Melco Bravo - Troubleshooting

To Next Page

To Previous Page

220 of 271

Troubleshooting

This troubleshooting section is provided for the purpose in assisting you in diagnosing failures and

malfunctions of the machine. It is not all inclusive and should be regarded as guidance rather than

specication.

Table of Contents

Main Page

Contents2
Liquid Cleaning Compounds15
Obstructions15
Use Proper Parts for the Job15
Use the Correct Tools When Making Repairs15
Drive Belt Tensions16
Scheduled Maintenance16
Lubrication16
Torque Measurements16
Static Electricity17
Grounding Strap Use17
Machine Orientation19
Voltages20
Explanation of Machine Symbols22
Keypad Operations23
Keypad Buttons26
Trace Button26
Arrow up Key (Y-Axis Back)26
Color Change/Needle Case26
Arrow Right Key (X-Axis Left)27
Center Key27
Adjustment Key27
Arrow down Key (Y-Axis Forward)27
Hoop Key28
Step Back Key28
Step Forward Key28
Laser Key28
Stop Button29
Emergency Stop Button29
LED Indicator30
Specifications31
Technical Specifications33
Torque Specifications34
Software Maintenance Menus36
Special Tools and Fixtures37
General Maintenance38
Cleaning38
Exterior Surfaces38
Interior Surfaces (PCB)38
Rotary Hook and Trimmer Assembly Area39
Lubrication Schedule and Specifications40
Maintenance Schedule40
Daily Maintenance40
Weekly40
Monthly41
Quarterly41
Yearly41
Weekly Maintenance43
Needle Drive43
Left Upper V-Rail44
Right Upper V-Rail44
Oil Needle Bars (Lower)44
Monthly Maintenance45
Oil Needle Bars (Upper)45
X-Drive Rails45
Y-Bearing Blocks47
X-Cable Tension (Test)48
Quarterly Maintenance51
Thread Cutter Blade Replacement61
Centering the Needle Plate62
Head up Position Adjustment63
Mechanical Head-Up Position63
Adjusting Head-Up (Z-Home) Position64
Hook Timing Inspection/Adjustment65
Rotational Hook Timing Inspection Procedure65
Needle to Hook Gap Inspection Procedure67
Adjustment Procedure67
Thread Clamp Replacement71
Thread Clamp PCB Replacement72
Thread Clamp Harness Replacement72
Laser Light - Adjustment74
Laser Light Focus75
Laser Lens75
Needle Depth76
Setting the Needle Depth by Eye76
Presser Foot Height77
X/Y Home Adjustment78
Home Adjustment Procedures78
Determining if an X-Cable Is Set to Required Specifications81
Adjusting X-Cable that Is Tensioned Outside Required Specifications82
Centering the X-Carriage82
Positioning the X-Cable Tension Gauge82
Inspecting X-Cable Tension82
Adjusting the Tension on a Replacement X-Cable83
X-Cable Tension Adjustment83
Y-Axis Timing Belt Tensioning84
Y-Axis Belt Tension Inspection84
Y-Axis Belt Tension Adjustment85
When Belt Tensions Are Correct85
Y-Motor Timing Belt Tensioning86
Inspection and Adjustment86
Z-TIMING: Bottom Center & Head-Up87
Bottom Center (Z Timing)87
Needle Clamp and Weight88
Turn Z-Axis Flag Counter-Clockwise (CCW)88
Dial Indicator Installed on Needle Plate Bracket89
Z-Index LED (Location D50)90
Z-Drive Belt Tensioning92
Procedure to Identify the Closest Needle95
Needle Case Calibration98
Fine Calibration Procedure98
Rough Calibration Process99
Get Table Button100
Rotary Hook Support Adjustment101
Hook Retaining Finger Gauge101
Needle Plate Screws101
Head Timing Tab102
Hook Support Position Left-To-Right102
Retaining Finger Gauge Usage103
Hook Support Screws103
Rotary Hook Basket Notch103
Hook Support Adjustment104
Color Change, Take-Up, Feeder Housing Assembly105
Replacement Procedure for Entire Color Change/Take-Up/Feeder Assembly105
Color Change Linear Actuator Replacement107
Color Change Linear Actuator107
Right Color Change Spindle Mounting Bracket107
Anti-Backlash Nut108
Left Color Change Spindle Mounting Bracket108
Thread Feeder Gear Replacement110
Thread Feeder Optical Sensor PCB Replacement112
Thread Feeder Assembly112
Thread Feeder Radial Bearing Replacement113
Radial Bearing113
Radial Bearing Behind Needlecase113
Thread Feeder Stepper Motor Assembly114
Thread Feeder Stepper Motor114
Steppers Menu115
Laser Pointer Assembly116
LED Cluster PCB Replacement118
LED Cluster Assembly118
Presser Foot Assembly Replacement119
Presser Foot Assembly Installed119
Wire Installed through Take up Levers119
Reciprocator122
Reciprocator Assembly Installed122
Reciprocator Assembly122
Take-Up Lever Cam Replacement124
Take-Up Lever Connecting Arm124
Remove Center Screw124
Screws on Back of Take-Up Lever Cam125
Remove Hex Nut125
Endplate W/Spring Pin Pressed in Endplate- Back View125
Alignment Groove in Z-Shaft125
Z-Drive Repair and Adjustment127
Z-Drive Belt Replacement and Tensioning127
Z-Motor Drive Belt127
Z-Home Flag with Index Mark128
Lower Z-Shaft Drive Pulley128
Z-Home Sensor PCB Replacement129
Z-Home Sensor Fixture129
Z-Home PCB Mounting Bracket130
Cable Tie Around PCB130
Z-Belt Idler Assembly Replacement131
Z-Belt Idler Pulley131
Index Mark on Z-Index Flag131
Lower Z-Shaft Pulley131
Z-Motor Assembly132
Measuring Resistance between Motor Phase Wires132
Z-Motor PCB Connections132
Z-Motor Mounting Screws133
Clearing Thread from Thread Feeder Roller135
Removing Thread Feeder Front Cover135
Prying Thread Feeder Roller Loose135
Pulling Thread Feeder Roller out135
Color Change Spindle Mounting Bracket Replacement137
Grabber Blade Replacement139
Grabber Blade (Bottom View)139
Upper Trap Assembly Front Screw139
Upper Trap Assembly Hex Nut140
“Steppers” Submenu141
Needle Case Removal142
Needlecase Assembly142
Needlecase Access Cover Removed143
Loosen Top Screw143
Remove Nut143
Remove Thread Tubes143
Needlecase Installation144
Reciprocator at “Head Up” Position144
Grabber Stepper Motor Replacement146
Grabber Eccentric146
Grabber Stepper Motor Mounting Screws146
Take up Lever Replacement147
Right Take up Lever Bar Mounting Block147
Screws on Take up Lever Bar147
Retaining Clip148
Thread Feeder (Replacement and Adjustment)149
Needle Case Assembly149
Thread Tubes Connected to Thread Feeder Assembly149
Thread Feeder Assembly, Left Bracket149
Thread Feeder Assembly, Right Thread150
Thread Feeder Gears150
Gage Pin151
Thread Feeder Clicker151
Thread Sensor Assembly Replacement152
Bobbin Shaft Overhaul154
Bobbin Shaft Front View154
Bobbin Shaft Timing Pulley (Rear)154
Rotary Hook Replacement156
Main PCB158
Main PCB Installed158
EMI Cover159
Power Input Assembly Replacement160
Power Input Assembly Removal160
Power Supply Ground Wires160
Power Input Assembly Component Replacement161
Power Supply Harness Connection161
In-Line Coupler161
Power Input Switch Replacement162
Bottom Wiring Block (Switch Interface Leads)162
Top Wiring Block (Wire Leads from Power Interface Harness)162
Fuse Replacement163
Power Input Switch (with Fuse)163
Power Input Switch Wiring163
Fuse Holder163
Power Switch Interface Harness Replacement164
Power Switch Interface Harness Wiring to Power Supply164
Power Switch Interface Harness Wiring to Switch164
Power Supply Interface Harness Replacement165
Power Supply Interface Connector165
Power Supply Interface Harness Wiring to Power Supply165
Power Input Assembly Installation166
User Interface Assembly Replacement167
User Interface167
Keypad Submenu167
Keyboard Harness Connection168
Harnesses170
Color Change Motor Harness171
Color Change Harness Connection to Motor171
Right Wire Channel172
Harnessing Routed under Y-Motor172
Wire Access Hole172
Ethernet Harness174
Ethernet Harness Connected to Coupler174
EMI Cover over Main Board175
Ethernet Connector Location on Main PCB (J1)175
Grabber/Threadfeed Motor Harness176
Grabber Motor Lead176
Thread Feed Motor Lead176
Grabber/Thread Feed Motor Connection at PCB177
Harness Tie at Top Left of Needlecase Assembly178
Grabber/Threadfeed/CC Home Harness179
Grabber Home Harness Lead179
Thread Feeder Home PCB180
Grabber/Threadfeed/CC Harness Connection at Main PCB180
Laser Harness182
Laser Harness Connection to Laser Pointer Assembly182
Right Upper Arm Access Hole183
LED Cluster Harness184
Left LED Cluster Harness184
LED Cluster Harness Tied to Z-Motor Mounting Bracket184
Left Lower Arm Access Hole185
LED Cluster Harnesses Connected at Main PCB185
Right LED Cluster Assembly186
Right LED Cluster Harness186
Thread Break Harness188
Threadbreak Harness Connected to Sensor PCB188
Connection at Main PCB189
Routing of Harness to Top of Needlecase189
Z Home Harness191
Connection to Z-Index PCB191
Connection to Main PCB (J32)192
User Interface Harness193
User Interface Harness Connection193
User Interface Harness in PCB194
X/Y Home Harness195
Connection at X/Y Home PCB195
Retaining Clip in Channel of Y-Home Flag195
X/Y Home Harness Access Hole195
X/Y Harness Connected at Main PCB (J3)196
Bearing Block Assemblies197
Y-Rail Retaining Screw198
X-Beam Assembly199
X-Beam and Carriage Installed on Machine199
Cable Bracket Removal199
Bearing Block Assembly Installed on Machine199
X-Carriage Assembly201
Remove Two Screws on Cable Pulley Bracket201
X-Drive Cable Removal203
X-Cable Removal Procedure203
Cable Tensioner Bracket204
X-Drive Cable Installation205
X-Cable Assembly Installation205
X-Cable Spool (Taped and Installed)206
Right Rear Pulley206
Right Rear Pulley Close up206
Right Beam Cable Pulleys207
Center Beam Cable Pulley207
S 7 - X-Cable Clamp207
Left Rear Cable Pulley207
Left Beam Cable Pulleys208
Cable Tensioning Bracket (Left Side of Machine)208
X-Drive Motor Replacement209
Wrap Tape Around X-Drive Pulley210
X-Cable Tensioning Screw210
X-Motor Harness Connections211
X-Motor Mounting Screws211
X-Home Optical Switch Assembly Replacement212
X-Home Sensor Mounting Bracket212
X-Home Sensor and Mounting Screws212
X/Y Home PCB Replacement214
Y-Drive Belt Replacement216
Y-Drive Belt Adjusting Nuts (Left Side)216
Left Timing Belt Clamp and X/Y Home PCB217
Right Y-Drive Timing Belt Clamp217
Y-Motor Assembly218
Y-Motor Installed218
Y-Motor Connections at PCB219
Grabber Function Test221
Final Functional Tests223
Visual Inspection223
Functional Tests223
Burn-In223
Test Sew Outs224
Optical Sensors Test225
Power Supply Test226
Check the Power Supply Unit Itself226
Power Supply Voltage Measurement Points226
Power Supply Unit Terminal Jumpers227
Power Supply Indicator LED227
Servo Motor Resistance Test229
Stepper Motor Resistance Test230
Resistance Measurement of Servo Motors231
Troubleshooting Stepper Motors232
Grabber Phase Indicator Leds233
Test Designs235
Thread Tension Test236
Belt Tension Test237
Long Stitch Test237
Looping Test237
Orientation Test238
Registration Test238
Small Alphabet Test238
Thread Break Sensor Test239
Thread Break Test239
Trimmer Test240
Electrical Failures241
AC Power Failure241
Color Change Failures241
LED Cluster Assembly Failures242
Machine Initialization Failure242
Mechanical Failures244
False Thread Breaks244
Loose/Looping Stitches244
Needle Breaks244
Skipped Stitches245
Thread Breaks246
Miscellaneous Problems251
X-Axis Failures252
Z-Axis Failures254
Software Error Messages255
DSP Command Errors256
Can’t Initialize Stepper Motors256
No Trace Data256
XY Home Not Set256
Goto Func Error257
Hoop Center Error257
Stepper Motor Time out and Index Errors257
E-Stop Engaged258
Possible Causes of a False E-Stop Engaged Message258
Servo Motor Errors (Move Time Out, Tracking, and over Current Errors)260
Critical Measurements262
Contents & Critical Mechanical Settings and Assemblies262
Needle Drive Stud to Reciprocator Fit263
Hook Timing263
Upper Arm to Lower Bed Alignment263
Needle to Hook Gap264
Hook to Rotary Support Gap264
Take-Up Lever Stroke264
Head Alignment Procedure264
Take-Up Lever Fit to Shaft265
Take-Up Lever Endplay265
Cam Follower Preload265
Pull Force on Take-Up Lever266
Color Change Lead Screw266
Color Change Housing Location267
Bobbin Tension267
Presser Foot Adjustment at Bottom Dead Center268
Checking Bobbin Tension268
Thread Feed Forward 200269
Thread Feed Forward Measurement269
Needle Orientation269
Thread Clean Thread Path270
Z-Belt Tension270
X-Cable Tension271
Y-Axis Timing Belt Tension271
Proper Lubrication of Moving Parts271

Melco Bravo - Troubleshooting

Table of Contents

Related product manuals