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Melco Bravo, Technical Manual

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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.

13.  Cut any cable ties tieing the x-harness leads to the z-motor harnesses.

Figure 4 - X-Motor Mounting Screws

14.  Remove the X-motor bracket mounting screws and remove the x-motor together with the bracket 

from the machine.

15.  Remove the x-motor bracket from the x-motor and install it on the replacement x-motor and tight-

en the screws to the torque specifications.

16.  Reinstall the x-drive pulley to the x-motor so that the index arrow (marked on the pulley rim when 

originally installed) is facing straight up and tighten the screw to 8 in-lbs[0.9 Nm] of torque using 
a torque wrench.

17.  Run the x-harness on top of the z-motor harness and along the same path as the z-harness down 

to the main PCB and tie them together using cable ties about every 3-4 inches.

18.  Connect the x-motor harness leads into the main PCB at locations J5 and J6.

19.  Tension the x-cable using the procedures provided in X-drive cable installation.

20.  Reinstall the left upper arm side cover and tighten the screws.

21.  If you do not have any further work on the inside of the machine, install the covers in the reverse 

that you removed them.

Table of Contents

Summary of Contents for Bravo

Page 1: ...Technical Manual Rev 082115 ...

Page 2: ...ations 21 Explanation of Machine Symbols 22 Keypad Operations 23 Keypad Buttons 26 Trace Button 26 Arrow Up Key Y Axis Back 26 Color Change Needle Case 26 Arrow Left Key X Axis Left 26 Arrow Right Key X Axis Left 27 Center Key 27 Adjustment Key 27 Arrow Down Key Y Axis Forward 27 Hoop Key 28 Step Back Key 28 Step Forward Key 28 Laser Key 28 Start Button 28 Stop Button 29 Emergency Stop Button 29 L...

Page 3: ...cedure 65 Needle To Hook Gap Inspection Procedure 67 Adjustment Procedure 67 Thread Clamp Replacement 71 Thread Clamp PCB Replacement 72 Thread Clamp Harness Replacement 72 Laser Light Adjustment 74 Needle Depth 76 Setting the Needle Depth by Eye 76 Presser Foot Height 77 X Y Home Adjustment 78 Home Adjustment Procedures 78 X Cable Tension 81 Determining if an X Cable is Set to Required Specificat...

Page 4: ... Linear Actuator Replacement 107 Replacement Procedures 107 Thread Feeder Gear Replacement 110 Replacement Procedures 110 Thread Feeder Optical Sensor PCB Replacement 112 Replacement Procedure 112 Thread Feeder Radial Bearing Replacement 113 Replacement Procedures 113 Thread Feeder Stepper Motor Assembly 114 Replacement Procedure 114 Laser Pointer Assembly 116 Replacing the laser assembly 116 LED ...

Page 5: ...ad Sensor Assembly Replacement 152 Bobbin Shaft Overhaul 154 Rotary Hook Replacement 156 Main PCB 158 Power Input Assembly Replacement 160 Power Input Assembly Removal 160 Power Input Assembly Component Replacement 161 Power Input Assembly Installation 166 User Interface Assembly Replacement 167 Harnesses 170 Color Change Motor Harness 171 Ethernet Harness 174 Grabber Threadfeed Motor Harness 176 ...

Page 6: ...cement 209 X Home Optical Switch Assembly Replacement 212 X Y Home PCB Replacement 214 Y Drive Belt Replacement 216 Y Motor Assembly 218 Troubleshooting 220 Grabber Function Test 221 Final Functional Tests 223 Optical Sensors Test 225 Power Supply Test 226 Servo Motor Resistance Test 229 Stepper Motor Resistance Test 230 Servo Motor Resistance Test 231 Troubleshooting Stepper Motors 232 Table of C...

Page 7: ...re 242 Mechanical Failures 244 False Thread Breaks 244 Loose Looping Stitches 244 Needle Breaks 244 Skipped Stitches 245 Thread Breaks 246 Miss Starts 250 Cap Frame Issues 250 Miscellaneous Problems 251 X Axis Failures 252 Y Axis Failures 253 Z Axis Failures 254 Software Error Messages 255 DSP Command Errors 256 Can t Initialize Stepper Motors 256 No Trace Data 256 XY Home Not Set 256 Goto Func Er...

Page 8: ...p Lever Fit to Shaft 265 Take Up Lever Endplay 265 Cam Follower Preload 265 Pull Force on Take Up Lever 266 Color Change Lead Screw 266 Color Change Housing Location 267 Bobbin Tension 267 Presser Foot Adjustment at Bottom Dead Center 268 Thread Feed Forward 200 269 Needles 269 Thread Clean Thread Path 270 Z Belt Tension 270 X Cable Tension 271 Y Axis Timing Belt Tension 271 Proper Lubrication of ...

Page 9: ...ion of the author to notify any person or organiza tion of such revisions or changes All precautions have been taken to avoid errors or misrepresentations of facts equipment or products However the manufacturer does not assume any liability to any party for loss or damage caused by errors or omissions The machine technology is protected by but not limited to the following patents U S 4 955 305 U S...

Page 10: ... 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 Table of Contents ...

Page 11: ... function correctly Performing repairs to the machine may result in damaged components poor machine performance and potential injury to the technician or operator If you do not fully understand any information in this manual contact technical support for assistance before performing the procedure The technical support staff are professional service technicians trained on this equipment They have a...

Page 12: ...ial attention is required In these situations certain images and text styles are used to attract your attention to a particular message The following styles are used to denote certain types of messages WARNING Situations which may result in personal injury if not performed correctly CAUTION Situations that might result in damage to equipment or property but is not likely to result in personal inju...

Page 13: ...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 Table of Contents ...

Page 14: ...y The maintenance philosophy used in this manual is to isolate potential problems within the system to the smallest practical replacement assembly Therefore components are typically not repaired but rather a circuit board or mechanical subassembly may be replaced In the process of isolating problems in the machine the person performing the troubleshooting must also practice good troubleshooting te...

Page 15: ... very important that you use the proper parts for the job especially needles Refer to the Operator Manual for information on needle selection Using the wrong needle will increase the frequency of frays and thread breaks and will decrease performance of the machine Avoid using substandard substitute parts on the machine Always use manufacturer distributed parts or better to ensure superior quality ...

Page 16: ... is replaced or repaired and as prescribed according to the Lubrication Specifications When applying lubricants to any parts use only the approved lubricants and application methods specified in the Lubrication Specifications CAUTION Damage to the machine will result if inadequate or excessive lubrication is applied to machine parts Failure to adhere to lubrication specifications will result in pr...

Page 17: ... remove the ground connection needed to dissipate the electrical static build up prior to work ing on the internal components in the machine Always make contact with the exterior metal portion of the machine for about one minute to dissipate any electrical static build up in your body before touching any electronic component of the machine especially the main board Grounding Strap Use A grounding ...

Page 18: ...UTION 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 Table of Contents ...

Page 19: ...cover since it is installed on the left side oriented as you face the machine from the front Left Side Right Side The left and right sides of the machine are oriented just as if you were facing it from the front side of the machine directly The rear of the machine refers to the entire back side of the machine The front part of the machine refers to the entire front section of the machine The upper...

Page 20: ... without the covers creates a risk of severe electrical related injury Hazardous Material Notices WARNING The lubricants specified in this Manual contain known carcinogens Do not allow lubricants to come into contact with your eyes mouth or nose Always wash your hands thor oughly after performing lubrication procedures WARNING When using solvents to clean components in the machine always ensure ad...

Page 21: ...er Performance of these items requires special training and or tools and involves a great deal of difficulty If technician only items are repaired in stalled incorrectly it will void all applicable warranty considerations and can cause further damage to the machine The use of other than manufacturer issued or recommended parts hardware and lubricants can affect warranty considerations It is strong...

Page 22: ...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 Keep clear Vertical Pinch Point Keep clear Horizontal Pinch point Keep clear Needle Pinch point Keep clear Table of Contents ...

Page 23: ... E Stop To release turn a quar ter turn in the direc tion of the arrows and release Select Machine Center Selects the machine to be displayed in the software To move the hoop up Hoop Down Arrow Always trace after moving To move the hoop down Hoop Up Arrow Always trace after moving To move the hoop left Hoop Right Arrow Always trace after moving To move the hoop right Hoop Left Arrow Always trace a...

Page 24: ...o the hoop Hoop Left Down Always trace after moving To center the current hoop Hoop Center Center hoop before beginning to sew Clears and ignores the Trim Required message Hoop Adjustment This indicates to the machine that no thread is through the cloth To trace the design Hoop Trace Repeat to trace again To frame back one stitch at a time Hold down the Frame Back key Press the stop key to stop fr...

Page 25: ...ch Left Arrow Right Arrow If a hoop has been moved during the sew ing of a design pressing this combination will move the hoop back to the position of the most recent stitch to sew To turn the laser on Laser This will allow you to see the active needle position Toggle front grabber Adjustment Center Toggle to thread the needle Trim Immediate Adjustment Needlecase To manually feed thread Laser Up A...

Page 26: ...ch point to the top of the design The hoop actually moves towards the front of the machine The sew speed stitches per minute is increased Color Change Needle Case When used in conjunction with the arrow keys the machine will perform a color change function mov ing the hoop or move needle case left or right Needle case to the left Needle case to the right Color change to next color Color change to ...

Page 27: ...played in the software Adjustment Key The adjustment key is used to adjust the thread feed or the machine speed Adjustment key and the Arrow Up key increase the sew speed stitches per minute Adjustment and Arrow Down key decrease the sew speed stitches per minute Adjustment and the Center key toggles the safety grabber in and out for needle threading access Arrow Down Key Y Axis Forward The Arrow ...

Page 28: ...r position Step Back Key The step back key moves the machine backwards on the design to a lower numbered stitch point This allows the operator to restitch a certain portion of a design if needed Step Forward Key The step forward key moves the stitch point in the design forward to a higher numbered stitch position Laser Key Press and hold the laser key to turn the laser on The laser stays on as lon...

Page 29: ...ot disconnect electrical supply to the motors and electronics Do not confuse this button with the Emergency Stop button The machine can still start if there is a machine fault somewhere The stop button does not disconnect power from the motors or internal components Emergency Stop Button The emergency stop button breaks the electrical circuit to all of the motors to prevent its operation Table of ...

Page 30: ... Green blinking Machine is on but no RSA files loaded yet Start software check connections Green continuous Machine is on and ready for operation Red blinking slow Indicates a thread break Re thread the needle with thread break Red blinking fast Indicates the machine has run out of bobbin thread Replace the bobbin Red continuous Indicates the machine is in E Stop engaged mode Release the red emerg...

Page 31: ...t machine data for troubleshooting Simplified User Interface Step by Step Guide Software Step by Step Guide Software Design Memory Limited only by hard drive Max file size 500k Limited only by hard drive Max file size 500k Pre Sew Trace Laser Laser Needle to Garment Garment to Hoop Position Laser Positioning System Laser Positioning System Thread Feed Technology Patented Acti Feed Patented Acti Fe...

Page 32: ...Machine Construction Material Aluminum Aluminum Physical Specifications with Cart Width 724mm 28 5 724mm 28 5 Height 1541mm 60 7 1541mm 60 7 Depth 944mm 37 2 944mm 37 2 Weight 95 4kg 210 3 lbs 95 4kg 210 3 lbs Physical Specifications without Cart Width 724mm 28 5 724mm 28 5 Height 907mm 35 7 907mm 35 7 Depth 737mm 29 0 737mm 29 0 Weight 75kg 165lbs 75kg 165lbs Table of Contents ...

Page 33: ... back at a dead stop 8 1 0 3 lbs 3 67 0 14 kg using Y Axis Timing Belt Tensioning procedure Y Motor Belt Tensioning 100 120 Hz 7 5 9 5 lbs 3 4 4 3 kg using Y Motor Timing Belt Tensioning procedure Z Motor Belt Tensioning 72 78 Hz 6 8 0 3 lbs 3 08 0 14 kg measured using Z Drive Belt Tensioning procedure X Carriage Drag Friction 5 5 9 5 lbs Disconnect motor from control board Y Carriage Drag Frictio...

Page 34: ...XX 010171 XX 010172 XX 010174 XX 010175 XX M2 5 5 7 0 66 0 80 M3 10 13 1 2 1 4 M4 23 26 2 6 3 2 M5 46 56 5 1 6 3 M6 79 96 8 9 10 9 M8 190 234 21 6 26 4 Zn Plated Property Class 4 5 Slotted and Phillips Machine Screws PN 006558 XX 004262 XX 009862 XX 009863 XX M2 5 1 2 0 19 0 23 M3 3 4 0 40 0 48 M4 8 10 0 92 1 12 M5 16 19 1 8 2 2 M6 27 33 3 1 3 7 M8 45 55 5 1 6 3 Black Oxide Property Class 12 9 Bla...

Page 35: ...90 XX M4 40 48 4 45 5 45 Stainless Steel Property Class 10 9 Button Head Cap Screws PN 011161 XX 011162 XX 011163 XX M3 15 19 1 73 2 11 M4 34 40 3 77 4 61 M5 65 78 7 29 8 91 Zn Plated Property Class 04 Metric Hex Nuts PN 680430 XX Torque based on screws they attach to M4 23 28 2 6 3 2 M5 46 56 5 2 6 3 Machine Specific and Custom Hardware Self Tapping Plastic DURO Screw PN 30737 01 8 10 0 9 1 10 M6...

Page 36: ... 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 Figure 2 Maintenance Menu Table of Contents ...

Page 37: ...Gauge PN 009027 01 Take Up Lever Timing Fixture PN 32413 Needle Depth Fixture PN 32650 Fixture Z Home Flag PN 32980 Pin Gauge Thread Feed Gear PN 32996 Gauge Height Take Up Lever PN 33017 12 Gram Weight PN 10082 Metric Ruler Feeler Gauge Set All of the above fixtures can be ordered through the manufacturer It is strongly recommended that the fixtures recommended in this manual are used Making adju...

Page 38: ...re wiping the surfaces Do not get water or any other fluids inside the machine or on any of the working mechanical surfaces If an accidental spill occurs turn the machine off then wipe up excess fluid with a clean dry cloth and allow the machine to dry completely before turning the power on Interior Surfaces PCB The main PCB can be damaged by dust accumulation It is important that you periodically...

Page 39: ...Trimmer Assembly area Lint and dust can build up in the trimmer assembly and the rotary hook Clean this at least once per day 1 Turn off the machine 2 Remove the needle plate by removing the two screws on the underside of the extrusion 3 Clean the exposed area with canned or compressed air Note Excessive thread or lint buildup may require removal or disassembly of the trimmer You should also frequ...

Page 40: ...izes the lubrication points and schedule for your machine The table also lists which type of lubrication you should use for each lubrication point Please note that these schedules are meant to be used as guidelines Depending on many circumstances such as environment garment types sewn on etc you may need to lubricate your machines more or less frequently Follow a lubrication schedule that best fit...

Page 41: ...ese checks you will need to purchase the following tools fixtures and follow the procedures in this Technical Manual Fixture Y Belt Tensioning PN 32108 Force Gauge 0 10 lbs PN 995591 01 Universal Force Gauge Adapter PN 32498 see Y axis timing belt Tensioning Z drive Belt Tensioning sections CAUTION Some of the lubrication procedures instruct you to remove the right left front cov ers Do not turn t...

Page 42: ...se It can be removed from the lower arm of the machine by locating the release lever on the bobbin case 3 Pull forward on this lever until the case is free from the machine This would also be a good time to clean and test the tension the bobbin case 4 Clean the rotary hook and trimmer area with a brush or canned air a Keeping this area clear of lint and debris will help ensure proper trimming and ...

Page 43: ...achine please remove it Failure to fully remove a clamping system can result in damage to the machine Needle Drive 1 Color change to Needle 16 2 Go to Tools Maintenance Head Timing Tab 3 Go to Top Center 4 Using a small oiler bottle put twenty five drops 25 of sewing machine oil in the oiling change as shown in the image Note You may have to add a few drops and wait before adding more to prevent t...

Page 44: ... V Rail 9 Color change to needle 1 10 Using a piece of lint free cloth wipe clean both the front and back surfaces of the upper v rail on the RIGHT side of the needlecase 11 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 Apply the oil close to the needlecase Oil Needle Bars Lower 12 Using a small oiler bottle apply on...

Page 45: ...intenance procedure Monthly Maintenance X Drive Rails WARNING If you currently have a hoop or clamping system on the machine please remove it Failure to fully remove a clamping system can result in damage to the machine 1 Move the x beam all the way forward and all the way to the left using the hoop and the arrow keys on the keypad 2 Remove the end cap cover on the right side of the x beam as show...

Page 46: ...he x beam as shown in the image 7 Wipe any lint dust and old grease from the front and back steel rails inside the x beam as shown in the image 8 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 9 Replace the end cap cover that was previously removed 10 Press the hoop and the center key on the keypad of the machin...

Page 47: ...s of sewing machine oil into the oiling port as shown in the image Note You may need to add a few drops and wait before adding more to prevent the oiling port from overflowing 15 Position the left side cover in its original location on the machine as shown in the image 16 Loosely install one 1 of the rear shorter mounting screws to hold the cover in place 17 Install the other two 2 mounting screws...

Page 48: ...t you use the same screws for the original position later in this procedure 21 Remove the right side cover from the machine 22 Using a small oiler bottle place twenty five 25 drops of sewing machine oil into the oiling port as shown in the image Note You may need to add a few drops and wait before adding more to prevent the oiling port from overflowing X Cable Tension Test 23 Position the x cable ...

Page 49: ...ge the tension is out of specification and needs adjustment a Remove but do not discard the side cover support foam b Locate the M4 nut and the x cable tension stud and the end of the x cable where it mounts to the front of the upper arm as shown in the image c Using a 7mm wrench grip the M4 nut and with a pair of pliers or adjustable wrench grip the x cable stud at the end of the x cable as shown...

Page 50: ...not removing the tension gauge 26 Position the right side cover in its original location on the machine as shown in the image 27 Loosely install one 1 of the rear shorter mounting screws to hold the cover in place 28 Install the other two 2 mounting screws The longer of the screws secures the front The shorter of the screws secures the rear 29 Carefully tighten all three 3 screws only enough to se...

Page 51: ...ever and remove the small screwdriver This completes the monthly maintenance procedure Quarterly Maintenance Take Up Lever Cam Presser Foot Cam Follower Right Needle Bar Guide WARNING If you currently have a hoop or clamping system on the machine please remove it Failure to fully remove a clamping system can result in damage to the machine When you click on the next button the machine will move to...

Page 52: ...e grease applicator apply some HP grease to the back surface of the take up Lever Cam as shown in the image 7 To gain access to the next maintenance point the presser foot must be manually raised Place a finger below the back bend of the presser foot and lift the presser foot as shown in the image 8 Using the grease applicator apply a small amount of the HP grease to the upper presser foot cam fol...

Page 53: ... tightened in a future step Important Ensure that the button head screw is installed in the lower left side location of the cover as shown in the image 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 p...

Page 54: ...e grease applicator for better control of the cloth 16 With a clean piece of cloth apply a thin film of HP grease to the inside of the channel as shown in the image 17 Color change to needle 16 18 Using a 3mm Allen wrench loosen and remove the four 4 screws shown in the image 19 After removing the mounting screws move the left upper arm front cover slightly away from the machine Then rotate it clo...

Page 55: ...ce in the reverse of the way it was removed 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 24 With the needlecase holding the left upper arm cover in th...

Page 56: ...ted in the image The image uses cloth wrapped around the grease applicator for better control of the cloth 28 With a clean piece of cloth apply a thin film of HP grease to the inside of the channel as shown in the image 29 Color change to needle 8 30 Lift all sixteen 16 thread feed roller arms as shown in the image Although not necessary it is helpful to move the threads up between the rollers and...

Page 57: ...ide of the roller and prying against your fingers as shown in the image Set the rollers to the side They will be cleaned and inspected in future steps Important Do not get grease on the thread feed surface of the roller 33 Using a clean cloth remove any lint and old grease from the cradle that holds the rollers In the image this is done with the cloth wrapped around the grease applicator for bette...

Page 58: ... thread feed roller 37 Carefully reinstall the thread feed roller The gear side of the roller should fall to the left Align the roller with the slot and gently press forward and down until the roller snaps into place Take care to clean up any grease that may transfer to the front of the slot 38 Reinstall the front covers by holding them at the bottom and tilting them up Insert the top of the cover...

Page 59: ...ward and free from the ma chine If the lever beside the roller is in the way gentle pressure may be applied to move it slightly out of the way Set the rollers to the side They will be cleaned and inspected in future steps Important Do not get grease on the pinch surface of the roller 42 Using a clean cloth clean all the old grease lint and residue from the lever hub In the image the cloth was wrap...

Page 60: ... shown in the image 47 With one lever up and one lever down hold the pinch lever at an angle and slide it back into place 48 Rock it back onto the hub and slowly rotate to begin spreading the grease evenly around the hub 49 Snap the roller back onto the hub and spin the roller to ensure that it is locked into place and the grease is spreading evenly 50 If you moved the threads originally move them...

Page 61: ...ve the two thread cutter blade screws carefully using a small flat blade screwdriver provided in the machine operator s kit 4 Remove the thread cutter blade and replace with a new one purchased in the thread cutter kit Do not try to sharpen the blade precision is very important 5 Tighten the two thread cutter blade screws 6 Reassemble the hook guard removed in step two 7 Reassemble the needle plat...

Page 62: ...stop and rotating the z shaft to control the decent of the needle 3 With the needle lowered loosen the screws securing the needle plate and center the hole in the needle plate around the needle 4 Tighten the screws securing the needle plate 5 Raise the needle back up by releasing the E stop button Turn the button a quarter turn in the direction of the arrows and release Table of Contents ...

Page 63: ... the machine is considered to be timed 1 Remove the needlecase access cover and the needlecase cover 2 Launch the software 3 Turn on the machine 4 Click Tools Maintenance in the main menu and then click the Head Timing tab 5 Click the Head Up command button This will take the ma chine to electrical Head Up position 6 Click the Bottom Center button This will put the machine at electrical bottom cen...

Page 64: ... Timing tab If it is not between 179 5 and 180 5 loosen the two screws on the z home flag and rotate the flag clockwise or counterclockwise depending on the Current Z Position reading NOTE A small adjustment will change the reading substantially Make small incremental adjustments 7 Tighten the z home flag screws 8 Click the Lock Z button 9 Click the Head Up button twice to reset the electronics to...

Page 65: ...ench 2mm Hex Wrench 2 5mm Hex Wrench 1 5mm bent short arm Magnifying Glass Optional 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 As an al...

Page 66: ...he microstep forward command on the keypad press and hold the Trace key then press the Up Arrow button to increase the z position by tenths of degrees until the cor rect hook timing position 201 5 is displayed in the Current Z Position box NOTE If you microstep too far use the GoTo function of the software to move to 201 and microstep forward Do not microstep backward 13 You can now inspect the ho...

Page 67: ...a guide the image above displays the correct needle to hook gap width 16 If the needle to hook gap or the rotational hook timing are not correct proceed to the next sec tion to perform hook timing adjustment Adjustment Procedure 1 Open the Tools Maintenance menu and then click the Head Timing tab Click the Head Up button or on the machine keypad press the Adjustment key and the Up Arrow key 2 Use ...

Page 68: ...age The following image reflects the view of the needle and hook point when looking from the front of the machine Remember the optimal position is such that the hook point is even with the left side of the needle Please note that it is not uncommon to repeat the adjustment several times to obtain the correct hook timing 6 Slightly loosen the three timing set screws highlighted in blue in the image...

Page 69: ...nd the Go to Position button to move the machine to that z axis position To do this a Enter 201 in the Set Position box then click the Go to Position button Check the number dis played in the Current Z Position box see image below 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 p...

Page 70: ...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 15 You have verified that both the needle to hook gap and the rotational hook timing are correct re fer to the Rotary Hook Support Adjustment section of this document to finish adjusting the rotary hook Table of Contents ...

Page 71: ...m extrusion cover 4 M3 cap head screws 2 on the right and 2 on the left and remove cover 4 Remove lower arm casting top cover 4 M4 socket head cap screws 5 Disconnect the thread clamp solenoid assembly harness 6 Remove the thread clamp assembly mounting screw M3 cap screw 7 Remove thread clamp assembly 8 Follow steps 2 6 in reverse order for installation Table of Contents ...

Page 72: ...d remove the thread clamp PCB 4 M3 button head cap screws 4 Install the new thread clamp PCB following previous steps in reverse order Thread Clamp Harness Replacement 1 Disconnect the A C power input cord and the external Ethernet cable from the back of the machine 2 Loosen lower arm extrusion cover 4 M3 cap head screws 2 on the right and 2 on the left and remove cover 3 Remove lower arm casting ...

Page 73: ...lenoid 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 Table of Contents ...

Page 74: ...unauthorized personnel to prevent inadvertent exposure to the laser light The laser light is pointed away from any person in the area Everyone is cautioned to stay out of the path of the laser light 2 Remove the laser assembly from the machine using the procedures provided in Laser Pointer Assembly 3 TURN THE MACHINE OFF CAUTION DO NOT allow the laser housing to touch any part of the machine If th...

Page 75: ...beam turn the lens clockwise b To loosen the focus of the laser beam make the dot bigger less concentrated turn the lens counter clockwise CAUTION DO NOT over tighten or loosen the laser lens too far or you will damage the internal components 7 When the laser is adjusted properly turn the machine OFF WARNING DO NOT proceed past this step until the machine is turned OFF Failure to turn the machine ...

Page 76: ... the through portion the portion that you can see through of the needle eye should be visible in the hook assembly If the needle s eye is in the acceptable range skip the next few steps and go to Step 7 If the needle s eye is not in the acceptable range contin ue this procedure with the next step 5 Loosen the set screw on the needle bar drive stud and move the needle bar up or down until needle de...

Page 77: ...nd the current needle is taken to bottom dead center Presser foot height may vary slightly with each machine and with each operator It will be dependent on many variables such as thread type and thickness fabric needles and operator preference The ideal setting on presser foot height is so that the presser foot just touches the fabric at the point where the needle begins the upstroke it starts to ...

Page 78: ... carefully removing the screw Figure 1 X and Y Home LEDs 5 Being careful not to touch the main PCB while it is powered up locate the X and Y Home LEDs at locations D37 and D40 respectively You will need to observe whether these LEDs are on or off while setting home Home for these LEDs is set correctly right at the point where these LEDs are brightly illuminated not dim or off 6 Remove the left arm...

Page 79: ...ews back to The torque specifications 12 Move the x beam all the way to the back to a dead stop observing the centering of the y home flag in between the sensors on the X Y home PCB Stop if the beam starts to hit one of the sen sors If needed loosen the screws on the Y Home flag and center the flag between the optical sensors Move the x beam all the way to the front to a dead stop and repeat the p...

Page 80: ...80 of 271 Figure 5 33322 Series EMI Cover 14 Install the EMI Cover carefully 15 Install the base cover Table of Contents ...

Page 81: ...X Cable is Set to Required Specifications 1 Remove the right Side Cover shown in picture 2 below Using a 4mm bent Allen wrench remove the three indicated screws and carefully remove the Side Cover Figure 2 Removing the right cover 2 Center the Y Belt Clamp between the two black indicator marks on the Y Belt as shown in picture 3 below by moving the X Beam forward or back Figure 3 Centering the X B...

Page 82: ...able Tension Gauge 6 An improperly adjusted X Cable will be positioned outside either above tension too low or be low tension too high the cutout area as shown in pictures 7 and 8 below In this case the ten sion of the X Cable requires adjustment Follow steps 1 5 in the section below to properly adjust the tension of the X Cable Figure 6 Inspecting X Cable Tension Adjusting an X Cable that is Tens...

Page 83: ...epeat steps 1 4 in Adjusting an X Cable that is Tensioned Outside the Required Specifications section until the X Cable tension is adjusted correctly Adjusting the Tension on a Replacement X Cable 1 If a new X Cable had to be installed on the machine the initial X Cable tension adjustment should align the X Cable with the smaller cutout area just below the main tension cutout on the X Cable Tensio...

Page 84: ...iver CAUTION DO NOT over tension timing belts If you do the belts will stretch excessively and might cause heavy internal damage to the machine Y Axis Belt Tension Inspection 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 2 Remove the left and right covers use 3mm hex wrench to remove screws 3 Move the x beam all th...

Page 85: ...ine OFF 2 Move the x beam back and forth a few times bring it to the front to a dead stop then adjust the tension up or down at the tension adjusting screws indicated in the image below To increase the tension turn both adjusting screws clockwise by the same amount To decrease the belt tension turn both adjusting screws counterclockwise by the same amount Figure 3 Y Drive Timing Belt Adjusting Scr...

Page 86: ...the tip of the adapter on the y motor belt see the following image 5 Push the force gauge toward the machine until the flat portion of the adapter just touches the casting The force should be between 7 5 and 9 5 lbs 6 If the tension measurement is not correct loosen the three cap head socket screws that mount the y motor mounting bracket to the upper arm body 7 Increase or decrease the y motor mou...

Page 87: ...erating System OS Maintenance Head Timing menu Bottom Center Z Timing Measurement 1 Color change to needle 9 Figure 1 Tools Maintenance Head Timing Menu 2 Open the Maintenance Menu then click the Head Timing tab 3 Remove the bobbin case and the needle plate 4 Assemble the Head Timing Adaptor PN 33065 to the dial indicator PN 32453 01 as shown in Figure 2 Figure 2 Adaptor and Dial Indicator 5 Insta...

Page 88: ... the bottom dead center position using the Hoop command 9 Using the micro stepping command Trace and Arrow Down keys increase the angular position until the dial indicator needle stops moving Z Lower Dwell Start Continue to increase in angular position all the while there should be no movement through 179 5 180 5 10 Increase the angular position to the point where the needle starts to rise Z Lower...

Page 89: ...stall the dial indicator PN 32453 01 with the adaptor PN 33065 on the lower arm extrusion as shown in Figure 4 Tighten the screws enough to hold the fixture securely Figure 4 Dial Indicator Installed on Needle Plate Bracket 14 Cycle the machine to its Bottom Center position by pressing the Adjustment and Arrow Downkeys simultaneously on the keypad Be careful not to let the needle slam against the ...

Page 90: ...rs the dial indicator plunger After that support the weight step upward in 5 increments or more stopping roughly 5 7 before reaching the β z index setting position 23 At this position let the weight once again hang freely and use the micro step command to slowly increase angular position to exactly β z index setting Note It is very important that you don t overshoot this value If this happens rota...

Page 91: ...er position and replace the weight Be careful not to let the gauge pin slam against the indicator plunger because this may cause damage 28 Decrease the angular position by at least 0 004 from this position 29 Increase the angular position to the point where the needle starts to rise Z Lower Dwell Stop 30 Continue to increase the angular position until 0 001 rise Z 0 001 Rise is measured The corres...

Page 92: ...lb Force Gauge PN 995591 01 screw adapter on the end of the gauge 2 Turn the machine OFF 3 Remove either one of the upper arm covers and the innermost back screw of the other one re move screws with a 3mm hex wrench 4 Remove the upper arm back cover remove screws with a 3mm hex wrench 5 Locate the z drive belt and the z motor mounting bracket 6 Using a ruler preferably metric mark the z motor moun...

Page 93: ...kwise to increase the tension counter clockwise to reduce tension and then tighten the screw to the Torque Specifications Measure the tension again as specified in Steps 7 and 8 and if it is not correct repeat step 9 until the tension is set to the specification 10 Reinstall the covers in the reverse order that you removed them Tighten the screws to The torque specifications 11 Do a short machine ...

Page 94: ...94 of 271 Z Home Adjustment Align the z home flag using procedures defined for Head Up Position Alignment Table of Contents ...

Page 95: ...eedle plate PN 33111 4 Remove the bobbin case PN 004267 01 5 Mount the closest needle gauge fixture to the lower arm extrusion It should appear as shown in Figure 2 Figure 2 6 In the software enter the Maintenance Menu 7 Under the Maintenance Menu enter the Head Timing Menu 8 YOU MUST PULL OUT THE PLUNGER of the closest needle dial indicator and KEEP IT HELD OUT as you hit the Frame Back button on...

Page 96: ... if needed 11 Record the zero measurement under Needle 1 on the worksheet that is provided with this TAB See example of worksheet below 12 Pull the plunger back and hit the Frame Back button again The machine changes to Needle 2 and goes to needle depth 13 Record the measurement under Needle 2 on your worksheet Anything on the left side of zero on the dial indicator is a negative number Estimate t...

Page 97: ...ements 17 You need to calculate the total variance to be sure that it is within the total allowed variance of 006 You do this by adding the most positive number and the most negative number Using the example above you would add 00425 to 00075 You get 0035 and this is within the total allowed variance of 006 If your machine does not fall in this range you can replace the needle bar in the closest n...

Page 98: ...enter 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 3 In the Bravo OS got to Tools Maintenance as shown below Figure 1 Maintenance Window 4 Next click on the Steppers tab as shown below Figure 2 Steppers Tab 5 Next click on the Color Change Home button as shown below...

Page 99: ...s are necessary repeat steps 7 13 16 If the needle is centered exactly to the post then you may move to the next needle 17 Using the Frame Back key is the quickest way to get to the next needle in this situation It will bring the needle to the Head Up position move to the next needle and bring that needle to the Needle Depth position 18 From there you can repeat Steps 7 13 as needed until all 16 n...

Page 100: ...urther adjustment is needed raise the machine to Head Up and repeat steps 5 thru 7 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 Close out the Maintenance menu in the Bravo OS as shown below Tab...

Page 101: ...009027 01 Thickness 0 020 Tolerance 0 002 2mm Allen Wrench 2 5mm Allen Wrench for the needle plate Figure 1 Hook Retaining Finger Gauge Inspection Procedure 1 Remove the bobbin case 2 Remove the hook gaurd and needle plate a 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 The screws do not need to be completely ...

Page 102: ... it aligns to the needle It should be centered left to right If not it may be necessary to bend the hook support to the cor rect alignment by hand without tools being careful not to scratch the highly polished surface If this is not possible you may need to replace the hook support PN 33046 Figure 4 Hook Support Position Left to Right 6 Once the left to right position of the hook support is correc...

Page 103: ...he gauge is 0 020 and the tolerance is 0 002 8 The tip of the hook support should be flush with the top of the hook basket 9 If the adjustment is not correct continue to the Adjustment Procedure below Adjustment Procedure Note Prior to adjustment be sure to follow steps 1 through 9 in the Rotary Hook Support Inspection Procedure above 1 Use the 2mm Allen wrench to loosen the 2 screws holding the h...

Page 104: ... 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 6 Tighten the 2 screws holding the hook support Figure 3 Hook Support Adjustment 7 Verify that the gauge still slides freely between the basket and hook support 8 You may now reinstall the needle plate and bobbin case Table of Contents ...

Page 105: ...cement Thread Feeder Optical Sensor Replacement Thread Feeder Radial Bearing Replacement Thread Feeder Stepper Motor Assembly Replacement Figure 2 Take Up Lever Drive Gear Assembly CAUTION Do not attempt to do any repairs or adjustment to the take up lever drive gear tor sion spring or shaft These components require a special fixture and specific training to adjust properly If this component is ta...

Page 106: ...embly until it is the same as the replacement assembly 8 Mount the replacement Color Change Take Up Feeder Assembly to the upper arm body loosely 9 Align the base of the Color Change Take Up Feeder Assembly to the outline traced on the upper arm body from the old assembly and tighten the screws to The torque specifications 10 Install the needlecase assembly 11 Check and adjust the needlecase align...

Page 107: ...t Needed Actuator Linear Color Change Replacement Procedures Figure 1 Color Change Linear Actuator Note If you do not have the ability to color change because the motor has failed electrically or because of a mechanical failure go to Step 2 1 Color change to needle 8 2 Turn the machine OFF 3 Remove the needle bar access cover the needlecase cover and the color change covers 4 Disconnect the color ...

Page 108: ...ack of the machine and down as shown in Figure 1 11 Re tighten the 3 motor mounting screws 12 Turn the spindle clockwise and insert the left end of the spindle into the left spindle mounting bracket until the threaded portion of the spindle is flush against the bracket 13 Tighten the screw that clamps the bracket to the spindle 14 Mount the right color change spindle mounting bracket to the needle...

Page 109: ...2 Run a short functional test using the test design AMPASSxxx with the machine in the unthread ed mode Visually observe the color change functions and make sure everything was properly installed and adjusted It is only necessary to run the machine through all 16 needles then the functional test can be stopped as long as everything is correct 23 Run test design AMTTTESTXXX to test color change func...

Page 110: ...eeder gear Replacement parts needed P N 34178 Gear Thread Feeder Z 28 M 1mm P N 10454 08Ring Retaining External 5mm Shaft always use a new retaining ring P N 30853 08 Washer S S 5 1mm ID X 8 3mm OD P N 32205 Feeder Drive Gear Shaft Tool Replacement Procedures Figure 1 Thread Feeder Gear 1 Color change to needle 1 and turn the machine OFF 2 Remove the Right Color Change Cover P N 33093 3 Position t...

Page 111: ...reads 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 9 Using the T handle on the tool finger tighten using tips of thumb and forefinger only the shaft only Figure 4 10 Replace the Color Change Cover to complete the instructions Table of Contents ...

Page 112: ...thread feeder PCB then remove the PCB 6 Remove the M3 screws from the PCB Throw the old M3 screws away 7 Apply red loctite MS 222 to the replacement screw threads and install the replacement PCB on the color change housing loose 8 Align the sensor so that the thread feeder flag is centered in the optical sensor and tighten the screws to the torque specifications 9 Reconnect the harnesses to the PC...

Page 113: ...ring Behind Needlecase 3 The radial bearing will then be accessible as shown in Figure 2 above Remove the two thread tubes above the bearing 4 Remove the screw with a 074 or 3mm Allen wrench and the split lock washer 5 Install the replacement bearing and start the screw with a split lock washer loose Note The radial bearing is a sealed bearing and does not require any additional lubrication 6 Posi...

Page 114: ...e PCB 3 Remove the three screws lock washers and flat washers mounting the stepper motor and remove the motor 4 Loosen the set screw in the pulley collar and remove the feeder drive gear from the motor spindle 5 Remove the set screw and replace it with a new one Add red loctite MS 222 to the set screw threads and install it into the feeder drive gear loose 6 Install the feeder drive gear onto the ...

Page 115: ...gure 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 Table of Contents ...

Page 116: ...oncentrated light beam that can cause permanent blindness Use extreme care in handling the laser assembly to make sure it is not going to be inadvertently aimed at some one s eyes or face DO NOT LOOK DIRECTLY AT THE LASER LENS WHILE IT IS ENERGIZED Replacement Parts Needed 1 inch laser assembly Replacing the laser assembly 1 Color change to Needle 1 and then engage the E stop button WARNING DO NOT...

Page 117: ... the block 7 Disengage the E stop button on the keypad 8 Place a round dot or piece of tape over the needle plate hole Take the machine to needle depth and then back to head up this is to make the focus point of the laser easier to see CAUTION Do not color change with the upper right front cover removed 9 Adjust the position of the laser mounting block so that the laser beam is focused and centere...

Page 118: ...placement of a LED Cluster Assembly this repair can be completed by the machine operator Figure 1 LED Cluster Assembly 1 Each LED cluster is accessible from underneath the upper arm of the sewing head WARNING The LEDs may be hot to the touch when illuminated They must be turned off for a few minutes before handling or they can cause minor burns 2 Turn off the machine and allow the LED s to cool fo...

Page 119: ...Remove the needlecase cover and let it hang on the bottom by the threads 7 Loosen the top screws on both the left and right color change spindle mounting brackets Figure 2 Wire Installed Through Take Up Levers 8 Slide a stiff wire e g a piece of hanger wire through the take up levers as shown above to keep the take up levers together to make it easier to reinstall the needlecase later 9 Slide the ...

Page 120: ...th the others and slide the needlecase over to the right When all of the needles are up and aligned center needlecase Lift the presser foot to clear the right side of the grabber 21 Adjust the needle case left or right as needed so that the end of the color change spindle is even with the outside edge of the right color change spindle mounting bracket 22 Tighten the top screws on both the left and...

Page 121: ... hex wrench does not fit the distance is too small proceed to step 31 If the hex wrench fits you then need to verify that the distance is not too large To do this place a 2mm 5 64 wrench between the drill blank and the presser foot If it fits snugly the distance is correct If it fits loosely then this distance is tool large proceed to step 32 31 If you determine that the distance needs to be adjus...

Page 122: ...ian Replacement Parts Needed Reciprocator Repair Kit Replacement Procedure 1 Remove the needle case as described in the Needle Case Removal section 2 Remove the left and right upper arm covers 3 Locate the reciprocator assembly as shown below Figure 1 Reciprocator Assembly Installed Figure 2 Reciprocator Assembly Table of Contents ...

Page 123: ...ft down through the ball bearing the bushing below the ball bearing and the bottom felt 9 Turn the reciprocator guide shaft until the flat position at the top of the shaft faces towards the front of the upper arm casting 10 Pull the reciprocator guide shaft down until it is positioned below the upper surface at the top of the upper arm casting by 0 5 to 1 0mm 11 Position the z shaft at top dead ce...

Page 124: ...and discon nect the connecting rod from the take up lever cam Use a screwdriver that fits the slot correctly as the screw threads have red loctite MS 222 applied and may be difficult to break loose CAUTION DO NOT DISASSEMBLE THE Z SHAFT ITSELF OR ATTEMPT TO REMOVE IT If you remove the retaining rings at either end of the z shaft the machine will have to be sent in to the factory for repair The ill...

Page 125: ...orque Figure 5 Endplate w Spring Pin Pressed in EndPlate back view 9 Push the spring pin into the z shaft end plate from the front until it is flush to the back of the end plate see figure 5 Important When inserting the spring pin make sure the spring pin teeth are facing down Figure 6 Alignment Groove in Z Shaft 10 Align the spring pin in the z shaft end plate with the groove of the upper z shaft...

Page 126: ...o 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 Install the needlecase Table of Contents ...

Page 127: ...only by authorized field service technicians Do not at tempt to perform any of the procedures below unless you have received specific training that allows you to do so Click on the link to get to the procedure Take Up Lever Cam Replacement Z Motor Assembly Replacement The following procedures may be performed by the machine operator Z Drive Belt Replacement and Tensioning Z Idler Pulley Replacemen...

Page 128: ...ys aligned to their respective index marks as shown in Figures 2 and 3 above 8 Place the belt on the z motor drive pulley CAUTION The head must be timed at this point Check head timing using the procedures pre scribed in Head Up Position Adjustment 9 Position the belt over the idler pulley Figure 1 and slowly rotate the idler pulley clockwise until the belt is tensioned and then tighten the screw ...

Page 129: ...over and set the hardware aside for reuse 4 Disconnect the z home harness lead from the PCB connector socket 5 Remove the two M4x10mm cap head socket screws M4 split lock washers and M4 flat washers that mount the bracket to the upper arm and remove the Z home sensor PCB assembly from the machine 6 Install the replacement Z Home Sensor PCB Assembly using the hardware you removed from the old assem...

Page 130: ...d tie the connector snug by attaching the cable tie around the PCB such that the cable tie holds the connector in place Failure to do this might result in the connec tors coming loose which can create difficulties in troubleshooting See Figure 3 Figure 2 Cable Tie Around PCB 11 Reinstall the upper arm back cover and tighten the screws to the torque specifications 12 Reinstall the left and right ar...

Page 131: ...f the upper and lower z shafts make index marks on the z index flag and the bottom pulley as shown in Figures 2 and 3 above 4 Slowly loosen the screw mounting the z belt idler pulley to release the tension on the belt then remove the idler pulley 5 Mount the replacement idler pulley with the same screw from the old one leaving the screw loose 6 Tension the z drive belt and tighten the idler pulley...

Page 132: ...ether to replace a mo tor or not Examples of other issues that should be considered is how freely and smoothly the spindle on the motor turns These factors are covered in the troubleshooting section of this manual Replacement Parts Needed Z Axis Brushless Servo Motor 6 11 inch Cable Ties to re tie the harnesses after installing the new motor available in the elec trical section at most hardware st...

Page 133: ...l the x cable out of the way and remove the z motor from the machine 14 Remove the z motor timing pulley from the z motor 15 Remove the z motor mounting bracket from the z motor install it on the replacement motor and tighten the screws to the torque specifications CAUTION Do not drop the z motor timing pulley or allow the star washers that are pressed inside the bore to come loose If the star was...

Page 134: ...ether right before the clamp 21 Tie the z motor harness to the adjacent harnesses at about every 3 inches and route the z motor harness leads down the back of the machine to the cable access hole Connect the motor harness and hall encoder leads to the main PCB 22 Tension the z drive belt as specified in Z Belt Replacement and Tensioning 23 Unless you have additional work to do on the inside of the...

Page 135: ...er of the thread feeder where the thread has wrapped around the roller and the two adjacent thread feeders and remove all three thread feeder front covers Figure 2 Prying Thread Feeder Roller Loose 2 Using two thin bladed flat screw drivers carefully pry the roller out of the assembly as shown in Figure 2 above until you can pull it out easily with your finger Figure 3 Pulling Thread Feeder Roller...

Page 136: ...o the assembly until it snaps back into place Make sure the thread is centered critical over the thread feeder front cover 7 Rethread the machine if necessary and then make sure the thread is centered in the grooves on the thread feeder front cover and push the thread feeder arm back down 8 In the Bravo OS open up the Tools Settings menu and then click on the Thread Feed tab Check the settings for...

Page 137: ...ully bend the ends of the cotter pin together and release the spring from the bracket Do not let the spring snap back on its own d Loosen and remove the cap head screw on the top of the bracket and set it aside for reuse e Remove the two cap head screws and split lock washers on the side of the bracket and set the hardware aside for reuse f Remove the mounting bracket and throw it away g Install t...

Page 138: ...et them aside for reuse d Remove the damaged bracket and throw it away e Install replacement bracket in place on the color change linear actuator spindle f Apply red loctite MS222 to the two M4x6mm cap head socket screws on the side of the bracket and install the bracket to the needlecase Leave the screws loose for now g Release the emergency stop button if it is engaged h Color change to needle 1...

Page 139: ...2 Apply red loctite MS222 on the screw threads and install the replacement grabber blade in position starting all four screws loose Tighten them to the torque specifications when all of the screws are started 3 Loosen the four M3x6mm button head screws on the back of the lower trap assembly 4 With the machine tuned off move the grabber blade by hand between the upper and lower trap assemblies and ...

Page 140: ...re tightening down the nut g Tighten the four M3x6mm button head screws that mount the lower trap assembly to the upper trap assembly to the torque specifications h Move the grabber blade back out of the needle case to it s full extended position i Move the grabber blade in and out of the upper and lower trap assembly several times It should just brush against the grabber trap velcro on the upper ...

Page 141: ...erference noticed when stepping the grabber through it s normal cycle press Start Test to test the grabber located under the Grabber column and let the grabber test run for a few minutes If the grabber fails to function correctly during the test make adjustments as necessary To end the grabber test click on End Test under the Grabber column 9 Run the Trim Test sew design AMTRIM01A exp on the machi...

Page 142: ...ools Maintenance menu and then Head Timing tab Click on the Head Up button to bring the head to the HEAD UP position If the machine is jammed or will not go to the head up position contact Technical Support for instructions 2 Color change to either Needle 5 or 6 3 Engage the emergency stop by pressing in WARNING Do not proceed without engaging the emergency stop button or by turning the machine of...

Page 143: ...in Figure 4 Figure 4 Remove Nut 8 Loosen the top screw and remove the two side screws from the right color change spindle mount ing bracket Remove the right color change spindle mounting bracket 9 Remove all of the thread tubes from the back of the thread feeder Figure 5 Remove Thread Tubes 10 Disconnect the harnesses from the two PCB s and the stepper motor 11 Slide the needle case to the left wh...

Page 144: ...nd right upper arm covers as shown in Figure 2 above 3 Handle the needlecase carefully so you do not damage any components 4 Slide the needle case to the right while lifting the presser foot to clear the grabber bracket 5 Connect the harnesses to the two PCB s and the stepper motor Figure 1 6 Install the 2 screws holding the needle case cover and tighten the screws to the torque specifications 7 I...

Page 145: ...access cover to the needle case assembly IMPORTANT Verify needle depth and hook timing anytime you reinstall the needle case 12 Complete any remaining work you have left on the machine then turn the machine back on To do so disengage the emergency stop if it is engaged by twisting in the direction of the arrows until the red button pops out and turn the main power switch ON 13 Verify needle depth ...

Page 146: ...t mount the grabber mounting plate to the needlecase frame 5 Remove the four M3x4mm cap head socket screws mounting the motor to the grabber mounting bracket and set them aside for reuse 6 Mount the grabber mounting bracket to the replacement motor 7 Apply red loctite MS222 to the four M3x4mm cap head socket screws Start the screws loose and then tighten them to the torque specifications 8 Align t...

Page 147: ...t use a black marker and mark on the axis where the inside edge of the left take up lever mounting block clamps onto the axis 4 Turn the main power switch ON 5 Color change to Needle 5 6 Shut the machine OFF 7 Remove the two screws mounting the right color change shaft mounting block and loosen the screw clamping the color change shaft Remove the mounting block Figure 1 Right Take Up Lever Bar Mou...

Page 148: ...hough the end of the last take up lever install the spacer into place and tap the take up lever though the spacer 16 Install the retaining ring in the groove on the left end of the take up lever axis 17 Tap the take up lever axis into the bore on the right take up lever bar mounting block so that the space between the last take up lever body and the right block is 020 003 with all of the take up l...

Page 149: ... Thread Feeder Assembly 16 Needle comes with hardware installed Replacement Procedure 1 Turn the machine off 2 Remove the needle case access cover 3 Remove the needle case cover Figure 2 Thread Tubes Connected to Thread Feeder Assembly 4 Remove the thread tubes from the back of the thread feeder Figure 3 Thread Feeder Assembly Left Bracket Table of Contents ...

Page 150: ...the factory 8 Turn the machine on and Color change to needle number 1 9 Slide the replacement thread feeder assembly onto the needle case 10 Replace and tighten the two bolts on the right side as shown in Figure 4 above Tighten the bolts only enough to secure the bracket to the needle case 11 Install the nuts on the left bracket and tighten them just enough to hold the left bracket in place 12 Adj...

Page 151: ...t the red thread feeder clicker for needle 1 is compressed about 50 from the fully extended position See Figure 7 Make sure the bearing is also centered left to right on the thread feeder clicker Figure 7 Thread Feeder Clicker 15 Color change to needle 16 Repeat step 12 and then tighten the two nuts on the left side of the thread feeder assembly 16 Color change between needle 1 and needle 16 sever...

Page 152: ...damage use normal precautions when handling electrical components Parts that are damaged due to mishandling are not covered under the machine warranty CAUTION DO NOT allow the PCB or bracket to hang by the wires Support the weight of the PCB during installation or removal Replacement Parts Needed Thread Sensor Assembly If the assembly is loose you may want to re assemble with tape seating each bra...

Page 153: ...self and mount the replacement thread sensor assembly and base in the same position as the old one that was previously removed 8 Mount the base and thread sensor assembly using the two M4x8mm button head socket screws attached to the thread sensor assembly and tighten the screws to the torque specifications 9 Mount the thread sensor PCB in position with two M3 nuts and tighten to the torque specif...

Page 154: ...under thread sewing operations Replacement Parts Needed Radial Bearing order two PN 30951 05 When replacing the radial bearings always replace both of them as a pair Figure 1 Bobbin Shaft Front View Figure 2 Bobbin Shaft Timing Pulley Rear Replacement Procedure 1 Remove the needle plate 2 Remove the rotary hook support 3 Remove both of the rotary hook guards 4 Remove the rotary hook 5 Remove eithe...

Page 155: ...ion spring and the rear linear bearing 12 Replace the timing pulley on the bobbin shaft and make sure that the rear radial bearing is in con tact with the pulley 13 Push the bobbin shaft back into the lower arm until it makes solid contact 14 While holding the shaft in place push the front radial bearing onto the shaft and insert the retain ing clip This is usually easier with two people 15 Instal...

Page 156: ...ency stop 3 Remove rotary hook support finger 4 Rotate Z axis manually as to have access to all 3 Hook Set Screws 5 Loosen the 3 Hook Fastening Screws highlighted in red 6 Remove the Hook 7 Install the new rotary hook lining up the notch cut in the rotary hook with the index pin in the hook fastening collar 8 Put a little bit of pressure with one finger on the hook center and tighten the 3 Hook Se...

Page 157: ...ten 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 12 Move Z Axis to 201 5 and check distance to closest needle see hook timing procedure 13 Install the needle plate and hook guard 14 Run Sew test Table of Contents ...

Page 158: ...l Support as other causes may cause machine failure that looks like a Main PCB fault when it really might be an electrical short in a harness a software corruption issue or the like Figure 1 Main PCB Installed Replacement Parts Required Main PCB CAUTION There must always be thermal pads installed on the four flat pad supports that are located underneath the Main PCB If these are removed or not ins...

Page 159: ...ing it only by the edges especially if it is going to be sent to Quality Assurance for failure analysis 8 Place the old Main PCB in a protective anti static bag 9 Remove the replacement Main PCB from the protective anti static bag it was shipped in handling it only by the edges and place it in position on the machine base 10 Install the M4 X 8mm flanged socket head screws and tighten the screws to...

Page 160: ...herwise damaged For testing of the power supply refer to Power Supply Test Procedure Repair Parts Replace order only damaged or defective parts Power Switch Interface Harness PN 301110 Power Supply Interface Harness PN 301109 360W 36V 10AMP 88 264VAC IN Power Supply PN 31014 8 position in line coupler PN 000434 02 6 AMP Line Filter IEC Input Switch w DPD PN 31039 Not all of the parts in the Power ...

Page 161: ...ly other than to remove the entire unit from the machine 6 Remove the power input assembly and replace repair any defective parts Power Input Assembly Component Replacement In Line Coupler Replacement Figure 1 In Line Coupler 1 Use a screw driver and push the retaining clip against the coupler body and remove it through the inside of the power supply mounting plate 2 Replace it with a new in line ...

Page 162: ... interface harness to the power supply wiring blocks as shown in Figure 1 above Tighten the screws enough to hold them securely but do not over tight en them Figure 2 Top Wiring Block Wire Leads from Power Interface Harness 5 Connect the leads of the power supply interface harness coming from white 8 position connector above switch to the top wiring block on the side of the power supply as shown i...

Page 163: ... from the power switch interface harness and ground cable to the back of the power switch as shown in Figure 2 above The leads are labeled as indi cated by the text below each connection Fuse Replacement Do not remove the power input assembly if all you need to do is replace fuses Figure 1 Fuse Holder 1 With your finger nail or a screwdriver pry the fuse holder out of the power input switch as sho...

Page 164: ... the power supply and power switch energized with dangerous levels of voltage even when turned off and can result in severe injury from electrical shock 1 Disconnect the leads from the power switch interface harness from the bottom wiring block of the power supply unit and the back of the switch Figure 1 Power Switch Interface Harness Wiring to Power Supply 2 Install the replacement harness to the...

Page 165: ...injury from electrical shock 1 Disconnect the leads from the power supply interface harness from the top wiring block of the power supply unit Figure 1 Power Supply Interface Connector 2 Use a screwdriver or similar tool and push the retaining clips in and push the white 9 position con nector out of the power input assembly plate as shown in Figure 1 above 3 Push the replacement interface harness ...

Page 166: ...al block and the terminal block on the side of the power supply unit to the back of the machine body as shown in Figure 1 3 Connect the power supply harness to the connector on the top of the power switch bracket 4 Install the lower bed rear cover and tighten the screws to the torque specifications 5 Connect the A C power input cord to the power input connector on the back of the machine 6 Turn th...

Page 167: ...sent back as a warranty part return Repair Parts Needed User Interface Assembly Replacement Procedure Figure 1 User Interface 1 Turn the machine ON and then start the software Figure 2 Keypad Submenu 2 Click on Tools Maintenance and then on the Keypad tab in the Maintenance Menu screen This immediately puts the machine in the test mode purely for testing the keypad Table of Contents ...

Page 168: ...the entire user interface assembly must be replaced as a whole unit do not disassemble it CAUTION Turn the machine off before disconnecting the keyboard harness from the user in terface Failure to do so might result in internal damage of machine components 5 Turn the machine OFF Figure 2 Keyboard Harness Connection 6 Disconnect the keyboard harness from the back of the user interface 7 Remove the ...

Page 169: ...ess to the socket in the back of the user interface panel 13 Turn the machine ON 14 Repeat the keypad test described in paragraphs 2 through 4 and verify that the user interface is fully functional If you have difficulty in installation or should the problem still persist after com pleting the above procedures contact Technical Support for assistance Table of Contents ...

Page 170: ... connecting any harness At the minimum engage the emergency stop button by pressing in on the user interface CAUTION As with any electrical component always observe ESD safety procedures before handling any internal electrical components CAUTION Use extreme care not to drop metallic objects tools or other conductive material on the Main PCB when you have the base cover removed If you drop such obj...

Page 171: ...rn the machine OFF 4 Remove the right arm cover and the back screw of the left 5 Remove the upper arm back cover 6 Remove the lower arm rear cover CAUTION Use extreme care not to drop metallic objects tools or other conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to...

Page 172: ... harness through until about 3 inches extend from the front of the thread tree base Connect the color change harness to the color change actuator interface cable 14 Apply a single twist lock cable tie in front of the thread tree base to all of the harnesses that run underneath the thread tree base and neatly bundle them together 15 At the back side of the thread tree base apply a twist lock cable ...

Page 173: ...nect 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 Turn the machine ON 22 Do a short functional test and execute several color changes to ensure that the harness is properly connected and works properly Table of Contents ...

Page 174: ...wn without being handled Replacement Parts Needed harness Ethernet twist lock cable ties available at most hardware stores in the electrical section Replacement Procedures 1 Turn the machine off CAUTION Use extreme care not to drop metallic objects tools or other conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage...

Page 175: ...own in the instructions for the appropriate EMI cover 8 Connect the other end of the Ethernet harness to the back of the Ethernet coupler on the power input assembly plate and coil any excess length in back of the coupler as shown in Figure 1 Note Make sure that you replace radio interference ferrite exactly as shown in Figure 1 9 Replace the twist lock cable ties on the harness tieing it to adjac...

Page 176: ...chine on 2 Color change to Needle 1 3 Turn the machine OFF CAUTION Use extreme care not to drop metallic objects tools or other conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to repair 4 Remove the right arm cover base cover upper arm back cover and lower arm rear ...

Page 177: ...rom the wiring channel down to where it enters the access cover towards the main PCB Figure 2 EMI Cover over Main Board 12 Remove the EMI cover from the main control board Figure 4 Grabber Thread Feed Motor Connection at PCB 13 Disconnect the grabber thread feed motor harness from the Main PCB at connector location J33 14 Remove any remaining twist lock cable ties bundling the grabber thread feed ...

Page 178: ...at the back of the base 20 Run the harnesses running out from under the thread tree base to the right wiring channel and bundle them together with a cable tie at the point where they meet the other harnesses running into the wiring channel 21 Run the grabber thread feed motor harness down the right wiring channel following the path of the adjacent harnesses all the way down to the access hole to t...

Page 179: ...ive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to repair 4 Remove the base cover upper arm back cover and the lower arm rear cover 5 Remove any twist lock cable ties that bundle the grabber threadfeed cc harness to adjacent ones behind the needle case assembly and any cab...

Page 180: ...motor interface cable Figure 3 8 Remove any twist lock cable ties bundling the harnesses together behind the thread tree base and pull the grabber threadfeed cc harness from under the thread tree base all the way to the back down to the right lower arm access hole 9 Remove the EMI cover from the main control Figure 4 Grabber Threadfeed CC Harness Connection at Main PCB 10 Disconnect the grabber th...

Page 181: ...able ties between the harness wires on the center of the connector 14 Run the grabber threadfeed cc harness along the same path as the adjacent harnesses bundling them together with twist lock cable ties Add another twist lock cable tie where they meet to gether in the right wiring channel of the upper arm 15 Run the cable through the right wiring channel down to the right lower arm access hole to...

Page 182: ... WHILE IT IS ENERGIZED The laser harness connects the laser pointer assembly to the Main PCB at connector location J30 Replacement Parts Needed harness laser twist lock cable ties available at most hardware stores in the electrical section Replacement Procedures 1 Color change to Needle 1 2 Turn the machine OFF 3 Remove the right upper arm front cover 4 Remove the right arm cover and the back scre...

Page 183: ...ad that is labeled LASER through the right upper arm access hole and connect it to the laser pointer assembly as shown in Figure 1 12 Right behind the right upper arm pull the unneeded slack out of the harness and use a twist lock cable tie to bundle the laser harness to the other two adjacent harnesses that run through the hole 13 Run the laser harness down to the right wiring channel following t...

Page 184: ... LED Cluster Harness 1 Turn the machine ON 2 Color change to Needle 16 3 Turn the machine OFF CAUTION Use extreme care not to drop metallic objects tools or other conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to repair 4 Remove the left upper arm front cover the r...

Page 185: ...e new LED cluster harness to the left LED cluster assembly and run it through the z mo tor mounting bracket and use a twist lock cable tie to tie it with the adjacent harnesses to the z motor mounting bracket Figure 2 12 Run the LED cluster harness following the adjacent harnesses down to and through the left lower arm access hole Figure 3 13 Run the LED cluster harness through the left lower arm ...

Page 186: ...from the left LED cluster assembly 6 From the back side of the right upper arm pull the harness through the access hole located just above the x cable clamp Figure 5 7 Pull the harness through the right access hole to the back of the machine removing any twist lock cable ties that tie it to the adjacent harnesses and pull it through the right lower arm access hole 8 Remove the EMI Cover from the m...

Page 187: ...he EMI cover carefully 14 Install the right upper arm front cover and tighten the screws to the torque specifications 15 Install the remaining covers in the reverse order that you removed them and tighten the screws to the torque specifications 16 Turn the machine ON and verify that the LEDs come on in the right LED cluster assembly Table of Contents ...

Page 188: ...ther conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to repair 4 Remove the upper arm back cover lower arm rear cover and base cover Figure 1 Threadbreak Harness Connected to Sensor PCB 5 Disconnect the thread break harness from the thread break sensor PCB 6 Remove ...

Page 189: ...ol board Figure 3 Connection at Main PCB 10 Disconnect the thread break harness from the connector socket at location J29 on the Main PCB and cut any remaining cable ties bundling the thread break harness to adjacent harnesses Remove the harness from the machine 11 Connect the end of the thread break harness labeled THREAD BREAK SENSOR PCB to the con nector socket on the thread break sensor PCB Fi...

Page 190: ...d break harness with the adjacent harnesses to the right into the right wiring channel and tie them together where they meet the harnesses in the channel 16 Run the thread break harness down the wiring channel following the path of adjacent harnesses down to the Main PCB and connect it at the connector socket at location J29 on the Main PCB 17 Replace the EMI cover carefully 18 Reinstall the cover...

Page 191: ...lower arm rear cover CAUTION Use extreme care not to drop metallic objects tools or other conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to repair 4 Remove the base cover 5 Remove any twist lock cable ties that bundle the trimmer z home harness to adjacent ones Fig...

Page 192: ...ing See Figure 1 12 Run both leads along the same path as adjacent harnesses and tie them together with twist lock cable ties and pull the harness through the right lower arm access hole 13 Connect the harness to the Main PCB at connector location J32 and tie the harness to adjacent ones at 3 4 inch intervals 14 Carefully install the EMI Cover 15 Install the covers in the reverse order that you re...

Page 193: ...st hardware stores in the electrical section Replacement Procedures 1 Turn the machine off CAUTION Use extreme care not to drop metallic objects tools or other conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to repair 2 Remove the right plastic side cover base cover...

Page 194: ... the EMI cover carefully 11 Run the User Interface harness through the right wiring channel following the same path as the adjacent harnesses 12 Connect the other end of the User Interface harness to the back of the User Interface assembly as shown in Figure 1 13 Replace the twist lock cable ties on the harness tieing it to adjacent ones 14 Replace the base cover 15 Reinstall the rear covers and t...

Page 195: ... or other conductive material on the Main PCB when you have the base cover removed If you drop such objects on the Main PCB it can severely damage the electronics which will be very expensive to repair 3 Remove the upper arm back cover the base cover and the lower arm rear cover Figure 1 Connection at X Y Home PCB 4 Disconnect the x y home harness from the x y home PCB mounted to the left y belt c...

Page 196: ...ss around the left perimeter of the base interior and out the left access hole Replace a twist lock cable tie to bundle all the harnesses together in front of the access hole 12 Follow the adjacent harnesses running up to the z motor and tie the x y home harness to the ad jacent harnesses in 3 4 inch intervals up to where it runs under the z motor 13 Run the harness flat and neat down the channel ...

Page 197: ...NOT attempt to disassemble or rebuild the bearing block assemblies The in ternal bearings are impregnated with lubricant and are easily damaged if improper tools and procedures are used for assembly CAUTION Never allow the internal impregnated sinterbronze bearings to come into contact with an absorbtive surface Doing so will damage the bearings Replacement Parts Needed left bearing block assembly...

Page 198: ...s on the bottom edge facing to the front 13 Reinstall the y rail back into position in the upper arm body and tighten the cap head retaining screw to the torque specifications 14 Apply red loctite MS 222 to the button head screws and mount the x beam assembly to the bearing block assembly Tighten the screws to the torque specifications 15 Reinstall the cable onto the pulleys on the right bearing b...

Page 199: ...ere indicated in the below procedures X Beam w Rails Assembly Replacement Repair Procedures Figure 1 X Beam and Carriage Installed on Machine 1 Color change to Needle 16 2 Turn the machine OFF 3 If the machine has a hoop installed remove it from the machine Figure 2 Cable Bracket Removal 4 Remove the two screws holding the cable bracket on the rear of the x carriage 5 Remove the cap on either side...

Page 200: ...ead socket screws to the torque specifications 9 Remove the x home optical switch mounting bracket with the sensor mounted from the old beam and install it in the replacement beam using the installation procedures prescribed in X Home Optical Switch Assembly Replacement 10 Install the end caps on both ends of the x beam assembly 11 If you do not have any further work on the machine reinstall all o...

Page 201: ...rosion due to misalignment of the bearings or lack of proper lubrication see Carriage Rail Lubrication Note If corrosion of the carriage rails occurs the x beam assembly must be replaced using pro cedures prescribed in X Beam Assembly Replacement Parts two 2 rear straight linear bearing assemblies PN 30781 03 two 2 front straight linear bearing assemblies PN 30782 03 Removal Repair Procedures Note...

Page 202: ...ont to back fit between the two rails is tight no freeplay and tighten the nut to the torque specifications Adjust the carriage so that it moves freely left and right without any resistance but no freeplay is notice able when you try to move the carriage front to back in the x beam d CAUTION Adjusting the bearings on the carriage accurately to the x beam is very import ant Too much play between th...

Page 203: ...ymptoms of an x cable tensioned too low might be x move timeouts x tracking errors or stitch length being too long on the x axis CAUTION Use extreme care not to damage the cable and protective coating during assembly If the protective coating is damaged the cable will wear out very fast impacting the quality of the sew outs CAUTION At any time when the machine is either powered down or in E Stop m...

Page 204: ... hex nut on the tensioning bolt on the right side of the machine 8 Pull the cable through the access hole on the right side of the machine from around each of the pulleys and let it hang loose on the backside off the x drive cable spool 9 Loosen the screw located at the center of the x drive cable spool from the back and remove the cable and spool from the machine 10 If you are going to reinstall ...

Page 205: ...oating on the x drive cable If the coating is damaged the cable will eventually fray and or corrode CAUTION At any time when the machine is either powered down or in E Stop mode neither the X Carriage nor the X Beam should be moved at a high rate of speed If there is a desire to manually move either the carriage or the beam they should be pushed or pulled GENTLY to prevent serious damage to the ma...

Page 206: ...Install the x cable spool assembly on the x motor shaft with an 8mm bushing 5 16IDx 031 THK shaft spacer four 8mmIDx18mmOD external star washers one 173IDx 375OD D Shaped washer and one M4x10mm cap head socket screw Tighten the screw to 11 in lbs 1 2Nm of torque The four external washers are already inside the X Cable spool assembly Handle with care to prevent the washers from falling out Figure 2...

Page 207: ...un the cable from the top right beam cable pulley around the right center beam cable pulley to the bottom right beam cable pulley 10 Run the cable around the bottom right beam pulley see figure 5 around the right front carriage pulley into the cable access hole to the front of the machine Figures 7 X Cable Clamp 11 Attach the washer and nut to the threaded end of the stud Use needle nose pliers to...

Page 208: ...ne 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 15 Tension the x cable using the procedures prescribed in X Cable Tensioning 16 Install the upper arm back cover 17 Install the left and right arm covers Table of Contents ...

Page 209: ...not the only factor to be used in determining whether to replace a mo tor or not Examples of other issues that should be considered is how freely and smoothly the spindle on the motor turns These factors are covered in the troubleshooting section of this manual Replacement Parts Needed x axis brushless servo motor 6 11 inch Cable Ties to re tie the harnesses after installing the new motor availabl...

Page 210: ...come loose These star washers are precision aligned and pressed inside the spool with a fixture at the factory If the star washers come loose or fall out replace the x cable assembly comes with a spool Installing a spool with star washers out of position or missing will likely result in damage to the machine 7 Wrap some tape around the x drive pulley to secure the cable to the pulley and prevent i...

Page 211: ...stall it on the replacement x motor and tight en the screws to the torque specifications 16 Reinstall the x drive pulley to the x motor so that the index arrow marked on the pulley rim when originally installed is facing straight up and tighten the screw to 8 in lbs 0 9 Nm of torque using a torque wrench 17 Run the x harness on top of the z motor harness and along the same path as the z harness do...

Page 212: ... off when the carriage is moved further left or right Replacement Part Needed X home optical switch assembly 3 2mm IDx9mm ODx 8mm THK fender washer M3x0 5mmx10mmLG cap head socket screw Replacement Procedures 1 This procedure is done with the machine turned ON However engage the emergency stop by pushing it in Figure 1 X Home Sensor Mounting Bracket 2 Remove the x beam end cap from the left end of...

Page 213: ...ll damage the sensor CAUTION DO NOT over tighten the screw mounting the optical sensor to the mounting brack et You will either strip the threads or crack the sensor housing if you do so 8 Run the x home sensor into the access hole at the top of the beam and pull it out the end of the beam mount it to the bracket and tighten the screw just enough to hold the sensor securely 9 Slide the x home sens...

Page 214: ...lustration WARNING A small risk exists of unpredictable movement of internal parts when the optical sensors are disconnected This creates a risk of personal injury if parts suddenly move Always turn off the machine before disconnecting optical sensors Replacement Parts Needed X Y Home PCB Replacement Procedure 1 Turn the machine OFF 2 Make contact with a metal part of the machine to dissipate any ...

Page 215: ...or the other to center the flag and tighten the screws just enough to secure the PCB and recheck the position of the flag again 10 Tighten the screws to the minimum Torque Specification 10 less than specified for the screws 11 Turn the machine ON 12 Install any size hoop with one piece of backing 13 Select the appropriate size hoop in the Bravo OS 14 Measure and mark the center of the hoop by meas...

Page 216: ...e other side can cause both belts to wear prematurely CAUTION At any time when the machine is either powered down or in E Stop mode neither the X nor Y carriage should be moved at a high rate of speed If there is a desire to manually move either carriage it should be pushed or pulled GENTLY to prevent serious damage to the main control board Replacement Parts Needed Belt Timing Open AT5 16 X 1124 ...

Page 217: ... belt and leave the screws installed loose for now 13 Adjust the x y home PCB using the procedures prescribed in X Y Home PCB Replacement 14 Adjust the y axis timing belt tensions using the procedures prescribed in Y Axis Timing Belt Adjustment 15 Reinstall the left upper arm front cover and tighten the screws to the torque specifications 16 Color change to Needle 1 17 Remove the right upper arm f...

Page 218: ... section Replacement Procedures WARNING Risk of serious personal injury exists when handling internal motors belts and cabling due to electrical shock and moving parts hazards Always turn off the embroidery ma chine when working on or adjusting motors belts or gears 1 Turn the machine off and disconnect the A C wallpower input cord from the A C wallpower sup ply outlet CAUTION Use extreme care not...

Page 219: ...assemble the y motor assembly any further especially if it is to be returned to the factory 9 Install the new y motor in position and place the y motor belt over the motor pulley 10 Start the four M6x20mm cap head socket screws M6 split lock washers and M6 flat washers loose 11 Pull up on the y motor with about 30 lbs pull and tighten the M6x20mm cap head socket screws to the torque specifications...

Page 220: ...his 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 Table of Contents ...

Page 221: ... adjustment The grabber blade should touch the velcro on the upper trap assembly but it should not depress the loops on the velcro pad The grabber blade should also be completely parallel to the upper and lower traps 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 ...

Page 222: ...atus It should be alternating between Open and Blocked In addition the grabber blade should be extending and retracting be tween the upper and lower traps without any obstruction or resistance If all this is happening everything in the grabber circuitry is good 7 Return to the Steppers menu and click on End Test button to stop the test 8 If you still get grabber related errors at this point contac...

Page 223: ... pull outs unusual noises or behavior Burn in Immediately after replacing a motor the Main PCB or the power supply assembly the machine should be burned in using the test design AMPASSxxx The machine has to be in the unthreaded mode for this test The machine should be periodically observed by the customer or machine operator for correct oper ation during the machine burn in The burn in should last...

Page 224: ...ice technicians Several small test designs have been created to test for specific functions This reduces the amount of labor that a customer will be charged for The main test design AMPASSxxx has been broken down into smaller designs that are focused on specific machine functions AMPASSxxx test design should be run on a machine when a repair has affected all or most of the machine functions Howeve...

Page 225: ...cal component When you move an object between the two sensors on the optical sensor PCB the corresponding LED on the Main PCB will illuminate on breaking the signal and turn off when you remove the object from between the two sensors If the corresponding LED on the Main PCB fails to illuminate but the Main PCB is functioning proper ly then the optical sensor is probably defective provided continui...

Page 226: ...uld be between 34 5V to 38V DC 5 If the voltage input measured from any of the red wires in the 36V power harness is not between 34 5V to 38V DC wriggle the cable and look for voltage change Figure 1 Power Supply Voltage Measurement Points wires disconnected for illustration only 6 If the voltage changes measure 36V DC output at the power supply terminal block If the power output is stable and mea...

Page 227: ...reen LED is not illuminated measure the A C input voltage at the location shown in Figure 1 above You should be getting 110V or 220V AC 10 depending on the wallpower supply If you have no or low power input at these two terminals replace the fuse b If the fuse is good but you still have no AC input verify that the wallpower supply outlet is supplying sufficient power to the machine c If correct po...

Page 228: ...ply assembly 16 If the green LED on the side of the power supply unit is illuminated and the 36V DC output is be tween 34 5 to 38V DC then the power supply assembly is good Follow the power supply installa tion procedures entitled Power Supply Assembly to install the Power Supply Assembly into the machine 17 If none of the above indicates a failure the power supply assembly is good and can be inst...

Page 229: ...er and pushing the reset button If the meter you are using does not have a reset button take note of the resistance measured when the two leads are touched together and subtract that from the actual measurement to get the true resistance measurement If the resistance is zero ohms or close to it it indicates the motor has a short If the measurement is high it indicates a break in the circuitry of t...

Page 230: ...ter to the ohm scale and zero it out by touching the two leads together and pressing the appropriate button to zero your meter see your meter instruction manual on how to do this If you do not know how to zero your meter take note of the resis tance measured when the two leads are touched together and subtract that from the actual measurement This gives you the true resistance measurement Measure ...

Page 231: ...ion that if the read ings between the phase leads of the motor are consistent nonzero resistance that the motor is probably good The machine should be considered defective if the measurements are substantially lower than the ranges specified in Step 1 shown in the above table If you have a phase that has close to a zero reading or measurements between phase leads that are not consistent then the m...

Page 232: ...ividual stepper motor The location numbers are indicated below You will generally find the indicator LEDs located by the respective stepper motor harness connection When you are referred to the stepper motor phase indicator LEDs you will need to watch the state red green or off of these LEDs WARNING Always make sure that you keep away from moving parts on the machine and do not touch electronic pa...

Page 233: ...g Find the col umn pertaining to the stepper motor You will be working with these command buttons when they are referenced in this procedure 7 Ensure the stepper motor that you are testing is in the correct state and then click on the Step command button As you click the step button write down the state of the respective phase in dicator LEDs red green or off For this test step the motor in one di...

Page 234: ...s defective and needs replacing 8 In addition to watching the LEDs as you step the motor through a cycle observe its mechanical performance Look for some kind of mechanical bind or other defect that interferes with the per formance and then fix any that you find 9 If the machine cycles through all eight phase states both the software and the firmware main PCB are in good condition Look for mechani...

Page 235: ...itizing conflicts involved in the trouble shooting This design produces more information when sewn on white broad cloth or any white polyester materi al and one layer of backing The use of a white colored fabric is important so that the thread contrasts against the white and makes defects in the sew patterns more visible Avoid the use of white or similar colored threads as they will blend in to th...

Page 236: ...s validate repairs and adjustments made to the machine and help to identify whether repairs and adjustments were successful Thread Tension Test The thread tension test tests for upper and bobbin tension When you look at the back side of the sewn material approximately 1 3 of the width of the bars should show bobbin thread This however is sub ject to a variety of conditions such as the type of thre...

Page 237: ...s This design is recommended to be sewn prior to running any design with a significant number of long stitches or to verify adjustments after repairs made due to failures on long stitch patterns The design should be sewn with no thread breaks long tails or pull outs The long stitch test should be sewn on one layer of white broad cloth or equivalent with one layer of 2 oz cut away backing Looping T...

Page 238: ...to ensure that the adjust ments to the x and y axis is correct There should be no missed stitches and the repeatability should be within one stitch point 0 1mm This should all be done with no thread breaks or pull outs The registration test sshould be sewn on one layer of white broad cloth or equivalent with one layer of 2 oz cut away backing Small Alphabet Test The small alphabet test design chec...

Page 239: ...eedle a few times to see if valid thread breaks are detected properly There should be no thread breaks or pull outs other than those that you initiated deliberately for testing purposes Also there should be no inconsistency in the fill portion of the design The thread break test should be sewn on one layer of white broad cloth or equivalent with one layer of 2 oz cut away backing Thread Break Test...

Page 240: ...t location of the fabric It is further recommended that you make any necessary adjustments to eliminate thread break problems while this design is running It is recommended that this design is run while you observe it so you see the machine behavior at the time machine errors occur in this design However the primary focus of this design is to detect and eliminate trimmer and grabber related errors...

Page 241: ...bad Replace the fuses Fuses good Go to Step 4 4 Conduct power supply test to verify condition of power sup ply assembly No 36V output from power supply but power input is good Replace power supply unit No or low AC input to Power Supply Unit Replace Switch Intermittent failure in power input to Power Supply Unit Replace Switch Power Supply good Go to Step 5 5 Remove the base cover and observe the ...

Page 242: ...een the phase wires Disregard the ground green wires Resistance than 7 ohms Short in the stepper motor replace it Resistance 10 ohms Open in the stepper motor replace it Resistance between 7 and 10 ohms Go to Step 6 6 Above steps failed to find problem Contact Technical Support for assistance LED Cluster Assembly Failures Condition Solution Both LED Cluster Assemblies do not illuminate with the re...

Page 243: ...ntroller PCB has failed replace it LED On Go to Step 2 2 Check for any loose harness connections Loose connections Connect the harnesses No problems Contact Technical Support 3 Design will not load or ma chine locks up on initialization User Interface Harness connec tors bad Replace Harness Main PCB bad Replace Main PCB If the 5V indicator LED D43 is off it indicates a catastrophic failure of the ...

Page 244: ... to Step 4 4 Replace thread break sensor assembly Problem goes away Sensor is bad Problem still occurs Contact Technical Support Loose Looping Stitches Possible Causes Solutions Thread feed settings too low Troubleshoot the thread feeder assembly Check the adjustment of the tread feed parameters in the Bravo OS software Contact Technical Support if necessary Bobbin tension too low Adjust the bobbi...

Page 245: ...ator manual Needle Depth Needle bar lowest dead point is incorrect Adjust needle depth Rotary Hook Hook timing is incorrect Adjust hook timing Hook point is dull Replace hook Upper Bobbin Tension Bobbin thread does not feed out smoothly Replace the bobbin and or bob bin case Upper thread does not feed out smoothly Check the condition of the thread feeder roller If it is bad replace it Adjust the t...

Page 246: ...eaks and bobbin show ing on the top of the fabric Stitches may be too short and or too dense 1 Check the design for short and or dense stitches and edit the design to remove them One effective method of removing dense stitches is to run the Stitch Proximity Filter One way to remove short stitches is to open Design Filter Tools Design Filter Adjusting the setting of After 1 Short to After 0 Short w...

Page 247: ...right or left 6 Inspect the needle plate hole to be sure it s free of nicks burrs or anything that may cause the thread to fray Replace if necessary Thread thread path 1 Make sure the machine is threaded properly see Upper Threading for instructions Make sure that there is no misguided thread The thread should be centered in the groove under the thread feed rollers Make sure that no thread is caug...

Page 248: ...e if the arms and or clips are loose is to sew a fill pattern inside a border You will likely notice poor registration The concentric circles in the test design are good for this as well You will notice more distortion in the X direction than in the Y direction 4 Check the backing you are using Inadequate backing allows fabric to be pulled into the needle plate hole If needed increase the number o...

Page 249: ...ou sew the test design use the following table to troubleshoot problem areas If thread breaks occur when sewing Check the following items Horizontal or verti cal bars at startup or soon after also called miss starts Hook timing and needle guard gap Make sure tail length length of thread tail left after a trim is adequate Make sure that thread is being held in trap in grabber assembly during trims ...

Page 250: ...Needle orientation Miss Starts Possible Causes Solutions Tail length length of thread tail left after a trim may be set too short In the software select the Tools Settings then click the Machine tab Change the tail length set ting to Medium or Long Thread is not held in grabber trap during trims Grabber blade and or grabber trap assembly may be to be adjusted or replaced Cap Frame Issues Possible ...

Page 251: ...eck 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 Solutions Birdnesting Thread may be wrapped around the rotary hook check hook timing Table of Contents ...

Page 252: ...on too high Adjust x cable tension Damaged x cable Replace the x cable Damaged bearing s Replace the radial bearings on top of the x carriage Damaged pulley Replace the damaged pulley Excess noise when carriage moves Lack of lubrication to the carriage rails Lubricate the carriage rails Improper adjustment of the x carriage linear bearings Adjust the linear bearings Cable tension too high Adjust x...

Page 253: ...g block assemblies Lack of lubrication Lubricate the bearing block assemblies Damaged belts Replace both y axis timing belts Binding in the motor windings Replace the y motor Excess noise when the x beam moves Lack of lubrication to the y axis rails Lubricate the bearing block assemblies Incorrect belt tension Adjust the y timing belt tensions Fretting corrosion of the carriage rails Replace the y...

Page 254: ...oo loose Adjust the z belt tensions Damaged z axis timing belt Replace the z axis timing belt Binding in the motor windings Replace the z motor Excess noise in the needle bar area Lack of lubrication to the needle bars Lubricate the needle bars Lack of lubrication to the recipro cator or presser foot Lubricate the needle drive and presser foot Damaged needle bar Replace damaged needle bar Z axis r...

Page 255: ...me Out and Index Errors DOS checksum error DSP Command Errors DSP timeout error DSP Command Errors Error trying to read stepper motor status Error trying to read stepper motor status E Stop Engaged E Stop Engaged ES segment register error DSP Command Errors FEEDER stepper index error Stepper Motor Time Out and Index Errors FEEDER timeout error Stepper Motor Time Out and Index Errors GOTO func erro...

Page 256: ...ame design so you will likely be asked to send us a copy of the design Can t Initialize Stepper Motors The actual messages generated by the software are Can t init color Z not in SAFE ZONE Can t init grabber Z not in SAFE ZONE These errors are generated when the firmware installed on the Main PCB attempts to put the color cut ter or grabber in the home position to allow Z axis movement to occur sa...

Page 257: ...om the index sensors that the motor is at the index position to allow some other function of the machine to proceed If you are getting this error frequently troubleshoot the problem using the steps shown in the table below Step Action Symptom Next Action 1 Check for a bind or obstruc tion of the assembly the motor controls Obstruction found Remove the obstruction No obstruction Go to Step 2 2 Veri...

Page 258: ...tware loaded Step Action LED D49 Condition Next Step Solution 1 Inspect the user interface harness and the harness connections Make sure the harness connections are secure Disconnect and reconnect both ends of the harness and make sure they are both securely connected OFF Problem was a loose or improper connection ON Replace the harness if kinked chaffed or connectors damaged or worn Otherwise go ...

Page 259: ... Solution 4 Close the software on the computer ON Replace Main PCB OFF 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 Table of Contents ...

Page 260: ...tion No damage or corrosion Go to Step 2 2 Check the belt tensions and condition of the belts for the respective motor servicing the axis Tensions loose or tight Retension belt For x axis errors also check the adjustment on the carriage bearings Tensions in specification Go to Step 3 3 Inspect the main PCB for obvi ous damage around the area where the motor harness con nects to especially the fret...

Page 261: ...rcuit with the error Ohms measure near zero or inconsistent with other phases Replace the motor Resistance is within specifications Go to Step 8 8 Problem is caused by some thing in the circuitry of the main controller PCB You will probably need to re place the main controller PCB Contact Technical Support and discuss the problem with them Table of Contents ...

Page 262: ...30 0 040 0 75 1 15mm Cam Follower Preload 4 5 5 0 in lbs Pull Force on Take Up Lever 1 4 1 5 lbs Color Change Lead Screw 0 025 0 64mm straightness Color Change Housing Location Bobbin Tension 22 to 25grms force Presser Foot Adjustment BDC 0 1 0 6 mm Thread Feed FWD 200 88 90 mm Needles DBxK5 75 11 Needle Orientation 5 to the right recommended range of 0 20 to the right is acceptable Z Belt Tension...

Page 263: ...indicated or how to install them on the machine These instructions also assume that the technician performing these procedures is fully knowledgeable with the machine parts and their orientations Needle Drive Stud to Reciprocator Fit Measurement 1 Needle drive stud to reciprocator fit is measured in terms of the amount of vertical free play in the needle with the machine powered up 2 Color change ...

Page 264: ...med at the factory with specialized tools and fixtures Please contact your technical support provider for specific instructions Needle to Hook Gap Hook gap repeatability refers to the hook gap on all of the needles compared to the closest needle Measurement See needle to hook gap section in this manual Hook to Rotary Support Gap See hook to rotary support gap section in this manual Take Up Lever S...

Page 265: ...icant resistance in the rotation replace the take up levers Take Up Lever Endplay Measurement Take up lever endplay refers to the left or right play of the take up levers on the take up lever shaft Measure the endplay by sliding the take up levers all the way to the right and measure the distance be tween the right edge of the last take up lever to the retaining clip This distance cannot exceed th...

Page 266: ...orce 2 Using a force gauge PN 995591 01 measure the amount of pull force it takes to lift the take up lever up to a point just before it hits a hard stop Do not allow the take up lever to hit the hard stop or the measurement will be inaccurate Adjustment If the measurement is not between 1 4 to 1 5 lbs readjust the preload on the take up lever spring Color Change Lead Screw Measurement 1 The strai...

Page 267: ... the base of the assembly just enough so that you can move the assembly 2 Position the assembly to obtain the required squareness and then re measure the color change housing location After adjusting the squareness of the color change housing it needs to be checked that the take up lever drive gear still clears all 16 take up levers Should this not be the case the drive gear needs to be readjusted...

Page 268: ...cally and false bobbin and other errors result If this happens replace the bobbin thread with a new spool and recheck the bobbin tension Presser Foot Adjustment at Bottom Dead Center Measurement Measure the presser foot adjustment at bottom dead center BDC without a hoop installed This is the distance from the bottom of the presser foot to the top portion of the needle plate dome Use a feeler gaug...

Page 269: ...be tween 88 90 mm Needles The quality and type of needles used can greatly affect the operation of the machine and nee dles which have burrs worn tips or that are bent should not be used Needle Orientation Embroidery needles have a front and a backside The needle must be installed correctly or the sewing quality will suffer The front of the needle has a long groove while the back has an in dented ...

Page 270: ...be checked for thread clean 50 times If the thread breaks or begins to fray prior to the end of 50 strokes then the area checked is not thread clean The affected part will require replacement 2 Only the section of parts where thread will pass over or through is required to meet thread clean standards Z Belt Tension Z belt tension is most accurately measured using a BRECO meter Should a BRECO meter...

Page 271: ...ension is 45 50 Hz or 8 1 0 3 lbs with the force gauge The x beam must be pushed all the way to the front of the machine when using the gauge The measure ment should be taken at the center of the Y belt Should the belt tension be out of the specified range it needs to be re tensioned Use the guidelines out lined in Y Axis Timing Belt Tensioning Proper Lubrication of Moving Parts Check all moving p...

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