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Happy HCD2 trim issues

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Both our Happy HCD2 machines have the same issue. 

When trimming, the trim length is inconsistent either leaving tails or cutting too short and thread comes out of needle with next stitch. 

We have the new style knife, have been thru all kinds of tension adjustments, a few techs have looked at this and can not fix it. It has even been in the shop for that issue.

Any ideas?

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