Melco EMT 10/4T Specifications

• Four Melco Embroidery Heads• Tubular Goods Hooping• 10 Needles with automatic color change• Automatic Trimmer Option• CompliantTechnical Man

Electrical GroundingWARNING! It is very important that the power cord be pluggedinto a properly wired electrical outlet. Failure to have aproperly wi

6. The beam makes two moves that clears the top thread (now called the tail) outof the material. 7. At approximately the same time the threads are be

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 grabbe

Grabber AdjustmentsTo check grabber blade travel follow these steps: 1. Insure the embroidery heads are synchronized and position them to headup. 2. T

When fully retracted, the grabber blades should be inside the guide just behind theVelcro wiper bar at the bottom of the needle case area. There are t

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.Trimmer Drive AssemblyTrimmer CamThe trimmer

5. Loosen the set screw in the top of the solenoid mount, then rotate the solenoidassembly out of the mount. 6. Rotate a new solenoid assembly into t

CAUTION! Be careful not to lose the solenoid return spring in thenext step. 3. At the solenoid plunger, loosen the set screw in the picker swivel clam

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

11. After replacing a movable knife refer to the trimmer adjustment procedures laterin this chapter for the adjustable fixed knife.Adjustable Fixed Kn

Another distinct section of the EMT 10/4T is the embroidery head section. Thissection consists of each of the 4 heads, the Z drive motor and associate

8. Install the socket head cap screw to secure the adjustable fixed knife and theunder thread presser. Snug the cap screw until the parts are held se

Trimmer Adjustment ProceduresOne procedure combining all the required adjustments organized in specific order ispresented in this section for providin

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

Trimmers Not Trimming ProperlyWhen the trimmers are not providing adequate trim quality, there are three generalareas that may be contributing to the

This situation may result if the adjustable fixed knife is worn or is not parallel to thetrimming action of the movable knife. Check this condition of

Checking the under thread presser is done in two parts. First by looking at the partitself to see if there has been any "crumpling" as shown

6. If the under thread presser does not provide the required action, replace it andcheck using steps 2 to 4 again. 7. After you are satisfied with th

Knife AdjustmentAfter performing the ink wipeoff test and determining that adjustment to theadjustable fixed knife is required, follow these steps to

11. Check the tightness of the top socket head cap screw and recheck theadjustment by performing the ink wipeoff test once again.Cut ThreadsWhen you a

If the CPU PCB is ever replaced, you must reconfigure the peripheral before using itagain.CAUTION! If the EMT 10/4T is not configured with the correct

5. The movable knife should be located under the adjustable fixed knife, positionedas shown in Figure 4-18. If the sloped rear tip of the movable kni

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

12. Check the reading of the display to be between 311 and 313 degrees.13. If the movable knife does not contact the fixture between 311 and 313, orco

3. Loosen the large sockethead screw in the lockingcollar for the Top BobbinDrive Pulley (see Figure4-21) and rotate the beltand pulley slightly unti

Picker Finger PositionIf the cap frame option is not part of your system, you may refer to the followingprocedure to center the picker fingers, should

Picker Home PositionNote: This procedure requires the use of a special service tool: the Melco pickerset fixture (p/n 995339-01). 1. Install the picke

Under Thread Control (UTC) ReplacementTo remove the UTC assembly refer to the steps that follow: 1. With the machine in the head up position, turn the

8. Place the UTC assembly under the needle plate support bracket as shown inFigure 4-25 and install the 2 UTC assembly mounting screws. 9. Perform th

UTC AdjustmentsIt is very important that you follow these instructions any time the rotary hook orUTC is loosened or moved. Please follow the instruct

GREEN (all but (5) should be ON) 10) +5V (+24V based) OK 9) +5V (+12V based) OK 8) +12V OK 7) -12V OK 6) +24V OK 5) Always OFF - Not Used

8. Position the UTC assembly until the gap between the retaining finger tab and therotary hook inner basket notch is set to the thickness of the gaug

14. Check that the movable knife clears the UTC detection arm by physically movingthe knife under the UTC detection arm and back.15. If the knife touc

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 i

5. Accessory AdjustmentsWide Angle Cap FrameThe Wide Angle Cap Frame (also referred to as "WACF") has several adjustablecomponents. Refer t

Cap Support PadsCheck the pads under the cap supports regularly (see Figure 5-3). When padsbecome worn, they must be replaced.Follow these instruction

Spindles On The ClampsThe clamps form a positive lock on the frame when it is installed on the driver. Theclamps press the spindles against the roller

Cap FrameThe strap on the cap frame may need tobe adjusted for different cap materials.The factory adjustment will suffice formost cap types, but if y

#24V Power Supply Removal/Replacement 2 - 32AAC Input Voltage Selection 2 - 30Accessory AdjustmentsWide Angle Cap Frame 5 - 1 Adjustable Fixed Knife

Needle Case RemovalHead #1 3 - 29Head #s 2, 3, and 4 3 - 31Needle Depth 3 - 44PPhysical/Functional Arrangement 1 - 4 Picker Assembly 4 - 9 Finger Po

ZZ Drive Mechanical System 3 - 1 Z MotorReplacement 3 - 2 Z Motor BeltTensioning 3 - 4 Z Shaft Encoder 3 - 7 Calibration 3 - 10Inspection 3 - 8 I

Various Technical SpecificationsThe following is a list of various tension and force specifications for the EMT 10/4T(All specifications to be within

2. Service Maintenance (except head and trimmer)GeneralThis section of the manual provides parts replacement procedures and variousadjustments require

Disk Drive Panel Assembly 1. To remove the disk drive panel assembly from between the needle cases of themiddle two heads, remove the 2 screws at the

4. To remove the panel assembly completely you must disconnect all harnessconnections associated with the switches in the panel assembly. 5. For rein

Right CoverTo remove the right end tensioner cover, loosen two screws at the rear (going intothe rear tensioner cover) and remove three screws at the

Display Screen Intensity 1. Turn OFF the power switch to the EMT 10/4T. 2. Refer to the removalprocedures earlier in thischapter and remove thetension

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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

X Beam AssemblyThe X beam assembly consists of the X carriage, X motor and belt, X drive belt, andvarious other mechanical components that make up the

Belt TensionNOTE: This procedure requires a specific Melco force gauge (p/n 995586-01) forproper adjustment. 1. Refer to Figure 2-6 and ensure the two

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

Lint WiperLocated on the underneath side of the X drive belt tensioner block is a piece ofVelcro attached with adhesive. This item is used to keep the

10. If replacing the motor belt, remove the screws securing the motor mountbracket to the X beam.11. Carefully slide the motor mount bracket away from

16. Reconnect the X motor drive harness and encoder harness into their respectivemating connectors on the X beam PCB.17. Carefully tuck the two X moto

Y Drive BeltThere are four Y drive belts used on the EMT 10/4T. One each is associated with theY carriage assemblies in the channels at either end of

4. Position a hex wrench onto one of the two cap head screws in the front of theframe for adjusting the belt tension (see Figure 2-10). 5. Note the l

Caution: Overtightening the screws in the next step may cause thebelt clamp to be damaged. 8. Place the new belt around the two pulleys. Secure both e

Table of Contents1. IntroductionScope Of Manual 1 - 1Standard Conventions Used In Manual 1 - 1Glossary Of Terms 1 - 2Maintenance Philosophy 1 - 2Good

10. Check the Y drive belt tension on the other three belts the same method as inthe previous steps.The tensions of the four belts should be within 0.

Under Carriage SectionThis section of the peripheral consists primarily of the assemblies lying in and aboutthe support frame of the machine (see Figu

3. There are two harnesses leading from the motor and one harness connected tothe motor encoder. Disconnect the motor encoder harness connection. 4.

10. Rotate the four socket head cap screws until the slack is taken up between thescrew head and the associated hardware. DO NOT, however, tighten the

6. At the front of the machine loosen each Y drive belt by loosening the two sockethead cap screws at each of the four belt tensioning pulley idler a

13. Slip the Y drive belt off the open end of the Y shaft drive pulley assembly andthen slip the Y motor belt off the pulley assembly and out of the Y

XYZ Motor Drive AmplifiersThere are three identical XYZ Motor Drive Amplifiers located inside the motoramplifier assembly in the top support platform

Module ReplacementTo replace one or more of the XYZ Motor Drive Amplifiers refer to the followingsteps: 1. Turn the peripheral OFF. 2. WAIT ONE MINUTE

Electronics SectionThe electronic section consists of the major electronic printed circuit boards locatedwithin an RFI controlling box called the card

Card Cage ComponentsInside the card cage is found the Backplane PCB lying against the end of the chassisleg with its respective PCBs inserted into its

Under Carriage Section 2 - 17Y Drive Motor Replacement 2 - 17Y Motor Belt Replacement 2 - 19Adjustments 2 - 21XYZ Motor Drive Amplifiers 2 - 22Current

CPU PCB ReplacementThe CPU PCB is the first PCB located toward the front of the card cage as shown inFigure 2-19. Refer to the following procedure for

6. Replace the Ethernet PCB by reversing the previous steps. 7. Install the screw and washer at the card edge mounting bracket to secure theprinted c

5. Grasp the PCB at the corners and gently rock it out of its connectors in thebackplane board. Remove the PCB.CAUTION! It is advised to place the r

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 backpla

Power Distribution SectionThe AC voltage distribution panel, power supplies, and associated circuitry for theEMT 10/4T are located inside the left cha

Voltage AdjustmentsAll voltage values are regulated within the operating ranges of the machine design.Therefore, NO adjustments are required for volta

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 id

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

Power and Light Switch Removal/Replacement 1. Refer to Figure 2-24 and unplug the main power cord at the entry module on theAC voltage distribution pa

3. Embroidery Head MaintenanceGeneralThis section of the manual provides parts replacement procedures and variousadjustments required during repair ma

Jump Stitch Solenoid 3 - 17Replacement 3 - 17Adjustment 3 - 19Plunger Positioning 3 - 19Bracket Positioning 3 - 20Color Change 3 - 21PCB Replacement 3

The alignment and calibration of this mechanical system is critical for properoperation of the EMT 10/4T Embroidery Peripheral.Z Motor Replacement N

3. Disconnect the Z motor harnesses from the associated in-line XYZ driver harnessconnections. 4. Remove the four socket head cap screws attaching th

7. Place the pulley on the new motor shaft and, before tightening the pulley setscrews, perform the next steps to insure the motor shaft pulley is po

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, ch

NOTE: It remains IMPORTANT to insure that the Z drive shaft stays at the HUposition during this procedure. 6. Loosen the socket head cap screw in t

Z Shaft EncoderIntroductionThe ability to place stitches precisely at high speed is dependent on the accurateoperation of the electronics and electrom

InspectionThis procedure is a guide for determining the condition of theencoder.Inspect the Z shaft encoder following the steps below. If therequireme

CAUTION! If the Z shaft encoder is replaced, DO NOT OPERATE THEEMBROIDERY PERIPHERAL until the new Z shaft encoder is properlycalibrated!To replace t

9. Insert the encoder shaft into the shaft coupling.10. Tighten the jam nut, and then snug the coupling socket head cap screws ontothe encoder shaft.

5. Slowly rotate the heads at the 5mm socket head cap screw in the right end ofthe Z drive shaft until the headup alignment pin tool inserts into the

Trimmer Adjustment Procedures 4 - 13General 4 - 13Z Timeout Errors 4 - 13Damaged Trimmer Cam or Trimmer Solenoid 4 - 14Checking "Head Up" Po

Thread Tensioner AssemblyAssembly RemovalThe thread tensioner assembly is attached to the top of the needle case. To removethe tensioner assembly refe

2. Carefully grasp the thread guide tubes individually and remove them from thethread tensioner bracket assembly by pulling on each thread guide tube

Changing A Check Spring 1. As described in the previous procedure, remove the thread tensioner associatedwith the check spring that is being changed.

Check Spring AdjustmentAfter replacing a thread check spring, install the thread tensioner into the threadtensioner mounting bracket. You must then ad

If you rotate less than 2 spokes you will begin to lose the force needed to make atight stitch. You may have enough stroke but not enough force to cin

Jump Stitch SolenoidReplacementIf a jump stitch solenoid must be replaced, follow these steps: 1. Color change the needlecase to needle #10 forbest ac

8. Replace with new solenoid by reversing the procedure above. Adjust the positionof the solenoid into the solenoid bracket using the "thread co

AdjustmentIf a jump stitch solenoid has been replaced, you may have to perform one or moreof the following adjustment procedures. The needle case must

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

Color ChangeThe color change PCB, the color change motor, the cam, and harnesses are locatedunder the color change covers behind the embroidery head t

1. IntroductionScope Of ManualThe EMT 10/4T Embroidery Peripheral Technical Manual is a guide for performingrepairs and adjustments that go beyond rou

CAUTION! The Color Change PCB is snapped into place on top ofthe color change bracket. Be careful not to damage the photosensors or any other compone

Color Change Motor ReplacementTo remove the color change motor refer to the following steps: 1. Remove the color change area covers and tensioner cove

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 c

Color Change Cam Assembly ReplacementIf replacing the color change cam and associated hardware, refer to the followingprocedure to allow the new assem

9. Position the outer split-hub clamp and spacer against the left outside of thebracket and the color change cam against the two 2.75mm thrust washer

Needle CaseReplacing a Needle Bar / Presser Foot / Associated PartsTo replace a needle bar, presser foot, or other parts associated with this area ref

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 andtransfer th

14. You may reinstall the upper needle case cover at this time. The lower needlecase cover must, however, remain off to perform the needle bar heighta

7. Hold the needle case securely with one hand while you remove the 4 socket headcap screws that secure the needle case to the bearing retainer plate

8. Lift the needle case slightly to disengage the lower rail from the lower railretainer coming from the bottom of the embroidery head arm. 9. The ne

• To indicate that two or more keys must be pressed to obtain a desiredresult, each key is indicated with commas between them. An example is:Press Shi

5. Check for proper adjustment of the retainer plate assembly bearings by referringto the retainer plate bearing adjustment procedure. 6. Reinstall t

4. Position the left edge of the cross roller bearing in line with the left edge of theretainer plate and the center of the needle bar guide shaft fe

6. Tighten the socket head cap screws securely and remove the fixture. 7. Push the retainer plate assembly left and right as far as possible without

7. Install the new reciprocator into the head (see Figures 3-31 and 3-32). Make sureit is oriented properly and insert the connecting stud onto the c

Installing Needle CaseTo reattach the needle case refer to the following procedure:Head #1 1. Insure the following conditions are set: a) The

2. Refer to Figure 3-28 and insert the needle case lower rail into the lower railretainer. Insure the grabber blade fits into the grabber bar assembl

7. Remove the clamping devises from each end of the V-rail and reinstall all coversthat were removed during the procedure. 8. Power up the peripheral

b) The needle case rests solidly and completely on the bearing retainer plateassembly and is positioned to the right so the right side of the

gap between zeropreload and .002"lower railretainerrollerbearingscrew (underlower rail retainer)needle caselower rail(needle caseremoved toshow d

Rotary HookHook ReplacementThis procedure includes steps for setting hook timing during the hook installationprocess. After completing this procedure,

Good Maintenance PracticeThe procedures in this manual are guidelines for performing repair maintenanceand must be used by personnel practicing good m

12. Press the keys. Thehead rotates to the ‘‘NeedleDepth’’ position without bringingthe needle down and the LCDdisplays NEEDLE DEPTH

19. Install the UTC assembly with the retaining finger tab inside the rotary hookbobbin basket notch. Install the screws.Adjust The UTC AssemblyYou mu

If the clearance needs to be adjusted proceed with the next step. If OK, go to theNeedle Depth adjustment procedure.25. Slightly loosen the two small

32. Next press . The head rotates one revolution. The LCD displays ONEREVOLUTION 110.0. The needle bar should be down with the presse

40. Loosen the screw on the upper-dead-stop clamp again and slide the clampagainst the upper stop bumper. The screw must be positioned directly forwar

Hook Timing Adjustments OnlyThis procedure is for checking and setting hook timing adjustments when the hookassembly is not being replaced. If you are

If hook timing is correct,proceed to the UTCAdjustments in the nextprocedure. If hooktiming is NOT correct,proceed to Step 11.11. While the hook is st

20. Position the POINT of the HOOK directly behind the SCARF of the needle. Leavea THREAD distance between the POINT of the hook and the needle.21. T

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4. Trimmer MaintenanceGeneralThis section of the manual provides parts replacement procedures and variousadjustments required during repair maintenanc