjust height of block plate and confirm that pressure foot
block B should goes into groove of guide bar boss B as
photo below, then fix screws.
9. Put moving head and other removed parts back to finish.
65
Exchange of take-up lever 3-3-9
4. Remove the take up lever shaft first then remove the take-
1. Referring to [3-2-1 Exchange of crank], remove moving up lever and plastic washer.
head.
<Caution> Do not lost simm material. 5. Install take-up lever and plastic washer.
2. Loosen screw on take-up shaft.
6. Set the E-ring.
Leave space of [0.03mm] between take-up lever and
3. Remove the E-ring. plastic washer.
7. Put moving head in previous position to finish.
66
Exchange of thread adjusting spring 3-3-10
1. Referring to [3-2-1 Exchange of crank], remove Front 4. Remove Thread adjusting plate and Thread adjusting
cover. spring.
2. Remove Thread guide ass'y.
5. Exchange thread adjusting spring.
Set the thread adjusting plate and thread adjusting spring
to same position as picture below.
3. Insert (-) screw driver as picture below and slide the thread
guide to arrow marked direction, then you can remove the
thread guide.
6. Put removed parts back in reverse order.
67
Adjustment of tension of thread adjusting spring 3-3-11
1. Referring to [3-3-10 Exchange of thread adjusting spring],
remove Thread guide.
2. The Thread adjusting plate has a latch to be able to adjust
tension in three steps.
Loosen screw of the thread adjusting plate, then you can
adjust the latch to desired position.
Also the thread adjusting plate have five spring grooves for
fine adjustment.
Middle
Weak Strong
Strong
Weak
Spring groove (Fine adjustment)
3. Put removed parts back in reverse order.
68
Adjustment of laser pointer 3-3-12
1. Referring to [3-2-1 Exchange of crank], remove 4. Press key on display of control box.
Font cover.
Do not disconnect the laser pointer cord.
5. Adjust position of laser pointer that the ray of laser should
goes into theneedle hole.
Fix the nut.
Laser pointer (DLP)
2. Set paper on needle plate and make hole on the paper.
In the case of a cross laser pointer, please make each 1
hole in the left, right, up or down which separated about 20
mm from the first hole.
About 20mm
About 20mm
About 20mm
About 20mm
Cross laser pointer (CLP)
3. Holde the the laser pointer unit by 10mm wrench,
Loosen nut to the extent that laser pointer unit moves.
Laser pointer unit
<Spanner> 10mm 6. Put moving head and other removed parts back to finish.
69
Adjustment of thread holder 3-3-13
1. Referring to [3-2-1 Exchange of crank], remove Font (2)Turn gear with finger.
cover.
4. Take the hook in and out by finger to check movement of
hook goes smoothly.

th th
2. Loosen screw to the extent that thread hoIder moves. Check this at 1th , 4 , 7 needle.
<Positional relationship between hook and holder (lower)>
(1)press on control box.
The distance between the needle

tip and the hook is needle tip and
hook is about 1 mm.
70
5. If you can not set the correct position with procedure no.4,
then Thread catcher device should be adjusted.
6. Check up with thread trimmer function.
7. Assemble lower front cover to terminate this procedure.
71
1. Referring to [3-2-1 Exchange of crank], remove Font cover 4. Exchange the majic-tape.
2. Remove thread holder ass’y. 5. Assemble holder (lower).
3. Remove holder (lower). 6. Install holder ass’y to moving head in reverse order
to finish.
Please refer to [3-3-13 Adjustment of thread holder].
72
Fixing of needle bar change unit 3-4-1
1. Place needle bar change unit assembly. 3. Turn drive gear B by finger and set needle bar to no.4.
please set positioning hole on unit assembly to
positioning pin.
Insert arrow marked screws temporary. Connect cable.
2. Turn slit collar and adjust angle that groove of slit collar (1) press on control box.
should be located same position of sensor.
Refering to 4-2-3 [Adjustment of stop position of needle
bar change unit]
(2) Turn gear with finger.
Confirm that the slit does not tough the sensor.
73
Fixing of needle bar change unit 3-4-1
5. Bring needle down, turn upper shaft to set near to [L point]. 8. Please check and adjust the following timing to finish.
(1)Shuttle hook timing

(2))Needle height
(3) pressure foot
6. Adjust position of unit assembly so that needle comes to
center against needle hole on needle plate.
7. Return other parts to previous.
For adjustment of fixing of each unit, please refer to
74
Adjustment of rotary hook timing 3-5-1
1. Remove needle plate.
3. Tighten screw on rotary hook. (3 places)
2. Bring pressure foot down. (Either way mentioned below) 4. Bring needle bar down by finger.
(1)press on control box. mode through menu of control box.
5. Turn upper shaft and set dial disc to [25 degrees].
75
Adjustment of rotary hook timing 3-5-1
6. Adjust rotary hook timing.
This procedure is preconditioned to use needle type
[DB-K5] in which contains with our standard accessory.
At this moment, clearance between needle and rotary
hook should be [0.1-0.2mm].
Check and adjust with 1st, 6th and 12th needle and
tighten screws.
0.1-0.2mm
7. For making sure, check position of retainer on bobbin case
holder.
Please refer to [3-5-2 Adjustment of retainer on rotary hook]
for adjusting value and follow it.
Retainer
R t i on rotary
8. Adjustment has finished.
76
Adjustment of retainer on rotary hook 3-5-2
1. Loosen screw to the extent that retainer on bobbin case
‘holder moves. (2pcs)
Retainer
R t i on rotary
2. Adjust position back and forth, left and right.
Space has to be [0.8mm] and the position right and left is
center of the needle.
Needle center and retainer center should come to same
position
Space
Needle center position
77
Assemble the arm ass’y 3-6-1
1. Assemble the arm ass’y tentatively. 4. Hold the right side of arm to arrow pointed direction
at below picture and tighten screw.
2. Hold arm to backward and tighten only hithermost screw.

<Caution> 5. Assemble detecting plate.
Make sure that there is clearance between arm and Make sure that detecting plate is mount perpendicular and
body. parallel to the arm.
3. Hold the left side of arm to body and tighten screw.
78
Assemble the arm ass’y 3-6-1
6. Check of interference between detecting plate and two A part or conector
sensors or connector of sensor board.
A part of sensor
Detecting plate
Sensor Conector Sensor 7. Adjust by bending detecting plate by hand if you find
any interference with sensor or connector.
Sensor
Detecting plate
8. Finish this process.
Conector
79
Exchange of pulse motor for thread cutting driver 3-6-2
1. Referring to [3-2-1 Exchange of crank], 5. Loosen the screw for coupling of the Y carriage.
Remove
Thread stand and outer covers.
2. Referring to [3-7-4 Exchange of Y carriage

belt],
Remove arm.
11. Remove Bobbin winder, power supply.
Screw 4 pcs
Bobbin winder 6. Remove the screw of Y carriage bracket (left).
7. Remove the Y carriage.
Power supply
4. Disconnect cable from sensor board.
80
Exchange of pulse motor for thread cutting driver 3-6-2
8. Remove thread cutting driver. 12. Remove Drive gear.
9. Disconnect cable.
13. Install Drive gear on good Pulse motor
Position of Drive gear is space from Pulse motor.
2mm
10. Remove Pulse motor.
13. Place parts back in accordance with manual.
14. Check and adjust position of moving knife to finish.
Please refer to respective adjustment.
81
Exchange of bobbin thread holder 3-6-3
1. By referring the “3-3-4 check of needle position”, open 1. 5. Remove and exchange the bobbin thread holder to
By referring the “3-3-4 check of needle position”, open good one.
the hole into the seal of needle plate.
*Note the number of needle. 6. Attach the thread cut unit.
* Adjust the needle point should be match with the hole
of seal.
7. By Referring “3-6-10 Adjustment of bobbin thread
holder”, finalize the work by checking and adjustment
for bobbin thread out.
2. Remove needle plate. (Fixing screws 2pcs)
3. Remove the thread cut unit.
4. Remove the bobbin thread holder fixing screw.
81a
Exchange of moving knife 3-6-6
1. By referring the “3-3-4 check of needle position”, open 5. Remove the knife shaft.
the hole into the seal of needle plate.
*Note the number of the needle.
Loosen
6. Exchange moving knife.
2. Remove needle plate. (Fixing screws 2pcs)
7. Fix moving knife with knife shaft and screw
3. Remove the thread cut unit.
Loosen
8. Attach the thread cut unit.
* Adjust the hole of seal should be match with needle
point.
4. Remove the screw of knife shaft.
9. Referring to [3-6-8 Adjustment of moving knife and
fixed knife], check how well thread is cut and adjust,
then finish this process.
82
Exchange of fixed knife 3-6-7
1. Remove needle plate. (Fixing screws 2pcs) 3. Attach the needle plate.
4. Referring to [3-6-8 Adjustment of moving knife and
fixed knife], check how well thread is cut and adjust,
then finish this process.
2. Remove fixed knife and exchange to good one.
At this time, place the sim ring under the hole on
the left side.
Tighten fixed knife pushing to backward as full
as possible.
Make sure the fixed knife is in the same position as
Shown in fig.
Sim ring
83
Adjustment of moving knife and fixed knife 3-6-8
1. Remove needle plate. (Fixing screws 2pcs) ＜Spanner＞ 5.5mm
2. Open the keeper cover. 4. Cut thread and check how well it is cut.
Use two polyester threads for checking.
Threads
5. Check several times and it no mistakes are found,
3. Adjust slant of fixed knife with [upper adjustment finish this process.
screw] and [lower adjustment screw] that fix fixed knife.

＜Note＞
Rub these screws together to the extent that you
don’t feel resistance.
84
Adjustment of position of moving knife 3-6-9
1.Remove Needle plate and Cover (front). 5. Press Separate, then the Moving knife will be opened.
Please confirm that the tip of Moving knife is located at
center of Rotary hook retainer.
2. Enter maintenance mode in reference to [9-1 How to enter Tip of moving knife
maintenance mode]
6. In case the tip of moving knife is not in the right position,
3. Press Machine Test . loosen screw on Thread cutting rod, then adjust position of
the Moving knife with turnning Eccentric pin.
Tighten screws.
4．Press #2 Cutter Adjust,
85
Adjustment of position of moving knife 3-6-9
7. Press Origin, then the Moving knife will be closed.
Please confirm that the Moving knife is located as
drawing below.
1mm
Make sure that the tip of the moving knife is positioned
as shown in the figure with respect to the fixed knife.
8. Press Separate and Origin by turns to confirm that t
he Moving knife is closed in the right position.
Press ESC to finish「Maintenace mode」.
9. If necessary, please refer to [3-6-8 Adjustment of moving
knife and fixed knife] and check how well thread is cut,
then finish.
86
Adjustment of bobbin thread holder 3-6-10
1. Remove needle plate. 4. Adjust height of bobbin thread holder with
adjusting screw.
2. Remove keeper cover. (Fixing screws 2pcs)
5. Pull bobbin thread toward arrow mark and see that
bobbin thread comes off with tensile gauge [5 - 8g].
Threads
3. Close moving knife like putting bobbin thread between 6. Tighten lock nut. (Don’t move adjusting screw)
moving knife and bobbin thread holder. ＜Spanner＞ 5.5mm
7. Check several times and if OK, finish this process.
87
Exchange of keeper solenoid 3-6-11
3. Remove keeper solenoid ass’y.
1. Remove connector for keeper solenoid. ( Fixed screw 2pcs. )
4. Exchange keeper solenoid. (Fixing screw 2pcs)
Keeper plunger
Solenoid base.
Connector
Clearance between keeper plunger and solenoid base
2. Remove screw for keeper rod and stopper. should be kept as much as equally.
5. Put keeper solenoid ass’y in previous position then
adjustment of position of keeper finished.
Referring to [3-6-9 Adjustment of position of keeper].
8.5 ㎜
<Caution>
When installing the bed cover (lower), make sure it does
not touch the connecting plate.
Connecting plate
Bed cover (lower)
88
Adjustment of position of keeper 3-6-12
1. Loosen screw for stopper. (Fixing 1 screw) ＜View form right＞
Keeper positioning
About 0.5mm gauge (bobbin)
Keeper
2. Pull the stopper backward and adjust the keeper
waiting position. 4. Perform sewing test and verify upper thread should not
tangled with the keeper at waiting position.
3. Adjust opening between tip of keeper and lower thread
bobbin should be 0.5 mm.
Use a keeper positioning jig (EJIG-R40) and adjust
opening between tip of keeper and lower thread bobbin
should be 0.5 mm.
At this position, retighten the screw for stopper.
89
Adjustment of X carriage belt tension 3-7-1
1. Remove frame base. 4. Remove X carriage cover. (Screw : 2 pcs)
2. Disconnect X carriage cable. 5. Remove sensor bracket.
3. Remove X carriage. (Screw : 2 pcs) 6. Loosen fixing screw for tension pulley bracket slightly.
(front side)
90
Adjustment of X carriage belt tension 3-7-1
7. Loosen fixing screw for tension pulley bracket slightly. Adjustment, tighten fixing screw for tension pulley bracket.
(rear side)
8. Adjust belt tension.
Use push and pull gauge. 9. Tighten fixing screw for tension pulley bracket. (front side)
<Adjustment value>
[500cN] at the status of which both belt is touch.
10. Tighten fixing screw for tension pulley bracket. (rear side)
<Note> Slide connecting plate to right as full as possible.
Gauge in the middle of idler pulley and tension pulley.
Measurement point
Idler pulley Tension pulley
11. Return things back to previous places in reverse order.
91
Exchange of X carriage belt 3-7-2
1. Remove frame base. 4. Remove X carriage cover.
2. Disconnect X carriage cable. 5. Remove sensor bracket.
3.Remove X carriage. 6. Loosen screw for tension.
92
7. Remove the screw which fixes tension bracket. 10. Remove connecting plate.
Remove the plate nut located other side.
8. Loosen screw (rear) slightly to the extent that tension-
bracket moves.
9. Remove belt from motor pulley. 11. Exchange belt to good one.
<Important>
Exchange it so as not to break groove and convex on
belt of connecting plate.
93
12. Adjust the position of belt.
Space between edge of X base and belt is [10mm].
13. Referring to [3-7-1 Adjustment of X carriage belt tension],
adjust tension of belt.
14. Put removed screw and nut plate.
15. Return X carriage assembly and frame base to previous
places to finish.
94
Adjustment of Y carriage belt tension 3-7-3
1. Referring to [2-1 Removal of outer covers],

remove outer covers. 5. Adjust belt tension, to use belt tension gauge.
Use push and pull gauge.
<Adjustment value>
Adjusted to be [500cN] at state that Belt attaches to Rail.
2. Remove cover (front), referring to [3-6-1 Assemble the arm
ass’y], remove arm.
3. Loosen lock nut for tension adjustment screw.

<Spanner> 7mm
Push belt holding plate backward as full as possible.
Gauge in the middle of idler pulley.
Measurement point
Idler pulley (rear) Idler pulley (front)
4. Loosen tension screw so as to move tension.
Adjust with screw.
95
Adjustment of Y carriage belt tension 3-7-3
6. Tighten screw on tension.
7. Tighten lock nut for tension adjustment screw.
8. Put other removed parts back to finish.
96
Exchange of Y carriage belt 3-7-4
1. Referring to [2-1 Removal of outer covers],
remove outer covers. 6. Remove belt holding plate.
2. Remove cover (front), referring to [3-6-1 Assemble the arm
ass’y], remove arm.
3. Loosen lock nut for tension adjustment screw.
<Spanner> 7mm
7. Exchange belt.
4. Loosen tension screw so as to move tension.
8. Set belt to belt groove of guide frame base.
<Important>Exchange it so as not to break belt tooth
and convex on belt.
5. Loosen screw for tension.
Do not put belt tooth on the innermost groove of
the connecting plate.
97
Exchange of Y carriage belt 3-7-4
9. Fix belt holding plate.
10. Referring to [3-7-3 Adjustment of Y carriage belt tension],
adjust tension of Y belt.
11. Put other removed parts back to finish.
98
Adjustment of timing belt tension 3-8-1
1. Remove bobbin winder.
Please move tension shaft ass’y upward and
2. Remove Bobbin winder, power supply. downward to adjust.
Screw 4 pcs
Bobbin winder
4. Please return power supply to previous places.
5. Please return bobbin winder to previous places then
adjustment to finished.
Power supply
3. Adjust tension of timing belt.
<Important>
Tension shaft ass’y to be set at the center against screw
hole of the body.
No need to adjust tension.
99
Exchange of timing belt 3-8-2
1. Referring to [3-2-1 Exchange of crank], Remove thread 3. Loosen screws on upper shaft collar,
stand, outer covers, thread tension, front panel, moving upper pulley and drive pulley.
head and face plate.
2. Remove timing detecting board ass’y.
Cable 1 pcs, Screw 2 pcs
4. Loosen screw on fasten collar for take-up lever cam.
2. Remove winder and power supply.
Screw 4 pcs
Winder
5. Loosen screw on crank.
Power supply
Remove support roller ass'y.
100
Exchange of timing belt 3-8-2
<Important> Pay attention to following (1) - (4).
6. Pull out upper shaft. (1)When you install upper shaft collar, upper pulley,
drive pulley and crank, please fix them on flat surface
of upper shaft with screw.
7. Remove upper pulley and timing belt.
Install good timing belt. (3)Position of upper pulley is space from upper
shaft collar.
Type of small
collar
Timing belt has to be adjusted with [upper pulley position].
Motor belt has to be adjusted with [motor pulley position].
9. Check and adjust following timing to finish.
(1)Lowest needle point
8. Install parts in reverse order. (2)Upper shaft timing(L point, C point)
For installation and adjustment of each unit, (3)Take-up lever timing
please refer to respective manuals. (4)Rotary hook timing
(5) Needle height
Referring to [3-8-1 Adjustment of timing belt tension], (6) Height of pressure foot
adjust tensile strength of timing belt.
101
Adjustment of motor belt tension 3-8-3
１. Referring to [3-2-1 Exchange of crank], Remove thread

Screw
stand and outer covers.
Screw 4 pcs
Winder
Screw
4. Loosen screw on motor bracket.
Power supply
3. Remove two screws shown in the following figure and
inverter.
bending value
102
Adjustment of motor belt tension 3-8-3
5. Adjust motor belt tension. Move main motor upward and downward to adjust.
Use push and pull gauge.
<Adjustment value> 320 - 330 g / 3mm
Gauge in the near center between drive pulley and
motor pulley. 6. Tighten screw on motor bracket.
Measurement point Drive pulley
Motor pulley
Adjust of tension should be 320 – 330g at belt is pressed
3mm.
7. Return power supply bracket, power supply, bobbin winder
Belt is pressed 3mm and inverter to previous places to finish.
103
Exchange of motor and motor belt 3-8-4
1. Referring to [3-2-1 Exchange of crank], Remove thread 4. Loosen screws on upper shaft collar,
stand and outer covers. upper pulley and drive pulley.
2. Remove timing detecting board ass’y.
Cable 1 pcs, Screw 2 pcs
5. Loosen screw on fasten collar for take-up lever cam.
Screw 4 pcs
Winder
6. Loosen screw on crank.
Power supply
104
Exchange of motor and motor belt 3-8-4
<Important> Pay attention to following (1) - (4).
7. Pull out upper shaft. (1)When you install upper shaft collar, upper pulley,
drive pulley and crank, please fix them on flat surface
of upper shaft with screw.
8. Remove drive pulley and motor belt.
Install good motor belt. (3)Position of upper pulley is space from upper
shaft collar.
Type of small
collar
Timing belt has to be adjusted with [upper pulley position].
Motor belt has to be adjusted with [motor pulley position].
10. Check and adjust following timing to finish.
(1)Upper shaft timing (L point, C point)
9. Install each parts in reverse order. (2)Take-up lever timing
For installation and adjustment of each part, (3)Rotary hook timing
please refer to respective manuals. (4)Jump device
Referring to [3-8-3 Adjustment of motor belt tension],
adjust tensile strength of motor belt.
105
Remove LCD-T board 4-1-1
4. Remove core module.
1. Remove four setscrews as shown in the figure below
Spread the latches on the left and right of the arrow
and remove rear cover.
outward, and raise the module toward you to remove it.
5. Remove narrow flat cable for LCD unit.
2. Remove connectors for SW cable, Box cable, cable for
LCD inverter (red/white).
Latch
atch Connector
Co
When you pull the latch to cord side, the cord release.
When you push the latch to connector side, the cord
fixed.
Release Fix
cable
Box ca
Cable for LCD

D inverter
inve (red/white)
6. Remove two sets screws and two studs.
Release SW cable and USB relay cable.

3. Remove set screw and sealed case A.
Setscrew
Sealed case A
Stud USB relay cable
SW cable
106
7. Lift LCD-T board as shown in the figure below.
9. Remove touch panel.
Remove wide flat cable for LCD unit.
（ When the tape for fixing is stuck on connector, please
peel off.）
）
Connector
Touch panel
Please reverse procedure when installing LCD-T board.
Wide flat cable

When you pull the latch to cord side, the cord release.
When you push the latch to connector side, the cord
fixed.
R elease
Latch
Fix
8. Remove four setscrews and LCD unit.
LCD unit LCD bracket
107
Setting for LCD-T board 4-1-2
Memory card Back-up battery
Insert our official memory card (EPZ0122*). Refer to The battery is used for back-up power source of real-time
the latest parts list for the parts number. clock on an embroidery machine.
This memory card contains programs and data for an Replace new LCD-T board if clock dose not indicate
embroidery machine. the correct time after setting a clock and turning power
switch OFF.
<Notice> Please contact us if you need to use third
party’s memory card from local market.

The necessary information will be provided.
Make sure to use 4~16GB SD card capacity and
please ask us for needed data file.
Back-up battery
Disposal of back-up battery of LCD-T board
When disposing of the LCD-T board, remove the back-up
battery.
Dispose of the back-up battery by following the method
specified by each country or each region.
108
Power supply settings 4-1-3
(Disconnect power plug from electrical outlet before work.)
(Please use digital output tester)
1. Turn the machine on and put tester against terminal plate
or connector, then turn V-ADJ to adjust to [24.6V±0.1V].
for 100V For 200V
VR
109
Adjustment of upper shaft timing (C point / L point) 4-2-1
1. Remove bobbin thread winding motor ass’y. 5. With this state, turn to C point and check if LED1 Iights
between [265 and 282 degrees].
2. Fix 2 screws tentatively timing detecting board. * Check dose not scratch plastic slit to Timing sensor.
6. Put bobbin thread winding motor ass’y back to where
it was.
3. Set upper shaft to [0 degree].
4. Move circuit board up and down and set to position
where LED 2 disappears at [0 degree], then fix with screw.
110
Adjustment of TC board 4-2-2
Viewing from side of circuit board, set slit so that it comes to center of sensor, fix it.
4-2-3 Adjustment of stop position of needle bar change unit

1. Remove potentiometer ass’y.
Imagine figure of position sensor and cam
2. Set position where sensor on sensor board and slit don't cross to area where moving head doesn't move
when turning groove cam.
3. After installation, please fix potentiometer referring to [3-4-2 Setting to detect needle position].
111
Remove of Inverter 4-3-1
<Notice> 4. Loosen screw with Phillips screwdriver for precision
Please disconnect machine inlet from the wall. instrument and remove 9 cables. (Cable color:
<Check> ORANGE, BROWN, PURPLE, WHITE, GREEN,
Before you start to work, make sure the display of BLUE, YELLOW, BLACK, and GLAY)
inverter is off.
1. Remove outer cover. Refer to [2-2 How to

remove outer cover].
2. Remove control terminal cover.

Insert fingers in a gap (under the “PULL” indication)
on the underside of control terminal cover, and pull
the cover toward yourself and remove it.
5. Remove screws with Phillips screwdriver and
remove power cable and motor cable.
(Cable color: GLAY, WHITE BLACK, BLUE, and
Pull BROWN)
If screw is provided on
the cover, remove it.
3. Remove main terminal cover
Hold both left and right ends of main terminal cover
with fingers and slide the cover toward yourself and 6. Remove cable from clamp.
remove it.
Pull
Pull
112
7. Remove two screws shown in the following figure
and inverter.
Inverter for 110 - 120V
Inverter for 200 - 230V
End of process.
Screw
Screw
113
Inverter Installation 4-3-2
<Note>
Please check your replacement inverter type and machine 2. Remove main terminal cover
Voltage specification before replace inverter. Hold both left and right ends of main terminal cover with
fingers and slide the cover toward yourself and remove it.
Sticker on inverter
Main terminal cover
For 110 - 120V
HCS 110V TYPE

E S H C B 7 9 5 7*
For 200 - 230V
HCS 230V TYPE

E S H C B 7 9 5 6*
Refer to specification sticker for voltage specifications of
the machine.
1. Remove control terminal cover.

Insert a finger in a gap (under the “PULL” indication)
on the underside of control terminal cover, and pull 3. Install inverter in the machine with two screws tightened.
the cover toward yourself and remove it.
Control terminal cover
“Pull”
114
4. Tighten screws with screwdriver to install power cable and 5. Tighten screw and connect 9 cables the following
motor cable per the following connection diagram. connection diagram. (Cable color: ORANGE, BROWN,
(Cable color: GLAY, WHITE, BLACK, BLUE, BROWN) PURPLE, WHITE, GREEN, BLUE, YELLOW, BLACK, and
GLAY)
6. Fix cable to the clamp.
115
7. Set main terminal cover
Install main terminal cover

Hold both left and right ends of main terminal cover
with fingers and install the cover in the inverter
<Note>
Install main terminal cover not to apply stress to

the cable. If stress is applied to the cable, load is
applied to the screws for the main terminal and
the screws might be loosened.
Main terminal cover
8. Install control terminal cover
Install the cover by inserting the nail on top of the cover to
the ditch of the inverter.
Do not pinch any cables with the cover.
9. Referring to [4-4-4 Setting of revolution],

Perform [Initializing of machine speed].
Inverter Installation is done.
<Note>
Check if voltage specifications of the machine and inverter
are matched before installation.
11
How to set inverter 4-3-3
In case of spare parts supply, parameter is preset. Please contact HAPPY, when you need to change it.
Parameter cannot be set while machine is running .
Pay attention to electric wires as setting is done with power is on.
How to release the setting change prohibition Next, change each setting.
Release the prohibition by following the procedures below 6. Press Up key and function code is displayed. Select the
since parameter is set as setting change prohibition. function code whose parameter you would like to change.
(Press Up key and the function code returns to the previous
code.)
The following table shows function codes, setting details, and
factory default setting. Functions other than described below
are initial setting of inverter.
Refer to the next clause for the method of initial setting.
Code Function Setting

Prohibition of change Protect
Frequency set mode
Up key Down key Drive / Operation
Maxmum frequency
Base frequency volteage
1. Press PRG/RESET. Acceleration time 1
[ I.F _ _ ] is displayed. Deceleration time1
Motor thermal protection
Upper limit freq. limter
2. Press FUNC/DATA. DC brake. starting freq.
DC braking current
[F 0 0 ] is displayed. DC braking time
Start frequency
Carrier frequency
3. Press FUNC/DATA again. Tone
[ 1 ] is blinking. Load selection
Multi stage frequency 1
(This means setting change is prohibited.)
Analog input filter
Analog input adjustment
Bias frequency
4. Press Up key or Down key while pressing STOP.
Motor capacity
[ 0 ] is blinking. Motor rated current
(This means you can change settings.) 7. Select the code you would like to change and press
FUNK/DATA.
5. Press FUNC/DATA. Parameter of the function is displayed.
After [SAVE] is indicated,
[F 0 1 ] is displayed. 8. Change parameter by pressing Up or Down key.
By above process, you will be able to set parameters.
9. Press FUNK/DATA.
After [SAVE] is displayed, the next function code is displayed.
This means change of the function code is made.
117
How to set the prohibition setting
10. After each setting is done, select [ F 0 0 ] by pressing
Up or Down key to return to setting change prohibition.
11. Press FUNC/DATA.
[ 0 ] is blinking.
12. Press Up key while pressing STOP.

[ 1 ] is blinking.
13. Press FUNC/DATA.
After [ S A V E ] is displayed,
[F 0 1 ] is displayed.
14. Press PRG/RESET.
[ I.F _ _ ] is displayed.
15. PRG/RESET again.
Return to normal mode.
118
Initialization of parameter 4-3-4
Please note that you are unable to make this setting

while the machine is running.
When setting is mistakenly made in mid way, the
setting will return to parameter in normal standard in
one action.
Thereafter please change to parameter you want to set.
1. Enable parameter to be changed by referring 1. to 5. in
[How to set inverter].
2. Press PRG/RESET.
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,
[ 0.06 ] - [ 0.07 ] is displayed.
8. Press FUNC/DATA.
The settings of inverter become initial settings.
Then, change parameter and return to prohibition

setting by referring to the previous clause.
119
Program update procedure 4-4-1
* The sequence of procedures of program update is described below..

If you need more details, please refer to Instruction book for embroidely machine.
1. Insert the updated program downloaded USB memory to the USB port of the machine.
Maintenance Manual
4-4-3 Each program update
Instruction book
18-3 Version information and software
update
2. Press [MENU] button and select [Version] in menu of [OTHER] for update each program.
3. Press [MENU] button and select [System] in menu of [OTHER] for initialization of system. Instruction book
25-1 Initialize machine
4. [Replacement of LCD-T board] Instruction book

Calender setting 3-7 Calendar setting
5. end of process
* If there is a problem with the machine after updating the program, press [MENU] button and select [Speed] in menu of [OTHER]
for automatic speed setting. ( Instruction book 25-2 Initialize speed )
120
Preparation for program update 4-4-2
* Download updated program file.
Program
for HCS3 " UPDATE_*.**.**.IMG "
<NOTE 1>
・Copy the program to the root folder of USB memory.
121
Program update 4-4-3
1.Insert USB memory that contains data for version 5. Select the file “UPDATE***.IMG”.
up into insertion slot on the control box.
2. Press (MENU) and press
(OTHER).
When the version of each program and the version in

the update file are different, the version number is
displayed in red.
Update even if the version mutch

(OFF) : Only different versions of the program will
be updated.
(On) : All programs will be rewritten even if the
version number is the same.(Up to 16 minutes)
<NOTE>
* Please do not take out USB memory during
3. Press Version . installation.
* Please do not turn off the power during
installation (it will
take for a while for completion of installation).
Retry updating when the screen shows “Error” due

to writing error.
4. Press OK .
Installation of program begins.
Once update id complete, the machine will be
rebooted automatically.
4. Press UPDATE .
5. Press NEXT button.
6. Referring to [4-4-4 Setting of revolution],

Perform [Re-Initialization of machine system]
And [Initializing of machine speed].
* End of process.
122
Initialization / Initializing of machine speed 4-4-4
Initialization the system

Perform this function only to fix problems with
the machine. 5. Press OK .
When performed, all settings in the “OPTION” menu Formatting of the machines systems are carried
are lost.
out. Indicate HAPPY logo in screen.
Be sure to reset the “OPTION” menu after
performing this function.
End of process.
Initialize the PMS
Please activate this function when the embroidery
machine has malfunction after the operation with Initializing of machine speed
Happy PMS (Production management
system).Please refer to instruction book of “Happy Setting of revolution of main shaft, which is suitable
PMS” for more precise information. to the machine is required.
If setting is not done, the revolution may not speed
Initialize the Network
When performed, all settings in the “Network” menu up.
are lost.
1. Turn on the power. After the program start up,

１. Turn on the power. After the program start up,
press
press (MENU) and press

(MENU) and press (OTHER).
(OTHER).
２. Press System .
2. Press Speed .
Speed setting OK?

3. Press Initialize the system. CAUTION! <Main shaft turns>
Go on to step 5.
Cancel OK
Press Initialize the PMS.
Press Initialize the Network.
3. Press OK .
4. Press OK .
Main shaft adjusts its revolution speed
Reboot? automatically.
Message complete will be displayed when setting
Cancel OK is finished and it goes back to drive mode.
123
Maintenance mode 4-5
Maintenance mode consists of 9 items as shown below.
Machine Test Movement test, maintenance, and adjustment
Machine Setting Machine control setting
Memory All Clear Initialization of design memory.
Main Program Update Update of operation program and language data
Machine Program Update Update of control program and frame move data
Frame Position Entry Registration of coordinates for positioning sensor
Record Total number of stitches, Error occurrence record, Occurrence record by 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~)
How to enter maintenance mode 4-5-1
1. Turn on machine.
3. Change to Drive screen when you press .
1. Press NEXT while pressing START/STOP button at
the screen of the control box after booting the machine.
You can enter maintenance mode again by long key press
of (Menu) at the Drive screen after maintenance mode
is finished.
However, you cannot use the reentry method above once
the machine is turned off and rebooted.
124
Machine Test Machine movement 4-5-2
Below operation will be moved solely. In some operations, actuator of motor will be moved, Keep hands and face away during
movement for your own safety.
#13 Position Data Entry : Confirm registration of frame
#1 Needle Adjust : Input of Needle bar detect Potentiometer position data (Not used in HCH Plus)
(Not used in HCH Plus) You can use this function to check if Frame position data
are entered correctly.
#2 Cutter Adjust : Action test of moving knife Open-Close #14 Shaft Drive Test : Main shaft control test
Use this function to adjust stop position of Moving knife. You can turn main shaft with pushing “Start” or “Jump”
#3 Catcher Adjust : Action test of Thread catch hook key of Needle bar section.
This test is used to adjust stop position of Thread catch This function can be used for test run after maintenance
hook. work.
#4 Keeper Test : Action test of Keeper solenoid ON-OFF
This test is used to check action of Keeper. #15 Sequin test (Not used in HCH Plus)
#5 Jump Solenoid Test : Movement test of jump device This test is used to check or adjust of Sequin device.
ON-OFF
This test is used to check movement of Jump device. #16 Rotary Hook Adjust
#6 Catcher Test : Movement test of thread catch hook This function can be used for [Adjustment of
IN-OUT needle height] or [Adjustment of rotary hook
Use this test to check movement of Thread catch hook. timing].
#7 Cutter Test : Action test of moving knife Open-Close
Use this function to check opening-closing action of
Moving knife.
#8 Clip Solenoid : Action test of clip type thread holder
(Not used in HCH Plus)
This test is used to check movement of clip type thread
holder.
#9 Pointer Test : Action test of laser pointer
This test is used to check action of Laser pointer. 40, 220 degrees
#10 Fan Drive Test : Action test of cooling fan ON-OFF

(Not used in HCH Plus)
Use this function to check movement of cooling fan. 160, 340 degrees 100, 280 degrees
#11 Encoder Check : Input test of L point / C point timing [01]–[15]: Needle change
With turning main shaft, you can use this function to [L point]: Main shaft will turn and set Needle bar
check if L point signal, C point signal, and timing signal position for [Adjustment of needle height] (L+5
are correct or not. degree).
#12 Position Data Entry : Position Data Entry Confirm frame [Rotary hook]: Rotary hook will turn and stop every
moving sensor 120 degrees to access 3 fixing screws easier.
This test is used to check action of Frame moving [Ndl +1],[Ndl -1]: Needle bar moves to the left or
sensor. right, then sets Needle bar position for
The Pulse motor will be un-locked when you activate the [Adjustment of needle height] (L+5 degree).
test, then you can move the embroidery frame to your
desire position. #17 Needle Posi. Adjust (Not used in HCH Plus)
125
Machine Test Machine movement 4-5-2
1. Enter maintenance mode in reference to [9-1 How to enter
maintenance mode] 5. Return to drive mode by pressing ESC and .
2. Press Machine Test .
3. Select desired number to be confirmed.
Page is switched by pressing .
Selected item will be executed.
# * ***************
ESC
4. The screen returns to the [MACHINE TEST] screen by
pressing ESC .
(Unnecessary to press ESC if the item completes
automatically.)
126
Memory All Clear Initialization of design memory 4-5-3
Delete all the design memory.
Execute this function when occurring design breakage or impossibility of design input.
If abnormality is found after deleting all the data, replace LCD-T board (or Core module) since the board might be broken.
<NOTE>
All the internal design memory will be deleted by initialization of design memory.
You have to be careful when initializing design memory.
1. Enter maintenance mode in reference to [9-1 How to enter
maintenance mode ]
2. Press Memory All Clear .
3. Confirmation of free area and all delete will be started after
pressing OK .
4. Return to drive mode by pressing ESC and .
127
Record Operation data display 4-5-4
You can confirm history of operation.
Total number of stitch : Total number of stitch used for embroidery so far
Error occurrence record : Type of errors and its occurrence date for the last 32 errors
Occurrence record by error type : Accumulated number of each error occurrence
Thread break history : The number of thread break by needle bar
Total number of stitch 4-5-4-1
1. Enter maintenance mode in reference to [ 9-1 How to enter 4. Selection menu of Clear Total Stitch will be opened when
maintenance mode ] pressing CLEAR at Procedure 3.
2. Press Record.
Clear Total Stitch ?
Cancel OK
* Total number of stitch is cleared after pressing OK and
the screen shows one in the procedure 3. Total number of
stitch is 0.
3. Press STITCH.
The screen shows total number stitches used for * If you do not prefer to clear it, press Cancel and
embroidery so far. the screen shows of the procedure 3 is shown
5. Return to drive mode by pressing ESC and .
128
Record of Error occurrence 4-5-4-2
1. Enter maintenance mode in reference to [ 9-1 How to enter * Error record is cleared by pressing OK and the screen of
maintenance mode ] the procedure 3 is displayed.
2. Press Record . * If you do not prefer to clear it, press Cancel and
the screen of the procedure 3 is displayed..
3. Press ERROR.
Enable to confirm Record of error occurrence
* Enable to confirm Occurrence date and error number of last
32 cases with button.
Selection menu of Clear Error Record will be opened when
pressing CLEAR.
Clear Error Recode ?

Cancel OK
129
Number of occurrence in each error display 4-5-4-3
1. Enter maintenance mode in reference to [ 9-1 How to enter * You can confirm accumulated number for E-000 to E-255
maintenance mode ]
with .
2. Press Record . * The screen returns to the previous screen by pressing
BACK.
5. Selection menu of Clear Error Total Count will be opened
when pressing CLEAR and the screen of procedure 4
is displayed.
Clear Error Total Count ?
Cancel OK
3. Press ERROR.
You can confirm record of error occurrence.
* Error record is cleared by pressing OK and the screen of
the procedure 4 is displayed.
* If you do not prefer to clear it, press Cancel and
the screen of the procedure 4 is displayed.
4. Press COUNT .
You can confirm total number of occurrence in each error.
(E-000 to E-255 will be displayed )
130
Thread break history 4-5-4-4
・
1. Enter maintenance mode in reference to [ 9-1 How to enter 5. Selection menu of Clear Thread Break Count will be
maintenance mode ] opened when pressing CLEAR at the screen of procedure
3.
2. Press Record .
Clear Thread Break Count ?
Cancel OK
* Thread break history is cleared by pressing OK and
the screen of the procedure 3 is displayed.
3. Press THREAD. * If you do not prefer to clear it, press Cancel and
You can confirm thread break history by needle bar. the screen of the procedure 3 is displayed.
・ *The screen returns to the previous screen by pressing
BACK.
131
Machine setting 4-5-4-5
1. Enter maintenance mode in reference to [ 4-4-1 How to
enter maintenance mode ].
2. Press Machine Setting.
3. Select desired number and modify setting.
・Setting values become default by pressing .
・Page is switched by pressing .
4. Press ESC button after modifying of setting
number.
5. The screen returns to drive mode by pressing .
6. Turn off power and on again before use a machine.
132
Maintenance Register―Registration of machine maintenance date 4-5-4-6
Registration of machine maintenance date
When last maintenance date is registered, next regular ・ By pressing Days button, you can change the number of
maintenance date will be set automatically. days for regular maintenance. (1 ~ 3,650 dsys)
・ By pressing Hours button, you can change the number of
1. Enter maintenance mode in reference to [ 4-4-1 How to running time for regular maintenance. (1 ~ 50,000 hours)
enter maintenance mode].
4. Press ESC.
2. Press Maintenance Register. Return to maintenance mode.
3. Press Register. ・End of process.

The current date will be registered as last maintenance
date.
When the machine runs more than 2000 hours (default
setting) or 365 days are passed after last maintenance,
the machine will display the message to have regular
maintenance.
Registered
egis date
・ Pressing the RESET button delete the registered date.
・ When the Calender button is pressed, you can set
calendar of the machine.
133
Machine Setting Navigation after exchanging CONT board 4-5-4-7
After exchange CONT board, please activate [Machine 5．Press Skip.
Setting Navigation after exchanging CONT board] function.

2nd Step: Program Update
Then you can set necessary machine setting with one
process. OK
6．Press OK .
4-4-3 Program update
Save the latest program to USB memory
4-4-4 Initializing of machine speed And set USB to USB slot on panel.
OK
・Refer to [4-3-2 Preparation for program update] and 7. Press OK .
prepare latest update programs.
1. Insert USB memory that contains data for

version up into insertion slot on the control box.
2. Refer to [4-4-1 How to enter Maintenance mode] and
enter maintenance mode. The screen shows below:
8. Select the file “UPDATE***.IMG”
3. Press Replaced CONT Board.
When the version of each program and the version

Start Setup-Navigation? in the update file are different, the version number
is displayed in red.
Cancel OK
9. When the current machine program is older than latest
4．Press OK . version, press OK .
The installation will be started.
If the current machine program is same or newer version,

st
1 Step: Option Selection press Cancel .
OK 3rd Step: Select machine serial No.

(for auto-machine setting)
OK
134
10．Press OK .
11. Enter the corresponding machine number.
Final Step: Speed setting
OK
12．Press OK .
13．Press OK .
[Initializing of machine speed] will be started.
Refer to [Initializing of machine speed] of [4-3-5

Setting of revolution] for more details.
Setup is completed.
OK
14．Press OK .
The screen returns to the maintenance mode。
・ End of process.
135
Electrical connection diagram 5-1
136
Electrical connection diagrams 5-1
137
List of electrical connection diagrams 5-1
138
Connection of inverter 100V 5-2
Inverter set
139
Connection of inverter 200V 5-2
Inverter set
140
Explanation of function of circuit board 6
HCD8126*
LCD-T board Ass'y
Parts side
Back side
CN No. Function
X1 Core module I/F
X2 Machine CPU I/F
X3 TP-SW board I/F
X5 7in LCD I/F
X5-1 7in touch panel input
X5-2 10.4in touch panel input
X5-3 USB-A connector 3
X5-4 10.4in LCD I/F
X6-3 7in LCD backlight output
X6-5 USB-B connector
X7 LAN
X14 SD card
141
HCB8118*
USB connector board ass'y
CN No. Function
CN5 USB input
142
HCD8116*
TP-switch board ass'y
. 3-$2*.-
5*2$).32/32*-/32

143
HCB8120*
*0$3*2."0%117
. Function
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144
HCB8105*
TC12 board ass'y
. 3-$2*.-
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HCB8109*
Timing detecting board ass'y
. 3-$2*.-
32/32.'/.*-2/.*-2 "-(+&1&-1.0

145
HCJ8106*
SENS0R Circuit Board Ass'y
. 3-$2*.-
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HCR8129*
FRONT LED Circuit Board Ass'y
. 3-$2*.-
/.5&01.30$&*-/32

HCB8110*
X limit sensor board ass'y
. 3-$2*.-
&-1.04"+3&.32/32
&-1.0*-/32
&-1.0*-/32
&-1.0.32/32
&-1.0.32/32

146
How to respond for some question (As example step) 7-1
*When you receive some question from customer, please use this step for sold problem as sample.
Receive contact from customer
Ask machine serial number
Ask contents of question

*Circumstance of machine (Windy, Dusty, Floor condition and etc)
*Embroidery condition (Frame, Fabric, Thread, Pattern)
*Machine creations. (Create menu)
*Version of machine program.
*Version of Happylinf software.
*About connecting PC.
*etc.
You may prepare instruction book and parts book by customer.
Respond for customer’s question

*Advice by Instruction book and Parts book.
*Advice referencing maintenance manual.
*If you can not immediate, contact again after more detail check.
Ask customer’s contact number

*Phone, Fax and E-mail
OK
*If you find case of respond, contact customer kindly.
NG Visit your technician

*Ask schedule for visit
NG
Send or bring back machine for more detail check

*Estimate repair cost
*If still can not find the case, contact factory rep.
147
Trouble shooting(Electricity doesn’t turn on) 7-2-1
Trouble Factor Cause of trouble and measure Page
Electricity Mechanical 1. Did fuse blow?
doesn't turn on 1-1 If it did, replace it.
2. Check of defect on board.
2-1 Replace of CONT-** board ass'y.
2-2 Replace of LCD- ** board ass'y.
3. No problem in power supply?
3-1 Check and adjust the correct voltage. 4-1-3
3-2 Try to replace power supply.
4. Check of Cable catching causes short-circuit.
4-1 Please insulate the cable after removing outer cover.
4-2 Replace of cable.
5. Confirm not getting power 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 2-3machines)
Operator 1. Didn't press emergency switch?
1-1 Release lock. (3-8)
Environment 1. Is electricity in receptacle?
1-1 Supply power.
( ) ---Reference instruction book
148
Trouble shooting(Thread break) 7-2-2
Thread break Mechanical 1. Is needle drop unstable by vibration? (2-5)
1-1 Reconsider where to install the machine.
1-2 Move the machine to floor fully reinforced.
1-3 Use strong table to be able to endure vibration.
2. No burr or scratch in thread guide hole? 3-1-1
2-1 Remove burr and scratch.
2-2 Replace of thread guide.
3. No problem in thread adjusting spring? 3-1-1
3-1 Replace spring if it doesn't spring.
3-2 If weak or broken, replace it.
4. Does detecting roller make smooth turn?
4-1 Clean inside hole of bearing.
4-2 Correct so as for slit disc not to touch sensor. 4-2-2
4-3 Correct so as for cable not to touch slit disc.
4-4 Check cable of TC 7 Board is unconnected
5. No problem in thread guide unit and thread tension ass’y? 3-1-1
5-1 Remove burr and scratch if appeared.
5-2 Remove lints and clean.
6. Does disc on thread tension ass’y. turn smoothly? 3-1-1
6-1 Remove lints and clean.
6-2 Replace
7. Is backlash between take-up lever and take-up crank roller not bigger?
7-1 Replace of take-up lever. 3-3-9
8. No problem in needle holder?
8-2 Make proper fixing. (direction) 3-1-2
9. No burr and scratch on needle plate? 3-1-1
9-1 Remove burr and scratch in needle hole.
9-2 Remove burr and scratch around needle hole on back of needle plate.
9-3 Replace it if not furbished.
9-4 If furbishing made needle hole wider, replace it.
10. No problem in pressure foot?
10-1 Remove burr and scratch. 3-1-1
10-2 Correct bent. 3-1-1
10-3 Adjust height. 3-2-10
10-4 Replace of pressure foot. 3-2-11
10-5 Replace of pressure foot drive cam. 3-2-9
149
Thread break Mechanical 11. No problem in rotary hook? 3-1-1
11-1 Clean it to remove lints. (23-2)
11-2 Furbish scratch.
11-3 If backlash of bobbin case holder and outer hook grows bigger, replace them. 3-5-1
11-4 Replace.
12. No problem in rotary hook retainer?
12-2 Adjust position. 3-5-2
13. No problem in needle?
13-1 Fix it properly . 3-1-2
13-2 Select proper size of needle to match thread thickness. 3-1-4
13-3 If tip of needle is warped or bent, replace. 3-1-1
13-4 Replace.
14. No problem in bobbin case?
14-1 Remove rust and scratch.
14-2 If thread guide spring 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. 3-3-7
17. Does needle bar make smooth movement?
17-1 If bent, replace it. 3-3-7
18. No backlash in moving head?
18-1 Adjust positioning roller shaft. 3-3-2
19. Needle doesn't drop in the center of needle hole.
19-1 Adjust positioning plate and adjust needle drop back and forth. 3-3-4
19-2 Adjust position of needle selection unit, then adjust needle drop right and left. 3-4-1
20. Is the lowest needle position proper?
20-1 Adjust mechanical lowest needle position. 3-2-3
20-2 Adjust electric lowest needle position. 4-2-1
21. Is needle height proper?
21-1 Adjust as specified. 3-3-6
22. Is rotary hook timing proper?
23. Is clearance between needle and rotary hook proper?
150
Thread break Mechanical 24. Check tip of keeper hit the bobbin case.
24-1 Adjust it regularly. 3-6-12
25. ls take-up lever timing proper ?
26. No problem in timing belt?
26-1 Adjust tension. 3-8-1
26-2 If scratched or damaged, replace it. 3-8-2
27. No problem in motor belt?
27-1 Adjust tension. 3-8-3
27-2 If scratched or damaged, replace it. 3-8-4
28. Is revolution setting proper? (25-2)
28-1 Make automatic speed setting. 4-4-4
Operator 1. Operation is wrong (no proper [create] setting for sewing?)
1-1 Tell how to operate. (15-1)
2.Is pattern dwindled too much by pattern adjustment?
2-1 Adjust size so as to produce less thread break.
2-2 Use pattern edited again (density_ change).
3. Is thread tension properly set?
3-1 <Upper thread> Considering sewing finish, set tension. (8-1)
3-2 <Bobbin thread> Considering upper thread tension, set tension. (4-5)
5. Is bobbin put in bobbin case properly?
5-1 Viewing from front of bobbin case, set so that bobbin turns left-wise. (4-5)
6. Does thread cone stand properly? (4-6)
6-1 Keep thread from hitting felt.
6-2 Stand vertically.
7. Is passing of thread proper?
7-1 Pass thread properly. (4-7)
8. Is cloth properly stretched? (6-2) (7-5)
8-1 No loosening and no too much tightening. Even tension in depth and width.
8-2 Texture should be even in direction of X and Y.
9. Is frame properly set? (6-3) (7-6)
9-1 Frame should be put in positioning hole on tubular-frame.
9-2 No loosening of screw.
151
Thread break Operator 10. Is frame used to suit pattern size?
10-1 Use frame to suit pattern size.
11. When you dispose of thread (thread remains around rotary hook),
didn't you damage rotary hook, needle plate with scissors?
11-1 Tell to dispose of thread carefully.
11-2 Open needle plate to dispose of thread.
12. Didn't you neglect cleaning and oiling? (23-2)
12-1 Tell to always clean and use cleanly. (23-1)
12-2 Tell to oil regularly.
Thread & 1. Is thread used to suit needle size? 3-1-4
cloth 1-1 Use thread to suit needle size. (4-2)
2. Is thread used to suit embroidery? (thread twist, tender thread). 3-1-3
2-1 Don't use too strongly twisted thread. (4-2)
2-2 Twist of thread is to be left-wise.
2-3 Use tender thread.
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. humidity dust etc.)
6. Isn't poor unwoven cloth used? Is number of sheets used proper?
Environment 1. Is strength of table and floor enough? (2-5)
1-1 Reconsider place to install the machine.
1-2 Move the machine to place where floor is strong enough.
1-3 Use table with strength endurable against vibration.
2 Are room temperature and humidity proper against thread? (23-1)
2-1 It is desirable to install air conditioner to keep temperature and humidity
in a certain level.
3. Doesn't embroidery machine receive direct sunlight? (cause of inferior thread)
3-1 See not to expose to sunlight (spread curtain) (2-6)
152
Thread break Environment 4. Is there something that produce steam, wasted cotton, dust around.
the embroidery machine?
5-1 Keep the embroidery machine off those things. (2-6)
5. Does thread go out of control by taking wind from outside or heater etc.?
6-1 Keep the embroidery machine off such wind. (2-6)
6-2 Move the embroidery machine to proper place.
Pattern 1. Does thread break occur repeatedly at same place in design?
1-1 Check pattern to modify punching.
2. Is it too narrow between stitches?
2-1 Check pattern to modify punching.
2-2 Setting of [create] menu. (Stitch sweep) (10-3)
3. Too many empty stitches?
3-1 Make [create] setting. (this setting doesn't read empty stitches) (10-3)
Others 1. Using spray paste (adhesive material)
1-1 Clean around rotary hook. 3-1-2
1-2 Replace or clean needle. (23-2)
1-3 Use this paste at a given place and never use in front or back of (4-1)
the embroidery machine.
153
Trouble shooting(Erroneous thread cut) 7-2-3
Erroneous Mechanical
thread cut 2. Isn't rubbing of fixed knife and moving knife weak?
(E-190) 2-1 Adjust to be able to rub properly. 3-6-8
(E-193) 3. Does moving knife make smooth move? (23-3)
3-1 Check if rubbing of moving knife and fixed knife is not too strong. 3-6-8
4. Check Displace of moving knife.
4-1 Adjust of moving knife position. 3-6-9
5. Check defacement of moving knife or fixed knife.
5-1 If possible, furnish with file.
5-2 Replace 3-6-6
3-6-7
6. No backlash in up and down direction of knife drive shaft? 3-6-8
6-1 Check no loosening of screw on moving knife.
6-2 Check no loosening of screw on knife drive shaft.
7. No backlash in fixed knife? 3-6-8
7-1 Check no loosening of screw on fixed knife.
8. Does thread cut pulse motor work properly?
8-1 Check cable.
8-2 If trouble found in CONT-** board ass'y, replace.
8-3 If trouble found in thread cut pulse motor, replace.
9. Is number of revolution proper at time of thread cut?
9-1 Make automatic speed setting. (25-2)
9-2 If trouble in CONT-** board, LCD- ** board ass'y, replace. 4-4-4
10. Is there no skipped stitch?
10-1 Adjust needle depth. 3-3-6
10-2 Adjust clearance between needle and rotary hook. 3-5-1
10-3 Is height of pressure foot proper? 3-2-10
10-4 Is rotary hook timing proper? 3-5-1
10-5 Is relation between needle and thread proper?
154
Trouble shooting(Erroneous thread cut) 7-2-3
Erroneous Mechanical 11. Check the needle bar moves up and down during thread cut.
thread cut 11-1 Adjust position of jump device. 3-2-5
(E-190) 11-2 Replace needle bar cushion. 3-3-7
(E-193) 11-3 Replace needle bar driver. 3-2-4
12. Is position of keeper proper?
12-1 Adjust the fixed position regularly. 3-6-12
13. Check the movement of keeper goes smoothly.
13-1 Readjust if it is not smooth. 3-6-12
Operator 1. No negligence in cleaning thread cut device? (23-2)
1-1 Tell to clean regularly.
# It's desirable to prepare brush with soft hair and air gun.
2. Is timing of thread tension proper?
2-1 <Upper thread> Considering sewing finish, set tension. (8-1)
2-2 <Bobbin thread> Considering upper thread tension, set tension. (4-5)
Environment 1. Are power and voltage rated and stable?
1-1 Supply rated voltage.
Thread & 1. Is twist of thread too strong?
cloth 1-1 Use thread with proper twist.
2. No skipping by use of lots of paste?
2-1 Use small amount of paste.
2-2 Remove paste stuck to needle.
155
Trouble shooting(Off-registration of pattern) 7-2-4
Off-registration Mechanical 1. Does frame move smoothly?
of pattern 1-1 Avoid curling of thread and cloth.
1-2 Reinstall of outer cover in case of touch with outer cover. 2-1
1-3 Adjust with no clearance between Arm and Connecting plate B.
2. Is bound of frame base too big? (6-1b)
2-1 Fix frame base between bearing and base without gap.
3. Is carriage belt tension proper? 3-7-1
3-1 Adjust all belts as specified. 3-7-3
4. No loosening of screws on carriage drive?
4-1 Check screw. If loosened, tighten firmly.
5. No lints or dust around idler pulley on carriage?
5-1 Clean
6. No damage in carriage belt? 3-7-2
6-1 If damaged, replace. 3-7-4
7. No backlash of back and forth in moving head?
7-1 Adjust positioning roller shaft to remove backlash back and forth. 3-3-2
8. Is height of pressure foot proper?
9. No problem in motion of pulse motor for X/Y carriage ?
9-1 Check wiring. If screw got loosened, tighten more.
9-2 After 9-1, still problem, then replace.
10. No problem in motion of CONT-** board ass'y ?
10-1 Check wiring. If screw got loosened, tighten more.
10-2 After 10-1, still problem, then replace.
11. Does't other frame than genuine one used?
11-1 If frame is too heavy, don't use it.
11-2 If setting is not proper, set it so as not to move.
12. No problem in LCD-** board ass'y ?
12-1 Try to initialize. 4-1-1
12-2 Replace of LCD- ** board ass'y.
13. Is number of revolution proper? (25-2)
14. Not affected by noise?
14-1 Don't use the machine near where noise is generated.
Operator 1. Is setting of frame correct? (6-3) (7-6)
1-1 Frame should be put in positioning hole on tubular frame.
1-2 Set so as for screw not to loosen.
156
Trouble shooting(Off-registration of pattern) 7-2-4
Off-registration Operator 2. Is cloth properly stretched. (6-2) (7-5)
of pattern 2-1 Stretch properly.
3. Is thread tension proper? (4-5) (8-1)
3-1 Observing sewing rhythm, set thread tension properly.
4. Was the machine left for a long time in middle of sewing?
4-1 Try to finish sewing as soon as possible.
Environment 1. Is strength of table and floor enough? (2-5)
1-1 Check where to place the machine again.
1-2 Move to where floor is strong enough.
1-3 Use strong table to be able to endure vibration.
2. No problem in CONT-** board ass'y by low power and voltage (variation)?
2-2 Use transformer.
2-3 Use stabilizer.
3. Is there no place where noise is generated near the machine?
3-1 Don't use the machine near where noise is generated.
4. Doesn't drive frame hit obstacle? (2-5)
4-1 Remove obstacle.
4-2 When useing cap frame, see not to hit table. (2-6)
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. Is proper backing paper used? (4-3)
3-1 Use backing paper to match cloth.
4. Isn't cloth (embroidery) too heavy?
4-1 Don't use extremely heavy cloth.
Pattern 1. Pattern data may be destroyed. (5-4) (5-5)
1-1 Read again.
1-2 Let new pattern read.
2. Memory pattern was destroyed. (5-4) (5-6)
2-1 Let new pattern read.
3. No problem in USB memory ?
3-1 Initialize and read again.
3-2 Prepare new USB memory.
157
Trouble shooting(Upper thread comes off from needle hole) 7-2-5
Upper thread Mechanical 1. Is keeper in motion?
comes off 1-1 Check if cable was cut or there is something unusual.
from needle 1-2 In case solenoid is in trouble, replace. 3-6-11
hole 1-3 In case CONT-** board ass'y is in trouble, replace.
2. Is keeper put in right place?
2-1 Put it as specified. 3-6-12
2-2 Modify bent of keeper.
2-3 Adjust it again if movement is not smooth.
3. Is magic-tape on thread catch holder not worn?
3-1 Replace magic-tape. 3-3-14
4. Does bobbin thread holder hold bobbin thread?
4-1 Adjust pressure when contacting moving knife. 3-6-10
4-2 In case bobbin thread holder is in trouble, replace.
4-3 Clean bobbin thread holder.
5. No error in thread cut (2 threads cut)?
5-2 Position moving knife as specified. 3-6-9
5-3 Check and polish burr or scratch on moving knife.
5-4 In case moving knife is in trouble, replace. 3-6-6
6. Are clearance between needle and rotary point and needle height are proper?
6-1 Adjust clearance between needle and rotary hook as specified. 3-5-1
6-2 Adjust needle depth. 3-3-6
7. Doesn't thread catch hook cut upper thread?
7-1 Polish burr on hook.
7-2 In case hook is in trouble, replace.
8. Does thread catch hook hold upper thread?
8-1 Check if cable was cut or there is something unusual.
8-2 In case pulse motor is in trouble, replace.
8-3 Adjust fixing position. 3-2-18
8-4 If hook is bent, modify.
8-6 In case CONT-** board ass'y is in trouble, replace.
9. Check tension of thread adjusting spring is too weak.
9-1 Adjust of tension. 3-3-11
( ) ---Reference instruction book s ---Standard c ---Color monitor
158
Trouble shooting(Upper thread comes off from needle hole) 7-2-5
Upper thread Mechanical 10.Check the needle bar moves when start sewing.
comes off 10-1 Adjust position to fix jump device. 3-2-5
from needle 10-2 Replace needle bar driver. 3-2-4
hole 11. Is number of revolution proper when sewing started? (25-2)
12.Is height of pressure foot proper?
Operator 1. Isn't thread tension too strong? (4-5) (8-1)
1-1 Weaken tension not to cause trouble in sewing rhythm.
2. Keen in cleaning thread cut device? (23-3)
2-1 Clean bobbin thread holder regularly.
3. Is setting of bobbin thread proper? (4-5)
3-1 Pass thread on bobbin thread guide surely.
4. Is bobbin thread properly wound? (4-4) (4-5)
4-2 Pull out bobbin thread to check if it comes out smoothly.
5. Is upper thread properly passed? (4-6) (4-7)
5-1 Pass properly again.
6. Does thread cone stand properly? (4-6)
6-1 Keep thread from hitting felt.
6-2 Stand vertically.
7. Is [create] properly set? (15-1)
7-1 Select longer setting of upper thread length.
7-3 Select start lock stitch [effective].
Thread & 1. Is thread used to suit embroidery? (thread twist, tender thread). 3-1-3
Cloth 1-1 Don't use too strongly twisted thread.
Environment 1. Does wind let thread go beyond control? (outside wind, heater, and fan etc.) (2-6)
1-1 Keep the embroidery machine off from wind.
2. Is voltage of power as rated and stable?
Pattern 1. Is there stop sewing stitch for start sewing?
1-1 Modify pattern. 1-2 Set lock stitch function. (15-5)
159
Trouble shooting(Upper thread remains) 7-2-6
Upper thread Mechanical 1. Upper thread is difficult to come out of keeper at time of thread cut (bent or warp etc.).
remains 1-1 Modify bent or warp.
1-2 Replace keeper.
2. Keeper doesn't return properly at time of thread cut.
2-1 Modify bent of keeper.
2-2 Adjust position to fix. 3-6-12
2-3 Adjust it again if movement is not smooth.
3. Upper thread does not come off from magic tape of thread holder.
3-1 Insert something(Thickness 0.1-0.2mm) into holder then move it right and
left to put magic tape in order.
3-2 Replacement of magic tape. 3-3-14
4. Doesn't thread catch hook cut upper thread?
4-1 Polish burr on hook.
Operator 1. Setting of thread tension is weak. (4-5) (8-1)
1-1 Strengthen so as not to cause trouble in sewing rhythm.
2. Is [create] properly set? (15-1)
2-1 Select length of upper thread [standard].
Thread & 1. Using hard cloth make thread difficult to go through.
cloth 1-1 Select needle and thread. 3-1-4
2. Using thick cloth make thread difficult to go through.
2-1 Select needle and thread. 3-1-4
3. Is thread used to suit embroidery? (thread twist, tender thread). 3-1-3
3-1 Don't use too strongly twisted thread. (4-2)
160
Trouble shooting(Malfunction of thread break detection) 7-2-7
Malfunction of Mechanical 1. Trouble in turning detection roller.
thread break 1-1 Clean roller shaft holder.
detection 1-2 Check if slit disc doesn't contacts sensor. 4-2-2
(empty 1-3 Clean sensor if dust gets stuck.
detection) 1-4 Check if cord doesn't contacts slit disc.
1-5 Check Disconnection of cable.
2. Check circuit board.
2-1 Replace of LCD- ** board ass'y. 4-1-1
2-2 Replace of TC board.
3. Sometimes needle bar doesn’t work when start sewing.
3-1 Replace if cushion has been decrepit.
3-2 Replace of needle bar driver. 3-2-4
3-3 Adjust of jump device position. 3-2-5
3-5 Replace of Jump device.
3-6 Adjust position of Photo interrupter on Thread catcher.
Operator 1. No thread is passed through detecting roller.
1-1 Pass thread properly. (4-7)
2. Is thread tension proper?
2-1 Observing sewing rhythm, adjust thread tension properly. (4-5) (8-1)
3. Is proper detection sensitivity of thread cut selected? (5-1)
3-1 Select detection sensitivity according to sewing condition of thread and cloth etc.
Environment 1. Is there any device to yield lints etc. around the embroidery.
1-1 Keep it off the embroidery machine.
1-2 Move the embroidery machine to other place.
2. Doesn't thread go beyond control by wind? (thread comes off from needle hole by loosing) (2-6)
2-1 Keep thread off wind.
2-2 Move the embroidery machine to other place.
Thread & 1. Isn't silicone agent used on thread?
Cloth (Thread slips at detecting roller part due to adhere of silicone.)
1-1 Clean silicone agent attached to detecting roller groove.
161
Trouble shooting(Malfunction of thread break detection) 7-2-7
Malfunction of Mechanical 1. Check circuit board.
thread break 1-1 Replace of CONT-** board ass'y.
detection 1-2 Replace of TC board.
(not detected) Operator 1. Is thread tension proper?
(slow detected) 1-1 Observing sewing rhythm, adjust to proper thread tension. (4-5) (8-1)
(Adjust it little bits stronger.)
2. Is proper detecting sensitivity of thread cut selected? (15-1)
2-1 In case of being not detected, make [thread cut detection] setting to [yes].
2-2 Select detection sensitivity of thread cut according to sewing condition of thread and cloth etc.
162
Trouble shooting(Suspension of upper shaft) 7-2-8
Suspension Mechanical 1. Upper thread twine round rotary hook or rotary hook retainer.
of main shaft 1-1 Get rid of it.
(E-18) 2. Check return of keeper goes smooth. (when start sewing.)
(E-51) 2-1Adjust it regularly. 3-6-12
(E-52) 3. Check upper thread is sticking at thread guide part of bobbin case.
3-1 Get rid of it.
3-2 Do not use of bobbin case in which thread guide is coiled type. (use standard type)
4. Out of Needle bar block B from pressure foot block.
4-1 Insert needle bar block B into pressure foot block by doing
needle bar change manually.
5. Defect on drive part of pressure foot.
5-1 Modify Pin B and hit part of link A and B by sand paper.
5-2 Replace of pressure foot block ass’y and link ass’y. 3-2-13
6. Effect by breakage of parts.
6-1 Repair broken place.
7. No damage in electric parts?
7-2 Replace of Timing Board.
8. Trouble of software in LCD -** board ass'y. (25-1)
8-1 Initialize, then make automatic speed setting. (25-2)
4-4-4
9. Trouble in control of number of revolution. (25-2)
Operator 1. Isn't foreign stuff such as thread or cloth caught in where revolution is driven.
1-1 Get rid of foreign stuff.
1-2 Stretch properly. (6-2) (7-5)
2. Isn't thread tension too strong (stop at time of action of thread cut)? (4-5) (8-1)
2-1 Weaken tension so as not to cause trouble in sewing rhythm.
3. Check condition of lubrication.
3-1 Lubricate (refer to message) (23-1)
Environment 1. Check adequate level of voltage.
100V – 115V -10V / +15V
200V – 230V -10V / +10V
163
Trouble shooting(Malfunction of needle bar change) 7-2-9
Head does not Mechanical 1. Check lint or cloth is seized between Lower Moving rail and Bearing.
move 1-1 Remove seized lint or cloth.
(E-021) 2. Check lint or waste is seized in gap of Moving Cam.
(E-022) 2-1 Remove seized lint or waste.
3. Effect by breakage of parts.
3-1 Repair broken place.
Operator 1. Check Stopper of Moving Head is removed.
1-1 Remove Stopper.
Uncontrollable Mechanical 1. No problem in sensor circuit board ?
Move 1-1 Clean dust attached to sensor.
(E-024) 1-2 Replace sensor circuit board. 4-2-1
(E-025) 2. Needle number is not exactly recognized.
3-1 Check position of Photo interrupter on Needle bar change unit. 4-2-3
3. Breakage of Pulse Motor .
4-1 Replace Pulse Motor.
164
Trouble shooting(Defect on Thread catcher) 7-2-10
does not catch Mechanical 1. Thead catcher does not extend hook sufficiently.
thread 1-1 Adjust position of Thread catcher . 3-2-18
1-2 Adjust position of Thread holder. 3-3-13
2. Excessive distance between Hook and tip of Needle.
2-1 Adjust position of Thread catcher. 3-2-18
2-2 Adjust position of Thread holder. 3-3-13
Hook of Thread Mechanical 1. Check Hook of Thread catcher bent or not.
catcher does not 1-1 Repair bent Hook.
extend 1-2 Replace Hook.
2. Check position of Thread catcher is proper.
2-1 Adjust 3-2-18
3. Check position of Thread holder is proper.
3-1 Adjust 3-3-13
4. Check Thread catcher.
4-1 Check cable is securely connected.
4-2 Replace Pulse Motor with trouble.
5. Check CONT-** board ass'y.
5-1 Replace CONT-** board ass'y.
Hook hits or Mechanical 1. Check Hook is bent or not.
catches Needle 1-1 Repair bent Hook.
(E-193) 1-2 Replace Hook.
2. Check position of Thread catcher is proper.
2-1 Adjust 3-2-18
3. Check position of Thread holder is proper.
3-1 Adjust 3-3-13
Operator 1. Check if Needle is securely set.
1-1 Set Needle properly. (4-1)
3-1-2
Constant display Mechanical 1. Trouble of Photo interrupter for Thread catcher.
of E-193 1-1 Replace Photo interrupter.
165
Trouble shooting(Others / Mechanical) 7-2-11
Needle Breakage Mechanical 1. Check Needle is not bent.
1-1 Replace bent Needle. 3-1-2
2. Check Moving Head set securely.
2-1 Adjust Positioning Roller Shaft. 3-3-2
3. Secure adequate distance between Needle and Rotary Hook.
3-1 Adjust distance properly. 3-5-1
Operator 1. Is thread method in proper way? (4-6)
1-1 Threading again in a proper way. (4-7)
2. Check upper thread comes in a smooth way. (Thread stand, Thread tension point, double back etc)
2-1 Adjust place be caught in.
3. Check whether fabric is fixed firmly or not.
3-1 Hooping fabric firmly again. (6-2) (7-5)
Defect of pressure Mechanical 1. Check whether pressure foot and thread catcher holder touch each other or not.
foot movement 1-1 Adjust installment position of thread catch holder. 3-3-13
1-2 In case pressure foot is fixed at an angle, fix it vertically again.
2. Defect of censor circuit board for Pressure foot.
2-1 Replace of censor circuit board.
Abnormal noise Mechanical 1. By defect of cover installation. (Pressure foot drive, Carriage etc)
2-1 Take care of insert condition, clearance etc and fix again.
2. By lack of oil inside rotary hook. (23-1)
2-1 Refuel 3-5-1
2-2 Replace of rotary hook
3. Touching of cap switch bracket on X carriage to cover.
3-1 Adjust bend of bracket.
Big noise Mechanical 1. Gap between pressure foot block and needle bar boss B.
1-1 Replace of pressure foot block. 3-2-13
2. Bearing gap of take up crank ass’y.
2-1 Adjust bearing. 3-2-7
2-2 Replace of bearing.
3. Gap between take up lever ass’y and take up clank ass’y.
3-1 Replace of take up lever ass’y. 3-3-9
3-2 Replace of take up lever crank ass’y
166
Trouble shooting(Others / Electric) 7-2-12
Frame overrun Mechanical 1. Interference between censor circuit board and douser.
1-1 Position adjustment of douser.
1-2 Replace of censor circuit board.
2. Check whether cable has problem or not.
2-1 Replace in case damage exists.
2-2 Insert connector again.
3. Check CONT-** board ass'y.
Key on control box Mechanical 1. When removing panel in replacing circuit board , due to poor cable bundling,
can not be pressed circuit board being pushed from inside.
down and returned 1-1 Bundle cable again
Defect of LCD Mechanical 1. Check LCD .
1-1 Replace of LCD 4-1-1
2. Inadequate condition of cable insertion
2-1 Insert to the back firmly.
3. Check whether LCD-** board ass'y is out of order or not.
3-1 Replace of LCD-** board ass'y. 4-1-1
Defect of data Mechanical 1. Check whether cable (USB or LAN) is insert firmly between PC and Machine.
communication 1-1 Insert again
(E-90) 2. Check whether PC has problem or not.
(E-91) 2-1 Affirm whether there is problem or not.
3. Check whether LCD-** board ass'y is out of order or not.
3-1 Replace of LCD-** board ass'y . 4-1-1
Pattern disappears Mechanical 1. Trouble in back-up battery on LCD-** board ass'y
/ Watch doesn't 1-1 Replace of LCD-** board ass'y . 4-1-2
indicate time 2. No trouble in memory tip on LCD-** board ass'y ?
2-1 Conduct [memory all clear] in maintenance mode. 4-5-3
2-2 If above measure doesn't solve the trouble, replace LCD-** board ass'y.
167
Startup error and measure 7-3-1
Error message will be displayed if error occurs during machine startup.

After confirming contents, press button [OK] on control box to release error, then restore in accordance with
measure in this list.
Message Error Measure

Exchanged When only control box has been
control box or exchanged, open the menu of [4-5-4-5
CONT board does Setup — Machine setting] and just close
not match for the without any amendment.
installed data of When CONT board has been exchanged,
[Machine setting]. follow the procedure of [4-5-4-7 Machine
Setting Navigation after exchanging CONT
board].
Installed frame Check setting contents of [Machine setting]
drive data in the by referring [4-5-4-5 Setup—Machine
machine does not setting], then follow the procedure
match. [4-4-3Machine program update].
168
Error and measure 7-3-2
When trouble occurred while the machine is running, error number and error item will be displayed. After confirming contents,
press key [ENT.] on control box to release error, then restore in accordance with measure in this list.
No. Message Error Measure Page
001 Circuit board Trouble detected in control circuit board. (1)Turn power off once and turn on again.
(2)If recurred, replace LCD-** board ass'y.
004 System memory Trouble in system memory. Replace LCD-** board ass'y.
018 Main shaft Suspension of main shaft in mid way. (1)Check if trouble found between main shaft
and drive. If trouble found, restore. (25-1)
(2)If recurred, find cause and fix. (25-2)
(3)Make automatic speed setting again. Initializing
020 Needle detect Needle position not detected. (1)Turn needle selection cam by hand to set to
Trouble in stop position of needle regular position.
selection unit. (2)Fix needle selection related mechanical trouble.
(3)Replace sensor circuit board. 4-2-3
021 Needle move Suspension of needle selection motor (1)Turn needle selection cam by hand to set to
022 in mid way. regular position.
Trouble in take-up lever hinders. (2)Fix needle selection related and take up lever
Trouble in sensor circuit board related troubles.
(3)Replace sensor circuit board. 4-2-3
024 Needle center Stop position of needle bar is off center (1)Turn needle selection cam by hand to set to
regular position.
(2)If trouble occurs repeatedly, fix mechanical
trouble in needle selection & its vicinity.
025 Needle over Specified needle number went beyond Adjust position of needle selection cam and
needle number of the machine. Photo interrupter on Needle bar change unit. 5-5-1
026 Needle differ As needle number differed from memory (1)Turn power off once and turn on again.
when power turned on, it was renewed. (2)Let the machine recognize needle number. 5-5-1
169
No. message Error measure page
030 Slow mismatch Inadequate adjustment of number of (1)Make automatic speed setting. Initializing
low speed revolution. (2)If not solved even after speed adjustment, (25-1)
Low speed revolution doesn't come replace CONT-** board ass'y.. (25-2)
below 100rpm.
050 C point Main shaft stops off its position. Turn main shaft to plus direction to set to C point. (24-4)
051 L sensor Poor lowest needle position sensor (1)If photo sensor is stained, clean. 4-2-1
on timing detecting circuit board. (2)Adjust timing. (25-1)
Damage in timing detecting circuit (3)Replace main shaft timing circuit board. (25-2)
board, stained photo sensor, poor (4) Initializing, Initializing of machine speed
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 direction. (2)Correct pattern size and setting contents.
090 Miss reception Error occurred when transmitting data. Let the machine read pattern data from first. (5-4)(5-6)
091 No send Data is not put in for over 10 seconds. Let the machine read data from first. (5-4)(5-6)
103 Data format The machine can’t judge format of (1)Check format of pattern data. (5-6)
pattern data. (2)By setting reading of pattern data, (10-3)
set format properly.
104 Miss function Timing to read pattern data doesn't Read pattern data again from the first. (5-4)
conform. (5-6)
105 Dual function One stitch data has more than 2 (1)Read pattern data again from the first. (5-6)
functions. (2)Check and modify the design data if there is wrong. (10-3)
108 Improper read While reading pattern data, there Read pattern data again from the first. (5-4)
accrued error in internal processing. (5-6)
110 Memory full While reading pattern data, memory Delete unnecessary patterns and read from (5-5)(5-B)
exceeded its capacity. the outset. (23-1)
170
No. message Error measure page
111 Change over While reading pattern data, the (1)Modify pattern data and reduce frequency of color
frequency of color change (color No.) change of one pattern to less than 250 times.
exceeded 250 times. (2)Divide pattern data and reduce frequency of color
change of one pattern to less than 250 times.
112 Data error Pattern data of pattern to be (1)Read pattern data again from the first. (5-4)(5-6)
embroidered is damaged. (2)Read pattern data again if you have
a backup data.
114 Id over The number of pattern in memory has Delete unnecessary patterns and read. (5-5)
reached maximum of 3000. (5-B)
118 Trace data over The stitch number counts over 1024 Set Embroidery area of pattern data within
stitches during preparing Trace data. 2m(X) x 2m(Y).
120 Memory error It became impossible to retain contents (1)Turn power off once and turn on again.
of memory. (2)If problem recurs frequently, replace SD memory 4-1-2
or LCD-** board. 4-1-1
130 Card error Incapable of disposing of USB memory (1)Turn off power source once and turn it on again.
continuously. (2)USB Memory reading processor may defective.

Replace the circuit board.
131 Card no ready USB Memory is not set. Check if USB memory is properly set. (5-5)
133 Bad card USB Memory is not proper or broken. (1)USB Memory might be not readable with the machine. (5-5)
Prepare readable USB memory for the machine.
(2)USB Memory card might be defective.

Prepare another memory card which is not defective.
(3)Initialize the USB memory if it is not initialized.
141 Not found name Designated pattern is not found. USB Memory might be not readable with the machine. (5-5)
Prepare readable USB memory for the machine.
190 Cut blade Thread cut knife is not at stop position. (1)Restore the moving knife to stop position. (24-5)
(2)Modify the adjustment if the problem repeats.
193 Catcher Thread catch hook is not in its (1)Check if mistake is found in thread cut. (24-6)
stop position. If found, cut thread and move thread catch
hook to proper position.
(2)Adjust and correct trouble that hinders motion
of thread catch hook.
171
Tables for timing / adjustment value 7-4-1
Tables for Timing/Adjustment value
Take-up lever timing 10 degrees
Rotary hook timing 25 degrees
Needle height 5 degrees
L LED2 light out at 0 degrees

Main shaft timing
C LED1 light on at 265-282 degrees
X 500cN
Carriage
Y 500cN
Timing belt -
Motor belt 320 – 330 g
172
Use TAJIMA made tubular frame 7-4-2
173
2020 / 10
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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Maintenance Manual for Embroidery Machine

In order to conduct adjustment and repair safely and surely,

# Please conduct in accordance with work process in this manual.

When you handle circuit boards:

Special tool, Measuring equipment, Other 7

3-2 Fixed head

3-2-18 Exchange of thread catcher 48

3-3 Moving head

3-4 Needle bar change unit

3-5 Rotary hook

3-6 Thread cut unit

3-8 Transmission unit

4-4 Initialization of system

4-5 Maintenance mode.

5 Electrical connection diagram 136

6 Explanation of function of circuit board 141

Thread guide bracket Thread guide pillar Tread stand

Needle plate Rotary hook Rotary hook cover

Needle bar change unit

Pressure foot driver unit

Pulse motor (Needle bar change unit) CONT-S3 board

Pulse motor (Pressure foot ) Power swich Noise filter AC power

Timing detecting board

Power supply Pulse motor (Thread catcher)

1. Remove thread guide bracket.

2. Loosen a screw of thread guide pillar

3. Remove thread guide pillar and thread stand.

<Check> Be sure to turn power switch OFF before

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

Please reverse procedure when installing control box.

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

5. Disconnect cable for X carriage. 8. Take off rubber cap.

10. Unlock nail of the cover (left) by pressing an arrow point of

the cover (right).

the picture. picture which fixes cover (right).

(1) Upper part of the cover

(2) Front part of the cover

Male nail shape Female nail shape

14. Remove cover (light). (Remove screw in arrow mark)

15. Remove the cover (right).

16. 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.

1. Thread tension, detecting roller

a) Revolution must be smooth

b) No sticking of lint or dust

a) No burr and crack

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.

3. Thread path in lower side and needle holder.

clearance (A) from side.

If clearance is not equal, needle is bent.

Please replace it with new one.

5. Needle plate 7. Rotary hook

b) Hook point not warped.

c) Backlash between bobbin case holder and outer hook