Melco EMT16X - Troubleshooting

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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

Critical Measurements

Main Page

Copyright Notice9
About this Manual10
Scope of Manual11
Standard Conventions and Definition of Terms12
Regulatory Notices13
Best Maintenance Repair Practices14
Maintenance Philosophy14
Scheduled Maintenance16
Grounding and Static Electricity17
Static Electricity17
Machine Orientation19
Warranty Considerations21
Explanation of Machine Symbols22
Keypad Operations23
Keypad Buttons28
Step Forward Key30
Start Button30
Emergency Stop Button31
Led Indicator32
Specifications33
Technical Specifications35
Torque Specifications36
Software Maintenance Menus38
Special Tools and Fixtures39
General Maintenance40
Exterior Surfaces40
Lubrication Schedule and Specifications42
Maintenance Schedule42
Daily Maintenance44
Weekly Maintenance46
Monthly Maintenance52
Quarterly Maintenance58
Head up Position Adjustment68
Mechanical Head-Up Position68
Adjusting Head-Up (Z-Home) Position69
Hook Timing Inspection/Adjustment70
Rotational Hook Timing Inspection Procedure71
Needle to Hook Gap Inspection Procedure72
Adjustment Procedure73
Centering the Needle Plate90
Laser Light - Adjustment91
Needle Depth93
Setting the Needle Depth by Eye93
Presser Foot Height94
X/Y Home Adjustment95
Home Adjustment Procedures95
X-Cable Tension98
Determining if an X-Cable Is Set to Required Specifications98
Adjusting an X-Cable that Is Tensioned Outside the Required Specifications99
Y-Axis Timing Belt Tensioning101
Y-Axis Belt Tension Adjustment102
When Belt Tensions Are Correct102
Y-Motor Timing Belt Tensioning103
Inspection and Adjustment103
Bottom Center (Z Timing)104
Z-Drive Belt Tensioning109
Z-Home Adjustment111
Procedure to Identify the Closest Needle112
Needle Case Calibration115
Fine Calibration Procedure115
Rough Calibration Process116
Rotary Hook Support Adjustment118
Inspection Procedure118
Color Change, Take-Up, Feeder Housing Assembly122
Replacement Procedure for Entire Color Change/Take-Up/Feeder Assembly122
Color Change Linear Actuator Replacement124
Replacement Procedures124
Thread Feeder Gear Replacement127
Thread Feeder Optical Sensor PCB Replacement129
Replacement Procedure129
Thread Feeder Radial Bearing Replacement130
Thread Feeder Stepper Motor Assembly131
Laser Pointer Assembly133
Replacing the Laser Assembly133
LED Cluster PCB Replacement135
Presser Foot Assembly Replacement136
Take-Up Lever Cam Replacement141
Z-Drive Repair and Adjustment144
Z-Drive Belt Replacement and Tensioning144
Z-Home Sensor PCB Replacement146
Z-Belt Idler Assembly Replacement148
Z-Motor Assembly149
Clearing Thread from Thread Feeder Roller152
Color Change Spindle Mounting Bracket Replacement154
Grabber Blade Replacement156
Needle Case Removal159
Needlecase Installation161
Grabber Stepper Motor Replacement163
Take up Lever Replacement164
Thread Feeder (Replacement and Adjustment)166
Thread Sensor Assembly Replacement169
Bobbin Shaft Overhaul171
Rotary Hook Replacement173
Power Input Assembly Replacement178
Power Input Assembly Component Replacement181
Power Input Assembly Installation186
User Interface Assembly Replacement187
Color Change Motor Harness191
Ethernet Harness194
Grabber/Threadfeed Motor Harness196
Grabber/Threadfeed/CC Home Harness200
Laser Harness203
LED Cluster Harness205
Thread Break Harness209
Z Home Harness212
User Interface Harness215
X/Y Home Harness218
Bearing Block Assemblies221
X-Beam Assembly223
X-Carriage Assembly225
X-Drive Cable Removal227
X-Drive Cable Installation229
X-Drive Motor Replacement233
X-Home Optical Switch Assembly Replacement236
X/Y Home PCB Replacement238
Y-Drive Belt Replacement240
Y-Motor Assembly242
Troubleshooting244
Grabber Function Test245
Final Functional Tests247
Visual Inspection247
Optical Sensors Test249
Power Supply Test250
Servo Motor Resistance Test252
Stepper Motor Resistance Test253
Test Designs255
Long Stitch Test257
Looping Test257
Orientation Test258
Registration Test258
Small Alphabet Test258
Thread Break Sensor Test259
Thread Break Test259
Trimmer Test260
Electrical Failures261
Color Change Failures261
LED Cluster Assembly Failures262
Mechanical Failures263
Skipped Stitches264
Thread Breaks265
Miscellaneous Problems270
X-Axis Failures271
Y-Axis Failures272
Z-Axis Failures273
Software Error Messages274
DSP Command Errors275
Can't Initialize Stepper Motors275
E-Stop Engaged277
Servo Motor Errors (Move Time Out, Tracking, and over Current Errors)278
Critical Measurements280
Hook Timing281
Needle to Hook Gap282
Hook to Rotary Support Gap282
Take-Up Lever Stroke282
Cam Follower Preload283
Color Change Lead Screw284
Thread Clean Thread Path288
Z-Belt Tension288
Y-Axis Timing Belt Tension289
Proper Lubrication of Moving Parts289

Melco EMT16X - Troubleshooting

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