Page 1 Technical Manual Rev 082115...
Page 2 Contents Copyright Notice About This Manual Scope of Manual Standard Conventions and Definition of Terms Regulatory Notices Best Maintenance Repair Practices Maintenance Philosophy: Grounding and Static Electricity Machine Orientation Safety Issues Warranty Considerations Explanation of Machine Symbols Keypad Operations Keypad Buttons Trace Button Arrow Up Key (Y-Axis Back) Color Change/Needle Case...
Page 3 Software Maintenance Menus Special Tools and Fixtures General Maintenance Cleaning Lubrication Schedule and Specifications Maintenance Schedule Daily Maintenance Weekly Maintenance Monthly Maintenance Quarterly Maintenance Thread Cutter Blade Replacement Centering The Needle Plate Head Up Position Adjustment Mechanical Head-Up Position Adjusting Head-Up (Z-Home) Position: Hook Timing Inspection/Adjustment Rotational Hook Timing Inspection Procedure Needle To Hook Gap Inspection Procedure...
Page 4 Z-TIMING: Bottom Center & Head-Up Bottom Center (Z Timing) Z-Drive Belt Tensioning Inspection and Adjustment Z-Home Adjustment Procedure to Identify the Closest Needle Needle Case Calibration Fine calibration procedure: Rough Calibration Process: Rotary Hook Support Adjustment Inspection Procedure Adjustment Procedure Color Change, Take-Up, Feeder Housing Assembly Replacement Procedure for Entire Color Change/Take-Up/Feeder Assembly: Color Change Linear Actuator Replacement...
Page 5 Z-Belt Idler Assembly Replacement Z-Motor Assembly Clearing Thread from Thread Feeder Roller Color Change Spindle Mounting Bracket Replacement Grabber Blade Replacement Needle Case Removal Needlecase Installation Grabber Stepper Motor Replacement Take Up Lever Replacement Thread Feeder (replacement and adjustment) Thread Sensor Assembly Replacement Bobbin Shaft Overhaul Rotary Hook Replacement Main PCB...
Page 6 User Interface Harness X/Y Home Harness Bearing Block Assemblies X-Beam Assembly X-Carriage Assembly X-Drive Cable Removal X-Drive Cable Installation X-Drive Motor Replacement X-Home Optical Switch Assembly Replacement X/Y Home PCB Replacement Y-Drive Belt Replacement Y-Motor Assembly Troubleshooting Grabber Function Test Final Functional Tests Optical Sensors Test Power Supply Test...
Page 7 Test Designs Thread Tension Test Belt Tension Test Long Stitch Test Looping Test Orientation Test Registration Test Small Alphabet Test Thread Break Sensor Test Thread Break Test Trimmer Test Electrical Failures AC Power Failure Color Change Failures LED Cluster Assembly Failures Machine Initialization Failure Mechanical Failures False Thread Breaks...
Page 8 Critical Measurements Introduction Needle Drive Stud to Reciprocator Fit Hook Timing Upper Arm to Lower Bed Alignment Needle to Hook Gap Hook to Rotary Support Gap Take-Up Lever Stroke Take-Up Lever Fit to Shaft Take-Up Lever Endplay Cam Follower Preload Pull Force on Take-Up Lever Color Change Lead Screw Color Change Housing Location...
Page 9 Copyright Notice © Copyright Melco, 2014 ALL RIGHTS RESERVED. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without prior written approval from the author. The author reserves the right to revise this publication and to make changes in it at any time without obligation of the author to notify any person or organiza- tion of such revisions or changes.
Page 10 About This Manual This manual contains instructions on repairs and adjustments to the embroidery machine, in addition to other technical information. If you do not fully understand any information in this manual, you are advised to contact your local au- thorized technical support provider for assistance.
Page 11 • Note: This manual is written for individuals with adequate knowledge, Melco certified training or equivalent and experience in the use of tools required. No attempt is made to explain how to use tools required to make repairs to the machine other than graphical depictions within the procedures involved.
Page 12 Standard Conventions and Definition of Terms Throughout this manual abbreviations and specific terms may be used. When abbreviations or techni- cal terms are used, they are defined through the use of pop-up hot spots, which opens a dialog box to explain their meaning.
Page 13 Regulatory Notices (U.S.) The FCC (Federal Communications Commission) mandates that if a user makes changes or modi- fications to the machine not expressly approved by the manufacturer, the user’s authority to operate the machine may be voided. 13 of 271 Table of Contents...
Page 14 Best Maintenance Repair Practices The procedures presented in this manual are to be considered best maintenance repair practices. These procedures are intended to optimize the performance and durability of your machine. Best maintenance repair practices are to be performed using the correct tools and fixtures while adhering to all safety pre- cautions appropriate for each job.
Page 15 Using compressed air, blow the dust away from sensors and off the PCB’s in the machine. In addition, minimize dust accumulation cleaned on all exposed surfaces. Excessive dust will reduce the useful life span of the machine. Sensors should be cleaned with dry, compressed air during each of the lubrication cycles. Dust accumula- tion in the base around the control PCB should be blown out every month or whenever the base cover is removed for any type of maintenance.
Page 16 Drive Belt Tensions: • CAUTION! Damage to the machine may result if belt tensions are improperly adjusted. All drive belts require special procedures and tools for setting the proper tensions. If the tension adjust- ments are made without using the proper procedures and tools (and without training in some cases), poor performance, excessive wear, damaged components, personal injury, and voided warranty may result.
Page 17 Grounding and Static Electricity • WARNING!! It is very important that the power cord is plugged into a properly wired electri- cal outlet. Failure to have a properly wired outlet may result in damage to the equipment and personal injury. It is recommended that a licensed electrician be consulted to ensure that the electrical outlet is properly wired and grounded.
Page 18 • CAUTION !! Use extreme care not to damage the cable and protective coating during assem- bly. If the protective coating is damaged, the cable will wear out very fast impacting the quality of the sew outs. 18 of 271 Table of Contents...
Page 19 Machine Orientation The references in the manual to certain sections of the machine are oriented as if you were facing the front of the machine as shown below. Example: The “left” arm cover is on the left side of the machine when you face it from the front, but is on the right side if you face it from the rear.
Page 20 Safety Issues Voltages • WARNING!! Lethal voltages exist inside the power supply unit, at the back side of the electrical supply input connector, and in the wires between the two. If you plan to do any work with any of these components, turn the power switch off and disconnect the electrical input supply cord from the machine.
Page 21 Warranty Considerations Many areas of maintenance in this manual require factory trained personnel to ensure proper service. Any service that is improperly performed may void the warranty. Items that are marked “...should be done by an authorized service technician” should be performed by a repair technician that has been authorized by the manufacturer.
Page 22 Explanation of Machine Symbols These labels are placed on the machine at specified locations to warn you of certain machine hazards. Caution!! Indicates a machine component will move. Keep clear! Shock Hazard. No user replaceable parts behind this label. Do not open! Moving gears.
Page 23 Keypad Operations Function Press these key(s) Keypad Pictures Notes To Start Sewing Start Press the stop key to stop sewing To Stop Sewing Stop Press the start key to start sewing Cuts power to the Emergency Stop To release, turn a quar- motors.
Page 24 Function Press these key(s) Keypad Pictures Notes To move the hoop down Hoop + Right + Up Always trace after and to the left (moves moving needle position up and to the right in relation to the hoop) To move the hoop up Hoop + Right + Down Always trace after and to the left (moves...
Page 25 Function Press these key(s) Keypad Pictures Notes To move the needlecase Needlecase key + Left to the left Arrow To color change to the Needlecase key + Up next color Arrow To color change to the Needlecase key + Down previous color Arrow Return to Previous Stitch Left Arrow + Right...
Page 26 Keypad Buttons Trace Button The trace button is used to trace the design, a method used to help the operator determine if the design is properly centered and fits within the hoop used. To trace a design, press the Hoop button and the Trace button. Arrow Up Key (Y-Axis Back) The needle case moves to the next color.
Page 27 Arrow Right Key (X-Axis Left) The machine performs a “manual jog”, moving stitch point right. The hoop actually moves to the left. The needle case moves to the right. Center Key When used with the hoop key , the machine moves to hoop center. When used with the adjustment key, the machine toggles the safety grabber in and out.
Page 28 Hoop Key The Hoop key is used to move the position of the needle in relation to the hoop. The Hoop Key and the Arrow Up key move the needle position up, towards the top of the hoop (moves the hoop forward, toward the front of the machine. The Hoop Key and the Arrow Down key move the needle position down, towards the bottom of the hoop (moves the hoop towards the back of the machine).
Page 29 Pressing the start button while the machine is stopped will re-start the machineat the stitch number where the machine was stopped. Stop Button The stop button stops the machine operation but does not disconnect electrical supply to the motors and electronics.
Page 30 LED Indicator The Status Indicator LED is illuminated when the machine is turned ON. The LED color and whether it is blinking indicates the machine status or if it has a fault. Status Light Condition Definition Action to Take Green (blinking) Machine is on, but no RSA files Start software, check connections loaded yet...
Page 31 Specifications For indoor use only Operating Software Bravo OS Lite Bravo OS Flex Type/# of Heads Upper Arm-Lower Arm/1 Upper Arm-Lower Arm/1 to 4 Modular Modular # Needles Maximum Tubular Frame Size 360mm x 300mm (14.2”x 11.8”) 426mm x 430mm (16.8”x 16.9”)
Page 32 Operating Software Bravo OS Lite Bravo OS Flex Motor Type(s) Servo, Stepping Servo, Stepping Motor Capacity (kV) X and Z: 100 Watts Y: 250 Watts X and Z: 100 Watts Y: 250 Watts Machine Construction Material Aluminum Aluminum Physical Specifications with Cart Width 724mm (28.5”)
Page 33 Technical Specifications The following is a list of various tension and force specifications for your machine. See the Critical Measurements section for other machine specifications that are not listed below. Specification BRECO Meter Measurement Force Gauge Measurement X Drive Cable Tension 145 ±...
Page 34 Torque Specifications The following chart depicts the torque specifications for all screws and nuts used in the machine. They should be followed unless indicated otherwise in this manual (i.e., screws going into plastic materials require lower torque). • Note: Reduce torque specifications when attaching optical sensors by 10% to prevent damage to the sensor housing.
Page 35 Size Zn Plated, Property Class 8.8, Low Profile Socket Head Screws PN: 30750-XX 2.61 3.19 Black Oxide, Property Class 10.9, Flat Head Socket Screws (PN: 001935-XX, 007443-XX) 1.73 2.11 Zn Plated, Property Class 10.9, Flat Head Socket Screws (PN: 011197-XX, 011198-XX) 3.77 4.61 7.29...
Page 36 Software Maintenance Menus In order to access the maintenance menus in the software, the machine must be turned on and software must be loaded and launched. Figure 1 - Software Main Menu To access the maintenance menu, select the “Tools>Maintenance” from the main menu. The screen be- low will open.
Page 37 Special Tools and Fixtures The following fixtures and special tools are required to perform certain procedures and repairs described in this manual: • Fixture, Y-Belt Tensioning (PN: 32108) • Force Gauge (0-40 lbs.) (PN: 995595-01) • Force Gauge (0-10 lbs.) (PN: 995591-01) •...
Page 38 General Maintenance This section describes the procedures involved in maintaining your machine. This section is very import- ant, because maintenance is essential to the performance of your machine. Cleaning It is very important that you clean your machine regularly. Dust and lint accumulation can damage both electrical and mechanical systems.
Page 39 3. Carefully lift the EMI shield from the main PCB. If required, disconnect the fan connector from the main PCB. • CAUTION!! Be careful not to drop metallic hardware or tools onto the Main PCB while it is exposed. Doing so can result in severe damage to the electronics that might be expensive to repair.
Page 40 Lubrication Schedule and Specifications Tools and supplies needed for these procedures are provided in your operator’s kit. Using the correct lubricants properly and when specified by scheduled maintenance is critical to the operation of the machine. Failure to use the proper lubricants as specified can shorten the usable life of internal components and can void the warranty.
Page 41 Monthly Lubrication Point(s) Lubrication Used X-Drive Rails HP Grease Y-Bearing Blocks Sewing Machine Oil X-Cable Tension (Test) Grabber Eccentric HP Grease Quarterly Lubrication Point(s) Lubrication Used Take-Up Lever Cam, Presser Foot Cam Follower, & HP Grease Right Needle Bar Guide Presser Foot Cam &...
Page 42 Daily Maintenance Rotary Hook The rotary hook should be oiled approximately every 4-5 hours of solid running. This will keep the ma- chine running smoother, quieter, and prevent thread breaks. • WARNING!! Never attempt to remove or insert the bobbin with the machine is in operation. 1.
Page 43 6. This is now a good time to clean, rethread, and Insert the bobbin and case into the machine with the pigtail facing up. Push on the bobbin case until it snaps into place. 7. Trim the thread to 2-3 inches. This completes the hook maintenance procedure.
Page 44 Left Upper V-Rail 7. Using a piece of lint-free cloth, wipe clean both the front and back surfaces of the upper v-rail on the LEFT side of the needlecase. 8. After cleaning the v-rail, use a small oiler bottle to apply a drop of oil each to the front and the back surfaces of the v-rail.
Page 45 Oil Needle Bars (Upper) 13. Using a small oiler bottle, apply one (1) drop of sewing machine oil to each of the sixteen (16) needle bars by guiding the oiler applicator through the vertical slots of the needlecase cover just below the take up lever arms as shown in the image.
Page 46 4. Using a clean piece of cloth, apply a thin film of HP grease to the front and back steel rails inside the x-beam as shown in the image. 5. Replace the end cap cover that was previously removed. 6. Remove the end cap cover on the left side of the x-beam as shown in the image. 7.
Page 47 Y-Bearing Blocks 11. Color change to move the needle case to needle #16. 12. Using a 3mm Allen wrench, loosen and remove the three (3) screws securing the left side cover as shown in the image. • Note: The screw in the front of the cover is slightly longer than the two (2) rear screws. Ensure that you use the same screws for the original position later in this procedure.
Page 48 19. Color change to move the needle case to needle #1. 20. Using a 3mm Allen wrench, loosen and remove the three (3) screws securing the right side cover as shown in the image. • Note: The screw in the front of the cover is slightly longer than the two (2) rear screws. Ensure that you use the same screws for the original position later in this procedure.
Page 49 24. Determine if the cable tension is within specification. • If the x-cable is positioned within the large cut-out on the right side of the x-cable tension gauge as shown in the image, the tension is within specification. Continue to step 25. •...
Page 50 e. When the x-cable is roughly at the lower edge of the cut-out on the right side of the ten- sion gauge, remove the wrench, pliers and the tension gauge. f. Remove the tools and the x-cable tension gauge before proceeding. g.
Page 51 32. With a small flat blade screwdriver, carefully move and hold the grabber connecting lever over to the left as shown in the image. 33. Using the grease applicator, apply a small amount of HP grease onto the grabber eccentric surface between the grabber connecting lever and the grabber home flag as shown in the image.
Page 52 5. After removing the mounting screws, move the right upper arm front cover slightly away from the machine. Then, rotate it counter clockwise as shown in the image and remove it completely from the machine. 6. Using the grease applicator, apply some HP grease to the back surface of the take-up Lever Cam as shown in the image.
Page 53 WARNING!! If you proceed without mounting the right upper arm front cover, damage to your machine will occur and a service call will be necessary. • Note: Melco will not be responsible for any damage to the machine or related service costs caused by not performing this step. 11. Color change to needle #12.
Page 54 13. Color change to needle #1. 14. Now tighten the three remaining screws on the left side of the right upper arm front cover as shown in the image. 15. With a clean piece of cloth, wipe clean the needle bar guide channel indicated in the image. The image uses cloth wrapped around the grease applicator for better control of the cloth.
Page 55 WARNING!! If you proceed without mounting the left upper arm front cover, damage to your machine will occur and a service call will be necessary. • Note: Melco will not be responsible for any damage to the machine or related service costs caused by not performing this step. 23. Color change to needle #5.
Page 56 25. Color change to needle #15. 26. Now tighten the two (2) remaining screws on the right side of the left upper arm front cover as shown in the image. 27. With a clean piece of cloth, wipe clean the needle bar guide channel indicated in the image. The image uses cloth wrapped around the grease applicator for better control of the cloth.
Page 57 31. With a small flat blade screwdriver or your fingernail, disengage all sixteen (16) thread feed front covers and remove them from the machine. 32. Using two thin-bladed flat screwdrivers or the thread feed gear removal tool, carefully pry the thread feed rollers out of the assembly.
Page 58 • Important: Do not get grease on the thread feed surface of the roller. 35. Inspect the roller for wear, nicks, or grooves that may catch thread. If the roller is damaged, re- place it with a new one. 36. Using the image as a guide, apply three (3) small dots of EMB Polymer grease to the side of the hub.
Page 59 39. Rock the cover forward and down until it snaps into place. Keep in mind that the covers overlap and will reinstall easiest starting with needle 1. 40. Next you need to remove the pinch rollers. This is easiest if you leave the thread feed levers up. Then steady the lever with one hand and pull the roller to the right with the other.
Page 60 44. Inspect the roller for wear, nicks, or grooves that may catch thread. If the roller is damaged, re- place it with a new one. 45. Using EMB Polymer grease, apply a small amount of grease to the lever hub as shown in the image.
Page 61 Thread Cutter Blade Replacement 1. Remove the needle plate by removing the two screws from the bottom of the lower arm using a 2.5mm hex wrench. 2. Remove the hook guard by loosening the screws on both sides of the lower arm using a 2mm hex wrench, and sliding the hook guard forward.
Page 62 Centering The Needle Plate 1. Center the needle plate as best you can by feel and by eye. 2. Lower the needle to its bottom most rotation. This can be done manually by pressing the e-stop and rotating the z-shaft to control the decent of the needle. 3.
Page 63 Head Up Position Adjustment Mechanical Head-Up Position Figure 1 - Reciprocator Drive Groove at “Head Up” Position Mechanical head up is when the drive slot of the reciprocator (the part that engages the drive stud on the needle bar) is aligned with the needle bar drive slots on the left and right upper arm front covers. Checking Electrical Head-Up (Z-Home) Position: Electrically, head up is correct when the mechanical head up is set and the z-position reading on the Head Timing menu is 26 °...
Page 64 Adjusting Head-Up (Z-Home) Position: • This procedure is performed after Checking Head Up procedures above are completed. This procedure is also referred to as Head Timing. 1. Remove the left arm cover and remove the back screw from the right arm cover. 2.
Page 65 • Flashlight (Optional) Rotational Hook Timing Inspection Procedure 1. Make sure your machine is turned on and Bravo OS is running. 2. Engage the emergency stop button (by pushing it in). 3. Push the x-beam all the way to the back of the machine to ensure that the hoop arms will be out of the way during the procedure.
Page 66 7. Replace the base cover. 8. Open the Tools>Maintenance menu and then click the Head Timing tab. 9. In the Head Timing tab, click the Head Up button (or on the machine keypad, press the Adjustment key and the Up Arrow key. 10.
Page 67 Needle To Hook Gap Inspection Procedure 15. You can now inspect the needle to hook gap (front to back position of the rotary hook). The needle to hook gap refers to the gap between the hook point and the needle scarf. To check this gap, stand on the right side of the machine, then look behind the needle.
Page 68 b. This number may not be the exact number you entered. If it is not, use the microstep forward command on the keypad (press and hold the press and hold the Trace key, then press the Up Arrow button) to increase the z position by tenths of degrees until the correct hook timing position (201.5) is displayed in the Current Z Position box.
Page 69 7. Repeat step 4, then verify that the rotational hook timing is still correct. If it is not, repeat the rota- tional hook timing adjustment. 8. While still at 201.5°, check and adjust, if needed, the needle to hook gap. 9.
Page 70 13. Lightly tighten each of the three Hook Fastening Screws before fully tightening them. Press and hold the Adjustment key, then press the Right Arrow key to provide access to the screws if needed. 14. Repeat step 11 and verify hook gap did not change. Repeat steps 9-13 if hook gap is larger than 0.1mm (.004”).
Page 71 Thread Clamp Replacement 1. Disconnect the A/C power input cord and the external Ethernet cable from the back of the machine. 2. Remove needle plate 3. Loosen lower arm extrusion cover (4 M3 cap head screws, 2 on the right and 2 on the left) and remove cover 4.
Page 72 Thread Clamp PCB Replacement 1. Disconnect the A/C power input cord and the external Ethernet cable from the back of the machine. 2. Remove lower arm rear cover (7 M4 Socket head cap screws) 3. Disconnect the 3 harnesses from the thread clamp PCB and remove the thread clamp PCB (4 M3 button head cap screws) 4.
Page 73 4. Disconnect the thread clamp solenoid assembly harness 5. Remove lower arm rear cover (7 M4 Socket head cap screws) 6. Disconnect the thread clamp harness from the thread clamp PCB 7. Install the new thread clamp harness following previous steps in reverse order 73 of 271 Table of Contents...
Page 74 Laser Light - Adjustment • WARNING!! This procedure is intended to be performed only by specially trained and authorized service technicians and personnel. Disassembly by untrained individuals will void any warranty protection and can result in personal injury or damage to the machine. •...
Page 75 Figure 2 - Laser Light Focus Figure 1 - Laser Lens 6. Adjust the focus of the laser light by aiming it at a wall or a similar flat surface about from a distance of about 10 feet and using a screw driver to adjust the size of the reflected light on the wall.
Page 76 Setting the Needle Depth by Eye 1. Click the Maintenance menu on the Bravo OS main menu screen, and then click the Head Timing tab to open up the Head Timing menu.
Page 77 Presser Foot Height To adjust the presser foot height, the machine must be turned on and Bravo OS must be launched. A hoop with fabric must also be installed. You can set the presser foot height in the middle of a design.
Page 78 X/Y Home Adjustment Setting X/Y home requires the use of the X/Y Home Fixture (PN: 30873). The use of this fixture is strongly recommended as it provides for consistent accuracy in the home settings. Home Adjustment Procedures: 1. Turn the machine ON. 2.
Page 79 Figure 3 - Y-Home Flag (Bottom View) 9. Loosen the screws mounting the Y-Home Flag to the bottom of the upper arm body on the left side. The Y-home flag also serves as a wiring channel for the X/Y home harness (the rainbow col- ored ribbon cable).
Page 80 Figure 5 - 33322 Series EMI Cover 14. Install the EMI Cover carefully. 15. Install the base cover. 80 of 271 Table of Contents...
Page 81 X-Cable Tension The following instructions will guide you through checking and, if necessary, adjusting the X-Cable tension on your machine. The X-Cable Tension Gauge (PN 33909), shown in picture 1 below, is used to indicate the permissible range for proper X-Cable tension. Figure 1: X-Cable Tension Gauge, PN 33909 Determining if an X-Cable is Set to Required Specifications 1.
Page 82 4. Position the X-Cable Tension Gauge on the X-Cable as shown in picture 5 below. Center the Gauge between the indicated Pulley and the Upper Arm. Figure 4: Centering the X-Carriage 5. A properly adjusted X-Cable will fall within the cutout area shown in picture 6 below. If the X ca- ble falls within the cutout area, remove the fixture and re-install the Side Cover.
Page 83 Figure 7:X-Cable Tension Adjustment 2. Using a small wrench grip the M4 Nut (shown in picture 7 above) and with a pair of pliers or cre- sent wrench grip the X-Cable Stud at the end of the X-Cable as shown in picture above. •...
Page 84 Y-Axis Timing Belt Tensioning The Y-axis timing belt tensioning requires that the machine is turned off while measuring the tensions. This procedure can be performed by the machine operator as long as the following procedures are followed explicitly. This procedure requires the use of a 0-10 lb. Force Gauge, a Universal Force Gauge Adapter, Y-Belt Tensioning Fixture, a 3mm Hex wrench, and a 7mm nut driver.
Page 85 5. Push the force gauge (attached to adapter) down on the upper y-belt until the belt touches the Y-belt tensioning fixture. The force should read 8.1 ± 0.3 lbs. 6. Repeat steps 4 and 5 for the other side of the machine. If the belt tension on either side needs to be adjusted, proceed to the adjustment procedure.
Page 86 Y-Motor Timing Belt Tensioning • This repair requires timing and other adjustments and must be done by an authorized service technician. This procedure requires the use of a Force Gauge and a Universal Force Gauge Adapter. Inspection and Adjustment 1. Attach the Universal Force Gauge Adapter, PN 32498, to the 0-10 lb. Force Gauge, PN 995591-01 (screw adapter on the end of the gauge).
Page 87 The Z-flag is manually adjusted such that a Bottom Center command initiated either by the keypad or software will generate the lowest possible mechanical position of a corresponding needle at 180 ° ±0.5 ° z-axis position (displayed in the Bravo Operating System (OS) Maintenance > Head Timing” menu). Bottom Center (Z Timing) Measurement 1.
Page 88 6. Cycle the machine to its Bottom Center position by pressing the Adjustment and Arrow Down keys simultaneously on the keypad (be careful not to let the needle “slam” against the indicator plunger because this may cause damage). 7. With the indicator plunger in full contact with the needle, hang the 3 lb weight from the needle clamp as shown in Figure 4.
Page 89 3. At the rear of the machine, loosen the z-axis flag; and while facing the z-axis flag, rotate it com- pletely counter-clockwise and re-tighten it. See Figure 3. • Note: If the machine loses power after this step, it will be necessary to “roughly” reset z-timing. Do so by following the steps outlined below.
Page 90 18. Using the micro-step command on the keypad, increase (press the Trace key and the Arrow Down key the angular position back to the lowest needle position. After the needle stops moving, note the angular position and continue to micro-step in the same direction for at least 1.5 ° more; the needle should not move.
Page 91 position at which the z-index LED changes state. Again, this should be within ± 0.2 ° of β z-index setting. 26. Remove the weight and cycle the machine to Head-Up at least 3 consecutive times (be sure the needle in the needle bar clears the dial indicator plunger during this step). 27.
Page 92 Z-Drive Belt Tensioning This procedure can be performed by the machine operator as long as the following procedures are followed explicitly. This procedure requires the use of a 0-10 lb. Force Gauge and a Universal Force Gauge Adapter, a 3mm hex wrench. Inspection and Adjustment 1.
Page 93 The right side of the adapter should be lined up with outside edge of the motor mounting bracket. 8. Push down on the force gauge until the top of the belt lines up with the mark on the mounting bracket. The force should be 6.8 ± 0.3 lbs. 9.
Page 94 Z-Home Adjustment Align the z-home flag using procedures defined for “Head-Up Position Alignment”. 94 of 271 Table of Contents...
Page 95 Procedure to Identify the Closest Needle When the needle case has been replaced, it is necessary to reestablish the closest needle and make sure that it falls under the total allowable variance of.006. The following is the procedure to identify to the closest needle: 1.
Page 96 Figure 3 • Note: You may also need to adjust the height of the closest needle measurement gauge so that the plunger touches the needle and NOT the needle clamp. Figure 4 9. Zero your closest needle dial indicator on the first needle. 10.
Page 97 Needle Number Measurement .000 -.002 .000 -.00125 -.00025 -.00025 .00025 .0005 .00075 -.005 -.00025 -.00375 -.00325 -.00425 -.001 -.00275 Example of a Completed Worksheet Table 15. The most negative number is your closest needle. If no negative numbers are recorded, then the needle with value ‘0’...
Page 98 Needle Plate installed and the needle is aligned to the center of the needle hole. Fine calibration procedure: 1. Make sure the Bravo OS is up on your computer screen and your machine is ON. 2. Remove the Bobbin Case Assembly and the Needle Plate.
Page 99 18. From there, you can repeat Steps 7-13 as needed until all 16 needles have been centered. 19. Upon completion of the 16 needle calibrations, hit the “Get Table” key in the Bravo OS. By hitting this key, you will be storing a backup copy of the calibration table in the computer.
Page 100 9. If the needle is centered, hit the Frame-Back key and move to the next position. 10. Repeat this process for the remaining needles. 11. Upon completion of all 16 needles, hit the Get Table button in the Bravo OS as shown below. Figure 5: Get Table Button 12.
Page 101 Remove the 2.5mm Allen screws that secure the needle plate. Figure 2 – Needle Plate Screws 3. In the Bravo OS, click on Maintenance Menu and then click the Head Timing Tab. 101 of 271 Table of Contents...
Page 102 4. Click the button labeled Bottom Center. • CAUTION: The needle will move without any on-screen prompting when you are in the Maintenance Menu. Figure 3 – Head Timing Tab 5. Inspect the left-to-right position of the tip of the hook support (the portion of the hook support that is positioned inside the notch of the rotary hook –...
Page 103 • CAUTION: If the gauge does not slide in easily, do not force it. You may scratch the highly pol- ished surface of the hook support or hook basket, resulting in thread breaks. Figure 5 – Retaining Finger Gauge Usage The retaining finger gauge should slide between the hook support and hook basket with no resis- tance.
Page 104 4. Holding the hook support from the side with the adjustment screws, adjust the position of the hook support to the requirements specified in the inspection procedure. 5. Remove the gauge while holding the position of the hook support, being careful not to scratch the highly polished surface (this is critical to proper operation).
Page 105 Color Change, Take-Up, Feeder Housing Assembly The Color Change/Take-Up/Feeder Assembly is a sensitive component that should be repaired carefully following the procedures contained for each individual component. When repairing components on this assembly, do not loosen the screws that mount the housing to the upper arm body. Figure 1 - Color Change/Take-Up/Feeder Housing Assembly Do not attempt to repair or replace any component on the Color Change/Take-Up/Feeder Assembly ex- cept as provided by the below procedures:...
Page 106 5. Remove the Color Change/Take-Up/Feeder Assembly by removing the three cap head screws mounting it to the upper arm assembly. 6. Measure the amount of the color change shaft that extends from the left side of the old color change motor. 7.
Page 107 Color Change Linear Actuator Replacement The color change linear actuator will show obvious signs such as overheating or electrical burn when it needs to be replaced in the majority of situations. However, signs such as uneven or “jumpy” movement noticed when turning the actuator shaft by hand or other troubleshooting tests that indicate that the actuator has failed are other situations in which replacement is appropriate.
Page 108 • CAUTION: Do not remove the spindle from the motor as this will cause the anti-backlash nut to spring off. Figure 3 - Anti-backlash nut Figure 4 - Left Color Change Spindle Mounting Bracket 7. Move the needlecase assembly by hand to the left until the spindle is freed from the left color change mounting bracket.
Page 109 20. If any noticeable binding occurs, repeat steps 18-20 until color changing from Needle 1 to Needle 16 and back is smooth and consistent. 21. Install the needlecase cover and access cover, and color change covers. 22. Run a short functional test using the test design AMPASSxxx with the machine in the unthread- ed mode.
Page 110 Thread Feeder Gear Replacement • This repair requires timing and other adjustments and can only be done by an authorized ser- vice technician. The thread feeder gear will need replaced only when the teeth on the plastic gear are broken or worn excessively.
Page 111 Figure 3. 5. Remove the retaining ring, washer and broken gear from shaft. 6. Assemble the new gear and re-install the washer and retaining ring. 7. Apply #222 Loctite to the threads of the Feeder Drive Gear Shaft. 8. Using the tool, carefully thread the shaft back into the drive base making sure the gear teeth are aligned with the gear on the Thread Feeder Assembly.
Page 112 Thread Feeder Optical Sensor PCB Replacement The thread feeder optical sensor PCB requires replacement when the sensors are damaged due to im- proper installation or the sensors become so dirty that they cease to function correctly. It is not expected that the circuitry on the PCB itself will fail.
Page 113 Thread Feeder Radial Bearing Replacement The thread feeder radial bearing will have obvious defects when it requires replacement. The radial bearings inside will develop flat spots from damage or wear and the bearing will turn on the center rim roughly, or the sealed bearing will show lubricant leakage. Replacement Part Needed: •...
Page 114 Thread Feeder Stepper Motor Assembly The thread feeder stepper motor requires replacement when it fails. Failure of the thread feeder motor is usually obvious: overheated motor, electrical smell, or motor fails to feed thread or fails to function satis- factorily in both directions. There are other situations which will be determined through the troubleshoot- ing processes that will require the stepper motor to be replaced.
Page 115 12. Turn the machine on and launch Bravo OS. Figure 2 - Steppers Menu 13. Open the “Tools>Maintenance” menu from the Bravo OS main menu and select the “Steppers” tab. 14. Under the “Thread Feed” column, click on “Home”. Check the alignment of the white thread feed gears by color changing and verify that there is no clicking sound during the movement.
Page 116 Laser Pointer Assembly • WARNING!! This procedure is intended to be performed only by specially trained service techni- cians and personnel. Disassembly by untrained individuals will void any warranty protection and can result in personal injury or damage to the machine. •...
Page 117 • CAUTION!! Do not touch the metal laser housing to the casting. Do not ground the laser hous- ing to other metal components. This will damage the laser. 2. Remove the upper right front cover and set the four M4x8mm flanged head socket screws and one M4x6mm button head cap screw aside for reuse.
Page 118 LED Cluster PCB Replacement The purpose of the LED cluster is to illuminate the fabric while the machine is sewing. None of the indi- vidual LEDs have any particular significance or indication as to the condition or position of the machine. Failure of either LED cluster or any of the individual LEDs on them will not affect the functionality of the remainder of the machine.
Page 119 Presser Foot Assembly Replacement • This procedure should be done only by an authorized service technician. Repair Parts Needed: • Presser Foot Assembly Repair Kit Figure 1 - Presser Foot Assembly Installed 1. When replacing the presser foot assembly, replace ALL of the parts that are in the presser foot assembly repair kit.
Page 120 25. Turn the machine on. 26. Go to bottom dead center in the Maintenance Menu in the Bravo OS software and verify left and right needle centering in the needle plate hole.
Page 121 One way to verify this distance is described below. 28. Replace any needle with a drill blank (or straight wire) with a diameter of 1.6mm (0.0625in) and a length of approximately 30mm (1 3/16”). 29. By rotating the upper z-shaft, move the corresponding needle bar down until the presser foot reaches its lowest position.
Page 122 Reciprocator • This repair requires timing and other adjustments and should be performed by an authorized service technician. Replacement Parts Needed: • Reciprocator Repair Kit Replacement Procedure 1. Remove the needle case as described in the Needle Case Removal section. 2.
Page 123 4. Remove the two screws that hold the retaining finger in place. 5. Loosen the set screws at the top and bottom of the head that secure the reciprocator guide shaft. 6. Remove the reciprocator guide shaft by sliding it up and through the hole at the top of the upper arm casting.
Page 124 Take-Up Lever Cam Replacement The take-up lever cam may wear out over time and need replacement. Replace the cam following these procedures. • This repair requires timing and other adjustments and should be done by an authorized service technician. Replacement Part Needed: •...
Page 125 Figure 3 - Screws On Back of Take-Up Lever Cam 6. Remove the screws mounting the z-shaft end plate to the take-up lever cam. Figure 4 - Remove Hex Nut 7. Remove the M4 hex nut from the take-up lever cam and put it in the replacement cam. 8.
Page 126 13. Apply red loctite (MS 222) to the upper connecting rod bolt and assemble the connecting rod assembly to the take-up lever cam. Tighten the bolt to 35 in-lbs[4 Nm] of torque. (Figure 1) 14. Install the left and right front arm covers. 15.
Page 127 Z-Drive Repair and Adjustment The Z-Shaft assembly should never be disassembled by other than factory authorized personnel. There are no user or field technician serviceable parts on the z-shaft assembly. Service all z-drive components only by using the procedures contained in these instructions. •...
Page 128 Replacement Procedure 1. Remove the left and right upper arm covers. 2. Remove the upper arm back cover. 3. Remove the lower arm rear cover. Figure 2 - Z-Home Flag With Index Mark 4. Using a permanent marker, mark a common index mark on both the z-home flag and the upper arm body as shown in Figure 2 above.
Page 129 Z-Home Sensor PCB Replacement • This repair requires timing and other adjustments and should be performed by an authorized service technician. Repair Parts Required: • Z-Home Sensor PCB Assembly (includes the bracket) • WARNING!! Do not take the covers off the machine without either turning the machine off or engaging the emergency button.
Page 130 Figure 2 - Z-Home PCB Mounting Bracket • NOTE: Make sure that the flag is centered front to rear between the sensors on the optical PCB. Adjust PCB if required. 8. Tighten the screws to the torque specifications and remove the fixture. 9.
Page 131 Z-Belt Idler Assembly Replacement The z-belt idler assembly has internal bearings that may get damaged by a machine fault or an operator error such as over tensioning the z-drive belt. Replacement Part Needed: • Z-Belt Idler Assembly Figure 1 - Z-Belt Idler Pulley 1.
Page 132 Z-Motor Assembly The Z-motor assembly should also be replaced when the resistance between each of the phases is incon- sistent or substantially different than 1.04±10%Ω for the short z-motor and 0.57±10%Ω for the long z-motor. In addition, the resistance between each of the phase wires should be relatively consistent with the other wires.
Page 133 6. Disconnect both the z-motor harness and motor and hall sensor leads (marked “CONTROL PCB Z MOTOR” and “CONTROL PCB Z HALL/ENC”) from the main PCB at connector locations J7 and J8. 7. Use a small pair of wire cutters and cut off the cable ties that tie the z-harness to the user inter- face harness.
Page 134 19. Attach the cable clamp to the z-motor lead (marked “CONTROL PCB Z MOTOR”) and attach the cable clamp at the bottom of the z-motor mounting bracket as shown in Figure 4. Tighten the screw to The torque specifications. 20. Use a cable tie and tie the z-motor harness leads and the adjacent leads together right before the clamp.
Page 135 Clearing Thread from Thread Feeder Roller When the thread or material feed settings are too loose, birdnesting often results when thread is pulled into the thread feeder and wraps around the thread feeder roller. This is easily cleaned out by following the below procedures.
Page 136 8. In the Bravo OS, open up the “Tools>Settings” menu, and then click on the “Thread Feed” tab. Check the settings for the thread and material feed and make sure they are correct. You will prob- ably need to adjust them.
Page 137 Color Change Spindle Mounting Bracket Replacement Parts needed for repair: • left color change spindle mounting bracket (only if damaged) • right color change spindle mounting bracket (only if damaged) The color change spindle mounting brackets require replacement only when the screw holes are stripped out beyond repair or the bracket is cracked or otherwise damaged.
Page 138 l. Color change to Needle 8 and then apply red Loctite (MS 222) to the M4x8mm cap head screw and install the screw into the top of the bracket, tightening it to the torque specifications. Figure 2 - Right Color Change Spindle Mounting Bracket 5.
Page 139 Grabber Blade Replacement The grabber blade will need to be replaced if it is damaged due to a machine or operator error. It should be replaced anytime the blade is nicked, bent or damaged in any manner. Damage to the grabber blade usually occurs because the path of the grabber blade is obstructed, the grabber assembly is not properly adjusted, or the screws are loosened or not properly torqued.
Page 140 b. Loosen the front M4x6mm cap head socket screw mounting the upper trap assembly to the needlecase. Figure 3 - Upper Trap Assembly Hex Nut c. Loosen the two M4 hex nuts located at the bottom of the right side of the needlecase. d.
Page 141 Figure 4 - “Steppers” Submenu 7. Open the “Tools>Maintenance” menu in the Bravo OS software and click on the “Steppers” menu tab. Under the “Grabber” column, click on the “Step>” button and manually run the grabber through it’s cycle. Observe any rubbing of the grabber blade and look for other parts that might be out of adjustment and hitting the grabber blade.
Page 142 Figure 1 - Needlecase Assembly 1. Turn ON the machine and open the Bravo OS. Click on “Tools>Maintenance” menu and then “Head Timing” tab. Click on the “Head Up” button to bring the head to the HEAD UP position.
Page 143 Figure 2 - Needlecase Access Cover Removed 5. Remove the 2 button head screws at the left and right of the access opening, holding the needle case cover, and remove the needle case cover (see Figure 2). 6. Loosen the top screw to the left color change spindle mounting bracket as shown in Figure 3. Figure 3 - Loosen Top Screw 7.
Page 144 Needlecase Installation • This repair requires timing and other adjustments and should be done by an authorized service technician. Figure 1 - Needlecase Assembly 1. 1. Verify that the machine is turned OFF. Figure 2 - Reciprocator at “Head Up” Position 2.
Page 145 9. Reconnect the thread tubes to the back of the thread feeder assembly in the correct numerical order from right to left (as you face the front of the needlecase). 10. Reinstall the needlecase cover. 11. Replace the needlecase access cover to the needle case assembly. •...
Page 146 Grabber Stepper Motor Replacement The grabber stepper motor requires replacement when the grabber assembly fails to function and power supply failure to the motor has been eliminated as a cause. Before replacing the motor, conduct trouble shooting procedures to evaluate the failure between the main PCB, grabber harness and the motor. Replacement Parts Needed: •...
Page 147 Take Up Lever Replacement Take up levers require replacement whenever they are damaged in anyway. No fixtures are required to perform this procedure, but it must be completed by following these instructions explicitly. Replacement Parts Needed: • One (1) take up lever assembly (for each take up lever requiring replacement) Replacement Procedure 1.
Page 148 Figure 4 - Retaining Clip 10. Remove the retaining ring from the groove on the left side of the left take up lever axis. Set it aside for reuse. 11. Tap on the right side of the take up lever axis until the spacer on the right side can be removed and set it aside for reuse.
Page 149 Thread Feeder (replacement and adjustment) Figure 1 - Needle Case Assembly Replacement Parts Needed: (for part numbers and description, click on the links) • Thread Feeder Assembly, 16 Needle (comes with hardware installed) Replacement Procedure 1. Turn the machine off. 2.
Page 150 5. Loosen the two nuts on the left side at the end of the long bolts as shown in Figure 3 above. Figure 4 - Thread Feeder Assembly, Right Thread 6. Remove the two socket head screws on the right side as shown in Figure 4 above. 7.
Page 151 Figure 6 - Gage Pin 13. Click the Thread Feed Home button in the Stepper menu and ensure that the teeth of both gears do not touch. Adjust the position of the thread feeder PCB as required until gear teeth do not touch.
Page 152 Thread Sensor Assembly Replacement The thread sensor assembly has to be replaced when diagnostic tests indicate it has failed. Symptoms such as inconsistent thread feed, inconsistent thread tension, and an increase in tension can be related errors during embroidery operations. •...
Page 153 5. Use a piece of string or light wire and tie the PCB to the center of the thread sensor base. Do not allow the PCB to hang by the wires that are soldered to it. 6. Remove the two button head screws mounting the thread sensor base to the needle case and remove the thread sensor assembly and base.
Page 154 Bobbin Shaft Overhaul • This repair requires timing and other adjustments and can only be done by an authorized ser- vice technician. Bobbin shaft components that might require replacement are the two radial bearings located on the front and back of the machine. The bobbin shaft affects the under thread sewing operations. Replacement Parts Needed: •...
Page 155 6. Remove the rear upper and lower arm covers. 7. Release the tension from the z-belt by loosening the belt tensioner screw with a 4mm Allen wrench. 8. Remove the timing pulley by punching out the roll pin. The manufacture recommends that the roll pin not be re-used after it has been removed.
Page 156 Rotary Hook Replacement Should you need to replace your rotary hook, use the following procedure. This procedure is not to be used to time a rotary hook already installed on the machine. List of Tools • Hex Wrench, 2mm • Hex Wrench, 2.5mm Replacement Procedure 1.
Page 157 10. While holding the rotary hook support in place, re-install the button head cap screws that you removed previously and loosely tighten both screws. 11. Set the gap between the hook support and the rotary hook using the instructions described in the Rotary Hook Support Adjustment section and fixture P/N 009027-01.
Page 158 Main PCB • CAUTION!! Always observe ESD precautions when handling the main PCB. While the main PCB is resistant to electrostatic discharge, the potential to damage electronic components still exists. • CAUTION!! Do not handle the main PCB without turning the machine off. While the voltage input to the PCB is only approximately 36 volts DC, handling the PCB will short the components out while the PCB is still energized and damage the PCB severely.
Page 159 3. Remove the base cover from the machine. • CAUTION!! Before installing the EMI cover, ensure there is enough slack on all of the harnesses underneath the cover to prevent pinching the harnesses or pulling the connectors loose when the EMI cover is installed. DO NOT force the EMI cover down onto the harnesses. Figure 2 - EMI Cover 4.
Page 160 Power Input Assembly Replacement • WARNING!! This procedure is intended to be performed only by specially trained Manfacture service technicians and personnel. Disassembly by untrained individuals will void any warranty protection and can result in personal injury or damage to the machine. •...
Page 161 Power Supply Replacement • WARNING!! This procedure is intended to be performed only by specially trained Melco service technicians and personnel. Disassembly by untrained individuals will void any warranty protec- tion and can result in personal injury or damage to the machine.
Page 162 Power Input Switch Replacement • WARNING!! This procedure is intended to be performed only by specially trained Melco service technicians and personnel. Disassembly by untrained individuals will void any warranty protec- tion and can result in personal injury or damage to the machine.
Page 163 3. Apply red loctite (MS 222) to the screws and install the replacement switch in the position shown in Figure 1 above. Tighten the screws to Melco Torque Specifications. Figure 2 Power Input Switch Wiring 4.
Page 164 Power Switch Interface Harness Replacement • WARNING!! This procedure is intended to be performed only by specially trained Melco service technicians and personnel. Disassembly by untrained individuals will void any warranty protec- tion and can result in personal injury or damage to the machine.
Page 165 Power Supply Interface Harness Replacement • WARNING!! This procedure is intended to be performed only by specially trained Melco service technicians and personnel. Disassembly by untrained individuals will void any warranty protec- tion and can result in personal injury or damage to the machine.
Page 166 Power Input Assembly Installation: 1. Install the four M6x12mm cap head socket screws, M6 split lock washers, and M6 flat washers and connect the power input assembly mounting plate to the inside of the lower bed machine body. Tighten the screws to the torque specifications. 2.
Page 167 User Interface Assembly Replacement • The user interface assembly has no user or field serviceable parts inside. DO NOT disassemble the user interface assembly if it is to be sent back as a warranty part return. Repair Parts Needed: • User Interface Assembly Replacement Procedure Figure 1 - User Interface 1.
Page 168 communications. Pressing any of the keys will not affect the machine in any manner until you press the “Reset Keypad Latch” command button on the “Keypad” Submenu screen. 3. One at a time press each key on the keypad. If the keypad is working properly and communicating to the software and the main PCB, the corresponding key on the screen will turn purple while the key is pressed on the user interface panel.
Page 169 11. Tighten the hex nut just enough so that the user interface stays in position, yet it can be adjusted by hand up and down easily. 12. Connect the keyboard harness to the socket in the back of the user interface panel. 13.
Page 170 Harnesses The replacement procedures are broken down for each individual harness. To retrieve the replacement procedure, click on the appropriate link provided at the bottom of this page. To service any harness that is not provided in this manual, contact Technical Support. Such harnesses are usually not a user or field serviceable item.
Page 171 Color Change Motor Harness The color change motor harness connects the color change actuator assembly (stepper motor) to the main PCB at connector location J34. • CAUTION!! Do not pull on the wires in the connectors. They will pull out or break if you do. When disconnecting the harness, handle and disconnect the connectors only.
Page 172 Figure 2 - Right Wire Channel 10. Pull the color change harness to the back of the machine out of the right wire channel, removing any twist-lock cable ties that connect the harness to adjacent ones. Figure 3 - Harnessing Routed Under Y-Motor 11.
Page 173 19. Run the color change harness from the back side into the right access hole to the main PCB and connect it at the color change connector socket located at J34 on the main PCB. 20. Install the covers in the reverse order that you removed them. 21.
Page 174 Ethernet Harness The Ethernet harness connects the user interface (keyboard) to the Main PCB at connector location J1. • CAUTION!! Do not confuse the user interface harness with the similar looking Ethernet harness. The user interface harness connects to J23 on the Main PCB while the Ethernet harness con- nects to J1.
Page 175 10. Reinstall the rear covers and tighten the screws to the torque specifications. 11. Turn the machine on and load the Bravo OS. 12. If the software shows the machine being connected, the Ethernet harness and the circuitry on the main PCB is working correctly.
Page 176 Grabber/Threadfeed Motor Harness The grabber/threadfeed motor harness connects the grabber and thread feed stepper motors to the connector socket at location J33 on the main PCB. The grabber/threadfeed motor harness has two leads coming off of it, one labeled “THREAD FEED MOTOR” and the other labeled “GRABBER MOTOR”. These leads connect to the interface cables coming off the respective stepper motors.
Page 177 7. On the left side of the needlecase, remove any twist-lock cable ties bundling the thread feed mo- tor lead to adjacent harnesses. 8. Disconnect the thread feed lead from the thread feed stepper motor interface cable. 9. Remove the twist-lock cable tie behind the thread tree that bundles the harness running under it. 10.
Page 178 Figure 5 - Harness Tie at Top Left of Needlecase Assembly 17. Connect the grabber motor lead to the interface cable coming off the grabber stepper motor. Loop it and tie it with a cable tie as shown in Figure 4 above. Allow just enough slack so that the connectors will not disconnect during machine operation.
Page 179 Grabber/Threadfeed/CC Home Harness The grabber/threadfeed/cc home harness connects the grabber home PCB and the threadfeed/cc home PCB to the Main PCB at connector location J31. Replacement Parts Needed: • harness, grabber/threadfeed/cc home • Twist Lock cable ties (available at most hardware stores in the electrical section) Replacement Procedures: 1.
Page 180 Figure 2 - Thread Feeder Home PCB 7. Disconnect the grabber/threadfeed/cc harness from the thread feeder home PCB located at the top center right behind the needlecase assembly (on the right above the thread feeder stepper motor). The grabber/threadfeed/cc harness threadfeed home lead is the four pin connector identi- fied in Figure 2 above.
Page 181 11. Connect the replacement grabber/threadfeed/cc harness leads to the grabber home PCB and threadfeed home PCB as appropriate. The leads are marked “GRABBER HOME/CC POSITION” and “THREAD FEED/CC HOME” respectively to indicate where they are to be connected. 12. Insert the other end of the harness underneath the thread tree base and pull it through from the rear and leave it hanging loose.
Page 182 Laser Harness • WARNING!! This procedure is intended to be performed only by specially trained and authorized Manfacture service technicians and personnel. Disassembly by untrained individuals will void any warranty protection and can result in personal injury or damage to the machine. •...
Page 183 • CAUTION!! When disconnecting the harness DO NOT pull on the wires. Handle only the con- nector housings. You will damage the harness if you pull on the wires themselves. 6. Disconnect the laser harness from the laser pointer assembly. Figure 2 - Right Upper Arm Access Hole 7.
Page 184 LED Cluster Harness There are two led cluster harnesses connecting the LED cluster assemblies to the Main PCB at locations J9 (left harness) and J10 (right harness). The led cluster harnesses will rarely require replacement at the same time. The usual cause for replacement of either harnesses will likely be due to damage caused in handling the harnesses during repairs and/or maintenance procedures.
Page 185 7. Pull the harness through the left to the back of the machine and remove the twist-lock cable tie from the z-motor mounting bracket. Figure 3 - Left Lower Arm Access Hole 8. Remove any twist-lock cable ties from the left LED cluster harness and pull it through the left wir- ing access hole in the lower arm body to the Main PCB.
Page 186 17. Install the remaining covers in the reverse order that you removed them and tighten the screws to the torque specifications. 18. Turn the machine ON and verify that the LEDs come on in the left LED cluster assembly. Right LED Cluster Assembly: 1.
Page 187 Figure 5 - LED Cluster Harnesses Connected at Main PCB 12. Replace all twist-lock cable ties that were removed from the harnesses. 13. Replace the EMI cover carefully. 14. Install the right upper arm front cover and tighten the screws to the torque specifications. 15.
Page 188 Thread Break Harness The thread break harness connects the thread break sensor PCB to the Main PCB at connector socket J29. Replacement Parts Needed: • harness, thread break • twist-lock cable ties (available at most hardware stores in the electrical section) Replacement Procedures: 1.
Page 189 8. Pull the harness to the back of the machine, remove any twist-lock cable ties that bundle it to adjacent harnesses, all the way down to the right access hole to the Main PCB. Figure 2 - EMI Cover over Main Board 9.
Page 190 12. Run the harness to the left and then straight up and tie it at the top of the needlecase where the grabber motor harness is bundled. Pinch the harness with your finger to give it a 90 ° bend as shown in Figure 4 above.
Page 191 Z Home Harness The z home harness connects the trimmer home optical sensor and the z-index PCB to the Main PCB at connector location J32. Replacement Part Needed: • harness, trimmer/z home • twist-lock cable ties (available at most hardware stores in the electrical section) Replacement Procedures: 1.
Page 192 Bravo OS software. 21. Click on the “Steppers” menu tab, and then on the “Home” button under the “Trimmer” col- umn. If the trimmer detects home, then no related error message will be reported by the Bravo OS software.
Page 193 User Interface Harness The User Interface harness connects the user interface (keyboard) to the Main PCB at connector location J23. • CAUTION!! Do not confuse the user interface harness with the similar looking Ethernet harness. The user interface harness connects to J23 on the Main PCB while the Ethernet harness con- nects to J1.
Page 194 6. Remove the EMI cover from the main control board. Figure 2 - EMI Cover over Main Board 7. Remove any twist-lock cable ties that tie the User Interface harness to adjacent ones and discon- nect it from the main PCB at connector location J23. 8.
Page 195 X/Y Home Harness The x/y home harness (rainbow colored ribbon cable) connects the x/y home PCB to the Main PCB at con- nector location J3. Replacement Parts Needed: • harness, x/y home • twist-lock cable ties (available at most hardware stores in the electrical section) Replacement Procedures: 1.
Page 196 6. Remove the x/y home harness from the y-home flag channel and pull it through the 1/2 inch di- ameter access hole in the casting right above the y-home flag channel. 7. Pull the harness down to the left lower arm access hole to the main PCB, removing any twist-lock cable ties that tie it to the adjacent harnesses.
Page 197 Bearing Block Assemblies • This repair requires timing and other adjustments and should be done only by an authorized service technician. The bearing block assemblies would require replacement if they are damaged or if the sinterbronze bear- ings that are inside the block slip loose. The sinterbronze bearings are impregnated with oil and in the center is a y-guide felt that is soaked with oil at the factory when the bearing block is assembled.
Page 198 4. Remove both left and right upper arm covers. 5. Loosen the tension on the x-cable at the cable tensioner bracket located on the left upper arm front section. 6. Remove the cable from the pulleys that are attached to the right bearing block assembly. 7.
Page 199 X-Beam Assembly • This repair requires timing and other adjustments and should be done only by an authorized service technician. The only two reasons to remove the x-beam assembly for repair would be if the two steel rails inside the x-beam are damaged because of fretting corrosion due to improper adjustment or lack of lubrication.
Page 200 7. Remove the 3 screws mounting each of the two bearing block assemblies to the top of the x-beam and remove the beam. 8. Apply red loctite (MS222) to the threads of the button head socket screws and reinstall the x-beam assembly to the bearing block assemblies.
Page 201 X-Carriage Assembly • This repair requires timing and other adjustments and should be done only by an authorized service technician. The only reason for removal of the x-carriage assembly is to replace the bearings, located on top of the carriage, if they are damaged. Damage will usually result from an x-motor fault that causes it to runaway, operator error, or some kind of impact to the x-carriage assembly.
Page 202 3. Loosen and remove the two screws holding the cable pulley bracket in the rear center of the x-car- riage assembly. 4. Remove the x-beam end cap from the right end of the x-beam. 5. Slide the x-carriage assembly out of the x-beam from the right side of the beam. 6.
Page 203 X-Drive Cable Removal • This repair requires timing and other adjustments and should be done only by an authorized service technician. The x-drive cable should be replaced when excessive wear and tear or fraying of the cable is noticed. It is critical that the instructions given for the replacement of the x-drive cable be strictly adhered to as im- proper installation, especially tensioning, of the x-drive cable will lead to failures very difficult to trouble- shoot, especially in the x/y registration during embroidery operations.
Page 204 Figure 1 - Cable Tensioner Bracket 5. Start on the left side of the machine and loosen the hex nut on the x-cable tensioning bolt slowly and then remove it. Hold onto the cable as you do this and do not let it drop. 6.
Page 205 X-Drive Cable Installation • This repair requires timing and other adjustments and should be done by an authorized service technician. When installing the x-drive cable it is extremely important that you do not damage the protective coat- ing of the cable, ensure that the windings on the cable spool are correct, that the cable is correctly ten- sioned, and the installation is done precisely as provided in these instructions.
Page 206 Figure 1 - X-Cable Spool (Taped and Installed) • CAUTION!! DO NOT remove the tape from the x-cable spool when you install it until the cables are tightened up. The cable will become unwound and will be extremely difficult to rewind with the precise lengths needed to install it on the machine.
Page 207 7. Run the cable around the pulley shown in Figure 3 and Figure 4. Figure 5 - Right Beam Cable Pulleys (Arrows indicate direction of cable to the front) 8. Run the cable through the through hole in the back of the upper arm casting to the right rear carriage cable pulley down to the top right beam cable pulley.
Page 208 Figure 9 - Left Beam Cable Pulleys 13. Repeat steps 8-10 for the left side cable. Figure 10 - Cable Tensioning Bracket (Left side of machine) 14. Install the washer and nut to the threaded end of the stud. Use needle nose pliers to hold the cable stud before tightening the nut to prevent the cable from twisting.
Page 209 X-Drive Motor Replacement • This repair requires timing and other adjustments and should be performed by an authorized service technician. Besides in case of an x-motor failure, the X-motor assembly should also be replaced when the resistance between each of the phases is inconsistent or substantially different than 3.65±10%Ω. In addition, the resistance between each of the phase wires should be relatively consistent with the other wires.
Page 210 Figure 2 - Wrap Tape Around X-Drive Pulley • IMPORTANT!! If the x-cable is not secured to the x-drive pulley it will most likely unwind off the pulley when the latter is disassembled from the X-motor. This results in a longer ma- chine-downtime due to the time it takes to reassemble the cable.
Page 211 Figure 3 - X-Motor Harness Connections 11. Disconnect the x-harness hall and motor leads (marked “CONTROL PCB X MOTOR” and “CONTROL PCB X HALL/ENC”) from the main PCB at locations J5 and J6. 12. Use wire cutters and cut any cable ties tieing the x-motor harness leads to any of the other har- nesses and pull the x-motor harness through the cable access hole to the lower bed.
Page 212 X-Home Optical Switch Assembly Replacement • This repair requires timing and other adjustments and should be performed by an authorized service technician. The x-home sensor is installed inside the x-beam. It requires replacement when it gets too dirty or if the cable attached to it is damaged in any manner (chaffing, pinched wires, shorts or breaks).
Page 213 6. Slide the x-home sensor mounting bracket out of the beam, carefully pushing the cable through the access hole at the top of the beam. Do not allow the cable to rub on the edge of the access hole as you pull it through. 7.
Page 214 X/Y Home PCB Replacement • This repair requires timing and other adjustments and should be performed by an authorized service technician. The X-home PCB needs to be replaced when the sensors fail to detect home. This condition normally results when the optical sensors are damaged due to mechanical interferences or incorrect adjustment. Optical sensors should be cleaned only with compressed air.
Page 215 15. Click on the “Commands” menu in the Bernian E16 OS main menu, and then on the “Set Home” and then center the hoop. 16. Click on “Tools>Maintenance” menu in the Bravo OS main menu, on the “Head Timing” menu, and then on the “Bottom Center” button.
Page 216 Y-Drive Belt Replacement The Y-drive belts will wear out and stretch over time. To extend the useful lifetime of these belts, always ensure they are properly tensioned at all times. Incorrect tensioning of the belts will cause them to wear prematurely and might also cause damage to the machine itself.
Page 217 Figure 2 - Left Timing Belt Clamp and X/Y Home PCB 6. Remove the x/y home PCB from the y-drive belt clamp. Leave it hanging on the connected harnesses. 7. Remove the timing belt clamp and remove the old belt. 8.
Page 218 Y-Motor Assembly • This repair requires timing and other adjustments and should be performed by an authorized service technician. Figure 1 - Y-Motor Installed Besides the case of a y-motor failure, the y-motor assembly should be replaced when the resistance between each of the phases is inconsistent or substantially different than 2.28±10%Ω.
Page 219 Figure 2 - Y-Motor Connections at PCB 3. Disconnect the Y-motor harness and y-hall/encoder harness from the Main PCB as shown in Figure 2 above. 4. Carefully cut any cable ties that tie Y-motor and encoder harnesses running underneath the y-mo- tor through the lower arm access hole to the main PCB.
Page 220 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 specification. 220 of 271 Table of Contents...
Page 221 To “step” the grabber stepper motor incrementally through its cycle, click on the “Tools>Maintenance” menu in the Bravo OS, select the “Steppers” tab and click the “Step>” button in the grabber column, observe the movement and click it again for the next step.
Page 222 5. If no failure is found, or you have restarted the test after finding an earlier failure, then click on the “Start Test” button under the grabber column. Figure 2 - Sensors Menu 6. Click on the “Sensors” tab and observe the grabber status. It should be alternating between “Open”...
Page 223 Final Functional Tests Final functional tests should always be conducted on the Embroidery Peripheral whenever any major re- pairs or adjustments are made. The purpose of these functional tests is to ensure that the correct repairs and adjustments have been made and that no further machine functional issues remain. Visual Inspection: Always inspect the machine after making any repairs and make sure that: •...
Page 224 quality performance of the machine and helps to identify quality and functional issues. In the long run, using the burn-in test after major repairs will save the customer a significant amount of money in terms of service calls and additional diagnostic work. To burn in the machine, refer to the following procedures.
Page 225 Optical Sensors Test Prior to testing optical sensors, clean them using compressed air only. DO NOT use any liquid cleaners or solvents on the sensors. You will permanently damage them if you do. Testing optical sensors is simply done by using a nonmetallic object and break the signal between the two sensors on the optical sensor PCB (use nonmetallic material in order to avoid shorts if you acciden- tally touch an electrical component).
Page 226 Power Supply Test To test power supplies that are already installed in the machine, use the following procedures: 1. Check the 5V LED at location D43 and the 15VLED at location D32 on the main PCB. Both of them should always be illuminated when the machine is turned on. 2.
Page 227 Figure 2 - Power Supply Unit Terminal Jumpers 11. Check and make sure that the jumpers are installed as shown in the picture above. If the terminals are missing, either order replacement jumpers, or you can fabricate replacement jumpers with 16 gauge AWG wire and ring connectors available from any electrical supply store.
Page 228 a. The black (common) electrode of the voltage meter goes on the ground (black wire) terminal, and the red (positive or hot) electrode of the voltage meter goes on the positive (red wire) terminal. b. Measure the DC output voltages. The range should be between 34.5 to 38 DC volts. If the voltages are not in this range, then replace the power supply assembly.
Page 229 Servo Motor Resistance Test On stepper motors, disregard the green (ground) wires going into the connector and measure the resis- tance of the servo motor by pushing the leads of the ohmmeter into the connector until they contact the pins as shown in the image above. •...
Page 230 Stepper Motor Resistance Test Figure 1 Figure 2 Figure 3 Resistance in the stepper motors is measured on the two phases. To measure the resistance, disconnect the motor at the connectors (see Figure 1). There are four wires to each motor. Starting from either side, the first two wires are one phase and the remaining two wires are the second phase.
Page 231 Servo Motor Resistance Test Figure 1 - Resistance Measurement of Servo Motors Servo Mtr Resistance Specification 3.65±10%Ω 2.28±10%Ω 1.04±10%Ω When measuring the resistance with a ohmmeter or multimeter, it is strongly recommended that it be done with a calibrated meter rated with resistance reading accuracy equal to or better than ±1%. Fluke ™...
Page 232 Troubleshooting Stepper Motors The advanced troubleshooting procedures explained in this section are intended for a more detailed analysis of the condition and/or failure of stepper motors. These procedures are more detailed and should be used when the regular troubleshooting procedures prescribed for each individual motor fail to yield satisfactory data.
Page 233 PCB. Figure 2 - Steppers Menu 5. Open the Bravo OS, then click on the “Tools>Maintenance” menu from the main menu screen and select the “Steppers” tab. 6. Each stepper motor has a set of command buttons under their respective heading. Find the col- umn pertaining to the stepper motor.
Page 234 the LED’s are at the same intensity. If not, disconnect the motor. The LEDs should now be bright. If the LEDs are not bright, try replacing the motor. If this does not fix the problem, replace the main PCB. When doing the LED test if either LED never lights, or only one color lights (red or green only), unplug the motor from the harness and see if the LEDs change.
Page 235 This design has been broken down into individual components that are available as a separate design as indicated. The test designs can be found at: • for 32 bit systems, C:\Program Files\Melco\Bravo OS vXX\Test Designs\ • for 64 bit systems, C:\Program Files (x86)\Melco\Bravo OS vXX\Test Designs\ 235 of 271 Table of Contents...
Page 236 Design Feature Function Tested Horizontal and Vertical columns Thread Tension (upper and lower) Circles Belt Tension Rose Thread breaks on long stitches Diamond Registration Horse & Buggy Orientation Spiral Thread breaks Alphabet Small letter problems Triangle Fill and Outline Looping Tricolored Diamond Fill Thread Break Sensor Mark Trim...
Page 237 Belt Tension Test The belt tension test design is useful for verifying the adjustments of the x-cable or the y-axis timing belts. When the tensions on both are set to ideal conditions, the thickness of the circles should be consis- tent in all directions.
Page 238 Orientation Test The orientation test design should be sewn twice. Once as shown above, and once again by changing the direction of the orientation. A comparison of the two should be consistent with each other with no changes in appearance or stitch length. In addition, there should be no thread breaks or pull-outs in this design.
Page 239 If there is a val- id thread break, the Bravo OS should report a thread break (no thread running against the sensor bar). Conversely, if there are no thread breaks, there should be no thread break reports. Cut the thread where it runs into the needle a few times to see if valid thread breaks are detected properly.
Page 240 Trimmer Test The primary purpose of the AMTRIM01A test design is to test the trimmer and grabber functions. The goal in using this design to verify trimmer adjustments is to reduce trimmer errors down to the absolute minimum possible. If you have more than one trimmer related error for the entire design, you should adjust the trimmer assembly accordingly and then re-sew the AMTRIM01A on a different location of the fabric.
Page 241 The machine color change is controlled through the use of an encoder, a stepper motor, the controller chip on the Main PCB and the software. The Bravo OS will usually give an indication of what the actual failure is. The encoder and the color send a signal through the harness to the Main PCB and the status is reported by the firmware to the Bravo OS, and then displayed on the computer screen.
Page 242 Turn the machine off and turn Color change works Probably corruption of data in it back on again. Reboot the the RAM computer and reload the Bravo Color change fails Go to Step 4 Conduct an optical sensor test Either sensor bad...
Page 243 Symptoms of a machine initialization failure include global failure of all of the servo and stepper motors to initialize (power up). In addition to these, some LEDs might illuminate on the Main PCB, but most will probably stay dark. Step Symptom Condition Solution/Step Examine the status of the 5V...
Page 244 Inadequate rotary hook lubrication Lubricate the rotary hook Thread feeder roller worn or damaged Replace thread feeder roller Design density too tight Decrease density (refer to Bravo OS manual for design editing) Needle Breaks Possible Causes Solution Needle is bent...
Page 245 Check the condition of the smoothly thread feeder roller. If it is bad, replace it. Adjust the thread feed parameters in the Bravo OS software. If that does not solve the problem, replace the optical sensor switch assembly. Presser Foot...
Page 246 Thread Breaks Possible Problem Area Solution Checklist Material thickness setting 1. Check the material thickness and adjust if set too high or too low. may be incorrect If material thickness is set too high, too much thread is being fed into the system, and you may see some of these symptoms: looping, popping thread breaks, and no bobbin showing on the back of the fabric.
Page 247 Possible Problem Area Solution Checklist Needles / Needle Depth / 1. Check needle orientation. Needle Plate If a needle is installed backwards or turned too much, thread breaks can occur. It is recommended that the eye of the needle be tilted 5° to the right;...
Page 248 Possible Problem Area Solution Checklist Fabric and hoops 1. Check how the garment is hooped; garment may be hooped too loosely. If you can easily pull thread without lifting the pinch roller, the thread feeder roller may be worn / damaged and should be closely inspected.
Page 249 Possible Problem Area Solution Checklist Rotary hook 1. Check the hook timing and the needle gap; one (or both) may be out of adjustment. 2. Check to make sure the rotary hook is rotating smoothly & suffi- ciently oiled. If it is not, clean, oil, and if the problems persist, replace. If you are still experiencing thread breaks after checking all of the areas discussed in the above table, you may want to perform a more in-depth analysis.
Page 250 If thread breaks Check the following items: occur when sewing: Circles (after • Burrs on needle plate hole startup) • Needle orientation • Hoop may be hitting needle plate • Inspect thread feeder rollers & pinch rollers for wear and/or damage Diamond •...
Page 251 Possible Causes Solutions Loss of registration Adjust cap supports (if being used) Modify the design Check the driver bar tension Check the spindle adjustment Check that the driver was properly adjusted on the peripheral Cap frame is loose on the driver Check the spindle adjustment Miscellaneous Problems Problem...
Page 252 X-Axis Failures The x-axis motion on the machine is controlled through the electronics, a system of pulleys and a cable. The motor driver on the Main PCB will send certain commands to the X-axis servo motor. Feedback to the Main PCB is provided by the motor encoder and the X-home sensor. These devices tell the Main PCB where the motor is at during embroidering.
Page 253 Y-Axis Failures The y-axis motion on the machine is controlled by the electronics. The motor driver on the Main PCB sends commands to the motor. Feedback to the Main PCB is provided by the y-motor encoder and the x/y home sensor PCB. These devices tell the software and the Main PCB where the motor is during embroidering.
Page 254 Z-Axis Failures The z-axis movement on the machine is controlled by the electronics. The motor driver on the Main PCB sends signals to the Z-motor. Feedback to the Main PCB is provided by the encoder and the z-index optical sensor. These devices tell the software and the Main PCB where the z-motor position is at during embroidering.
Page 255 Software Error Messages The software generates messages pertaining to the condition of machine components and the electri- cal current used to power the machine in case changes to the machine status or a machine error occur. These messages make much of the machine a self-diagnostic machine. The messages below represent true error messages that the software might generate.
Page 256 Error Message See Section Below Y-Motor Home Timeout Servo Motor Errors Y-Motor OVER CURRENT error Servo Motor Errors Y not done X- or Y- Not Done Error Y timeout error Servo Motor Errors Y tracking error Servo Motor Errors Z-motor HALL error Servo Motor Resistance Test Z-Motor not at HEADUP error Servo Motor Errors...
Page 257 Goto Func Error This error occurs when you attempt to go to a stitch or color (i.e., color change, move, trace, etc) when the machine is already performing some function. Wait until the machine has completed the current function, then you can perform the function that you attempted to execute.
Page 258 E-Stop Engaged This message is not necessarily an error, but you might receive other related errors if the E-Stop is show- ing to be engaged, especially when you attempt to execute a machine function and the E-Stop button is not engaged (released and extending completely forward). Possible Causes of a False E-Stop Engaged Message •...
Page 259 Step Action LED (D49) Next Step/Solution Condition Close the software on the computer. Replace Main PCB Problem is probably software related. Reboot the computer. If the problem persists, reinstall the software. If that does not fix the problem, contact Technical Support. 259 of 271 Table of Contents...
Page 260 Servo Motor Errors (Move Time Out, Tracking, and Over Current Errors) This error occurs when the machine takes too long to find the home or index position when the software is prompted to move. Typically, this is a break in continuity of home sensor circuit. Troubleshoot motor timeout errors using the following procedures for the affected motor: Step Action Result...
Page 261 Step Action Result Next Step/Solution Conduct a Servo Motor Ohms measure near zero or Replace the motor Resistance Test to check the inconsistent with other phases. resistance of the windings on Resistance is within Go to Step 8 the motor servicing the circuit specifications with the error Problem is caused by some-...
Page 262 Critical Measurements Contents & Critical Mechanical Settings and Assemblies Introduction Set the angle of your PCB before you set the 179.5-180.5 Z-degrees - Bottom Dead Center Z-timing. Hook Timing: 201.5° ± 0.5° Z-TIMING: Bottom Center and Head Timing .001” [0.028mm] Z-Axis Rise: 182 ° - 183 ° Needle Depths 1/4-1/2 of through portion of needle eye Hook Timing...
Page 263 correctly adjust the settings described in this manual can result in unpredictable behavior of the machine and can cause premature failure of the machine. In most cases, it is necessary to use the prescribed procedure to measure the settings and adjustments on the machine.
Page 264 2. Color change to the closest needle (annotated in the base casting, right front corner). Move the needle to bottom dead center and center the needle plate on the needle. If you are not able to bring the needle down into the needle plate hole, the head is out of alignment and the machine will require shipment to the factory for depot repair.
Page 265 measuring point and take note of the measurement at the top dead center (TDC) and the bottom dead center (BDC) of the take-up lever stroke. Take the measurements several times to ensure a consistent measurement. The difference between the TDC and BDC measurements of the take-up lever, is the take-up lever stroke measurement.
Page 266 Adjustment Current procedures require the use of a fixture to adjust the cam follower preload. This requires that the color change housing assembly be removed and shipped to the factory for repair. If the cam follower preload is out of specification, contact Technical Support for instructions. Pull Force on Take-Up Lever Measurement 1.
Page 267 Adjustment If the straightness of the color change feed screw exceeds 0.010” [0.25mm] it must be replaced follow- ing procedures shown in this manual. Color Change Housing Location Measurement 1. The measurement of the color change housing location is done in reference to the top inside edge of the upper v-rail.
Page 268 Checking Bobbin Tension To check the tension of the bobbin, hold the bobbin thread with one hand. As you gently release the bobbin case, it should not drop. With the bobbin case hanging on the bobbin thread, bounce the case slightly and it should drop about ¼-½...
Page 269 Thread Feed Forward 200 Thread Feed Forward Measurement 1. In the Tools>Maintenance>Steppers menu of the the software, click the Fwd 200 button. 2. Trim the thread that is fed out at a common, repeatable reference point, such as the front edge of the grabber blade.
Page 270 The eye of the needle can be facing directly forward or be tilted to the right by a maximum of 20°. • Important: Do not tilt the needle so that the needle eye is oriented to the left. This will result in poor sewing performance (e.g., thread breaks).
Page 271 Should the belt tension be out of the specified range it needs to be re-tensioned. Use the guidelines out- lined in Z-Drive Belt Tensioning. X-Cable Tension X-cable tension is most accurately measured using a BRECO meter. Should a BRECO meter not be avail- able, the X-cable tension needs to be measured as described under X-Cable Tensioning in this manual.

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