Berninas Happy Service Manual - 166b7 PDF

Happy HCS 1201-30 Voyager
Berninas Happy HCS 1201-30 Voyager Service Manual

The information contained in this Manual is designed to assist in operating, troubleshooting, and servicing the Happy HCS 1201-30 Voyager. The information given is not to replace, but to accompany the original Happy HCS 1201-30 Voyager User/Operation/Service manuals. Strict ESD guidelines given by the manufacturer MUST be adhered to when servicing the machines and handling the circuit boards.
For the use of authorized BERNINA dealers only Happy HCS-1201 Voyager handouts
Last Revised 3/8/2007
Page 1 of 32 2007 Bernina of America Inc.
Needle Position (Left/Right)

The needle should be in the center of the stitch hole. Note: Due to shipping and rough handling the entire head can be displaced.
With machine on, bring pressure foot down. (P.FOOT key on control box.)
Bring needle #6 down.

Turn upper shaft to set near to [0 degreesL point].
Loosen three screws of unit assembly.
Align so that needle is centered left/right in stitch plate.

Push the unit assembly to the front of the machine.
Retighten three screws. After performing adjustment, check hook/needle clearance.
Needle Position (Front/Back)

Needle should be centered in the needle plate. Note: Due to shipping and rough handling the head can be displaced.
Turn upper shaft to set near to [0 degrees-L point].
Needle Position (Front/Back)

Unplug and remove light, loosen two screws, move head unit so that needle is in the center of the stitch hole, retighten the two screws. Check and adjust with 1st, 6th and 12th needles. After performing adjustment, check hook/needle clearance.
Hook/Needle Timing and Clearance

Remove needle plate.
Front view
Hook Timing When the upper shaft is at [23 degrees], the hook tip should be flush with the left side of the needle.
Hook Clearance When the upper shaft is at [23 degrees], the hook needle clearance should be from [0.1 to .15 mm].

Turn upper shaft to set near to [23 degrees].
Loosen three screws on collar. Attain correct hook /needle timing and clearance, retighten screws. (Check with 1st, 6th, and 12th needles.)
Bobbin Case Retainer (Bobbin stopper)

Bobbin case retainer must be centered in bobbin case basket cutout and center to the needle. The distance from stopper to bobbin case is [0.8mm].
Needle Basket
Retainer stopper
Bobbin Case Retainer (Bobbin stopper)

Loosen the screws to the extent that retainer on bobbin case holder is able to move.
Adjust bobbin case retainer to attain correct position.
0.8mm feeler gauge
Needle Height
When upper shaft is at [60 degrees], the needle tip must be flush with the tubular needle plate. Remember there are 12 needles that must be checked and adjusted individually.
Remove lower front panel. (Two Phillips screws and the take up lever cover clip, two screws.)
Remove bobbin case.
Bring needle down.
Needle Height
Turn upper shaft to set dial disk to [60 degrees], at this point the needle tip must be flush with the standard needle plate.
Remove the lower front panel (Tip: pull 1foot of thread each needle and knot them together.) Loosen needle bar boss and adjust the needle height
Check that the needle holder does not touch the needle guard.
Needle Height Boss B

After setting the needle height, check the distance between needle bar boss and boss B. It must be exactly [25.1mm]. (Measure with a caliper.) Adjust boss B accordingly. Check that the movement of the needle bar moves smoothly. Remember there are 12 needles that must be checked and adjusted individually.
Height of Pressure Foot

Between the pressure foot and the standard needle plate, the distance is [1.2mm]. The foot should be centered with respect to the needle hole in the needle plate. Note: Check if the presser foot is not bent and the foot is in line with the needle before making any adjustments.
Note: There are two separate needle plates [cap needle plate and tubular (standard) plate]. Using either one, the pressure foot position has to be selected accordingly. Tubular position lower, cap position upper.
Height of Pressure Foot

- Move to needle position #1 - Lower the pressure foot - Pull needle bar down - Rotate hand wheel to [0 degrees] - Loosen the screw of the guide bar block - The distance between the foot and the standard needle plate must be [1.2mm] and the foot centered on the needle hole - Retighten the guide bar block screw
Thread Holder
Remove the lower front panel (Tip: pull 1foot of thread each needle and knot them together.)
Measure the distance of 48.4mm (+/0.1mm) between lower part of moving head and holder.
Loosen the screw on each side and move the thread holder. Prior to tightening, pull the bar toward the front.
Thread Holder
Lower the pressure foot and manually move the hook in and out to check if the hook moves smoothly and that that the hook is 1.2mm above the needle. Check with 1st, 6th and 12th needles.
(Positional relationship between hook and holder (lower).) 1.2 mm
Before making any adjustments, make sure the catcher hook is not bent. Adjust height of thread catcher device by loosening two Philips screws and moving the mechanism.
Bobbin Thread Holder

Open the moving knife and place a piece of thread in the knifes cutting path. Close the knife to cut the thread. The upper part of the thread is cut and the lower part of the thread is held by the pressure plate.
Bobbin Thread Holder

Pull bobbin thread toward arrow mark and see that bobbin thread comes off with the pull gauge approximately [2025gr].
Loosen locknut and adjust pressure plate. Tighten lock nut. (Note: The end of the pressure plate must be parallel with the stationary knife.)
Thread Cutter Timing (Moving Knife)

1 Thread cutter timing: Move upper shaft dial disk to [90 degrees], pull down and hold the lever (1), rotate the hand wheel disk until a defined stop can be felt. At this point the disk should be at [116 degrees]. 1
Remove the power supply.
Thread Cutter Timing (Moving Knife)

Loosen the set screw on the aluminum collar. Set dial disc to [116 degrees], turn thread cutting cam clockwise while pushing release lever down until as stop can be felt. Push the black cam to the left against the collar to eliminate any play between cam and collar. Then tighten the screw. Recheck the adjustment.
Collar
Adjusting Moving and Fixed Knife

Check if knife drive shaft has no play up and down. If play is found, adjust by moving the collar (1) on the bottom of the shaft.
Adjusting Moving and Fixed Knife

Check the pitch of the fixed knife by checking the cutting action using two polyester threads. Adjust by loosening the locknut and moving the knife with the set screw.
Adjust slant of fixed knife with upper adjustment screws.
Adjusting Position of Moving Knife

B C C In the rest position, the end of the moving knife has to be flush with the edge of the stationary knife (point D).
A has to clear B
D Loosen screw on link pin.
Turn link pin to adjust position of moving knife.
Adjusting Position of Moving Knife

Adjust the fixed knife for the edge A to clear the edge of B. Adjustment is done with screws C.
C C
A has to clear B
Adjusting Position of Keeper

Push the keeper toward the bobbin. The tip of the keeper should be 1mm away or just slightly touching the bobbin. Adjust by moving the keeper base.
1mm

With the Keeper/solenoid activated, check that there is [2.0mm] clearance between solenoid bracket and slider.
2 mm

To adjust, loosen screw on solenoid base.
Adjust to attain a [2.0mm] clearance between solenoid bracket and slider.
Checking and Adjusting the Bobbin Tension

Check the bobbin tension by holding the thread and letting the bobbin drop, the bobbin should drop down slowly. (Equivalent to 20gr.) Adjust by turning screw on bobbin.
20 gr.
Checking and Adjusting the Upper Thread Tension

Basic Tension Settings
Using a calipers check the distances between the center posts and the front of the tension dials. The distance for the upper tension dials should be approximately 3.0mm and for the lower dials approximately 4.0mm.
Checking and Adjusting the Upper Thread Tension

Final Tension Settings
To check tensions, use the design called Tension Test Design Htest12.dst. Sew out the design and check the sample. Adjust tension dials (Lower first, then upper) to attain a sample were the top thread showing on the bottom is minimal. (1/3 of top thread visible, 2/3 of bottom thread visible) The test design is posted on the extranet.

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Happy HCS 1201-30 Voyager

Berninas Happy HCS 1201-30 Voyager Service Manual

Last Revised 3/8/2007

Page 1 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Needle Position (Left/Right)

Bring needle #6 down.

Last Revised 3/8/2007

Page 2 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Needle Position (Left/Right)

Loosen three screws of unit assembly.

Align so that needle is centered left/right in stitch plate.

Last Revised 3/8/2007

Page 3 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Needle Position (Left/Right)

Retighten three screws. After performing adjustment, check hook/needle clearance.

Last Revised 3/8/2007

Page 4 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Needle Position (Front/Back)

Bring needle #6 down.

Turn upper shaft to set near to [0 degrees-L point].

Last Revised 3/8/2007

Page 5 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Needle Position (Front/Back)

Last Revised 3/8/2007

Page 6 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Hook/Needle Timing and Clearance

Bring needle #6 down.

Last Revised 3/8/2007

Page 7 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Hook/Needle Timing and Clearance

Last Revised 3/8/2007

Page 8 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Hook/Needle Timing and Clearance

Last Revised 3/8/2007

Page 9 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Bobbin Case Retainer (Bobbin stopper)

Last Revised 3/8/2007

Page 10 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Bobbin Case Retainer (Bobbin stopper)

Adjust bobbin case retainer to attain correct position.

0.8mm feeler gauge

Last Revised 3/8/2007

Page 11 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Remove bobbin case.

Bring needle down.

Last Revised 3/8/2007

Page 12 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager

Last Revised 3/8/2007

Page 13 of 32 2007 Bernina of America Inc.

Happy HCS 1201-30 Voyager