EMT16 Technical Manual - Melco Tech

1 EMT16 Technical ManualRev, 904182 of 273 ContentsCopyright Notice 9 About This Manual 10 Scope of Manual 11 Standard Conventions and Definition of Terms 12 Regulatory Notices 13 Best Maintenance Repair Practices 14 Maintenance Philosophy: 14 Grounding and Static Electricity 17 Machine Orientation 19 Safety Issues 20 Warranty Considerations 21 Explanation of Machine Symbols 22 Keypad Operations 23 Keypad Buttons 26 Trace Button 26 Arrow Up Key (Y-Axis Back) 26 Color Change/ needle Case 26 Arrow Left Key (X-Axis Left) 26 Arrow Right Key (X-Axis Left) 27 Center Key 27 Adjustment Key 27 Arrow Down Key (Y-Axis Forward) 27 Hoop Key 28 Step Back Key 28 Step Forward Key 28 Laser Key 28 Start Button 28 Stop Button 29 Emergency Stop Button 29 LED Indicator 30 Specifications 31 Technical Specifications 33 Torque Specifications 343 of 273 Software Maintenance Menus 36 Special Tools and Fixtures 37 General Maintenance 38 Cleaning 38 Lubrication Schedule and Specifications 40 Maintenance Schedule 40 Daily Maintenance 42 Weekly Maintenance 43 Monthly Maintenance 45 Quarterly Maintenance 51 Thread Cutter Blade Replacement 61 Centering The needle Plate 62 Head Up Position Adjustment 63 Mechanical Head-Up Position 63 Adjusting Head-Up (Z-Home) Position.

2 64 Hook Timing Inspection/Adjustment 65 Rotational Hook Timing Inspection Procedure 65 needle To Hook Gap Inspection Procedure 67 Adjustment Procedure 67 Thread Clamp Replacement 71 Thread Clamp PCB Replacement 72 Thread Clamp Harness Replacement 72 Laser Light - Adjustment 74 needle Depth 76 Setting the needle Depth by Eye 76 Presser Foot Height 77X/Y Home Adjustment 78 Home Adjustment Procedures: 78X-Cable Tension 81 Determining if an X-Cable is Set to Required Specifications 81 Adjusting an X-Cable that is Tensioned Outside the Required Specifications 82Y-Axis Timing Belt Tensioning 84Y-Axis Belt Tension Inspection 84Y-Axis Belt Tension Adjustment 85 When Belt Tensions are Correct 85Y-Motor Timing Belt Tensioning 86 Inspection and Adjustment 864 of 273Z-TIMING: Bottom Center & Head-Up 87 Bottom Center (Z Timing) 87Z-Drive Belt Tensioning 92 Inspection and Adjustment 92Z-Home Adjustment 94 Procedure to Identify the Closest needle 95 needle Case Calibration 98 Fine calibration procedure: 98 Rough Calibration Process: 99 Rotary Hook Support Adjustment 101 Inspection Procedure 101 Adjustment Procedure 103 Color Change, Take-Up, Feeder Housing Assembly 105 Replacement Procedure for Entire Color Change/Take-Up/Feeder Assembly: 105 Color Change Linear Actuator Replacement 107 Replacement Procedures: 107 Thread Feeder Gear Replacement 110 Replacement Procedures: 110 Thread Feeder Optical Sensor PCB Replacement 112 Replacement Procedure: 112 Thread Feeder Radial Bearing Replacement 113 Replacement Procedures: 113 Thread Feeder Stepper Motor Assembly 114 Replacement Procedure.

3 114 Laser Pointer Assembly 116 Replacing the laser assembly: 116 LED Cluster PCB Replacement 118 Presser Foot Assembly Replacement 119 Reciprocator 122 Replacement Procedure 122 Take-Up Lever Cam Replacement 124 Replacement Procedure 124Z-Drive Repair and Adjustment 127Z-Drive Belt Replacement and Tensioning 127Z-Home Sensor PCB Replacement 1295 of 273Z-Belt Idler Assembly Replacement 131Z-Motor Assembly 132 Clearing Thread from Thread Feeder Roller 135 Color Change Spindle Mounting Bracket Replacement 137 Grabber Blade Replacement 139 needle Case Removal 142 Needlecase Installation 144 Grabber Stepper Motor Replacement 146 Take Up Lever Replacement 147 Thread Feeder (replacement and adjustment) 149 Thread Sensor Assembly Replacement 152 Bobbin Shaft Overhaul 154 Rotary Hook Replacement 156 Main PCB 158 Power Input Assembly Replacement 161 Power Input Assembly & Inline Coupler Replacement.

4 162 Power Input Assembly Component Replacement: 164 Power Input Assembly Installation: 169 User Interface Assembly Replacement 170 Harnesses 173 Color Change Motor Harness 174 Ethernet Harness 177 Grabber/Threadfeed Motor Harness 179 Grabber/Threadfeed/CC Home Harness 183 Laser Harness 186 LED Cluster Harness 188 Replacement Procedures: 188 Thread Break Harness 192Z Home Harness 1956 of 273 User Interface Harness 198X/Y Home Harness 201 Bearing Block Assemblies 204X-Beam Assembly 206X-Carriage Assembly 208X-Drive Cable Removal 210X-Drive Cable Installation 212X-Drive Motor Replacement 216X-Home Optical Switch Assembly Replacement 219X/Y Home PCB Replacement 221Y-Drive Belt Replacement 223Y-Motor Assembly 225 Troubleshooting 227 Grabber Function Test 228 Final Functional Tests 230 Optical Sensors Test 232 Power Supply Test 233 Servo Motor Resistance Test 235 Stepper Motor Resistance Test 236 Servo Motor Resistance Test 237 Test Designs 238 Thread Tension Test 239 Belt Tension Test 239 Long Stitch Test 240 Looping Test 240 Orientation Test 241 Registration Test 241 Small Alphabet Test 241 Thread Break Sensor Test 242 Thread Break Test 242 Trimmer Test 2437 of 273 Electrical Failures 244

5 Color Change Failures 244 LED Cluster Assembly Failures 245 Mechanical Failures 246 False Thread Breaks 246 Loose/Looping Stitches 246 needle Breaks 246 Skipped Stitches 247 Thread Breaks 248 Miss-Starts 252 Cap Frame Issues 252 Miscellaneous Problems 253X-Axis Failures 254Y-Axis Failures 255Z-Axis Failures 256 Software Error Messages 257 DSP Command Errors 258 Can t Initialize Stepper Motors 258No Trace Data 258XY Home Not Set 258 Goto Func Error 259 Hoop Center Error 259 Stepper Motor Time Out and Index Errors 259E-Stop Engaged 260 Servo Motor Errors (Move Time Out, Tracking, and Over Current Errors) 2628 of 273 Critical Measurements 264 Introduction 264 needle Drive Stud to Reciprocator Fit 265 Hook Timing 265 Upper Arm to Lower Bed Alignment 265 needle to Hook Gap 266 Hook to Rotary Support Gap 266 Take-Up Lever Stroke 266 Take-Up Lever Fit to Shaft 267 Take-Up Lever Endplay 267 Cam Follower Preload 267 Pull Force on Take-Up Lever 268 Color Change Lead Screw 268 Color Change Housing Location 269 Bobbin Tension 269 Presser Foot Adjustment at Bottom Dead Center 270 Thread Feed Forward 200 271 Needles

6 271 Thread Clean Thread Path 272Z-Belt Tension 272X-Cable Tension 273Y-Axis Timing Belt Tension 273 Proper Lubrication of Moving Parts 2739 of 273 Copyright Notice Copyright Melco , 2017 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 from the author. The author reserves the right to revise this publication and to make changes in it at any time without obligation of the author to notify any person or organiza-tion of such revisions or precautions have been taken to avoid errors or misrepresentations of facts, equipment, or products. However, the manufacturer does not assume any liability to any party for loss or damage caused by errors or machine technology is protected by - but not limited to - the following patents: Pat.

7 US 6,445,970 B1 Pat. US 6,736,077 B2 Pat. US 6,732,668 B2 Pat. US 6,823,807 Pat. US 6,871,905 Pat. US 6,983,182 B2 Pat. US 7,513,202 Pat. US 7,308,333 B2 Pat. US D474,785 S Pat. CH 693569 A5 Pat. US 8,851,001 B2 Other patents pending 10 of 273 About This ManualThis Manual contains instructions on repairs and adjustments to the embroidery machine, in addition to other Technical you do not fully understand any information in this Manual , you are advised to contact your local au-thorized Technical support provider for of 273 Scope of ManualThis Technical Manual is a guide to performing repairs and adjustments that go beyond routine operator these procedures are best understood and performed by professional service technicians in conjunction with specific factory Technical training, much of the information in this Manual is a useful reference for others who might possess appropriate Technical aptitude and skills.

8 Note: This Manual is written for individuals with adequate knowledge, Melco certified training or equivalent and experience in the use of tools required. No attempt is made to explain how to use tools required to make repairs to the machine other than graphical depictions within the procedures Technical Manual specifies that certain functions are to be performed only by authorized service tech-nicians. This is because specialized training and/or special tools or fixtures are required in order to per-form the function correctly. Performing repairs to the machine may result in damaged components, poor machine performance, and potential injury to the technician or operator. If you do not fully understand any information in this Manual , contact Technical support for assistance before performing the procedure. The Technical support staff are professional service technicians trained on this equipment.

9 They have acquired Technical expertise through experience and Technical training. Additionally, certified equipment technicians routinely receive up to date servicing information to further enhance their product Technical Manual is presented in six sections:1. Introduction to the Manual and various service requirements2. General information and specifications containing all of the engineering settings and specifications you need to know when adjusting the machine3. Lubrication schedules and procedures4. Service and repair - detailed instructions to service and repair the machine5. Options - maintenance and repair of optional equipment6. Troubleshooting - a troubleshooting guide for problems commonly encountered with the of 273 Standard Conventions and Definition of TermsThroughout this Manual abbreviations and specific terms may be used. When abbreviations or techni-cal terms are used, they are defined through the use of pop-up hot spots, which opens a dialog box to explain their meaning.

10 Hot spot text is green and underlined. To access a pop-up hot spot simply click the underlined word to read its procedures in the Manual require actions such as pressing a certain key, or typing some letters on the computer keyboard. The following is a list of some of the more commonly used conventions found in this Manual : To indicate a key on the computer keyboard, the key in question is enclosed in brackets, for exam-ple: Press the [Enter] key to initiate the application. A key on the interface keyboard is represented by a picture of that Styles:Occasionally in the Manual , special attention is required. In these situations, certain images and text styles are used to attract your attention to a particular message. The following styles are used to denote certain types of messages. WARNING!! Situations which may result in personal injury if not performed correctly.