Technical Manual for the EMT 10/4T embroidery peripheral • • • • • Part Number 110279-01, Revision B Four Melco Embroidery Heads Tubular Goods Hooping 10 Needles with automatic color change Automatic Trimmer Option Compliant
1575 West 124th Avenue Denver, Colorado 80234 United States of America Internet Address: publications@melco.com Copyright © Melco Embroidery Systems, 1997 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 Scope Of Manual Standard Conventions Used In Manual Glossary Of Terms Maintenance Philosophy Good Maintenance Practice Static Electricity Grounding Strap Use Warranty Considerations Electrical Grounding Physical/Functional Arrangement Configuring the EMT 10/4T Configuration Procedure Troubleshooting LEDs and Test Points Various Technical Specifications 1-1 1-1 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4 1-5 1-6 1-6 1-8 2.
Table of Contents Under Carriage Section Y Drive Motor Replacement Y Motor Belt Replacement Adjustments XYZ Motor Drive Amplifiers Current Limit Switch Settings Module Replacement Electronics Section Remove Card Cage Cover Card Cage Components CPU PCB Replacement Ethernet Network PCB Interface PCB Replacement Low Voltage Driver PCB Backplane PCB Power Distribution Section AC Input Voltage Selection Voltage Adjustments Power Supply Assembly Removal/Replacement Logic Power Supply Removal/Replacement 24V Powe
Table of Contents Jump Stitch Solenoid Replacement Adjustment Plunger Positioning Bracket Positioning Color Change PCB Replacement Color Change Motor Replacement Color Change Motor Belt Tension Color Change Cam Assembly Replacement Needle Case Replacing a Needle Bar / Presser Foot / Associated Parts Needle Case Removal Head #1 Head #s 2, 3, and 4 Replacing Needle Case Cross Roller Bearing Cross Roller Bearing Centering Retainer Plate Bearing Adjustment Replacing Reciprocator / Needle Bar Guide Shaft Instal
Table of Contents Trimmer Adjustment Procedures General Z Timeout Errors Damaged Trimmer Cam or Trimmer Solenoid Checking "Head Up" Position Trimmers Not Trimming Properly Physical Condition Of Trimmer Parts Adjustable Fixed Knife Under Thread Presser Adjustable Fixed Knife Adjustment Ink Wipeoff Test Knife Adjustment Cut Threads Movable Knife Home Position Home Position Sensor Checking Select Position Select Position Adjustment Picker Finger Position Picker Home Position Picker Height/Depth Position Under
1-1 1. Introduction Scope Of Manual The EMT 10/4T Embroidery Peripheral Technical Manual is a guide for performing repairs and adjustments that go beyond routine operator maintenance. These procedures are best understood and performed by professional service technicians in conjunction with specific factory technical training. However, much of the information in this manual may be useful reference for others who might possess appropriate technical aptitude and skills.
1-2 Maintenance Philosophy • To indicate that two or more keys must be pressed to obtain a desired result, each key is indicated with commas between them. An example is: Press Shift,8 to type an asterisk (*). Occasionally in the manual, special attention by the user is required. In this situation, "attention getters" are used to indicate the need for the user to be aware of a situation that is above and beyond the normal or routine.
Warranty Considerations 1-3 Good Maintenance Practice The procedures in this manual are guidelines for performing repair maintenance and must be used by personnel practicing good maintenance and repair technique. Good maintenance technique includes, but is not limited to, adhering to all precautions and safety considerations when working on the unit, and using the correct tools for the job being performed. WARNING! Personal injury may result if proper precautions are not observed.
1-4 Physical/Functional Arrangement Electrical Grounding WARNING! It is very important that the power cord be plugged into a properly wired electrical outlet. Failure to have a properly wired outlet may result in damage to the equipment and injury to personnel. It is recommended that a licensed electrician be consulted to assure that the electrical outlet is properly wired and grounded.
Warranty Considerations 1-5 Another distinct section of the EMT 10/4T is the embroidery head section. This section consists of each of the 4 heads, the Z drive motor and associated head drive mechanics and trimmer devices. Another area, the beam section, consists of the mechanical devices that hold the garments and move them forward and backward (the Y axis), and left to right (the X axis). The beam is located just above the table top and positioned under the embroidery head arms.
1-6 Configuring the EMT 10/4T If the CPU PCB is ever replaced, you must reconfigure the peripheral before using it again. CAUTION! If the EMT 10/4T is not configured with the correct Peripheral Program, it will not run properly, and may become damaged. The second configuration item is the Network Address. The address must be different for each peripheral attached to an EDS II or EDS III computer or network.
Troubleshooting LEDs and Test Points 1-7 GND * TEST POINT Voltage Tolerances +5 VDC (+4.9 to +5.1 VDC) +12 VDC (+11.4 to +12.6 VDC) -12 VDC (-10.8 to -13.2 VDC) +24 VDC (+22.8 to +25.2 VDC) +6 VDC ISO (+5.6 to +6.
1-8 Various Technical Specifications Various Technical Specifications The following is a list of various tension and force specifications for the EMT 10/4T (All specifications to be within plus or minus 10% unless otherwise indicated): X Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Motor Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y Drive Belt Tensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Front Covers 2-1 2. Service Maintenance (except head and trimmer) General This section of the manual provides parts replacement procedures and various adjustments required during parts replacement or other service repairs of all areas of the machine except the embroidery heads. Embroidery head service maintenance information other than trimmers is located in Section 3 of this manual. Trimmer service maintenance information is located in Section 4.
2-2 Removing Front Covers, Panels, and Tensioner Covers grabber cover keyboard panel assembly rear tensioner cover Left end tensioner cover start/stop panel assembly (2 ea) lower front cover (2 ea) disk drive panel assembly pin in top of lower front covers and disk drive panel right end tensioner cover Figure 2 - 1 Disk Drive Panel Assembly 1. To remove the disk drive panel assembly from between the needle cases of the middle two heads, remove the 2 screws at the front of the panel. 2.
Tensioner Covers 2-3 4. To remove the panel assembly completely you must disconnect all harness connections associated with the switches in the panel assembly. 5. For reinstalling the start/stop panel assembly refer to the diagram in Figure 2-2 for reattaching the harness connections to the various switches in the panel.
2-4 Keyboard Section Right Cover To remove the right end tensioner cover, loosen two screws at the rear (going into the rear tensioner cover) and remove three screws at the front. Slide the cover to the right carefully to remove it. Rear Cover 1. To remove the rear tensioner cover, first remove the 2 end covers. 2. Remove the remaining screws in the rear cover that hold it in place to the various panel assemblies. 3. Carefully slide the rear cover out to either side.
Display Screen Intensity 2-5 Keyboard Assembly attaching nuts (4 ea) Keyboard Cover standoff (1 of 4) Figure 2 - 3 Display Screen Intensity 1. Turn OFF the power switch to the EMT 10/4T. 2. Refer to the removal procedures earlier in this chapter and remove the tensioner covers if not already removed. 3. Turn ON the power switch to the EMT 10/4T. intensity adjustment knob 4. Locate the intensity adjustment knob on the top, rear of the keyboard/display printed circuit board as shown in Figure 2-4.
2-6 Disk Drive Disk Drive 1. Remove the disk drive panel assembly as previously described. 2. Remove the four screws holding the connectors cover at the rear of the disk drive assembly (see Figure 2-5) and disconnect the two harnesses from the rear of the disk drive. disk drive top cover disk drive panel cover floppy disk drive connectors cover disk drive support Figure 2 - 5 3. The assembly may now be moved to a work surface free of static electricity. 4.
X Drive Belt Replacement 2-7 X Beam Assembly The X beam assembly consists of the X carriage, X motor and belt, X drive belt, and various other mechanical components that make up the device that holds the hoop during the embroidery process. The X beam is attached to the Y drive system by connecting to the Y drive rails at the middle and either end of the beam.
2-8 X Beam Assembly X motor belt X home sensor motor pulley drive pulley x beam drive belt return pulley block drive belt tensioning screw mounting screws socket screws clamp spacer Figure 2 - 6 Belt Tension NOTE: This procedure requires a specific Melco force gauge (p/n 995586-01) for proper adjustment. 1. Refer to Figure 2-6 and ensure the two return pulley block mounting screws are installed and holding the drive belt return pulley block loosely to the X beam frame.
X Drive Belt Replacement 2-9 4. Move the X carriage all the way to the left of the beam until it mechanically stops. 5. Maneuver the pull-end the Melco force gauge (p/n 995586-01) under the upper loop of the belt and adjacent to the left side of the #2 head. This will position the force gauge approximately mid-way on the belt (see Figure 2-7). feeler blade read between 3.5 to 4.
2 - 10 X Beam Assembly Lint Wiper Located on the underneath side of the X drive belt tensioner block is a piece of Velcro attached with adhesive. This item is used to keep the top surface of the X carriage "brushed" clean and smooth for accurate reading by the X home sensor in that area of the carriage. In the unlikely event this needs to be replaced, it must be formed with a ripple in it to reach the X carriage surface but with some yielding of position.
X Motor and Belt 2 - 11 X beam cable connection X beam PCB cover X motor cover drive pulley assembly X motor belt X beam PCB X drive motor motor mount bracket motor pulley x axis shaft x beam Figure 2 - 8 10. If replacing the motor belt, remove the screws securing the motor mount bracket to the X beam. 11. Carefully slide the motor mount bracket away from the X beam and allow the drive pulley assembly to separate from the X axis shaft. 12.
2 - 12 X Beam Assembly 16. Reconnect the X motor drive harness and encoder harness into their respective mating connectors on the X beam PCB. 17. Carefully tuck the two X motor harnesses between the motor and X beam PCB and reconnect the X beam PCB cover. 18. Refer to the following motor belt adjustment procedure to adjust the X motor belt to the proper tension. Adjustment . . . TBD.
Y Drive Belt 2 - 13 Y Drive Belt There are four Y drive belts used on the EMT 10/4T. One each is associated with the Y carriage assemblies in the channels at either end of the peripheral. Two are associated with the middle Y carriage assembly in the middle channel. Figure 2-9 shows an illustration of the middle channel parts.
2 - 14 X Beam Assembly 4. Position a hex wrench onto one of the two cap head screws in the front of the frame for adjusting the belt tension (see Figure 2-10). the left side and middle Y drive belt assemblies are basically identical to the right side assembly depicted here. right side Y belt tension adjustment socket head cap screws right side cover Figure 2 - 10 5. Note the location of the wrench handle and rotate the socket head cap screw approximately 3 revolutions counter clockwise. 6.
Y Drive Belt 2 - 15 Caution: Overtightening the screws in the next step may cause the belt clamp to be damaged. 8. Place the new belt around the two pulleys. Secure both ends of the belt between the Y-belt bracket and the belt clamp piece with the two screws and associated hardware removed in the previous step. Be certain the teeth on the new belt are positioned in the proper location in the rear pulley to maintain the parallelism between the X beam and Y carriages. 9.
2 - 16 X Beam Assembly Figure 2 - 12 10. Check the Y drive belt tension on the other three belts the same method as in the previous steps. The tensions of the four belts should be within 0.25 pounds of each other. 11. If needed, adjust the other Y drive belts to the proper tension according to the above specifications. 12. Repeat this procedure until the proper tension adjustments are attained. 13. Replace all covers removed during this procedure.
Y Drive Motor Replacement 2 - 17 Under Carriage Section This section of the peripheral consists primarily of the assemblies lying in and about the support frame of the machine (see Figure 2-13). It contains the power supply area located inside the left support leg and the electronics cage located inside the right support leg. Located inside the top support platform between heads #3 and #4 is the XYZ Amplifier assembly and between heads #2 and #3 is the Y drive motor.
2 - 18 Under Carriage Section Y motor/belt cover Y shaft pulley Y motor bracket Y motor belt motor mounting socket head cap screw (4 each) Y motor drive pulley Y motor Figure 2 - 14 3. There are two harnesses leading from the motor and one harness connected to the motor encoder. Disconnect the motor encoder harness connection. 4. Remove the cover from the harness way located on the inside front wall of the frame top support platform to access the in-line connections for the two motor harnesses. 5.
Y Motor Belt Replacement 2 - 19 10. Rotate the four socket head cap screws until the slack is taken up between the screw head and the associated hardware. DO NOT, however, tighten the four socket head cap screws at this time. 11. Locate a length of strong cord or cable sufficient to loop over the motor pulley with four to six inches of cable hanging below the motor. 12. Loop this cable around the motor pulley between the belt and the pulley flange nearest the motor body.
2 - 20 Under Carriage Section 6. At the front of the machine loosen each Y drive belt by loosening the two socket head cap screws at each of the four belt tensioning pulley idler assemblies. 7. At the rear of the machine loosen the locking collars on each of the two end pulleys (refer to Figure 2-15 for this and the several steps following).
Y Motor Belt Replacement 2 - 21 13. Slip the Y drive belt off the open end of the Y shaft drive pulley assembly and then slip the Y motor belt off the pulley assembly and out of the Y shaft area. 14. Install a new Y motor belt around the Y shaft drive pulley assembly and position it down to the Y motor pulley area. 15. Reinstall the rear end of the Y drive belt onto the outside pulley of the Y shaft drive pulley assembly. 16.
2 - 22 XYZ Motor Drive Amplifiers XYZ Motor Drive Amplifiers There are three identical XYZ Motor Drive Amplifiers located inside the motor amplifier assembly in the top support platform between heads #3 and #4 (see Figure 2-13). Refer to the following procedure for replacement. WARNING! When the cover is removed, and the machine is ON, potential harmful voltage and current is exposed.
Module Replacement 2 - 23 Module Replacement To replace one or more of the XYZ Motor Drive Amplifiers refer to the following steps: 1. Turn the peripheral OFF. 2. WAIT ONE MINUTE, then remove the cover over the XYZ Motor Drive Amplifier section under the top support platform of the chassis (see Figure 2-13). 3. Disconnect the harnesses and remove hardware associated with the defective XYZ Motor Drive Amplifier (see Figure 2-17).
2 - 24 Electronics Section Electronics Section The electronic section consists of the major electronic printed circuit boards located within an RFI controlling box called the card cage. The card cage is located inside the right chassis leg (see Figure 2-13). Remove Card Cage Cover 1. Turn OFF the power switch to the EMT 10/4T. 2. To remove the card cage cover, remove the screws and associated hardware from around the cover as shown in Figure 2-18 and lift the cover off.
Card Cage Components 2 - 25 Card Cage Components Inside the card cage is found the Backplane PCB lying against the end of the chassis leg with its respective PCBs inserted into its connectors. The PCBs installed are: • The CPU PCB • The Ethernet network PCB • The Interface PCB • Blank space • The LV Driver PCB Refer to Figure 2-19 for identifying where each PCB is specifically located. CAUTION! In removing any PCBs from the EMT 10/4T, use extreme care in handling.
2 - 26 Electronics Section CPU PCB Replacement The CPU PCB is the first PCB located toward the front of the card cage as shown in Figure 2-19. Refer to the following procedure for replacing the CPU PCB. 1. Turn OFF the power switch to the EMT 10/4T. 2. Remove the card cage cover and install a static grounding strap between the working surface and the personnel performing this procedure. 3. Grasp the CPU at the corners and gently rock it out of its connectors in the backplane PCB. Remove the CPU.
Low Voltage Driver PCB 2 - 27 6. Replace the Ethernet PCB by reversing the previous steps. 7. Install the screw and washer at the card edge mounting bracket to secure the printed circuit board. 8. Reinstall the Ethernet cable at the bottom end of the Ethernet PCB. 9. Remove the static grounding strap and replace the card cage cover.
2 - 28 Electronics Section 5. Grasp the PCB at the corners and gently rock it out of its connectors in the backplane board. Remove the PCB. CAUTION! It is advised to place the removed PCB into an anti-static bag before handling it any further. Portions of this board are very sensitive to static charges. 6. Replace the PCB by reversing the previous steps. 7. Install the screw and washer at the card edge mounting bracket to secure the printed circuit board. 8.
Backplane PCB 2 - 29 cover screws cover over the backplane PCB connectors Card Cage Figure 2 - 21 7. Remove the screws holding the backplane PCB to the base of the card cage. 8. Lift the backplane PCB out of the card cage. 9. Install a new backplane PCB using the same hardware that secured the previous one in the base of the card cage. 10. Replace the cover over the backplane PCB connectors using the same screws that previously secured it. 11.
2 - 30 Power Distribution Section Power Distribution Section The AC voltage distribution panel, power supplies, and associated circuitry for the EMT 10/4T are located inside the left chassis leg. In addition to the AC voltage distribution panel, there are two power supplies, one for logic voltages and another for motors, and the e-stop control PCB located in this section. AC Input Voltage Selection 1.
Power Supply Assembly Removal/Replacement 2 - 31 Voltage Adjustments All voltage values are regulated within the operating ranges of the machine design. Therefore, NO adjustments are required for voltage values for either supply. Power Supply Assembly Removal/Replacement 1. Refer to Figure 2-22 and unplug the main power cord at the entry module on the AC voltage distribution panel inside the left frame leg. Estop PCB Logic Power Supply 2.
2 - 32 Power Distribution Section 4 screws fastening the power supply assembly from the outside of the peripheral frame leg (see Step 4) POWER SUPPLY ASSEMBLY 4 screws securing the power supply assembly to the under side of the frame from the inside the leg (see Step 5) Figure 2 - 24 Logic Power Supply Removal/Replacement 1. Remove the power supply assembly from the left frame leg as described earlier. 2. Refer to Figure 2-23 to identify the location of the logic power supply and estop PCB.
Emergency Stop PCB Assembly Removal/Replacement 2 - 33 Emergency Stop PCB Assembly Removal/Replacement 1. Remove the power supply assembly from the left frame leg as described earlier. 2. Refer to Figure 2-23 to identify the location of the e-stop PCB and unplug the 2 power connectors (labeled P8 & P9) from the estop PCB. 3. Unplug the 4 spade terminals (wires colored blue, brown, black & white) from the Estop PCB. 4.
2 - 34 Power Distribution Section Power and Light Switch Removal/Replacement 1. Refer to Figure 2-24 and unplug the main power cord at the entry module on the AC voltage distribution panel inside the left frame leg. 2. Remove 4 screws fastening the power tray cover and remove the cover. 3. Remove 4 screws fastening the AC voltage distribution panel (see Figure 2-26), and lower the module to the bottom of the frame leg. AC VOLTAGE DISTRIBUTION PANEL 4 each panel fastening screws Figure 2 - 26 4.
3-1 3. Embroidery Head Maintenance General This section of the manual provides parts replacement procedures and various adjustments required during repair maintenance of the embroidery head only. Information for service maintenance on trimmers is located in Section 4 and the rest of the machine is located in Section 2 of this manual. These procedures are guidelines for performing repairs and must be used by personnel practicing good maintenance and repair techniques.
3-2 Z Drive Mechanical System Z Drive Motor Z Drive Shaft Z Drive Belt Z drive shaft to embroidery head shaft bevel gear exchange (1 of 4) Figure 3 - 1 The alignment and calibration of this mechanical system is critical for proper operation of the EMT 10/4T Embroidery Peripheral. Z Motor Replacement Note: This procedure requires a Gates 5M Tensiometer (Melco p/n 992165-01) for proper belt adjustment. 1. Turn the main power OFF, and remove the power source cable from the power supply assembly. 2.
Z Motor Replacement 3-3 a)Remove the 2 screws on the inside surface of the cover near the head, just above the Z drive shaft. Z motor drive area cover head #4 c)Remove the 2 screws located at the base of the outer (left) surface of the cover. c)Remove the only screw at the front surface of the cover FRONT VIEW b)Of the 3 screws located near the head and directly below the 2 screws removed in step a, remove the 2 outer screws. Leave the middle screw secure. Figure 3 - 2 3.
3-4 Z Drive Mechanical System 7. Place the pulley on the new motor shaft and, before tightening the pulley set screws, perform the next steps to insure the motor shaft pulley is positioned so the belt will ride in the middle of the two pulleys. 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.
Synchronizing The Embroidery Heads 3-5 3. Push down on the motor and, when the reading on the tensiometer is at 25, tighten the socket head cap screws. 4. After the screws are tightened, check the tension again to verify the proper measurement was maintained. Synchronizing The Embroidery Heads Head synchronization is very critical in maintaining proper stitch timing for all four heads.
3-6 Z Drive Mechanical System NOTE: It remains IMPORTANT to insure that the Z drive shaft stays at the HU position during this procedure. 6. 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 3-6). This will loosen the grasp of the Z drive shaft on the head.
Introduction 3-7 Z Shaft Encoder 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 other electronics 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.
3-8 Z Shaft Encoder Inspection This procedure is a guide for determining the condition of the encoder. 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. 1. Switch the peripheral OFF, lower the table top, and remove the rear head cover. 2. When switched back on it is important that the computer not down load a design to the peripheral.
Installation 3-9 CAUTION! If the Z shaft encoder is replaced, DO NOT OPERATE THE EMBROIDERY PERIPHERAL until the new Z shaft encoder is properly calibrated! To replace the encoder follow these steps: 1. Turn the machine OFF, then disconnect the power from the power source. 2. Remove the rear cover. 3. Disconnect the Z encoder harness from the z encoder. 4. Using proper antistatic precautions, disconnect the encoder cable from the CPU board. 5.
3 - 10 Z Shaft Encoder 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. Orient the connector on the encoder cable so the outside black wire is to the right and will plug into pin 1 of the new encoder (see Figure 3-8). Push the encoder cable connector onto the new encoder.
Calibration 3 - 11 5. Slowly rotate the heads at the 5mm 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. 6. Now loosen the encoder coupler socket head cap screw at the left end of the Z shaft (see Figure 3-10) and slowly rotate the coupling and encoder (encoder shaft socket head cap screw is still tight) in either direction.
3 - 12 Thread Tensioner Assembly Thread Tensioner Assembly Assembly Removal The thread tensioner assembly is attached to the top of the needle case. To remove the tensioner assembly refer to the procedure that follows. 1. Turn OFF the EMT 10/4T and disconnect the power cord from its power source. 2a. Remove the side, rear, end, and front covers from around the head that is having the tensioner assembly removed (refer to cover removal on page 2-1). 2b.
Individual Thread Tensioner Replacement 3 - 13 2. Carefully grasp the thread guide tubes individually and remove them from the thread tensioner bracket assembly by pulling on each thread guide tube near where it enters the hole in the thread tensioner bracket. NOTE: The thread guide tubes may be held in place with a bracket attached to the tensioner assembly. This bracket must be removed to remove the tubes.
3 - 14 Thread Tensioner Assembly Changing A Check Spring 1. As described in the previous procedure, remove the thread tensioner associated with the check spring that is being changed. 2. Remove the old check spring and discard it. 3. Attach the new check spring as follows: a) Position the check spring around the end of the tensioner shaft as shown in Figure 3-13. 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.
Check Spring Adjustment 3 - 15 Check Spring Adjustment After replacing a thread check spring, install the thread tensioner into the thread tensioner mounting bracket. You must then adjust the tension of the check spring against the thread break contact. To set this tension: 1. Slightly loosen the set screw in the top of the thread tensioner mounting bracket that secures the thread tensioner (see Figure 3-12). 2.
3 - 16 Thread Tensioner Assembly If you rotate less than 2 spokes you will begin to lose the force needed to make a tight stitch. You may have enough stroke but not enough force to cinch up the stitch tightly. You may also begin to have failure of thread break detection. You must have enough rotation to cause the check spring to make a good contact with the thread break contact post. A poor contact will often not provide the signal to stop embroidering when there is a thread break.
Replacement 3 - 17 Jump Stitch Solenoid Replacement If a jump stitch solenoid must be replaced, follow these steps: 1. Color change the needle case to needle #10 for best access to the solenoid area. 2. Remove the left arm front cover to expose the jump stitch solenoid mounting bracket area (see Figure 3-16). 3. Use a pencil or other suitable marking device and mark the bracket location in reference to the front surface of the arm casting at the locations shown in Figure 3-16).
3 - 18 Jump Stitch Solenoid Jump Stitch Solenoid and Bracket cover screws record solenoid threads here Mechanical Jump Stitch mechanism and cover 2 solenoid bracket screws Jump Stitch Solenoid locking nut SHOWN WITH NEEDLE CASE AND OTHER PARTS REMOVED FOR CLARITY ONLY Figure 3 - 17 8. Replace with new solenoid by reversing the procedure above. Adjust the position of the solenoid into the solenoid bracket using the "thread counts" or measurement you obtained above (see previous NOTICE). 9.
Adjustment 3 - 19 Adjustment If a jump stitch solenoid has been replaced, you may have to perform one or more of the following adjustment procedures. The needle case must be removed to perform these adjustments. See the procedure for needle case removal in this section. Plunger Positioning During the jump stitch solenoid replacement procedure you were to count the number of threads that are showing beyond the solenoid bracket.
3 - 20 Jump Stitch Solenoid 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.
PCB Replacement 3 - 21 Color Change The color change PCB, the color change motor, the cam, and harnesses are located under the color change covers behind the embroidery head tensioner area. PCB Replacement The color change PCB is an interface from the CPU for color change commands from the design and keyboard. It also has interfacing for thread break and needle position information from the tensioner PCB back to the CPU. To remove the color change PCB refer to the following procedure: 1.
3 - 22 Color Change CAUTION! The Color Change PCB is snapped into place on top of the color change bracket. Be careful not to damage the photo sensors or any other components when removing the PCB. 6. Remove the color change PCB by lightly prying up on the board near the 4 catch pins that hold the PCB in place (see Figure 3-20). The color change PCB should simply lift off of the color change housing.
Color Change Motor Replacement 3 - 23 Color Change Motor Replacement To remove the color change motor refer to the following steps: 1. Remove the color change area covers and tensioner covers as previously described (see Figure 3-19). 2. Remove the color change PCB as described in the procedure just previous to this procedure. 3. Remove the harness connection from the color change motor encoder (see Figure 3-21). 4. Loosen and remove the 4 color change motor mounting screws (see Figure 3-21). 5.
3 - 24 Color Change 9. The motor is now loose and can be removed. 10. Replace the motor and reverse the preceding steps. 11. Refer to (see Figure 3-21) for attaching the color change motor encoder harness connector to the motor encoder. 12. Refer to the color change motor belt tension adjustment procedure to adjust the belt. Color Change Motor Belt Tension The color change belt tension should cause the color change cam to rotate with minimum backlash.
Color Change Cam Assembly Replacement 3 - 25 Color Change Cam Assembly Replacement If replacing the color change cam and associated hardware, refer to the following procedure to allow the new assembly to rotate freely within the bracket. 1. Remove the tensioner bracket covers and the color change covers as described earlier. 2. Remove the color change PCB as described earlier. 3. Remove the color change motor as described earlier. 4.
3 - 26 Color Change split-hub clamp shaft thrust bearing spacer color change bracket spacer pulley thrust washer (2.75mm thick) thrust bearing color change cam split-hub clamp thrust washer (1.00mm thick) Figure 3 - 24 9. Position the outer split-hub clamp and spacer against the left outside of the bracket and the color change cam against the two 2.75mm thrust washers and thrust bearing combination to take up the slack. Tighten the split-hub clamp. 10.
Replacing a Needle Bar / Presser Foot / Associated Parts 3 - 27 Needle Case Replacing a Needle Bar / Presser Foot / Associated Parts To replace a needle bar, presser foot, or other parts associated with this area refer to the following steps: 1. Turn ON the EMT 10/4T and bring the head to the HEAD UP position. 2. Turn OFF the EMT 10/4T and disconnect the power cord from its power source. 3. Remove the thread tensioner bracket assembly as described in a previous procedure. 4.
3 - 28 Needle Case 7. Next, loosen the needle bar stop clamp (black clamp). 8. Loosen the top screw (see Figure 3-26) on the needle bar. (You will remove and transfer the screw in step 11.) CAUTION! After the next step, the needle bar is free to be moved out the top of the needle case. Use care so the springs and other parts do not suddenly fly out of position. 9. Loosen the needle bar clamp. 10.
Head #1 3 - 29 14. You may reinstall the upper needle case cover at this time. The lower needle case cover must, however, remain off to perform the needle bar height adjustment. 15. After installing a new needle bar, you must adjust the needle bar height. Refer to the peripheral operation manual for the adjustment procedure for needle bar height. 16. When the needle bar height has been properly adjusted, reinstall the lower needle case cover.
3 - 30 Needle Case 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 7. Hold the needle case securely with one hand while you remove the 4 socket head cap screws that secure the needle case to the bearing retainer plate assembly near the top of the needle case (see Figure 3-28).
Replacing Needle Case Cross Roller Bearing 3 - 31 8. Lift the needle case slightly to disengage the lower rail from the lower rail retainer coming from the bottom of the embroidery head arm. 9. The needle case will now be free to remove from the head. Using care not to damage any components, set the needle case aside. Head #s 2, 3, and 4 1. Turn ON the EMT 10/4T and bring the head to the HEAD UP position. 2. Turn OFF the EMT 10/4T and disconnect the power cord from its power source. 3.
3 - 32 Needle Case 5. Check for proper adjustment of the retainer plate assembly bearings by referring to the retainer plate bearing adjustment procedure. 6. Reinstall the clamping devises at each end of the V-rail. 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.
Retainer Plate Bearing Adjustment 3 - 33 4. Position the left edge of the cross roller bearing in line with the left edge of the retainer plate and the center of the needle bar guide shaft felt pad. (The second roller of the cross roller bearing should just be engaging between the embroidery head v-rail and the needle case v-rail.) 5. Slide the retainer plate assembly onto the embroidery head v-rail and cross roller bearing. 6.
3 - 34 Needle Case 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 3 - 30 6. Tighten the socket head cap screws securely and remove the fixture. 7.
Replacing Reciprocator / Needle Bar Guide Shaft 3 - 35 Guide Shaft flat Connecting Rod (behind the guide shaft) Reciprocator Needle Bar Guide Shaft large red-marked oil hole groove in guide shaft for Retaining Clip Set Screw in left side FRONT VIEW Figure 3 - 31 7. Install the new reciprocator into the head (see Figures 3-31 and 3-32). Make sure it is oriented properly and insert the connecting stud onto the connecting rod. 8.
3 - 36 Needle Case hole for removing or installing guide shaft Reciprocator Needle Bar Guide Shaft Roller Bearing Retaining Clip Lower Rail Retainer Figure 3 - 32 Installing Needle Case To reattach the needle case refer to the following procedure: Head #1 1. Insure the following conditions are set: a) The cross roller bearing is properly installed and centered as described in the section titled Cross Roller Bearing Centering.
Installing Needle Case 3 - 37 2. Refer to Figure 3-28 and insert the needle case lower rail into the lower rail retainer. Insure the grabber blade fits into the grabber bar assembly at the bottom of the needle case. 3.
3 - 38 Needle Case 7. Remove the clamping devises from each end of the V-rail and reinstall all covers that were removed during the procedure. 8. Power up the peripheral and position the needle cases to needle #5. 9. Go into the Head Timing menu and bring needle #5 down slowly, using the key. 10. Check for the needle centered in the needle plate hole. 11. If a slight recentering is required: a) Loosen the four needle case screws installed and tightened in steps 4 and 5.
Lower Rail Retainer Adjustment b) 3 - 39 The needle case rests solidly and completely on the bearing retainer plate assembly and is positioned to the right so the right side of the needle case is against the socket head cap screw in the bearing retainer plate as shown in Figure 3-33. 4. Align the 4 through holes on the upper section of the needle case with the 4 threaded holes in the bearing retainer plate assembly. 5. Install and tighten the 4 socket head cap screws. 6.
3 - 40 Needle Case gap between zero preload and .002" front of head roller bearing lower rail retainer NOTE: if trimmer option installed, grabber parts must be removed to access screw.
Hook Replacement 3 - 41 Rotary Hook Hook Replacement This procedure includes steps for setting hook timing during the hook installation process. After completing this procedure, hook timing adjustments are complete and there is no need to refer to any further hook timing procedure. If you are not replacing the hook but wish to check and adjust hook timing only, refer to that section later in this manual. 1. Move the the table top to the lower position, or remove it and set it aside. 2.
3 - 42 Rotary Hook 12. Press the keys. The head rotates to the ‘‘Needle Depth’’ position without bringing the needle down and the LCD displays NEEDLE DEPTH 180.0. If the hook point does not extend to the needle, it is referred to as "retarded" If the hook point extends beyond the needle, it is referred to as "advanced" 13. Press and the head rotates to the ‘‘Hook Timing’’ position. The LCD displays HOOK TIMING 200.0. 14. Clean and replace the current hook, or place a new rotary hook on the hook shaft.
Hook Replacement 3 - 43 19. Install the UTC assembly with the retaining finger tab inside the rotary hook bobbin basket notch. Install the screws. Adjust The UTC Assembly You must adjust the UTC assembly to a level where the needle will not contact the detection arm during the needle depth procedure. 20. Place the UTC Combination Gauge (p/n 009027-01) from the operator kit between the retaining tab of the UTC and the notch in the hook basket (see Figure 3-38).
3 - 44 Rotary Hook If the clearance needs to be adjusted proceed with the next step. If OK, go to the Needle Depth adjustment procedure. 25. Slightly loosen the two small screws on the underside of the UTC assembly shown in Figure 3-40. VIEW from UNDER the UTC ASSEMBLY (assembly shown removed from needle plate support bracket, but is actually attached during this adjustment) slotted screw hole UTC sensor body UTC sensor body screws Figure 3 - 40 26.
Hook Replacement 3 - 45 32. Next press . The head rotates one revolution. The LCD displays ONE REVOLUTION 110.0. The needle bar should be down with the presser foot about 1/4 inch from the needle plate. NOTE: If the needle does not come down the upper dead stop clamp may need adjustment as described later in this procedure. For now, however, complete the needle depth adjustment by grasping the presser foot and pulling down until the needle bar catches securely.
3 - 46 Rotary Hook lower needle case cover (removed) upper dead stop clamp screw (black) needle bar clamp screw (silver) Figure 3 - 42 40. Loosen the screw on the upper-dead-stop clamp again and slide the clamp against the upper stop bumper. The screw must be positioned directly forward. If it is rotated, it may rub the plastic guide plate or catch the needle bar next to it during its down stroke. Tighten the upper-dead-stop clamp screw. 41. Press . The head rotates to GO TO HEAD UP 110.0. 42.
Hook Timing Adjustments Only 3 - 47 Hook Timing Adjustments Only This procedure is for checking and setting hook timing adjustments when the hook assembly is not being replaced. If you are replacing the hook assembly, refer to the preceding section in this chapter. If you suspect your peripheral has gone out of timing due to hitting a hoop, bird nesting, or some other reason, follow these steps: 1. Move the the table top to the lower position, or remove it and set it aside. 2.
3 - 48 Rotary Hook If hook timing is correct, proceed to the UTC Adjustments in the next procedure. If hook timing is NOT correct, proceed to Step 11. This gap should be 0.002 - 0.008" Needle scarf 11. While the hook is still in the HOOK TIMING position, color the screw on the RIGHT side of the hook (see Figure 3-45) with a felt-tipped marker. DO NOT LOOSEN THIS SCREW AT THIS TIME. 12. Press until you see the 2nd screw. Loosen this screw. 13. Press until you see the 3rd screw. Loosen this screw. 14.
Hook Timing Adjustments Only 3 - 49 20. Position the POINT of the HOOK directly behind the SCARF of the needle. Leave a THREAD distance between the POINT of the hook and the needle. 21. Tighten the colored hook screw and check that the setting is correct as shown in Figures 3-43 and 3-44. 22. Press the key to rotate the the hook to access the other two hook screws and tighten them securely. UTC Adjustments 22. Refer to the UTC and Needle Depth adjustments on Pages 3-43 through 3-46. 23.
3 - 50 Rotary Hook This page intentionally left blank EMT 10/4T Technical Manual Melco Embroidery Systems
4-1 4. Trimmer Maintenance General This section of the manual provides parts replacement procedures and various adjustments required during repair maintenance of the embroidery head trimmer system. Information for service maintenance on the rest of the embroidery head is located in Section 3 and the rest of the machine is located in Section 2 of this manual. These procedures are guidelines for performing repairs and must be used by personnel practicing good maintenance and repair techniques.
4-2 Trimmer Replacement Procedures 6. The beam makes two moves that clears the top thread (now called the tail) out of the material. 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.
Grabber Drive Assembly 4-3 Grabber Blade Replacement 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 4-2). Grabber Blade 2 button head screws securing grabber blade Figure 4 - 2 3. Remove the 4 screws to free the front grabber blade cover (see Figure 4-3).
4-4 Trimmer Replacement Procedures the finger is pointing to the grabber blade top grabber blade cover front grabber blade cover grabber blade guide Velcro wiper bar Figure 4 - 3 Grabber Adjustments To check grabber blade travel follow these steps: 1. Insure the embroidery heads are synchronized and position them to headup. 2. Turn the machine OFF, and unplug the power cord from the power source. 3.
Grabber Drive Assembly 4-5 Motor Limit Stop Lever UP (grabber blades out) Grabber Blade out Figure 4 - 4 Motor Limit Stop Lever DOWN (grabber blades retracted) Grabber Blade retracted Figure 4 - 5 When fully retracted, the grabber blades should be inside the guide just behind the Velcro wiper bar at the bottom of the needle case area.
4-6 Trimmer Replacement Procedures 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 4-5. 2. Locate the socket head cap screw in the end of the grabber blade guide (see Figure 4-6). 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 - .
Trimmer Drive Assembly 4-7 Grabber Blade Transition Bracket and Guide Rod at rear of head Figure 4 - 7 4. Tighten the set screw in the wire swivel. 5. Replace all covers after making the grabber adjustments. Trimmer Drive Assembly Trimmer Cam The trimmer cam is mounted on the rotary hook shaft in the rear bed. Replacing the trimmer cam requires major embroidery head disassembly and critical adjustments during reassembly.
4-8 Trimmer Replacement Procedures set screw in top of solenoid mount hex nut between solenoid and mount trimmer solenoid solenoid mount cap head screw socket head cap screw mark solenoid mount position optical switch Figure 4 - 8 Trimmer Camming Mechanism 5. Loosen the set screw in the top of the solenoid mount, then rotate the solenoid assembly out of the mount. 6. Rotate a new solenoid assembly into the mount. Do not tighten the set screw in the top of the mount at this time. 7.
Picker Assembly 4-9 CAUTION! Be careful not to lose the solenoid return spring in the next step. 3. At the solenoid plunger, loosen the set screw in the picker swivel clamp and remove the picker wire from the end of the plunger. 4. Remove the old solenoid wires from the main connector and transfer the new solenoid wires into the same positions in the connector. 5. Transfer the solenoid return spring from the old solenoid to the new one and reattach the picker wire at the end of the solenoid plunger. 6.
4 - 10 Trimmer Replacement Procedures mounting screws Picker Link Picker Swivel Pivot Picker Base and shaft set screw Picker Bracket Mount External Retaining Ring Figure 4 - 9 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 4-10). 4.
Adjustable Fixed Knife/Under Thread Presser 4 - 11 Connecting Link Under Thread Presser pin on Movable Knife Drive Arm socket head cap screw securing adjustable fixed knife and under thread presser hex head screw alignment pin/hole Adjustable Fixed Knife Movable Knife Figure 4 - 10 11. After replacing a movable knife refer to the trimmer adjustment procedures later in this chapter for the adjustable fixed knife. Adjustable Fixed Knife/Under Thread Presser 1.
4 - 12 Trimmer Replacement Procedures 8. Install the socket head cap screw to secure the adjustable fixed knife and the under thread presser. Snug the cap screw until the parts are held securely. Do not over tighten. 9. After replacing an adjustable fixed knife or under thread presser, refer to the trimmer adjustment procedures later in this chapter for the adjustable fixed knife. Movable Knife Drive Arm 1. Remove the screws holding the needle plate. Remove the needle plate. 2.
Z Timeout Errors 4 - 13 Trimmer Adjustment Procedures One procedure combining all the required adjustments organized in specific order is presented in this section for providing the best success in making adjustments to the trimmer assembly. All the trimmer replacement procedures are found together in the previous section. The EMT 10/4T Embroidery Peripheral trimmer system is assembled and thoroughly tested before the machine is shipped.
4 - 14 Trimmer Adjustment Procedures 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 4-12. solenoid pin end shown engaged in cam groove Drill hole in rear of cam.
Z Timeout Errors 4 - 15 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. Refer to the procedure for replacing the trimmer solenoid and remove the solenoid. 9. While the trimmer solenoid is removed, inspect the trimmer cam for damage.
4 - 16 Trimmer Adjustment Procedures Trimmers Not Trimming Properly When the trimmers are not providing adequate trim quality, there are three general areas that may be contributing to the situation: 1) The physical condition of the trimmer parts, 2) The Movable Knife "home" position, and 3) The Movable Knife "select" position.
Under Thread Presser 4 - 17 This situation may result if the adjustable fixed knife is worn or is not parallel to the trimming action of the movable knife. Check this condition of the adjustable fixed knife by inspecting the marks left on the surface of the movable knife that is under the adjustable fixed knife. If the marks are more severe in the area that aligns with one edge of the adjustable fixed knife, the adjustable fixed knife may need to be adjusted or replaced, or both.
4 - 18 Trimmer Adjustment Procedures Checking the under thread presser is done in two parts. First by looking at the part itself to see if there has been any "crumpling" as shown in Figure 4-14. Crumpling is damage caused by the movable knife hitting the under thread presser. If you see visual evidence of any damage, replace the under thread presser as described earlier in this chapter. The second part of checking under thread presser is to check if the bobbin thread is in fact being held in place. 1.
Adjustable Fixed Knife Adjustment 4 - 19 6. If the under thread presser does not provide the required action, replace it and check using steps 2 to 4 again. 7. After you are satisfied with the under thread presser action, re-attach the connecting link (see Figure 4-12). Adjustable Fixed Knife Adjustment After replacing the adjustable fixed knife (or movable knife) per the instructions earlier in this chapter it will need to be properly adjusted. Refer to following steps in performing this adjustment.
4 - 20 Trimmer Adjustment Procedures Knife Adjustment After performing the ink wipeoff test and determining that adjustment to the adjustable fixed knife is required, follow these steps to perform the knife adjustment. 6. Refer to Figure 4-17 and locate the two small set screws in the bottom of the needle plate bracket directly under the under thread presser.
Movable Knife 4 - 21 11. Check the tightness of the top socket head cap screw and recheck the adjustment by performing the ink wipeoff test once again. Cut Threads When you are satisfied with the ink wipeoff test, you may check the thread cutting ability by performing actual thread cuts at several locations across the cutting range of the knives. To do this refer to the following steps: 12.
4 - 22 Trimmer Adjustment Procedures 5. The movable knife should be located under the adjustable fixed knife, positioned as shown in Figure 4-18. If the sloped rear tip of the movable knife is not showing in front of the leading edge of the adjustable fixed knife, the "home" position needs to be adjusted. DO NOT Adjust if the knife position looks like Figure 4-18.
Movable Knife 4 - 23 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 4 - 19 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 a
4 - 24 Trimmer Adjustment Procedures Checking Select Position After adjusting the movable knife home position, you must check for the movable knife "select" position. If adjustment is required refer to Select Position Adjustment procedure immediately after this checking procedure. 1. Replace the standard needle plate on the embroidery head arm (See Figure 4-13). Do not install the raised needle plate used with cap frames. 2. Turn the machine power ON. 3.
Select Position Adjustment 4 - 25 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 4 - 20 12. Check the reading of the display to be between 311 and 313 degrees. 13.
4 - 26 Trimmer Adjustment Procedures 3. Loosen the large socket head screw in the locking collar for the Top Bobbin Drive Pulley (see Figure 4-21) and rotate the belt and pulley slightly until the movable knife just contacts the select position fixture (see Figure 4-20). 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.
Picker Finger Position 4 - 27 Picker Finger Position If the cap frame option is not part of your system, you may refer to the following procedure to center the picker fingers, should it become necessary. If your EMT 10/4T has the cap frame option, you must give centering priority to the cap frame driver. When the cap frame driver is centered properly, the picker fingers will automatically come into proper center alignment.
4 - 28 Trimmer Adjustment Procedures Picker Home Position Note: This procedure requires the use of a special service tool: the Melco picker set fixture (p/n 995339-01). 1. Install the picker set fixture (shown in Figure 4-23) to set picker home position. Picker Height/Depth Position Picker Home Position Front End Bobbin End Picker Fixture Picker Height/Depth Position Picker Home Position Figure 2 - 23 2. Loosen the set screw inside the swivel pin body shown in Figure 4-22. 3.
Picker Height/Depth Position 4 - 29 Under Thread Control (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.
4 - 30 Under Thread Control (UTC) Replacement 8. Place the UTC assembly under the needle plate support bracket as shown in Figure 4-25 and install the 2 UTC assembly mounting screws. needle plate support bracket UTC assembly and rotary hook retaining finger UTC assembly mounting screws Figure 25 9. Perform the UTC adjustments.
Rotary Hook Retaining Finger Positioning 4 - 31 UTC Adjustments It is very important that you follow these instructions any time the rotary hook or UTC is loosened or moved. Please follow the instructions in the order they occur. Note: The procedures in this section require the following special tools: 1) a small straight blade screw driver with a thin blade, and 2) the Melco UTC combination gauge part number 009027-01. (This tool is located in the Melco tool kit that came with the machine.
4 - 32 UTC Adjustments 8. Position the UTC assembly until the gap between the retaining finger tab and the rotary hook inner basket notch is set to the thickness of the gauge finger. The gap is 0.020 inches as shown in Figure 4-26. 9. Additionally, align the center of the retaining finger tab to the center of the needle as indicated in Figure 4-26. 10. Tighten the UTC assembly mounting screws. 11.
Sew Test 4 - 33 14. Check that the movable knife clears the UTC detection arm by physically moving the knife under the UTC detection arm and back. 15. If the knife touches the arm, reshape the arm slightly until it clears then repeat steps 8 through 11. 16. Re-attach the connecting link to the pin on the movable knife assembly. Caution! When installing the covers, be sure not to pinch the UTC Assembly wires! 17. Re-attach the right side rotary hook cover, the needle plate, and the front bed cover.
4 - 34 UTC Adjustments 2. Embroider the test design until the thread is completely used. 3. Repeat steps 1 and 2 until the bobbin runs out at least once in both directions of diagonal stitching in the test design. 4. If the sensor does not detect when the bobbin runs out of thread, slightly loosen the UTC sensor body at the screws shown in Figure 4-29, and at the slotted screw hole (left side) move the sensor a very small amount away from the needle. Re-tighten the screws.
Cap Supports 5-1 5. Accessory Adjustments Wide Angle Cap Frame The Wide Angle Cap Frame (also referred to as "WACF") has several adjustable components. Refer to this section for instructions on how to properly adjust these components. Cap Supports cap supports If you are experiencing registration or sew quality problems in parts of your design, you may need to adjust the cap supports (Figure 5-1).
5-2 Wide Angle Cap Frame Cap Support Pads Check the pads under the cap supports regularly (see Figure 5-3). When pads become worn, they must be replaced. Follow these instructions to replace the pads: 1. Remove the old pads. 2. Clean the surface with a solvent such as isopropyl alcohol. 3. Remove the paper from the new pads (provided in the operator kit), exposing the adhesive surface. 4. Attach the new pads to the cap supports, and trim the new pads even with the supports.
Clip Posts 5-3 Spindles On The Clamps The clamps form a positive lock on the frame when it is installed on the driver. The clamps press the spindles against the rollers on the driver to form this lock. If the frame can move when it is installed on the driver, you should adjust the spindles. To adjust the spindle, follow these steps: 1. Loosen the upper nut on the spindle slightly (see Figure 5-7). 2. Move the spindle down until the upper nut contacts the spindle arm. 3.
5-4 Wide Angle Cap Frame Cap Frame The strap on the cap frame may need to be adjusted for different cap materials. The factory adjustment will suffice for most cap types, but if you need to adjust it, follow these steps: locator groove 1. Close the cap frame but do not fasten the latch. Make sure the strap is in the groove on the locator (see Figure 5-9). 2. Loosen the 2 wing nuts on the strap (Figure 5-10). Figure 5 - 9 3.
INDEX # G 24V Power Supply Removal/Replacement 2 - 32 Glossary Of Terms Grabber Blade Adjustments Replacement Grabber Drive Assembly Grounding Strap Use A AC Input Voltage Selection Accessory Adjustments Wide Angle Cap Frame Adjustable Fixed Knife Adjustment Replacement Arm and Bed Assembly 2 - 30 5- 1 4 - 16 4 - 19 4 - 11 3- 1 Hook Timing Adjustments EMT 10/4T Technical Manual 3 - 13 2 - 27 J 2 - 25 2 - 24 Jump Stitch Solenoid Adjustment Bracket Positioning Plunger Positioning Replacement 3 - 1
INDEX Needle Case Removal Head #1 Head #s 2, 3, and 4 Needle Depth 3 - 29 3 - 31 3 - 44 P Physical/Functional Arrangement 1- 4 Picker Assembly 4- 9 Finger Position 4 - 27 Height/Depth Position 4 - 28 Home Position 4 - 28 Picker Solenoid Assembly 4- 8 Home Position Optical Switch 4- 9 Power and Light Switch Removal/Replacement 2 - 34 Power Distribution Section 2 - 30 Power Supply Assembly Removal/Replacement 2 - 31 Voltage Adjustments 2 - 31 Presser Foot / Needle Bar / Associated Parts Replacing 3 - 27 T
INDEX Z Z Drive Mechanical System Z Motor Replacement Z Motor Belt Tensioning Z Shaft Encoder Calibration Inspection Installation Introduction Z Timeout Errors EMT 10/4T Technical Manual 3- 1 3- 2 3- 4 3- 7 3 - 10 3- 8 3- 8 3- 7 4 - 13 iii 110279-01, Rev.
