Technical manual for the EMC 10/4 embroidery peripheral • • • Four Melco Embroidery Heads 10 Needles with automatic color change Automatic Trimmer Option European Compliance Version Part Number 110305-01, Revision A A Saurer Group Company
1575 West 124th Avenue Denver, Colorado 80234 United States of America Internet Address: publications@melco.com Copyright © Melco Embroidery Systems, 1996 ALL RIGHTS RESERVED No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise) without prior written approval of Melco Embroidery Systems.
Table of Contents 1. Introduction 1-1 Scope Of Manual Warranty Registration Standard Conventions Used In Manual Explanation Of Symbols Glossary Of Terms Maintenance Philosophy Static Electricity And Grounding Strap Use Warranty Considerations System Overview Physical/Functional Arrangement Configuring the EMC 10/4 Configuration Procedure 2.
Table of Contents Plunger Positioning Bracket Positioning Color Change Motor Belt Tension Thread Break Brush Adjustment Head #4 Head #s 1, 2, and 3 Trimmer Option Sequence of Trim Events Trimmer Set Up And Adjustments Z Timeout Errors Trimmers Not Trimming Properly Spring Knife Under Thread Presser Movable Knife Checking Select Position Select Position Adjustment Picker Finger Centering Picker Home Position Picker Height/Depth Position Grabber Adjustments Under Thread Control (UTC) Adjustments Rotary Hook
Table of Contents Head Section General Arm and Bed Assembly Z Motor Replacement Z Shaft Encoder Installation Thread Tree Assembly Removal Removing the Thread Tensioner Bracket Assembly Replacing An Individual Thread Tensioner Changing A Check Spring Replacing A Thread Break Contact Post Replacing The Thread Break Wiper Brush Head #4 Head #s 1, 2, and 3 Replacing A Needle Bar Needle Case Removal Head #4 Head #s 1, 2, and 3 Installing Needle Case Head #4 Head #s 1, 2, and 3 Replacing Needle Case Cross Roller
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1-1 1. Introduction Scope Of Manual The EMC 10/4 Embroidery Peripheral Technical Manual is designed to provide the user with information necessary to perform repairs beyond routine operator maintenance. The Melco EMC 10/4 Embroidery Peripheral is one of several embroidery peripherals in Melco’s EDS II and EDS III family of products. The EMC 10/4 is a four head embroidery machine, which is assembled with the Melco ten-needle, cylinder arm embroidery heads.
1-2 Explanation Of Symbols • Typing with the computer keyboard is referred to in BOLD letters, for example: Type: run and press Enter to start. • To indicate that two keys must be pressed simultaneously the following conventions are used: with the computer keyboard, the first key to be pressed and held down is simply referred to, then the second key which needs to be pressed while the first key is held down is referred to after a comma, for example: Press Shift,8 to type an asterisk (*).
Warranty Considerations 1-3 Glossary Of Terms Several words or terms are used in this manual that are unique or specialized in use with the embroidery industry or Melco embroidery equipment. A glossary of these terms is located in the appendix section of the EMC 10/4 Operation manual. Refer to that appendix for information on terms that may be unfamiliar to you.
1-4 System Overview Physical/Functional Arrangement The EMC 10/4 may be divided into several distinct physical and/or functional areas of description (see Figure 1-1). All the computerized controls are housed under the rear covers between the far left (#4) embroidery head and the second embroidery head from the left (#3). This area is called the Controller Section.
Configuring the EMC 10/4 1-5 The Under Carriage Section is described as that area under the embroidery head platform and within the frame support legs. The X and Y drive motors are positioned directly under the embroidery head platform between the middle two embroidery heads ( #2 and #3). In addition to the motors, the under carriage section contains the X, Y, and Z motor drive electronics inside the left frame support leg; and the AC power input module inside the right frame support leg.
1-6 System Overview The second configuration item is the network address (or Unit Number). The Unit Number must be set and be different for each peripheral attached to an EDS II or EDS III computer or network. There may be up to 64 (16 if using EDS II software) total embroidery peripherals attached to any one computer, and each must have its own Unit Number. The number is selected from the peripheral Keyboard and is between 1 and 64 (16 if using EDS II software).
Configuring the EMC 10/4 1-7 The peripheral will now be in the ‘‘configuration mode,’’ and you can release the 3 keys. NOTE: If the unit is already ON, but has not yet "downloaded," you need only to depress and hold the 3 peripheral keyboard keys until the unit beeps to get into the configuration mode, then proceed. You do not need to turn the EMC 10/4 OFF, then ON again.
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Physical/Functional Identification 2-1 2. Service Adjustments General This section of the manual provides detailed information for performing machine adjustments required during maintenance or parts replacement. The procedures are guidelines for performing service maintenance, and must be used by personnel practicing good maintenance technique.
2-2 Keyboard Section Keyboard Section Operator control of the EMC 10/4 is performed through the keyboard keys. The display, in turn, provides machine communication back to the operator. Display Screen Intensity Adjusting the intensity of the display requires the removal of machine covers to gain access to the adjusting potentiometer on the keyboard PCB. 1. Turn OFF the power switch to the EMC 10/4. 2.
Carriage Set Home Position 2-3 Carriage Section This section consists of the mechanical device and associated parts for securing and moving the hoops in the x and y coordinates during the stitching process. This assembly is sometimes referred to as the pantograph. The main cross member consists of 2 basic parts, the X carriage and the Y beam. The X carriage has the 4 hoop holders attached to it and the X carriage itself is secured inside the Y beam.
2-4 Carriage Section 5. Position the X carriage left/right movement to center the cap frame driver hoop notch directly over the cylinder arm cover of the embroidery head as shown in Figure 2-2. (If no cap frame driver, center the hoop attaching mechanism over the cylinder arm as best as you can determine.) Cap Frame Driver Cap Frame Guide Cap Frame Guide to Arm Cover centerline Arm Cover Needle Plate Figure 2 - 2 6. Loosen the 2 phillips screws at each X carriage belt clamp (see Figure 2-5).
X Drive Belt Tension 2-5 Front Support Bracket left side of the Most Forward Disk protruding the same amount as the right side right side of the Most Forward Disk protruding the same amount as the left side Figure 2 - 3 10. Refer to the following X Drive Belt Tension procedure to retension the belt. X Drive Belt Tension "FACTORY SERVICE ADVISED" Note: This procedure requires using a special service tool: the X-Belt Fixture, part number 995509-01. 1.
2-6 Carriage Section belt clamp Left X carriage section socket head cap screw phillips head screw (2 ea) X carriage belt Figure 2 - 4 7. With the carriage still centered, attach the X-Belt Fixture (p/n 995509-01) onto the x carriage belt, centered between the spline drive pulley and one of the end clamps as shown in Figure 2-5. socket head cap screw threaded insert X carriage belt phillips screws X-Belt Fixture (995509-01) embroidery head bed Figure 2 - 5 8.
Y Drive Belt Tensions 2-7 Y Drive Belt Tensions Note: This procedure requires the use of a special service tool: the Gates 5M Tensiometer, available from Melco, part number 992165-01. 1. Remove all table tops and move the Y beam all the way to the rear. 2. Properly attach a Gates 5M Tensiometer to the belt, midway between the beam and the idler pulley tensioning assembly (see Figure 2-6) and check the tension.
2-8 Under Carriage Section Under Carriage Section This section is physically located in and about the peripheral support framework. The X and Y motors are attached under the embroidery head platform, and the power supply and motor drivers are found inside the frame support legs at either end. X Motor Belt Tension Note: This procedure requires using a 0 to 40 pound special service tool pull gauge. 1. Loosen the 4 X motor socket head cap screws enough for the motor to move on the motor bracket.
AC Input Voltage Selection 2-9 Y Motor Belt Tension Note: This procedure requires the use of a special service tool: a 0 to 40 pound pull gauge. 1. Loosen the 4 Y motor socket head cap screws enough for the motor to move on the motor bracket. (Refer to Figure 2-7.) 2. Wrap a piece of small, strong cable or cord around the Y motor drive pulley of the side nearest the motor. 3. Form loops in the ends of the cable or cord and hook a 0 to 40 pound pull gauge into the loops. 4.
2 - 10 Under Carriage Section Power Supply +5 Volt Adjustment This adjustment is for setting the +5 volts required for all electronic control systems. NOTE: There is no adjustment for the +24 volts that is used to operate the color change motor, trimmers, and jump stitch solenoids. Tools Required: Digital Voltmeter and insulated alignment tool. 1. Remove Rear Cover #4 (Controller Section), then remove the EMI Box cover to access the CPU PCB.
Power Supply +5 Volt Adjustment 2 - 11 7. Locate the +5 volt adjustment potentiometer on the 500 watt power supply, directly above the DC connector block when viewed from the front of the machine through the two heads (see the illustration in Figure 2-10). +5 volt adjustment potentiometer POWER SUPPLY (Front View) DC connector block AC connector block Figure 2 - 10 8. Using the alignment tool, adjust the potentiometer to +5 volts +/- 0.05 (between +4.95 and +5.05 volts).
2 - 12 Head Section Head Section Within this defined section, you will find the embroidery heads and associated parts such as, the thread tree, thread tensioners, and needle cases, as well as the color change system, top thread break detection, and jump stitch devices. The heads are obviously the predominant ingredient needed in performing the actual embroidery stitching. They are precision built, finely tuned, mechanical devices designed for quality production.
Z Drive Mechanical System 2 - 13 At the left end of the Z drive shaft is a pulley, driven by a belt, which in turn is driven by the Z drive motor. Also at this end of the Z drive shaft is an in-line shaft encoder which detects rotational position of the shaft. The alignment and calibration of this mechanical system is critical for proper operation of the EMC 10/4 Embroidery Peripheral. Z Drive Motor Belt Tension Note: This procedure requires the use of a special service tool: a Gates 5M Tensiometer. 1.
2 - 14 Head Section 1. Remove the #4, and then the #5 rear covers. 2. With the 5 mm hex wrench, rotate the Z drive shaft to the HU position on the disk at the right end of the Z drive shaft (see Figure 2-13). disk position indicator Head Timing Disk at the right end of the Z Shaft Socket Head Cap Screw for 5 mm hex wrench Figure 2 - 13 3. Turn ON the peripheral and ensure the Z encoder is at the headup position with the Z drive shaft at HU.
Z Drive Mechanical System 2 - 15 7. Loosen the socket head cap screw in the locking collar of the bevel gear on the Z drive shaft associated with the embroidery head (see Figure 2-14). This will loosen the grasp of the Z drive shaft on the head. Z Shaft Bevel Gear Z Shaft Left Shroud socket head cap screw Z Drive Shaft (shroud removed) Locking Collar TOP, REAR of Head (gear box cover removed) Figure 2 - 14 8.
2 - 16 Head Section Z Encoder System Introduction The ability to place stitches precisely at high speed is dependent on the accurate operation of the electronics and electromechanical assemblies. The "key" to this is the Z encoder. The information provided to the CPU and 4 axis driver by the Z encoder is the basis for all the embroidery head activity. The Z Encoder is a two channel quadrature output with index pulse.
Z Encoder Inspection 2 - 17 Z Encoder Inspection "FACTORY SERVICE ADVISED" This procedure is a guide for determining the condition of the encoder. If unauthorized personnel attempt to service this area, the Factory Warranty May Be Voided if the work is improperly performed and damage occurs. Inspect the Z shaft encoder following the steps below. If the requirements of this process are not met, replace the encoder by following the Shaft Encoder Installation procedure in Section 3 of this manual. 1.
2 - 18 Head Section 9. Inspect the electrical connectors (encoder cable plug and encoder body) for loose wires, loose fits, and any visual damage. Clean connections and/or replace components as necessary. If the "test" above fails or is in question, contact your local Melco service representative for advise. Refer to Section 3 of this manual for the installation procedure for a new Z shaft encoder.
Thread Tensioner Check Spring Adjustment 2 - 19 5. Locate the third LED in from the end on the top left of the CPU. Most likely this LED will not be glowing. It is only supposed to glow for a 1 degree duration each revolution of the Z shaft encoder. 6. Slowly rotate the heads at the 5 mm socket head cap screw in the right end of the Z drive shaft until the headup alignment pin tool inserts into the hole in the headup alignment collar on the Z shaft. This is the "mechanical" headup position for head # 4.
2 - 20 Head Section 2. Rotate the thread tensioner to the position where the check spring is just touching the left side of the thread break contact (brass post). See Figure 2-18. check spring just touching thread break contact 2 spokes rotation 2 spokes 1 spoke thread tensioner (front view) 0 spoke Thread Check Spring rotating disk thread tensioner (side view) thread break contact post Figure 2 - 18 3.
Cross Roller Bearing Centering 2 - 21 Cross Roller Bearing Centering The cross roller bearing must be installed between the embroidery head v-rail and the needle case v-rail attached to the retainer plate. When these two are slid together and the retainer plate is centered on the head, the cross roller bearing must be centered (equal distance from each end of the rails). 1. With the needle case and retainer plate assembly removed, lay the cross roller bearing onto the embroidery head v-rail.
2 - 22 Head Section 6. Check that the cross roller bearing is centered in the 2 v-rails by the following method: a) Center the retainer plate assembly on the embroidery head v-rail. b) Carefully insert a solid instrument, such as a straight hex wrench, into the opening at one end where the two v-rails join. Insert the instrument until it contacts the cross roller bearing. Do not force it any further.
Retainer Plate Bearing Adjustment 2 - 23 socket head cap screws retainer plate bearing (left side) retainer plate assembly (cross roller installed and centered) needle case V-rail retainer plate bearing (right side) v-rail adjustment fixture install v-rail adjustment fixture here embroidery head V-rail Figure 2 - 20 5. Carefully and slowly rotate the v-rail adjustment fixture (either clockwise or counter-clockwise) until you feel a slight resistance.
2 - 24 Head Section A5. Loosen the V-rail socket head cap screw on the side you are attending. (With the upper needle case cover off, you can reach the screw through the front of the needle case.) Needle Case right side plate pry lightly with a flat blade screw driver here A6. Lightly pry in this area and retighten the socket head cap screw. needle case V-rail A7. Check the adjustment as described in step 7 and repeat until it is properly achieved. A8.
Jump Stitch Solenoid 2 - 25 1. Install the needle case into the lower rail retainer and attach the needle case to the retainer plate assembly. Refer to Section 3 in this manual on installing the needle case assembly. 2. Loosen the screw under the lower rail retainer (see Figure 2-22) and push it toward the rear to remove the play between the retainer and the lower rail of the needle case. Note: If you have the trimmer option, you will have to remove the grabber blade guide assembly to access the screw.
2 - 26 Head Section Gap 0.015"- 0.045" (0.4 - 1.1 mm) solenoid bracket Needle Bar Driver Reciprocator Jump Stitch Solenoid locking nut Drawing Not To Scale Figure 2 - 23 Bracket Positioning When attaching the jump stitch solenoid and bracket, it is not only necessary to place the plunger correctly, but you must also position the assembly in the proper forward to backward relationship.
Color Change Motor Belt Tension 2 - 27 3. Attach the solenoid wires to the color change PCB on head #4 or the thread break harness connection on the other embroidery heads. Note: The two wires coming from the solenoid body and connecting at the small black plastic connector, can be damaged if they are twisted together. Twisting the wires together will reduce their length and can put undue stress at the connections at both ends. We therefore do not recommend twisting these wires together.
2 - 28 Head Section Thread Break Brush Adjustment Head #4 The thread break brush must be adjusted to make proper contact with the thread break contact posts coming off the rear of the thread tensioner assembly PCB. 1. Put the needle case in any selected needle position. 2. Loosen the thread break brush bracket mounting screws at the color change PCB (see Figure 2-25). Thread Break Brush Thread Break Contact Post Thread Break Brush Bracket Mounting Screws Color Change PCB Figure 2 - 25 3.
Thread Break Brush Adjustment 2 - 29 2. Loosen the thread break brush bracket mounting screws at the top of the head (see Figure 2-26). Thread Break Contact Post Thread Break Brush Bracket Mounting Screws Thread Break Brush Thread Break Brush Bracket Figure 2 - 26 3. Position the thread break brush so it is centered directly under the selected needle thread break contact post coming from the thread tensioner assembly PCB. 4. Tighten the thread break brush bracket mounting screws securely.
2 - 30 Head Section Trimmer Option The trimmer option for the EMC 10/4 Embroidery Peripheral is assembled and thoroughly tested before the machine is shipped. Although the set up of the trimmers should not change during normal use, there are a few things to be aware of to prevent problems. • Dirt, dust, and thread lint debris can build up and prevent the movable knife (in the rotary hook assembly) from actuating correctly. Keep the area clean and you shouldn’t have a problem.
Trimmer Option 2 - 31 7. At approximately the same time the threads are being cut and the beam is moving to clear the tail, the grabber reaches out from behind the needle area and "grabs" the tail, pulling it up and back into the Velcro wiper strip. 8. When the trim is complete the peripheral begins embroidering again automatically. Trimmer Set Up And Adjustments The following procedures provide a guide for adjusting various portions of the trimmer system.
2 - 32 Head Section Damaged Trimmer Cam or Trimmer Solenoid To check for a damaged trimmer cam or trimmer solenoid, refer to the following procedure: 1. Remove the rear bed cover of the head to expose the trimmer camming area as seen in Figure 2-27. solenoid pin end shown engaged in cam groove Drill hole in rear of cam.
Trimmer Option 2 - 33 You should not feel any restrictions during the rotation. If you do, you may have a damaged trimmer cam or trimmer solenoid. NOTE: You may remove the trimmer solenoid for inspection or replacement. However, when the trimmer solenoid mount is moved, the movable knife home position may become mis-adjusted. 8. Go to the Mechanical Disassembly section of the manual for the procedure to replace the trimmer solenoid. 9.
2 - 34 Head Section Physical Condition Of Trimmer Parts Component Identification Figure 2-28, identifies those components that comprise the trimmer system: the spring knife, movable knife, and the under thread presser. These components are covered by the front bed plate and the needle plate (see inset in Figure 2-28). Remove the screws holding these covers to gain access to the trimmer area. You may test the trimmer adjustments without the covers in place, but they must be installed to embroider.
Trimmer Option 2 - 35 2. Pull the movable knife forward with a small hex wrench hooked behind it. 3. With a black marking pen mark the areas of the movable knife as shown in the left illustration of Figure 2-29. Apply Ink in these areas of the Movable Knife ink wipeoff in this area Spring Knife tilted left ink wipeoff in this area Spring Knife tilted right ink wipeoff in these areas Spring Knife OK Figure 2 - 29 Ink Wipeoff Test 4.
2 - 36 Head Section 3. Obtain a piece of upper thread from the tensioner assembly and drape it over the movable knife (see Figure 2-30). 2. Push Movable Knife back with your thumb or forefinger, to cut the thread. 1. Drape some Thread over the Movable Knife from front to back. Figure 2 - 30 Checking The Cut 4. With the thread draped over the movable knife from back to front, gently hold the thread so there is some slack and then push the knife back until the thread is cut.
Trimmer Option 2 - 37 Under Thread Presser The under thread presser, shown in Figure 2-31, holds the bobbin thread after a trim. This permits a loop of bobbin thread for the next stitch. While the under thread presser holds the bobbin thread there should only be enough pressure applied to hold the thread in place under the movable knife. If the under thread presser is damaged it can cause problems that look like tension troubles.
2 - 38 Head Section The second part of checking under thread presser is to check if the bobbin thread is in fact being held in place. 1. While the machine is still turned OFF, remove the font bed cover and disconnect the connecting link from the movable knife drive arm by lifting it from the front pin (see Figure 2-28.) 2. Pull the movable knife forward with a small hex wrench hooked behind it. 3.
Trimmer Option 2 - 39 4. Go to the TRIM MENU and perform a TRIM IMMEDIATE command. 5. The movable knife should be located under the spring knife, positioned as shown in Figure 2-32. If the sloped rear tip of the movable knife is not showing in front of the leading edge of the spring knife, the "home" position needs to be adjusted. DO NOT Adjust if the knife position looks like Figure 2-32.
2 - 40 Head Section solenoid pin end shown engaged in cam groove Engage solenoid pin into cam groove by pushing here with flat bladed screw driver Indicator Tab trimmer solenoid Photo Sensor Movable Knife "home" position indicator adjustment screws Connecting Link screws for adjusting Movable Knife "home" position Figure 2 - 33 Home Position Sensor If the movable knife is mechanically adjusted correctly for home position, but the "Trimmer Not Home" message comes ON, the home position sensor needs ad
Trimmer Option 2 - 41 Checking Select Position After adjusting the movable knife home position, you must check for the movable knife "select" position. If adjustment is required it is recommended that Melco factory-trained personnel be consulted. 1. Replace the standard needle plate on the embroidery head arm (See Figure 2-28). Do not install the raised needle plate used with cap frames. 2. Turn the machine power ON. 3. Go to the HEAD TIMING MENU and press to turn HEAD TIMING ON. 4.
2 - 42 Head Section Select Position Fixture (p/n 995372-01) this pin fits into the top of the needle plate hole. Movable Knife "select" position (with the rear of the blade against the fixture pin Needle Plate (Do not install the raised needle plate) fixture installed in needle plate hole Figure 2 - 34 13. If the movable knife does not contact the fixture between 311 and 313, or contacts too soon, the select position adjustment may be required.
Trimmer Option 2 - 43 3. Loosen the large socket head cap screw in the locking collar for the Top Bobbin Drive Pulley (see Figure 2-35) and rotate the belt and pulley slightly until the movable knife just contacts the select position fixture (see Figure 2-34). Top Bobbin Drive Pulley socket head cap screw 4. Stop rotating and hold the belt and pulley in place while you tighten the large socket head screw in locking collar to 45 inch lbs (6.22 km) of torque.
2 - 44 Head Section 2b. With both trimmers and cap frame options on the machine, move the bracket to center the installed cap frame driver on the embroidery head arm. 3. Retighten the screws. Left Side View Front View The Picker should be centered on the Bobbin Shaft.
Trimmer Option 2 - 45 Picker Height Picker Home Picker Depth Front End Bobbin End Picker Fixture Picker Depth Position Picker Home Position Picker Height Position locking hex nut socket head cap screw Figure 2 - 37 1. To adjust the picker height/depth position, manually push the picker into place as shown in Figure 2-37. 2. Loosen the 2 screws on the left side of the picker as shown in Figure 2-36. 3. Position the height of the picker against the fixture location shown in Figure 2-37. 4.
2 - 46 Head Section 3. Manually move the grabber motor limit stop lever up to move the grabber blades all the way out and then down to move the blades back again. (see Figures 2-38 and 2-39). Motor Limit Stop Lever UP (grabber blades out) Grabber Blade out Figure 2 - 38 Motor Limit Stop Lever DOWN (grabber blades retracted) Grabber Blade retracted Figure 2 - 39 If you notice any binding in grabber blade movement, find the mechanical bind and correct it before continuing.
Trimmer Option 2 - 47 To Adjust For A: 1. Position the grabber blades as far back as they will go into the grabber blade guides by manually moving the motor limit stop lever down as shown in Figure 2-39. 2. Locate the socket head cap screw in the end of the grabber blade guide (see Figure 2-50). grabber blade guide Grabber Blade Guide grabber blade hook portion socket head cap screw Velcro Wiper Bar 1 1/2 to 2 1/2 mm (.060 - .100 inches) grabber blade hook portion FRONT VIEW Figure 2 - 40 3.
2 - 48 Head Section Grabber Blade Transition Bracket and Guide Rod at rear of head Figure 2 - 41 4. Tighten the set screw in the wire swivel. 5. Replace all covers after making the grabber adjustments. Under Thread Control (UTC) Adjustments It is very important that you follow these instructions any time the rotary hook retaining finger or UTC is loosened or moved. Please follow the instructions in the order they occur.
Under Thread Control (UTC) Adjustments 2 - 49 5. Place the finger of the UTC combination gauge (see Figure 2-43 for diagram of the gauge) between the retaining finger tab and the rotary hook inner basket notch (see Figure 2-42). inner basket notch needle TOP VIEW of UNDER THE NEEDLE PLATE rotary hook assembly 0.020" gauge finger CL retaining finger tab centerline of tab and needle UTC Assembly place gauge finger here to obtain proper gap Figure 2 - 42 6.
2 - 50 Head Section 11. Refer to Figure 2-44 and lift the connecting link off of the movable knife assembly. UTC detection arm connecting link movable knife lift connecting link here Figure 2 - 44 12. Check that the movable knife clears the UTC detection arm by physically moving the knife under the UTC detection arm and back. 13. If the knife touches the arm, reshape the arm slightly until it clears then repeat steps 9 through 12. 14.
Sew Test 2 - 51 Additionally, if the bobbin tension is set too loose, it may also falsely indicate that the machine is out of bobbin thread when it has bobbin thread. Preliminary Checks The following must be checked before performing the embroidering: 1. Check that the bobbin tension is within the proper adjustment specifications as described in the operation manual. 2. Verify that the BOB. COUNT in the BOBBIN MENU is set to 5.
2 - 52 Head Section B) Check that the UTC does not falsely signal the CHECK BOBBIN message when thread is still on the bobbin. 1. Test for this by simply sewing with the test design. For reliable results, embroider the design for at least 5 minutes, or about 4000 stitches at 750 stitches per minute. 2.
Static Electricity / Grounding Strap Use 3-1 3. Mechanical Disassembly General This section of the manual provides detailed information for performing parts replacements that may be required during the life of the product. The procedures are guidelines for performing repair maintenance; and must be used by personnel practicing good maintenance and repair technique.
3-2 Embroidery Peripheral EMI box flange Grounding strap alligator clip Figure 3 - 1 Embroidery Peripheral Removing the Rear Covers The rear covers are attached to the peripheral frame with plastic tabs in the front of the covers and with machine screws on the back side of the covers (see Figure 3-2).
Removing the Tensioner Covers 3-3 Controller Section Rear Cover #4 Rear cover #4 covers the Controller Section which houses the EMI (Electro-Magnetic Interference) box and its printed circuit boards. As with other covers, it is attached with screws at the rear and tabs on the front. Cover #4 overlaps covers #3 and #5, and is the first of the 5 covers to be removed and becomes the last cover installed.
3-4 Embroidery Peripheral 2. To remove any or all of the lower front covers (between needle cases), remove the 2 screws (c) for each cover. Pull down slightly on the cover to remove the pin in the top of the cover from the grommet in the bottom of the upper front cover (between the tensioner brackets), then carefully remove the lower front cover from the area. 3.
EMI Box Cover Removal 3-5 Controller Section Caution: When the EMI box cover is removed, three printed circuit boards are exposed. These are the CPU, the trimmer interface board, and the backplane board. DO NOT TOUCH THE BOARDS WITHOUT USING ANTISTATIC PRECAUTIONS. Caution: Never run the embroidery peripheral without the electronics cover in place. The cover forms the top of the EMI shield around the boards to reduce RF interference.
3-6 Controller Section CPU PCB Replacement 1. Turn OFF the power switch to the EMC 10/4 and remove the power cord from the power source electrical outlet and the rear of the machine. 2. Remove the controller section rear cover #4 as previously described. 3. Remove the EMI box cover as previously described. CAUTION! Failure to use a properly installed static grounding strap may cause damage to the electronics in the EMC 10/4. 4.
Trimmer Interface Board Replacement 3-7 CAUTION! Use care not to drop any hardware into the base of the Controller area. 7. Remove the various ribbon cables from the connectors on the CPU PCB. 8. Grasp the CPU PCB at the top corners of the board and carefully pull the board up and out of the card edge connectors mounted on the backplane PCB at the bottom of the EMI box. (Use a gentle rocking motion to make it slightly easier to release the board from the connectors.
3-8 Keyboard Section CAUTION! Once the Trimmer Interface board is removed from the EMC 10/4, use extreme care in handling it. Portions of this board are very sensitive to static charges. Any further handling of the Trimmer Interface board must be done with the continued use of the static grounding strap still installed as instructed in specific procedures in this manual. 8. To replace the Trimmer Interface board, perform the previous steps in reverse order.
Keyboard/Display Replacement Keyboard Cover 3-9 attaching screw and hardware (1 of 4) Keyboard Assembly standoff (1 of 4) zener diode assembly from keyboard PCB ground wire to the bottom of keyboard cover Figure 3 - 6 7. Refer to Figure 3-6 inset and remove the zener diode assembly ring terminal from the top of the #2 head needle case. 8.
3 - 10 Carriage Section Carriage Section This assembly and its installation to the peripheral requires specific factory tooling and training to maintain the assembly’s parallelism with the rest of the peripheral. Portions of the carriage assembly may be disassembled to replace various parts without sacrificing the overall orthogonal integrity. X Drive Belt Replacement "FACTORY SERVICE ADVISED" NOTE 1: The carriage assembly must be partially removed to replace the x carriage drive belt.
X Drive Belt Replacement 3 - 11 7. Lift the x carriage and y beam off the 3 supports and lay it up side down across the 2 end table top sections. 8. Remove the socket head cap screw and 2 phillips head screws at the remaining x drive belt clamp. 9. Remove the x drive belt clamp from ONLY ONE END of the old belt. Leaving one clamp on the old belt will provide you with a guide to work from when installing the first clamp on the new belt. 10.
3 - 12 Carriage Section 12. Remove the remaining clamp from the old belt and perform the previous procedure to attach the clamp to the other end of the new belt. 13. Attach the new x drive belt and clamp to ONLY ONE END of the x carriage by loosely attaching the socket head cap screw and 2 phillips head screws at the remaining x drive belt clamp. 14.
Y Drive Belt Replacement 3 - 13 4. Remove the two screws, flat washers, and lock washers at the top of the Y-belt bracket. These screws go through the belt and into the belt clamp underneath the belt to secure the Y drive belt between the two pieces. Y Belt screws, and hardware attaching belt to clamp Belt Clamp (underneath) Y Belt Bracket Figure 3 - 10 Caution: Overtightening the screws in the next step may cause the belt clamp to be damaged. 5.
3 - 14 Under Carriage Section Under Carriage Section X and Y Drive Motors and Belts The X and Y Drive motors are located below the embroidery heads and table top. The X motor provides "side to side" motion of the hoop carriage. The Y motor provides "front to back" movements of the pantograph (Beam). "FACTORY SERVICE ADVISED" Special tools are required for proper adjustment. Tools Required: A zero to 40 lbs. spring scale, 12 inch length of strong cord or cable, a set of socket head wrenches. 1.
X Y Z Motor Drives 3 - 15 6. Loosen the pulley set screws and remove the pulley from the motor shaft. 7. Place the pulley on the new motor shaft and tighten the pulley set screws. 8. Put the new motor in place in the support bracket and slip the drive belt over the pulley. Insure the other end of the drive belt remains on the pulley associated with the x or y mechanism. 9. With the existing hardware, attach the motor to the bracket, but DO NOT tighten the four socket head cap screws at this time. 10.
3 - 16 Under Carriage Section 2. WAIT ONE MINUTE, then remove the cover over the XYZ motor driver section inside the left frame support leg (see Figure 3-12). XYZ Motor Driver Section (inside left frame support leg) 3. Disconnect the harnesses and remove hardware associated with the defective XYZ motor drive PCB (see Figure 3-13). 4. Remove the defective XYZ motor drive module.
Power Supply Replacement 3 - 17 Power Supply Replacement The power supply is mounted under the top cover between heads #1 and #2. To remove the power supply assembly: 1. Turn the peripheral OFF and disconnect the power source. 2. Remove top cover #2 between heads #1 and #2. 3. Disconnect the AC and DC wiring (see Figure 3-14). DC Wiring POWER SUPPLY (Front View) AC Wiring self gripping posts Figure 3 - 14 Power Supply Section 4.
3 - 18 Head Section Head Section General The Melco embroidery head consists of several physical assemblies. This section of the manual describes the removal and replacement of most of the major assemblies of the head. Figure 3 - 15 Head Section Arm and Bed Assembly The arm and bed assembly provides a stable embroidery head platform. All other components of the heads are attached to this assembly. Inside the arm and bed assemblies are the shafts, belts, and pulleys that drive the needle and rotary hook.
Z Motor Replacement 3 - 19 Z Motor Replacement "FACTORY SERVICE ADVISED" Special tools are required for proper adjustment. Note: This procedure requires the use of a special service tool: a Gates 5M Tensiometer. 1. Turn the main power OFF, and remove the power source cable from the power supply assembly. 2. Remove the #4 rear cover, then the #5 rear cover (refer to the procedure for cover removal if information is needed). 3.
3 - 20 Head Section 8. Put the new motor in place in the support bracket and slip the drive belt over the pulley. Insure the other end of the drive belt remains on the pulley associated with the z drive mechanism. 9. With the existing hardware, attach the motor to the bracket, but DO NOT tighten the four socket head cap screws at this time. 10. Remove the motor pulley set screws and apply Loctite 222 or equivalent screw adhesive, then reinstall the set screws. 11.
Z Shaft Encoder Installation 3 - 21 encoder mount Jam Nut Z encoder shaft socket head cap screws (1 of 2 shown) Z Encoder shaft coupling Z Encoder Cable Figure 3 - 17 8. Insert the new encoder/shaft into the hole of the encoder mount, place the washer and then the jam nut onto the encoder shaft as you insert the shaft through the mounting plate. 9. Insert the encoder shaft into the shaft coupling. 10. Tighten the jam nut, and then snug the coupling socket head cap screws onto the encoder shaft. 11.
3 - 22 Head Section Thread Tree Assembly Removal If you need to remove the thread tree for any reason, refer to the following procedure: 1. Turn OFF the EMC 10/4 and disconnect the power cord from its power source. 2. Carefully grasp the thread guide tubes individually and remove them from behind the thread tensioner assembly by pulling on each thread guide tube (see Figure 3-18). 3 screws thread guide tubes thread tree thread tree bracket thread tensioner assembly Figure 3 - 18 3.
Removing the Thread Tensioner Bracket Assembly 3 - 23 Removing the Thread Tensioner Bracket Assembly The thread tensioner bracket assembly is attached to the top of the needle case. To remove the tensioner bracket assembly refer to the procedure that follows. 1. Turn OFF the EMC 10/4 and disconnect the power cord from its power source. 2. Remove the side, rear, end, and front covers from each side of the head where the tensioner bracket is coming off (refer to cover removal section. 3.
3 - 24 Head Section Replacing An Individual Thread Tensioner Each thread tensioner is secured by a set screw against the thread tensioner shaft inside the thread tensioner bracket. The set screw is accessible through a slot at the top of the tensioner bracket. 1. Using a 2.5 mm hex wrench, loosen the set screw associated with the thread tensioner to be removed (see Figure 3-20).
Changing A Check Spring 3 - 25 3. Attach the new check spring as follows: a) Position the check spring around the end of the tensioner shaft as shown in Figure 3-21. b) Insert the straight length of spring wire that is inside the check spring coil into the groove cut in the tensioner shaft as shown. straight spring wire into groove in tensioner shaft Thread Tensioner Check Spring Thread Tensioner shaft Figure 3 - 21 4.
3 - 26 Head Section Replacing A Thread Break Contact Post 1. As described previously in this manual, remove the thread tensioner associated with the thread break contact post to be replaced. 2. Remove the thread break contact post (see Figure 3-22) by rotating it counter-clockwise out of its location in the thread tensioner bracket. SHOWN WITH #10 TENSIONER REMOVED Thread Tensioner Bracket Thread Break Contact Post Figure 3 - 22 3.
Replacing The Thread Break Wiper Brush 3 - 27 Replacing The Thread Break Wiper Brush Head #4 1. Remove the two color change covers. 2. Locate the thread break wiper brush attached to the bracket coming from the color change PCB (see Figure 3-23). color change PCB thread break wiper brush bracket thread break ground wire flat washer thread break wiper brush attaching screw star washer Figure 3 - 23 3.
3 - 28 Head Section Head #s 1, 2, and 3 1. Remove the covers per the cover removal section. 2. Locate the thread break wiper brush attached to the thread break wiper brush bracket (see Figure 3-24). thread break wiper brush support bracket thread break wiper brush bracket thread break wiper brush thread break ground wire attaching screw star washer Figure 3 - 24 3. Remove the thread break brush by removing the screw, thread break ground wire, and associated hardware that secures it to the bracket.
Replacing A Needle Bar 3 - 29 3. Refer the the procedure for removing the thread tensioner assembly and remove is as described in the procedure. 4. Remove the 2 screws holding the upper needle case cover plate and set the cover plate aside (see Figure 3-25). upper needle case cover screws lower needle case cover screws Figure 3 - 25 5. Loosen one screw and then remove the other screw holding the lower needle case cover plate and set the cover plate aside.
3 - 30 Head Section 10. Carefully capture and retain the various parts that become released by the needle bar as you remove the needle bar upward and out the top of the needle case. Top Screw ** Needle Bar Holding Spring Needle Bar ** Note: The end of each spring with the Flat Washer smaller coil faces up. Felt Pad Upper Needle Case casing Needle Case Damper - 11. Transfer the screw from the top of the old needle bar to the top of the new needle bar.
Needle Case Removal 3 - 31 Needle Case Removal It may become necessary to remove the needle case from the front of the head to replace the needle bar driver, take up lever gear, needle bar reciprocator, or other associated parts. Refer to the following steps and Figures 3-27 and 3-28 to remove the needle case from embroidery head. Head #4 1. Turn ON the EMC 10/4 and bring the head to the HEADUP position. 2. Turn OFF the EMC 10/4 and disconnect the power cord from its power source. 3.
3 - 32 Head Section tensioner support bracket upper needle case cover screws embroidery head v-rail (left end) clamping devices on ends of v-rail bearing retainer plate assembly (left side) Figure 3 - 27 2 screws holding sensor interrupter blade Sensor Interrupter Blade Retainer Plate Assembly socket head cap screws (4 each) Needle Case Needle Case Lower Rail Lower Rail Retainer (on embroidery head arm) Figure 3 - 28 EMC 10/4 Technical Manual Melco Embroidery Systems
Installing Needle Case 3 - 33 3. Remove the thread tensioner bracket assembly as described in a previous procedure. 4. Position the needle case to mid-point (needle 5 or 6), then secure the bearing retainer plate assembly from sliding left or right by placing any workable clamping devise onto each end of the V-rail. 5. Remove the 2 screws holding the upper needle case cover plate and set the cover plate aside. 6.
3 - 34 Head Section 3. Rotate the upper part of the needle case into position on the front of the head as you insure the following alignments: a) All the take up lever slots are positioned onto the take up lever guide rail and the active take up lever gear teeth are engaged with the take up lever drive gear teeth. With the head still in the headup position, insure the top tooth of the take up lever drive gear engages with the 5th "valley" of the take up lever gears.
Installing Needle Case 3 - 35 Head #s 1, 2, and 3 1. Insure the following conditions are set: a) The cross roller bearing is properly installed and centered. Refer to Section 2 of this manual for adjustment procedure. b) The retainer plate assembly bearings are properly adjusted. Refer to Section 2 of this manual for adjustment procedure. c) The bearing retainer plate assembly is clamped from moving left or right by a clamping device on each end of the V-rail.
3 - 36 Head Section Replacing Needle Case Cross Roller Bearing Refer to the figures within the needle case removal and installation procedures for this procedure. 1. Remove the needle case as described previously in this manual. CAUTION! In the next step, some needle cases may become free to move off the sides of the embroidery heads if bumped. To account for this possibility, you should attach a clamping device on the outside ends of the v-rails of any embroidery heads that are put into this situation.
Replacing Reciprocator / Needle Bar Guide Shaft 3 - 37 Replacing Reciprocator / Needle Bar Guide Shaft 1. Remove the needle case as described previously in this manual. 2. Loosen the set screw from the left side of the head that secures the needle bar guide shaft (see Figure 3-30). Guide Shaft flat Connecting Rod (behind the guide shaft) Reciprocator Needle Bar Guide Shaft groove in guide shaft for Retaining Clip Set Screw in left side FRONT VIEW Figure 3 - 30 3.
3 - 38 Head Section 9. Install the needle bar guide shaft as follows (see Figures 3-30 & 3-31): a) Insert the guide shaft down through the hole in the top of the head. b) Insert the guide shaft through the reciprocator. c) Insert the guide shaft down through the roller bearing. 10. Turn the needle bar guide shaft until the flat near the top faces the left side of the head (see Figure 3-30). 11. Pull the needle bar guide shaft down until it seats into the lower hole. 12.
Jump Stitch Solenoid Replacement 3 - 39 Jump Stitch Solenoid Replacement If a jump stitch solenoid must be replaced, follow these steps: Head #4 1. Remove the left color change cover behind the tensioner bracket assembly by first loosening the top two screws then removing the side two screws. 2. Cut any and all cable tie wraps holding the jump stitch harness, then disconnect the jump stitch harness connector from the color change PCB.
3 - 40 Head Section Jump Stitch Solenoid and Bracket record solenoid threads here Jump Stitch Solenoid cover 2 screws of the solenoid bracket. Jump Stitch Solenoid locking nut Figure 3 - 34 5. Loosen the solenoid locking nut then rotate the bracket off of the solenoid. 6. Replace with new solenoid by reversing the previous procedure. Adjust the position of the solenoid into the solenoid bracket using the "thread counts" or measurement you obtained in that procedure (see previous NOTICE). 7.
Color Change PCB Replacement 3 - 41 NOTICE: Before you remove the solenoid from the bracket, record the number of threads of the solenoid that are showing beyond the solenoid bracket (or measure the distance that the end of the solenoid protrudes from the solenoid bracket). When the new solenoid is installed into the bracket, position the solenoid with the same number of threads (or distance) that you recorded in this step. 4. Loosen the solenoid locking nut then rotate the bracket off of the solenoid. 5.
3 - 42 Head Section color change cover (left side) top two screws (color change cover) color change PCB color change cover (right side) side two screws (color change cover) side two screws (color change cover) Figure 3 - 35 6. Locate and disconnect the thread break harness from the rear of the thread tensioner PCB. CAUTION! The Color Change PCB is snapped into place on top of the color change bracket. Be careful not to damage the LED sensors or any other components when removing the PCB. 7.
Color Change Motor Replacement 3 - 43 4 catch pins holding color change PCB Transfer the thread break brush assembly by removing 2 screws. Be sure to transfer the 2 nylon spacers under the bracket to the new PCB for insulation of the bracket from the PCB circuits. color change PCB Figure 3 - 36 11. Reinstall the thread break harness connection to the thread tensioner PCB, then refer to Section 2 of this manual to adjust the thread break contact brush position. 12.
3 - 44 Head Section 2 pulley set screws 4 motor mounting screws color change motor drive belt motor drive pulley Figure 3 - 37 4. When the motor is loose, pull off the drive belt. 5. Loosen the pulley set screws and remove the motor drive pulley. 6. The motor is now loose and can be removed. 7. Replace the motor and reverse the preceding steps. 8. Refer to the color change motor belt tension adjustment procedure in Section 2 of this manual and adjust the belt. 9.
Trimmer Assemblies 3 - 45 color change bracket (with cam) 2 color change bracket screws color change mount key Figure 3 - 38 5. Lay the color change mount key into the embroidery head key way, then put the new color change bracket (with the cam) into position. 6. Ensure the needle case is positioned with the needle centered in the needle plate hole by moving the color change bracket to obtain the needle centering, then tighten the color change bracket screws.
3 - 46 Head Section Figure 3 - 39 Grabber Drive Assembly Grabber Blade 1. Remove the 4 screws and take off the top grabber blade cover. 2. Remove the two button head screws that secure the grabber blade to the grabber drive assembly where it enters into the embroidery head arm casting (See Figure 3-40).
Trimmer Assemblies 3 - 47 3. Remove the 4 screws to free the front grabber blade cover (see Figure 3-41). Slide the grabber blade out of the grabber blade guide (just behind the Velcro wiper bar) as you remove the cover and grabber blade. the finger is pointing to the grabber blade top grabber blade cover front grabber blade cover grabber blade guide Velcro wiper bar Figure 3 - 41 4. Reverse order of the previous steps to replace the grabber blade.
3 - 48 Head Section Trimmer Drive Assembly Trimmer Cam FACTORY SERVICE ADVISED! This assembly is mounted under the head in the rear bed. To remove this mechanical assembly requires several steps, including removing the embroidery head from the frame. A factory trained technician is recommended for removal and installation of parts in this area. Trimmer Solenoid NOTE; When the trimmer solenoid mount is moved, the movable knife home position may become mis-adjusted.
Trimmer Assemblies 3 - 49 5. Loosen the hex nut between the the solenoid body and the mount, then rotate the solenoid assembly out of the mount. 6. Rotate a new solenoid assembly into the mount. Do not tighten the hex nut or set screw in the top of the mount at this time. 7. Reinstall the solenoid and mount to the movable frame and refer to the adjustments section of this manual to adjust for solenoid positioning and movable knife home position.
3 - 50 Head Section Home Position Optical Switch 1. Remove the cap head screw holding the body of the optical switch in position (see Figure 3-42). 2. Carefully manipulate the switch harness through the cutout in the bracket until you can access and disconnect the in-line connector. 3. Connect the new optical switch to the in-line connector and place the switch in position on the bracket. 4. Reconnect the optical switch with the cap head screw. Picker Assembly 1.
Trimmer Assemblies 3 - 51 Movable Knife 1. Remove the screws holding the needle plate. Remove the needle plate. 2. Remove the screws holding the front and rear bed covers and remove the covers. 3. Lift the forward end of the connecting link from the pin on the movable knife drive arm (see Figure 3-44).
3 - 52 Head Section 9. Rotate the knife and arm clockwise until the back side of the knife is resting against the left side of the needle plate bracket. 10. Tighten the hex socket screw. Spring Knife/Under Thread Presser 1. Remove the screws holding the needle plate. Remove the needle plate. 2. Remove the screws holding the front and rear bed covers. Remove the covers. 3. Lift the forward end of the connecting link from the pin on the movable knife drive arm (see Figure 3-44). 4.
Trimmer Assemblies 3 - 53 Movable Knife Drive Arm 1. Remove the screws holding the needle plate. Remove the needle plate. 2. Remove the screws holding the front and rear bed covers. Remove the covers. 3. Lift the forward end of the connecting link from the pin on the movable knife drive arm (see Figure 3-45). Movable Knife drive arm Connecting Link Needle Plate Bracket fixing clip small pan head screw Figure 3 - 45 4.
3 - 54 Head Section UTC Replacement To remove the UTC assembly refer to the steps that follow: 1. With the machine in the head up position, turn the power switch OFF. 2. Remove the table top insert from the machine to access the Hook and UTC area. 3. Remove the needle plate, front bed cover, and right side rotary hook cover to access the UTC assembly including the sensor cable and connection to the harnessing in the bed. 4.
UTC Replacement 3 - 55 8. Place the UTC assembly under the needle plate support bracket as shown in Figure 3-47 and install the 2 UTC assembly mounting screws. needle plate support bracket UTC assembly and rotary hook retaining finger UTC assembly mounting screws Figure 47 10. Perform the UTC adjustments in Chapter 2 of this manual. 110305-01, Rev A 3.
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INDEX # +5 Volt Power Supply adjustment K Keyboard/Display Replacement 2-10 L A AC Voltage Selection Lower Rail Retainer adjustment 2-9 B Backplane PCB Replacement 3-8 Maintenance Philosophy Movable Knife home position home position sensor select position Movable Knife Drive Arm 2-19 3-24 3-44 2-27 3-43 3-41 1-6 Needle Bar Guide Shaft Replacement Needle Bar Replacement Needle Case installation removal 1-7 1-7 1-7 Peripheral Program Picker height/depth position home position Picker Assembly home
INDEX Thread Tensioner replacement 3-24 Thread Tensioner Bracket removal 3-23 Thread Tree Assembly removal 3-22 Trimmer Cam 3-48 Trimmer Interface Board Replacement 3-7 Trimmer Solenoid 3-48 Trimmer System 2-30, 3-45 Trimmers components 2-34 grabber 2-45, 3-45 movable knife 2-38, 3-51 not trimming 2-33 picker finger 2-43 setup and adjustment 2-31 spring knife 2-34, 3-52 under thread presser 2-37, 3-52 Z timeout errors 2-31 Y Motor Belt replacement tension 3-14 2-9 Z Z Drive gear mesh adjustment Z Drive
