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Melco EMT 10T Installation, Operation And Maintenance Manual

Embroidery peripherals
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Installation, Operation, and
Maintenance manual for
the EMT 10T, 10/4, and 10/4T
embroidery peripherals
Part Number 11817, Revision A
•
Single- and four-head tubular
embroidery peripherals
•

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Summary of Contents for Melco EMT 10T

  • Page 1 Installation, Operation, and Maintenance manual for the EMT 10T, 10/4, and 10/4T embroidery peripherals • Single- and four-head tubular embroidery peripherals • Part Number 11817, Revision A...
  • Page 2 Melco Embroidery Systems. Melco reserves the right to revise this publication and to make changes in it at any time without obligation of Melco to notify any person or organization of such revisions or changes.

  • Page 3: Table Of Contents

    EMT 10T Specifications EMT 10/4 and 10/4T Specifications Explanation of Symbols 1. Installation Unpacking Moving the Peripheral Cart Assembly (EMT 10T only) Installing the Tabletop (EMT 10/4 and 10/4T only) Connecting cables 1-10 First Powerup 1-13 Support Brackets (EMT 10/4 and 10/4T only) 1-15 2.
  • Page 4 Table of Contents Configuration Menu 2-15 Move Function Menu 2-17 Define Custom Hoop 2-18 Test Mode 2-18 Diagnostics Menu 2-19 Disk Drive 2-19 Loading a Design 2-21 Hooping 2-22 Quick Start 2-23 Set Home 2-23 Select Hoop 2-23 Select Orientation 2-23 Center Hoop 2-23...
  • Page 5 Table of Contents 5. Troubleshooting Guide Thread Breakage Skipped Stitches Needle Breaks Loose Stitches 6. Error Messages 7. Glossary of Embroidery Terms Index Quick Reference Guides...

  • Page 6: Emt 10T Specifications

    Shipping weight Intended use 136.4kg 300 lbs The EMT 10T is designed to embroider on tex- tile products which are placed easily in a Melco embroidery hoop. The machine should not be Power consumption used on thick leather, wood, plastic, or other dense material.

  • Page 7: Emt 10/4 And 10/4T Specifications

    The EMT 10/4 and 10/4T are designed to Shipping weight embroider on textile products which are placed 355kg easily in a Melco embroidery hoop. The 780 lbs machine should not be used on thick leather, wood, plastic, or other dense material.

  • Page 8: Explanation Of Symbols

    Explanation of Symbols Caution! Indicates a machine component will move. Keep clear! Shock hazard. No user replaceable parts behind this label. Do not open! Pinch point, Keep clear! Pinch point, Keep clear! Pinch points, Keep clear! Needle pinch point, Keep clear! Use a forklift.

  • Page 9: Installation

    (until you have assembled the cart). If you purchased the foot option, install the 4 feet before removing the machine from the box. Two people are required to lift the EMT 10T. Refer to Figure 1-2 to locate the hand-holds, and lift as shown in Fig- ure 1-3.
  • Page 10 Remove the crate. Store all packing materials and hardware in a safe place. Reuse the Figure 1-4 packing materials if you ever relocate the peripheral. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 11 Unpacking International models Two people and a forklift are required to unpack the EMT 10/4 or 10/4T. Be careful when unpack- ing your new peripheral. On one end of the crate is a “window” of wood. This end is the door. Open the door by removing the nails from around the perimeter.

  • Page 12: Moving The Peripheral

    Observe the precautions below. You cannot remove the machine from the cart without first removing the 4 bolts securing the machine to the cart. Push carefully in the directions shown or the cart may tip. Brakes Figure 1-7 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 13 Moving EMT 10/4 and 10/4T Move the machine as indicated below. Disengage the brakes on the indicated wheels before attempting to move the machine. Engage the brakes when the machine is in the desired location. Push only in the direction of the arrows when moving the machine more than a short distance.

  • Page 14: Cart Assembly (Emt 10T Only)

    Insert the necessary screws (M5 phillips head screw with a flat washer between the screw and the cart piece) securing them tightly. Figure 1-11 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 15 Installing the feet Figure 1-13 If you have purchased the Foot option with your EMT 10T, refer to these steps to install the feet. 1. Remove the main tabletop. 2. Remove the side covers; there are 5 screws holding each side cover in place (see Figure 1-12).

  • Page 16: Installing The Tabletop (Emt 10/4 And 10/4T Only)

    1-15). Place the shelf pieces on top of the brackets located in the base of the machine and lay the mat on top of the shelf pieces. Left section Center section Right section 2-piece shelf Rubber Figure 1-15 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 17 Tabletop 3. Slide the last two pieces into place (see Figure 1-16). They fit on the table support tabs on the end and center sections. 4. Tighten the thumb screws under the table to secure the pieces. Figure 1-16 Special note on the tabletops You MUST remove all 5 tabletop inserts before embroidering tubular goods or caps on the EMT 10/4 or 10/4T.

  • Page 18: Connecting Cables

    Connecting cables Power requirements Melco suggests using a dedicated line with a line conditioner (available from Accessory Resource Corporation). Do not use any power cable that appears to be damaged. If your power cable appears to be damaged, order a new power cable from your Melco representative.
  • Page 19 Connecting cables 1-11 EMT 10/4 1. Figure 1-17 shows the power in the ON position. Turn the power OFF before connecting ANY cables. 2. If your peripheral is equipped with a voltage selector switch, set it to the correct position (115VAC or 220VAC) for your area.
  • Page 20 *Note: You may have as many licensed EDS III systems operating on an Ethernet network as you choose. Each computer running EDS III on the network must have a licensed EDS System (including the dongle) installed to operate properly. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 21: First Powerup

    Insert Boot Disk. If any of the diagnostics fail, the CPU will halt and the machine will not boot. This indicates a problem with the CPU. Contact your Melco Service Representative. Configuring the peripheral The first time the machine is turned on, it must be configured with a peripheral program and unit name.

  • Page 22: Language Selection

    First powerup Language selection All Melco products use English as the default language. If you wish to change the display to a dif- ferent language, follow these steps to select the machine language: Note: The machine must be configured before you can change the display language.
  • Page 23 Support brackets 1-15 Support brackets (EMT 10/4 or 10/4T only) Two supports brackets, one on the right needle case (sewing head 1) and one on the left needle case (sewing head 4) hold the needle case during shipping; these brackets must be removed prior to operation.

  • Page 24: Support Brackets (Emt 10/4 And 10/4T Only)

    1-16 Support brackets Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 25: Operation

    Operation 2. Operation This chapter outlines machine operation; in addition, operators must attend a Melco approved training course prior to operating the machine. Thread tree X-carriage Keypad Power switch Needle case Table Figure 2-1 Thread tree Needle cases Power Table-...

  • Page 26: Hazards Of Operation

    Do not place hands or other objects on or around the needle case dur- ing operation. Cap Frame Pinch Points Do not touch the cap frame, driver, or driver bar during operation. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 27 Operation Exposed Needles During Operation Do not place body parts or other foreign objects under the needles during operation. Pinch Points Do not rest hands or other objects on the table top during operation. Do not reach behind the x-carriage during operation with or without table top in place.

  • Page 28: Threading

    “hook” the thread on the cut and pull the thread through the tube. Figure 2-3 Pretensioner HE THREAD PATH Numbers here represent numbered steps from the following page. Figure 2-4 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 29: Tensions

    Operation 1. Pull the thread from the guide hole down between the pretensioner disks. 2. Route the thread down through the pretensioner, between the two metal wheels. 3. Pull the thread down to the main tensioner and wrap the thread around the disk clockwise 1 times.

  • Page 30: Keypad

    Holding the key for 10 seconds starts the auto-frame function; once the auto- frame function has started, you must press to stop framing. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 31 Keypad Moves from one menu to the next. After the last menu displays, it wraps back to the first menu. Never used alone. It is held down while pressing an additional key, allowing the other key to take on an alternate function. Moves the needle position to the right in the embroidery field (hoop moves left).

  • Page 32: The Menus

    (up to 16 designs may be queued—or up to 500K). Press (the machine will emit several beeps) to start embroidering the design. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 33: Function Menu

    The Menus Function Menu All the commands in this menu result in machine motion and multiple beeps. The com- mands are described below. Press to view selections. Go to hoop center? Forces an X/Y move to the center of the selected hoop. Only allowed if you are not in the middle of a design.
  • Page 34 ENTER COLOR CHANGE NUMBER 0 0 0 press Press to change the cursor 2. Use the arrow keys to enter the desired position color change number (see illustration). Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 35: Options Menu

    The Menus 2-11 3. Press ; the machine moves to that color change. 4. If you were in the middle of a design when you performed this function, press to return to the top-level menu, and press to resume embroidering. Go to headup? Forces a move to the headup position, ready to sew.

  • Page 36: Frame Menu

    Service/Maintenance Menu Contains all service and maintenance functions. Eleven submenus are in the Service/maintenance menu. Press to toggle between the Service/Maintenance menu and the Main menu. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 37: Head Timing Menu

    The Menus 2-13 Head Timing Menu Use the keystroke guide below to move to each position. Refer to the Hook timing section of Chapter 4 for more information. The Z position (in degrees) will be displayed after each function. Go to headup Forces the z axis to make one plus rotation and stop with needle in up position.

  • Page 38: Hr Lubrication Menu

    Go to this menu when the message 2100hr maintenance due appears. This menu forces the machine to move to the proper positions for oiling. Refer to the Lubrication section of Chapter 4 for the proper place to apply lubricant. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 39: Configuration Menu

    Bobbin detect: Turns ON or OFF the Under Thread Control Press to change a character (UTC). ON is the default. On the EMT 10T, press to change. On the EMT 10/4 or 10/4T, refer to the illustration to the right to turn it on or off Press on individual heads.
  • Page 40 Determines what short stitch length to use for filtering up to 0.9mm. The allowable range is 0-9 points. It accumulates stitches that are shorter than this value and adds them to the next stitch. The default is 4 points. Press to change. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 41: Move Function Menu

    The Menus 2-17 Language selection: Allows for different languages. Several languages are available. Inching count: Selects number of inching stitches (the slow stitches at the beginning of a design and on restart after a trim or color change) sewn before the machine begins to speed up. These stitches allow the top thread to catch and hold the bobbin thread.

  • Page 42: Define Custom Hoop

    Places the machine in test mode, where thread breaks are ignored and the queued design contin- ues to run until is pressed. Must be disabled to return to normal embroidery. This is pri- marily a service function. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 43: Diagnostics Menu

    The Menus 2-19 Diagnostics Menu The following service diagnostic test are available to run or view: RSA rev level Displays the current revision level of the RSA files and the selected machine type. BIOS rev level Displays the current revision level of the ROM BIOS. Motion Controller rev level Displays the current revision level of the DSP chip set.

  • Page 44: Disk Drive

    If a boot disk is not located in the disk drive, the message: INSERT BOOT DISK will show on the display. Insert the boot disk and press . After the machine boots correctly, it will display the model name. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 45: Loading A Design

    Loading a Design 2-21 Loading a Design Through the Network After the embroidery peripheral is booted, you may load designs into the embroidery peripheral buffer. If you are loading designs through the network, please refer to the EDS III Basic manual for a detailed explanation of sending designs from the computer to the peripheral.

  • Page 46: Hooping

    To hoop with a tubular or flat hoop, place the outer hoop on a clean, flat surface. Place the back- ing down, then the fabric, and then place the inner hoop inside the outer hoop with the mount- ing brackets facing UP (see Figure 2-8). Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 47: Quick Start

    Quick Start 2-23 Quick Start The following section outlines the required steps to embroider a design. Set home This is normally done on power-up; if the machine detects an error during its test sequence on power-up, you must correct the error condition (e.g., if the machine is not at HEADUP, you must GO TO HEADUP), then Set Home.

  • Page 48: Attach Hoop

    (behind nee- dle case) Figure 2-13 Push the hoop to the right (as you are facing the machine) then insert the left side of the hoop Figure 2-14 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 49 Quick Start 2-25 Flat hoops You can purchase an optional kit to embroider using flat hoops. Flat hoops attach to the peripher- al via the outer frame and attach to the peripheral differently than tubular hoops. Refer to the following steps to attach the flat hoop to the peripheral: 1.

  • Page 50: Select A Design

    The beep means the needle will strike the hoop if sewn. To correct this, re- center the hoop, select and use a larger hoop, or manually jog the hoop into position. Perform another trace after you have corrected the problem. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 51: Start Embroidering

    Quick Start 2-27 Start Embroidering After the tracing function is finished, press to return to the idle menu again. Press and the machine will move to the beginning of the design. Press again and the peripheral will embroider the design selected (you may have to press an additional time if the design began with a Needle Ups com- mand).
  • Page 52 2-28 Quick Start Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 53: Accessories

    Standard Cap Frames 3. Accessories Standard Cap Frames Because a cap is not flat, it cannot be hooped in a flat hoop. To solve this problem, a special device called a cap frame has been created to hoop caps. There are two sizes of cap frames: 7.0cm X 14.2cm (Large) and 6.3cm X 14.2cm (Small).
  • Page 54 5. Repeat step 4 for the remaining three screws. Figure 3-3 6. Move the beam to the left and right extremes one time. Repeat step 4 again, but this time, tighten the screws fully. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 55: Hooping A Cap

    Standard Cap Frames Using the Cap Hoop Gauge Because the cap hoop is curved, it is difficult to control on a flat surface. The cap hoop gauge clamps to a table edge to resolve this problem. Once the gauge is clamped, snap the cap hoop into it to hoop the cap.

  • Page 56: Raised Needle Plates

    0.090" higher than a standard needle plate, so you should add two 0.040" spacers to both sides of each sewing head (needles 1- 10). Lower cover Figure 3-5 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 57 Standard Cap Frames 5. The spacers must be cut on one side with a pair of scissors prior to installation. Refer to Figure 3-6 for the correct areas to cut. 6. Slide the spacer (with the cut side facing upward) in between the presser feet and the needle bars .

  • Page 58: Wide-Angle Cap Frame

    Thumb screw 6. Push the cap driver shaft into the hole in the rear mounting Dove-tail mounting bracket bracket until it reaches the pos- itive stop. Figure 3-9 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 59 Wide-Angle Cap Frame Note: When pushing the driver shaft into the hole in Driver bar the rear mounting bracket, make sure the cap supports are positioned over the needle plate. This prevents the shaft from binding. 7. Tighten the thumb screws on the rear mounting bracket and on driver dove-tail support bracket (see Figure 3-10).
  • Page 60 This adjustment only needs to be performed the first time the cap frame driver is installed on a machine. The Wide-angle cap frame does NOT require the use of raised needle plates. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 61 Wide-Angle Cap Frame Installing the wide-angle cap frame driver The steps in this section describe how to install the driver after it has been previously installed and adjusted. If you have not installed the driver previously, refer to the First Time Installation and Adjustment section.
  • Page 62 Tensioner then retighten the thumb nuts. Reverse these steps to remove the tensioner. Figure 3-16 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 63 Wide-Angle Cap Frame 3-11 The cap frame gauge To install the cap frame gauge, tighten the clamp until the gauge is held firmly. Figure 3-17 shows a mounted cap frame gauge. Figure 3-17 Hooping with the wide-angle cap frame Hooping on a wide-angle cap frame should be as straight-forward and simple as hooping on a regular cap frame.
  • Page 64 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 65 Wide-Angle Cap Frame 3-13 To achieve a snug fit of the cap frame's metal straps, perform step 17 whenever you change cap styles. Step 17 does not need to be performed if the cap style has not changed. In this case, simply latch and close the buckle.
  • Page 66 (pushing the disk out) is completely compressed. If you do, the tensioner disk may restrict the cap’s movement during embroidery, resulting in a loss of registration and reduced embroidery quality. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 67 Wide-Angle Cap Frame 3-15 Sewing field The height of the sewing field varies on caps because of the variation in crown sizes. You can use the following formulas to calculate the height of the sewing field for different crown sizes: Y=A - 1.18 Where: Y= height of the sewing field in inches...

  • Page 68: Cap Designs

    Modifying your designs to embroider on caps may give you more trims and color changes, but it will also provide you with much better embroidery quality. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 69: Sash Frame

    The sash frame has a maximum embroidery field per head of 11.02" x 16" (28cm x 40.6cm) for the EMT 10/4 or 10/4T and 11.02" x 19.69" (28cm x 50cm) for the EMT 10T. Often, only the backing material is hooped in the sash frame, and several smaller pieces of fabric are fixed on top of the backing with a non-permanent fabric adhesive.

  • Page 70: Spider Hoops

    3. Attach 6 of the 300cm clips along the back of the frame on the EMT 10/4 or 10/4T; use 1- 220cm clip and 1-300cm clip along the back of the frame on the EMT 10T. 4. Pull the fabric taut and attach the same number of clips at the front of the frame.
  • Page 71 The Sash Frame 3-19 To install spider hoops on the sash frame: 1. Attach the thumb screws for the spider hoop into the sash frame, but do not tighten yet. 2. Remove the inner hoop from the 21cm hoop with the two brackets (shown in Figure 3-21). Bracket A Opening for the hoop tightener...

  • Page 72: Lamps

    Insert the new bulb and twist into place. Use a 3’ 25W flu- orescent bulb (Melco part number 010394-01). Figure 3-23 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 73: Bobbin Winder

    Bobbin Winder 3-21 Bobbin Winder The Bobbin Winder is available in two basic configurations: as a built in feature of the EMT 10T and as a stand-alone option. See Figures 3-24 and 3-25. Built-in bobbin winder Stand-alone bobbin winder Figure 3-24...
  • Page 74 Adjust the winder tension, the thread path or the Bobbin Full switch to correct winder operation if you are experiencing any of the situations shown below. Figure 3-28 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 75 Bobbin Winder 3-23 Motor Protection The bobbin winder motor is equipped with a thermal switch to protect the motor and drive cir- cuitry in the event of an overload condition. If the bobbin winder stops due to an overload follow these steps to correct the problem: 1.
  • Page 76 Figure 3-31. Rotate the bobbin winder shaft by hand until the shaft moves smoothly and freely. Oil here Figure 3-31 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 77: Operator Maintenance

    Maintenance 4. Operator Maintenance This chapter outlines machine maintenance; in addition, operators and maintenance personnel must attend a Melco approved training course prior to maintaining the machine. Installing a Needle Each needle has a needle clamp set screw hold- ing it in place as shown in Figure 4-1. Use the...

  • Page 78: Cleaning

    Note: Depending on the type of material being used, this area may require cleaning more often. Some high-lint materials will require this area to be cleaned once per day for peak perfor- mance. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 79: Lubrication

    Lubrication Lubrication The EMT 10T, 10/4, and 10/4T require regular maintenance to perform their best. A message will display at the end of each design when it is time for maintenance. Press enter the Service/Maintenance menus (HEAD TIMING MENU will be displayed). Press to scroll to the required menu to perform the maintenance.

  • Page 80: Hr Maintenance

    (see Figure 4- 6). Press when done. The x-car- riage will move back and forth to distribute the oil. Plas- Figure 4-6 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 81: Hr Maintenance

    Lubrication 40hr maintenance due When this message appears, go into the 40 Put 1-3 drops of hour lubrication menu, then press oil here When upper connecting rod displays, press . This moves the needle case to its proper Red dot position for oiling (needle 1 and 180°...
  • Page 82 The head will oil in this hole move back and forth to distribute the oil. Put 1 drop of Top view of needle case oil in the v-rail Figure 4-10 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 83 Figure 4-12 to lubricate the y-rail. Press when done (the y-rail will move back and forth to distribute the oil). The y-rails on the EMT 10T are not Place 1-2 drops on located directly under the slot. you must both the front and the back...
  • Page 84 Press when done. Replace the needle plate. Put 1 drop of oil on each location (knife drive arm) Figure 4-16 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 85 Oil at each loca- Refer to Figure 4-19 to lubricate the x-carriage on tion; repeat for the other an EMT 10T. side of the beam Refer to Figure 4-20 to lubricate the x-carriage on an EMT 10/4 or 10/4T.

  • Page 86: 2100 Hr Maintenance

    4-24). You must lubricate the cam on all 4 heads. Use a flashlight if necessary. Replace the end cover when finished. Figure 4-22 Press when done. Screws Screws Figure 4-23 Figure 4-24 Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 87 Lubrication 4-11 3. If you are using a Wide-Angle Cap Frame, Dri- the message Wide-Angle Driver Shaft will appear; press . Remove the wide-angle driver from the peripheral. Wipe the lint off the driver shaft (see Figure 4-25). Figure 4-25 Loosen the 2 screws holding the rear sup- port bracket using the 2mm hex wrench Screw...

  • Page 88: Replacement Parts

    There are two operator-replaceable fuses. If a fuse must be replaced, use this chart for appropriate fuse ratings. Do not use a fuse with any rating other than what is listed here: PERIPHERAL 115V RATING (Melco part number) 230V RATING (Melco part number) EMT 10T 5 A (010162-05)

  • Page 89: Operator Kit

    Replacement Parts 4-13 Operator Kit The contents of the operator’s kit are identical for the EMT 10T, 10/4, and 10/4T except for the manual sets. Following is a list of all items found in the kit: PART NUMBER DESCRIPTION 761003-01...

  • Page 90: Spare Parts

    Replacement Parts Spare Parts EMT 10T To help reduce down-time, Melco suggests keeping certain spare parts on hand for easy replace- ment and maintenance. Melco provides a Spare Parts kit (p/n 10905); it contains the following items: Note: The spare parts kit for older EMT 10Ts (machines that pre-date spring 1998) is part num- ber 010431-01.
  • Page 91 Replacement Parts 4-15 EMT 10/4 or 10/4T To help reduce down-time, Melco suggests keeping certain spare parts on hand for easy replace- ment and maintenance. Melco provides 4 Spare Parts kits for the EMT 10/4 and 10/4T: • p/n 010901-01 contains mechanical items for the EMT 10/4 •...
  • Page 92 PCB, KYBD W/ KEYCAPS, DISPLAY, EMT, ASSY 007505-01 SHIM, NDL CS 110231-01 LIST, HARDWARE, SPARE, 4 HD 004803-01 ASSY, PKNG, SPARE PARTS KIT 010902-01 KIT, FUSE, EMT 10/4(T) Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 93 Replacement Parts 4-17 p/n 010900-01 PART NUMBER DESCRIPTION 010689-01 CABLE, ETHERNET, NTWRK, INTFC, 50 010107-01 UTC ASSY 001532-01 BAR, NDL 007924-01 FOOT, PRESSER, ASSY 008490-01 CASE, BOBBIN, SM, W/SPRING 009000-01 HOOK, ROTARY, SM BOBBIN 006520-01 PLATE, NEEDLE, UTC 001840-01 CLAMP, STOP, NDL BAR 001528-01 CLAMP, NDL, ASSY 001828-01...
  • Page 94 PCB, KYBD W/ KEYCAPS, DISPLAY, EMT, ASSY 007505-01 SHIM, NDL CS 110231-01 LIST, HARDWARE, SPARE, 4 HD 004803-01 ASSY, PKNG, SPARE PARTS KIT 010902-01 KIT, FUSE, EMT 10/4(T) Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 95: Troubleshooting Guide

    Troubleshooting Guide 5. Troubleshooting Guide Thread breakage PROBLEM POSSIBLE CAUSES SOLUTIONS Design Stitches are too short and/or too Check the design for short and/or dense dense stitches, and edit the design to remove them Needles Incorrect needle for thread size Replace with a compatible needle being used Needle is bent, damaged, or dull...

  • Page 96: Skipped Stitches

    Needle strikes the needle plate Adjust position of the needle case (refer to the technical manual) Needle strikes the UTC Reposition the UTC (refer to the technical manual) Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 97: Loose Stitches

    Troubleshooting Guide Loose stitches POSSIBLE CAUSES SOLUTIONS Upper thread tension too low Adjust the upper thread tensions (see tension section) Bobbin tension too low Adjust the bobbin case set screw Uneven thread size Replace with quality thread Upper tension inconsistent Clean tensioner parts Rotary hook timing is incorrect Adjust hook timing (refer to the technical...
  • Page 98 Cap frame is loose on the driver Adjust the spindles Cap frame driver doesn’t fit on Make sure you are using flat needle plates (and NOT raised needle the peripheral properly plates) Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 99: Error Messages

    Command in the Head Timing Menu was not understood by the Z axis controller. Wait a few sec- onds and try again. If it still fails, call your Melco Service Representative for assistance. Bad Instruction The CPU received an illegal instruction, resulting in a fatal error. Call your Melco service represen- tative for help. 11817 Rev. A...

  • Page 100: Bad Keyboard Code

    3. If the error message clears, press the key and continue sewing. If the problem is still not corrected, call your Melco service representative for help. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 101: Color Change Pause

    Error Messages Color Change Pause The embroidery peripheral will stop for all color changes when the character P is read in the color sequence. The embroidery peripheral will stop one time when the character 0 is encountered in the color sequence. Color List Full You cannot increase the color sequence to a value greater than 99.

  • Page 102: Dsp Command Error

    Try selecting a larger hoop size in the Options menu, or moving the design start point so the whole design fits into the hoop, then start over. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 103: Illegal Color Sequence

    To clear the MC buffer, turn the power OFF, then back ON. If cycling the power does not clear the screen message, there may be an error in the CPU. Reconfig- ure your peripheral. If this still does not clear the message, call your Melco service representative for assistance.

  • Page 104: Not At Headup

    To manually reset the cam, follow these steps: 1. Locate the Color Change Cam reset screw (it is a flat- head screw). On the EMT 10T, it is on the left side of the head (as you are facing the machine), behind the needle case.

  • Page 105: Thread Break

    Head Timing Func- tion is performed, but finds the cutting blade is not in its home position. Move the trimmer to the home position manually, then continue sewing. If this does not fix the problem, call your Melco representative.
  • Page 106 Y Axis Not Done This means the needle is trying to enter the cloth before the X or Y motion is complete. Try to continue sewing; if error returns, call your Melco service representative. Y Axis Tracking Error This error message means the Y axis motor is not tracking (or moving) as commanded by the Y axis controller software.
  • Page 107 Locate and correct the problem. If you cannot locate the problem or if this message continues to occur often, call your Melco service representa- tive .
  • Page 108 6-10 Error Messages Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...

  • Page 109: Glossary Of Embroidery Terms

    An example of this would be Sports Symbols. APPLICATION WINDOW The first window to appear when EDS III is opened; screen says Melco in large letters across the middle of the screen. The Application Window has three menu bar items; File, Peripheral, and Help.
  • Page 110 Pressing and releasing a mouse button in one quick motion. CLIPBOARD A temporary storage area in the computer's memory. Data in the storage area can be copied to another place. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 111 Glossary of Terms The three letter extension given to a Condensed file. See Condensed Format for more informa- tion. COLUMN FILL An option to turn wide column or satin stitches into a series of shorter stitches. Commonly used to make alphabet letters 2.5" or larger more durable. COLUMN STITCH A stitch formed with one needle penetration on either side of a column.
  • Page 112 A board used to communicate with a computer or an embroidery machine while creating a design. DIGITRAC The original Melco computerized digitizing system which uses an exceptionally large surface and its own vertical stand. DIRECTORY A named group of computer files stored on one of your computer drives. The hard drive of your computer is usually the C directory.
  • Page 113 Glossary of Terms EDIT Changing a design file by adding, deleting or moving Mk points, or by inserting and deleting functions. EMBROIDERY POINT A unit of measure equal to one tenth of a millimeter or 1/254th of an inch. The three letter extension given to an Expanded file. EXPANDED FORMAT A coding format that includes the data for every stitch in the design.
  • Page 114 LAYER BY COLOR Used to show specific colors of a design on the computer screen. Only works in the Object Edit Window. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 115 Glossary of Terms LAYOUT WINDOW The screen in which you can digitize designs, open files on the hard disk, import designs from floppy disks, export designs, modify designs, and create lettering. LETTER WIDTH Modifies the overall width of each letter, NOT the column width. In EDS III changes to letter width can be made in increments of 10% from +30% to -30%.
  • Page 116 NEEDLE UP A command used to move from one part of a design to another without stitching. NON-DOS FORMATS Any disk format other than DOS that is supported by EDS III, such as: Melco, Tajima, Barudan, ZSK. NORMAL STITCH A command that resets the stitching to a regular running stitch. It also brings the needle down to the sewing position after a needle-up function is performed.
  • Page 117 The three letter extension that identifies an Object file. ORIENTATION The direction that a design will sew. Melco uses an "F" to designate a normal sewing position. ORIGIN The point at which a design will start. Most designs will have x and y coordinates of 0,0; meaning that the design will start in the center and end in the center.
  • Page 118 A command that slants lettering in one degree increments up to fifteen degrees, positive or nega- tive. SPECIAL STITCH A user defined stitch that is digitized and stored temporarily in the computer memory. A Special Stitch is limited to 30 Mks or commands. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 119 Glossary of Terms 7-11 STATUS BAR The area at the bottom of the computer screen that displays information about the active window or selected command. STITCH One needle penetration made by the embroidery machine. STITCH COUNT The number of stitches in a design. STITCH LENGTH The length of the running stitches in a design.
  • Page 120 This command does not affect the sewing size of the design. To view the design as the size it will be sewn, click View→Actual Size. Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems...
  • Page 121 Operation Manual for the EMT 10T, 10/4, and 10/4T INDEX +5 Volt Current 2-19 Bad Power Fail Recovery Pointer 6-2 1 degree back 2-13 BIOS rev level 2-19 1 degree forward 2-13 Bobbin Control Test 2-19 10 degrees back 2-13...
  • Page 122 INDEX Operation Manual for the EMT 10T, 10/4, and 10/4T Ethernet network 1-12 Define custom hoop 2-18 Design Delete Failed 6-3 First powerup 1-13 Design filter stitch length: 2-16 Flat hoops 2-25 Design filter: 2-16 Format 2-21 Design Job Buffer Full 6-3...
  • Page 123 Operation Manual for the EMT 10T, 10/4, and 10/4T INDEX Lubrication 4-3 Hard reset 2-12 Hazards of operation 2-2 Machine Running 6-5 Head Timing Menu 2-13 Main Operator Menu 2-8 Hook timing 2-13 Main tensioners 2-6 Hoop Limit 6-4 Maintenance 4-1...
  • Page 124 INDEX Operation Manual for the EMT 10T, 10/4, and 10/4T Run Design Menu 2-8 Off Color Index 6-6 Run Job Error 6-7 One revolution 2-13 Run Menu 2-26 Operation 2-1 Operator Kit 4-13 Sash Frame 3-17 Options Menu 2-11 Select a design 2-26...
  • Page 125 Operation Manual for the EMT 10T, 10/4, and 10/4T INDEX Thread tree 2-1 X Axis Current Limit 6-7 Thread trimmer: 2-15 X Axis Move Timeout 6-7 Threading 2-4 X Axis Not Done 6-7 Time to oil hook 4-3 X Axis Tracking Error 6-7...
  • Page 126 INDEX Operation Manual for the EMT 10T, 10/4, and 10/4T...
  • Page 127 Quick Ref- erence Guide for the EMT 10T, 10/4, and 10/4T 11817 Revision A...
  • Page 128 EMT 10T, 10/4, and 10/4T QUICK REFERENCE Select a Hoop Size Run a Design Raise the Needle 1. Press until the display reads: OPTIONS 1. Press until the display reads: DESIGN 1. Press until the display reads: FUNC- MENU. MENU.
  • Page 129 Quick Ref- Frame Sizes erence Tube Frames Guide 11.8” * 17.3” (30 * 44 cm) 11.8” * 14.2” (30 * 36 cm) 8.3” (21 cm) 7.1” (18 cm) for the 5.9” (15 cm) 4.7” (12 cm) Round Wooden Frames 8.3” (21 cm) Spider Frames 7.1”...
  • Page 130 EMT MENU AND COMMAND QUICK REFERENCE...

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