Melco EMT 10/4 Specifications

• Four Melco Embroidery Heads• 10 Needles with automatic color change• Automatic Trimmer OptionTechnical manual forthe EMC 10/4embroidery peripheralPa

Physical/Functional ArrangementThe EMC 10/4 may be divided into several distinct physical and/or functional areasof description (see Figure 1-1). All

3. Rotate the upper part of the needle case into position on the front of the headas you insure the following alignments: a) All the take up

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 Secti

Replacing Needle Case Cross Roller BearingRefer to the figures within the needle case removal and installation procedures forthis procedure. 1. Remove

Replacing Reciprocator / Needle Bar Guide Shaft 1. Remove the needle case as described previously in this manual. 2. Loosen the set screw from the lef

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 o

Jump Stitch Solenoid ReplacementIf a jump stitch solenoid must be replaced, follow these steps:Head #4 1. Remove the left color change cover behind th

5. Loosen the solenoid locking nut then rotate the bracket off of the solenoid. 6. Replace with new solenoid by reversing the previous procedure. Adj

NOTICE: Before you remove the solenoid from the bracket, record the number ofthreads of the solenoid that are showing beyond the solenoid bracket (orm

6. Locate and disconnect the thread break harness from the rear of the threadtensioner PCB.CAUTION! The Color Change PCB is snapped into place on to

11. Reinstall the thread break harness connection to the thread tensioner PCB, thenrefer to Section 2 of this manual to adjust the thread break contac

The Under Carriage Section is described as that area under the embroidery headplatform and within the frame support legs. The X and Y drive motors are

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

5. Lay the color change mount key into the embroidery head key way, then put thenew color change bracket (with the cam) into position. 6. Ensure the

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 t

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 th

Trimmer Drive AssemblyTrimmer CamFACTORY SERVICE ADVISED!This assembly is mounted under the head in the rear bed. To remove thismechanical assembly re

5. Loosen the hex nut between the the solenoid body and the mount, then rotatethe solenoid assembly out of the mount. 6. Rotate a new solenoid assemb

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

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 r

9. Rotate the knife and arm clockwise until the back side of the knife is restingagainst the left side of the needle plate bracket.10. Tighten the he

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 co

The second configuration item is the network address (or Unit Number). The UnitNumber must be set and be different for each peripheral attached to an

UTC ReplacementTo 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. R

8. Place the UTC assembly under the needle plate support bracket as shown inFigure 3-47 and install the 2 UTC assembly mounting screws.10. Perform th

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#+5 Volt Power Supplyadjustment 2-10AAC Voltage Selection 2-9BBackplane PCB Replacement 3-8CCheck Springadjustment 2-19replacement 3-24Color Change Ca

Thread Tensionerreplacement 3-24Thread Tensioner Bracketremoval 3-23Thread Tree Assemblyremoval 3-22Trimmer Cam 3-48Trimmer Interface Board Replacemen

The peripheral will now be in the ‘‘configuration mode,’’ and you can release the 3keys.NOTE: If the unit is already ON, but has not yet "downloa

This page intentionally left blank1 - 8 System OverviewEMC 10/4 Technical Manual Melco Embroidery Systems

2. Service AdjustmentsGeneralThis section of the manual provides detailed information for performing machineadjustments required during maintenance or

Keyboard SectionOperator control of the EMC 10/4 is performed through the keyboard keys. Thedisplay, in turn, provides machine communication back to t

Carriage SectionThis section consists of the mechanical device and associated parts for securing andmoving the hoops in the x and y coordinates during

5. Position the X carriage left/right movement to center the cap frame driver hoopnotch directly over the cylinder arm cover of the embroidery head a

10. Refer to the following X Drive Belt Tension procedure to retension the belt.X Drive Belt Tension"FACTORY SERVICE ADVISED"Note: This proc

1575 West 124th AvenueDenver, Colorado 80234United States of AmericaInternet Address: [email protected] © Melco Embroidery Systems, 19

7. With the carriage still centered, attach the X-Belt Fixture (p/n 995509-01) ontothe x carriage belt, centered between the spline drive pulley and

Y Drive Belt Tensions Note: This procedure requires the use of a special service tool: the Gates 5MTensiometer, available from Melco, part number

Under Carriage SectionThis section is physically located in and about the peripheral support framework. TheX and Y motors are attached under the embro

Y Motor Belt TensionNote: This procedure requires the use of a special service tool: a 0 to 40 poundpull gauge. 1. Loosen the 4 Y motor socket head ca

Power Supply +5 Volt AdjustmentThis adjustment is for setting the +5 volts required for all electronic control systems. NOTE: There is no adjustment

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 thema

Head SectionWithin this defined section, you will find the embroidery heads and associated partssuch as, the thread tree, thread tensioners, and needl

At the left end of the Z drive shaft is a pulley, driven by a belt, which in turn isdriven by the Z drive motor. Also at this end of the Z drive shaft

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 thedisk at the right end o

7. Loosen the socket head cap screw in the locking collar of the bevel gear on the Zdrive shaft associated with the embroidery head (see Figure 2-14)

Table of Contents1. Introduction 1 - 1Scope Of Manual 1 - 1Warranty Registration 1 - 1Standard Conventions Used In Manual 1 - 1Explanation Of Symbols

Z Encoder System IntroductionThe ability to place stitches precisely at high speed is dependent on the accurateoperation of the electronics and electr

Z Encoder Inspection"FACTORY SERVICE ADVISED" This procedure is a guide for determining the condition of the encoder. Ifunauthorized personn

9. Inspect the electrical connectors (encoder cable plug and encoder body) for loosewires, loose fits, and any visual damage. Clean connections and/or

5. Locate the third LED in from the end on the top left of the CPU. Most likely thisLED will not be glowing. It is only supposed to glow for a 1 degr

2. Rotate the thread tensioner to the position where the check spring is justtouching the left side of the thread break contact (brass post). See Fig

Cross Roller Bearing CenteringThe cross roller bearing must be installed between the embroidery head v-rail andthe needle case v-rail attached to the

6. Check that the cross roller bearing is centered in the 2 v-rails by the followingmethod: a) Center the retainer plate assembly on the embr

5. Carefully and slowly rotate the v-rail adjustment fixture (either clockwise orcounter-clockwise) until you feel a slight resistance. The left and

A5.Loosen the V-rail sockethead cap screw on theside you are attending.(With the upper needlecase cover off, you canreach the screw throughthe front o

1. Install the needle case into the lower rail retainer and attach the needle case tothe retainer plate assembly. Refer to Section 3 in this manual o

Plunger Positioning 2 - 25Bracket Positioning 2 - 26Color Change Motor Belt Tension 2 - 27Thread Break Brush Adjustment 2 - 28Head #4 2 - 28Head #s 1,

Bracket PositioningWhen attaching the jump stitch solenoid and bracket, it is not only necessary toplace the plunger correctly, but you must also posi

3. Attach the solenoid wires to the color change PCB on head #4 or the threadbreak harness connection on the other embroidery heads.Note: The two wire

Thread Break Brush AdjustmentHead #4The thread break brush must be adjusted to make proper contact with the threadbreak contact posts coming off the r

2. Loosen the thread break brush bracket mounting screws at the top of the head(see Figure 2-26). 3. Position the thread break brush so it is centere

Trimmer OptionThe trimmer option for the EMC 10/4 Embroidery Peripheral is assembled andthoroughly tested before the machine is shipped. Although the

7. At approximately the same time the threads are being cut and the beam ismoving to clear the tail, the grabber reaches out from behind the needle a

Damaged Trimmer Cam or Trimmer SolenoidTo check for a damaged trimmer cam or trimmer solenoid, refer to the followingprocedure: 1. Remove the rear bed

You should not feel any restrictions during the rotation. If you do, you may have adamaged trimmer cam or trimmer solenoid.NOTE: You may remove the tr

Physical Condition Of Trimmer PartsComponentIdentificationFigure 2-28, identifies those components that comprise the trimmer system: thespring knife,

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

Head Section 3 - 18General 3 - 18Arm and Bed Assembly 3 - 18Z Motor Replacement 3 - 19Z Shaft Encoder Installation 3 - 20Thread Tree Assembly Removal

3. Obtain a piece of upper thread from the tensioner assembly and drape it overthe movable knife (see Figure 2-30). 4. With the thread draped over th

Under Thread PresserThe under thread presser, shown in Figure 2-31, holds the bobbin thread after atrim. This permits a loop of bobbin thread for the

The second part of checking under thread presser is to check if the bobbin thread isin fact being held in place. 1. While the machine is still turned

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 shownin Fig

Home Position SensorIf the movable knife is mechanically adjusted correctly for home position, but the"Trimmer Not Home" message comes ON, t

Checking Select PositionAfter adjusting the movable knife home position, you must check for the movableknife "select" position. If adjustmen

13. If the movable knife does not contact the fixture between 311 and 313, orcontacts too soon, the select position adjustment may be required.Note: I

3. Loosen the large sockethead cap screw in thelocking collar for the TopBobbin Drive Pulley (seeFigure 2-35) and rotatethe belt and pulleyslightly u

2b. With both trimmers and cap frame options on the machine, move the bracket tocenter the installed cap frame driver on the embroidery head arm. 3.

1. To adjust the picker height/depth position, manually push the picker into place asshown in Figure 2-37. 2. Loosen the 2 screws on the left side of

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3. Manually move the grabber motor limit stop lever up to move the grabber bladesall the way out and then down to move the blades back again. (see Fi

To Adjust For A: 1. Position the grabber blades as far back as they will go into the grabber bladeguides by manually moving the motor limit stop lever

4. Tighten the set screw in the wire swivel. 5. Replace all covers after making the grabber adjustments.Under Thread Control (UTC) AdjustmentsIt is v

5. Place the finger of the UTC combination gauge (see Figure 2-43 for diagram ofthe gauge) between the retaining finger tab and the rotary hook inner

11. Refer to Figure 2-44 and lift the connecting link off of the movable knifeassembly.12. Check that the movable knife clears the UTC detection arm b

Additionally, if the bobbin tension is set too loose, it may also falsely indicate thatthe machine is out of bobbin thread when it has bobbin thread.P

B) Check that the UTC does not falsely signal the CHECK BOBBIN message whenthread is still on the bobbin. 1. Test for this by simply sewing

3. Mechanical DisassemblyGeneralThis section of the manual provides detailed information for performing partsreplacements that may be required during

Embroidery PeripheralRemoving the Rear CoversThe rear covers are attached to the peripheral frame with plastic tabs in the front ofthe covers and with

Controller Section Rear Cover #4Rear cover #4 covers the Controller Section which houses the EMI (Electro-MagneticInterference) box and its printed ci

1. IntroductionScope Of ManualThe EMC 10/4 Embroidery Peripheral Technical Manual is designed to provide theuser with information necessary to perform

2. To remove any or all of the lower front covers (between needle cases), removethe 2 screws (c) for each cover. Pull down slightly on the cover to r

Controller SectionCaution: When the EMI box cover is removed, three printed circuit boards areexposed. These are the CPU, the trimmer interface board,

CPU PCB Replacement 1. Turn OFF the power switch to the EMC 10/4 and remove the power cord fromthe power source electrical outlet and the rear of the

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 P

CAUTION! Once the Trimmer Interface board is removed from the EMC 10/4, useextreme care in handling it. Portions of this board are very sensitive to

7. Refer to Figure 3-6 inset and remove the zener diode assembly ring terminalfrom the top of the #2 head needle case. 8. Remove the 4 screws holding

Carriage SectionThis assembly and its installation to the peripheral requires specific factory toolingand training to maintain the assembly’s parallel

7. Lift the x carriage and y beam off the 3 supports and lay it up side down acrossthe 2 end table top sections. 8. Remove the socket head cap screw

12. Remove the remaining clamp from the old belt and perform the previousprocedure to attach the clamp to the other end of the new belt.13. Attach the

4. Remove the two screws, flat washers, and lock washers at the top of the Y-beltbracket. These screws go through the belt and into the belt clamp un

• Typing with the computer keyboard is referred to in BOLD letters, forexample: Type: run and press Enter to start.• To indicate that two keys must be

Under Carriage SectionX and Y Drive Motors and BeltsThe X and Y Drive motors are located below the embroidery heads and table top. The X motor prov

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 scr

2. WAIT ONEMINUTE, thenremove the coverover the XYZmotor driversection inside theleft framesupport leg (seeFigure 3-12). 3. Disconnect theharnesses a

Power Supply ReplacementThe power supply is mounted under the top cover between heads #1 and #2. Toremove the power supply assembly: 1. Turn the perip

Head SectionGeneralThe Melco embroidery head consists of several physical assemblies. This section ofthe manual describes the removal and replacement

Z Motor Replacement"FACTORY SERVICE ADVISED" Special tools are required for proper adjustment. Note: This procedure requires the use of a

8. Put the new motor in place in the support bracket and slip the drive belt over thepulley. Insure the other end of the drive belt remains on the pu

8. Insert the new encoder/shaft into the hole of the encoder mount, place thewasher and then the jam nut onto the encoder shaft as you insert the sha

Thread Tree Assembly RemovalIf you need to remove the thread tree for any reason, refer to the followingprocedure: 1. Turn OFF the EMC 10/4 and discon

Removing the Thread Tensioner Bracket AssemblyThe thread tensioner bracket assembly is attached to the top of the needle case. Toremove the tensioner

Glossary Of TermsSeveral words or terms are used in this manual that are unique or specialized in usewith the embroidery industry or Melco embroidery

Replacing An Individual Thread TensionerEach thread tensioner is secured by a set screw against the thread tensioner shaftinside the thread tensioner

3. Attach the new check spring as follows: a) Position the check spring around the end of the tensioner shaft as shownin Figure 3-21.

Replacing A Thread Break Contact Post 1. As described previously in this manual, remove the thread tensioner associatedwith the thread break contact p

Replacing The Thread Break Wiper BrushHead #4 1. Remove the two color change covers. 2. Locate the thread break wiper brush attached to the bracket co

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 brus

3. Refer the the procedure for removing the thread tensioner assembly and removeis as described in the procedure. 4. Remove the 2 screws holding the

10. Carefully captureand retain thevarious parts thatbecome released bythe needle bar asyou remove theneedle bar upwardand out the top ofthe needle ca

Needle Case Removal It may become necessary to remove the needle case from the front of the head toreplace the needle bar driver, take up lever gear,

upper needle casecover screwsembroideryhead v-rail(left end)clampingdevices onends of v-railbearing retainerplate assembly(left side)tensionersupportb

3. Remove the thread tensioner bracket assembly as described in a previousprocedure. 4. Position the needle case to mid-point (needle 5 or 6), then s