Melco EMT 10/4 User manual

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

1575 West 124th Avenue
Denver, Colorado 80234
United States of America
E-mail: [email protected]
© Copyright 1998 by Melco Embroidery Systems
ALL RIGHTS RESERVED No part of this publication may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or
otherwise) without prior written approval of Melco Embroidery Systems. Melco reserves the right
to revise this publication and to make changes in it at any time without obligation of Melco to
notify any person or organization of such revisions or changes.
All precautions have been taken to avoid errors or misrepresentations of facts, equipment, or
products. However, Melco does not assume any liability to any party for loss or damage caused by
errors or omissions.
All trademarks and trade names contained within this publication are the property of their respec-
tive owners.
Printed in the United States of America
Revision A, November 1998

Table of Contents
General
EMT 10T Specifications iv
EMT 10/4 and 10/4T Specifications v
Explanation of Symbols vi
1. Installation
Unpacking 1-1
Moving the Peripheral 1-4
Cart Assembly (EMT 10T only) 1-6
Installing the Tabletop (EMT 10/4 and 10/4T only) 1-8
Connecting cables 1-10
First Powerup 1-13
Support Brackets (EMT 10/4 and 10/4T only) 1-15
2. Operation
Hazards of Operation 2-2
Threading 2-4
Tensions 2-5
Keypad 2-6
The Menus 2-8
Main Operator Menu 2-8
Disk Directory Menu 2-8
Design Menu 2-8
Color Menu 2-8
Run Design Menu 2-8
Function Menu 2-9
Options Menu 2-10
Frame Menu 2-12
Reset Menu 2-12
Service/Maintenance Menu 2-12
Head Timing Menu 2-13
4 Hr Lubrication Menu 2-14
8 Hr Lubrication Menu 2-14
40 Hr Lubrication Menu 2-14
80 Hr Lubrication Menu 2-14
480 Hr Lubrication Menu 2-14
2100 Hr Lubrication Menu 2-14
Table of Contents
i

Configuration Menu 2-15
Move Function Menu 2-17
Define Custom Hoop 2-18
Test Mode 2-18
Diagnostics Menu 2-19
Disk Drive 2-19
Loading a Design 2-21
Hooping 2-22
Quick Start 2-23
Set Home 2-23
Select Hoop 2-23
Select Orientation 2-23
Center Hoop 2-23
Attach Hoop 2-24
Select a Design 2-26
Color Menu 2-26
Run Menu 2-26
Trace the Design 2-26
Start Embroidering 2-27
Embroidery Speed 2-27
Idle Display 2-27
3. Accessories
Standard Cap Frame 3-1
Wide-Angle Cap Frame 3-6
Sash Frame 3-15
Spider Hoops 3-16
Lamps 3-18
Bobbin Winder 3-19
4. Operator Maintenance
Installing a Needle 4-1
Cleaning 4-2
Lubrication 4-3
Time to oil hook 4-3
8 Hr Maintenance 4-4
40 Hr Lubrication Menu 4-5
80 Hr Maintenance 4-5
480 Hr Maintenance 4-8
2100 Hr Maintenance 4-10
Replacement Parts 4-12
Table of Contents
ii

5. Troubleshooting Guide
Thread Breakage 5-1
Skipped Stitches 5-2
Needle Breaks 5-2
Loose Stitches 5-3
6. Error Messages
7. Glossary of Embroidery Terms
Index
Quick Reference Guides
Table of Contents
iii

iv
Single-Head Embroidery Peripheral
EMT 10T Specifications
Maximum embroidery speed
1000 stitches per minute
Number of heads
1
Needles per head
10
Dimensions
114cm W x 92cm H x 89cm D
45" W x 36" H x 35" D
Weight
97.7kg
215 lbs
Shipping weight
136.4kg
300 lbs
Power consumption
100 W
Noise level and test conditions
Equivalent continuous A weighted sound pres-
sure level at 1 meter from the floor is 78db.
The peak C weighted instantaneous sound
pressure level is 77db.
The noise level was measured sewing a test
design at 800 spm.
Recommended power conditioning equip-
ment
LC 1800 Line stabilizer (available from Accesso-
ry Resource Corporation)
Embroidering field size
28 x 50cm (11 x 19.7") with the Sash Frame
26 x 41cm (10.25 x 16.15") with a tubular frame
Options
Cap frame option
Wide-angle cap frame option
Sash frame option
Bobbin winder option
Cart option
Compatibility
EDS III and Wilcom
Intended use
The EMT 10T is designed to embroider on tex-
tile products which are placed easily in a Melco
embroidery hoop. The machine should not be
used on thick leather, wood, plastic, or other
dense material.
The EMT 10T is designed to embroider using
tubular and flat hoops, cap frames, and the
sash frame.

v
Multi-Head Embroidery Peripheral
EMT 10/4 and 10/4T Specifications
Maximum embroidery speed
1000 stitches per minute
Number of Heads
4
Number of needles
10 per sewing head
Dimensions
244cm W x 152cm H x 88cm D
96" W x 60" H x 34.5" D
Weight
332kg
730 lbs
Shipping weight
355kg
780 lbs
Power consumption
400 W
Noise level and test conditions
Equivalent continuous A weighted sound pres-
sure level at 1 meter from the floor is 84db.
The peak C weighted instantaneous sound
pressure level is 84db.
The noise level was measured sewing a test
design at 850 spm.
Recommended power conditioning equip-
ment
LC 1800 Line stabilizer (available from Accesso-
ry Resource Corporation)
Embroidering field size
28 x 40.6cm (11.02 x 16.0") with the Sash Frame
26 x 41cm (10.25 x 16.15") with a tubular frame
Options
Cap frame option
Wide-angle cap frame option
Sash frame option
Compatibility
EDS III and Wilcom
Intended use
The EMT 10/4 and 10/4T are designed to
embroider on textile products which are placed
easily in a Melco embroidery hoop. The
machine should not be used on thick leather,
wood, plastic, or other dense material.
The EMT 10/4 and 10/4T are designed to
embroider using tubular and flat hoops, cap
frames, and the sash frame.

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

Unpacking 1-1
11817 Rev. A 1. Installation
1.Installation
Read the entire manual before operating the machine. Save all packing material; if you ever need
to move the peripheral, use the original packing material.
Unpacking
EMT 10T
Remove the packing straps holding the box together using a knife. Lift off the top of the box, and
then remove the sides of the carton. Remove the plastic bag enclosing the equipment. When the
plastic is off, refer to Figure 1-1 for further instructions.
Prepare the designated area for the peripheral. If you have purchased the cart option, you must
clear a temporary location for the machine (until you have assembled the cart). If you purchased
the foot option, install the 4 feet before removing the machine from the box. Two people are
required to lift the EMT 10T. Refer to Figure 1-2 to locate the hand-holds, and lift as shown in Fig-
ure 1-3.
Figure 1-1
Remove these
boxes (one con-
tains the opera-
tor kit) Remove the
tabletop
Remove these
foam braces Remove these
foam braces
Figure 1-2 Figure 1-3

1-2 Unpacking
Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems
EMT 10/4 and 10/4T
There are two versions of the EMT 10/4 and 10/4T machines, and each are shipped in a different
way. Domestic models are shipped with a “coffin-style” crate surrounding the heads. International
models are shipped in a full crate and are packed on a palette within the crate. Determine which
style you have, and refer to the pertinent section.
Domestic models
Two people are required to unpack the EMT 10/4 or 10/4T. Be careful when unpacking your new
peripheral. On one end of the “coffin-style” crate is a wooden cover that protects the power
switches during shipment (refer to Figure 1-
4). 2 bolts secure this cover to the crate.
remove both bolts, and remove the cover.
Along the back of the crate are 2 “L” shaped
brackets; these brackets hold the crate to the
frame, protecting the heads. Remove the
bolts holding the bracket to the crate, then
remove the bolts holding the bracket to the
frame. When the bolts have been removed,
remove the bracket.
The crate weighs 115lbs (52.3kg) and is very
awkward, so use caution. With one person
standing at each end of the crate, carefully
lift the crate until it is clear of the heads.
Remove the crate. Store all packing materials
and hardware in a safe place. Reuse the
packing materials if you ever relocate the
peripheral. Figure 1-4
Bolts
Wood-
en cover

Unpacking 1-3
11817 Rev. A 1. Installation
International models
Two people and a forklift are required to unpack the EMT 10/4 or 10/4T. Be careful when unpack-
ing your new peripheral. On one end of the crate is a “window” of wood. This end is the door.
Open the door by removing the nails from around the perimeter. Next, remove the nails from
around the bottom perimeter of the box. Slide the crate off the pallet. Use a forklift to lift the
peripheral off the pallet. Place the forks in the locations shown below.
Figure 1-5
Do not make contact with
the motors located here!

1-4 Moving
Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems
Moving the Peripheral
Make sure you leave enough room around your peripheral
to have easy access to all sides.
EMT 10T
Use two people to lift the machine; use the hand-holds
shown in Figure 1-6.
If the machine is on a cart, disengage the brakes on the
indicated wheels before attempting to move the machine.
Engage the brakes when the machine is in the desired
location. Observe the precautions below. You cannot remove the machine from the cart without
first removing the 4 bolts securing the machine to the cart.
Figure 1-7
Push carefully in the
directions shown or
the cart may tip.
Figure 1-6
Brakes

Moving 1-5
11817 Rev. A 1. Installation
EMT 10/4 and 10/4T
Move the machine as indicated below. Disengage the brakes on the indicated wheels before
attempting to move the machine. Engage the brakes when the machine is in the desired location.
Figure 1-8
Push only in the direction of
the arrows when moving
the machine more than a
short distance.
Brakes

1-6 Assembly
Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems
Cart Assembly (EMT 10T Only)
If you purchased the optional cart with the EMT
10T, you must assemble the cart and mount the
peripheral on the cart. The following section
describes how to assemble the cart and attach the
EMT 10T. To dismantle, reverse these steps.
The cart has 5 pieces. They attach as shown in Fig-
ure 1-11. Use the enclosed hardware to build the
cart. Pieces 1, 4, and 5are identical to each other.
Pieces 2and 3are also identical to each other.
Referring to Figure 1-9 and 1-10, lay piece 1on top
of the existing cardboard packaging with the
straight flange pointing down. Attach piece 2 with
wheels on the same end as the straight flange on
piece 1(see Figure 1-10). The wheels with the
brakes on them should be on the ground as shown
in Figure 1-9. Insert the necessary screws (M5
phillips head screw with a flat washer between the
screw and the cart piece) securing them tightly.
Attach piece 3the same way. While standing in
area indicated in Figure 1-9, grasp and carefully lift
cart off of cardboard and place all four wheels onto
floor.
Referring to Figure 1-11, place pieces
4 and 5resting on top of the cross
bars of pieces 2 and 3and piece 4
resting on the straight flange of piece
1. The straight flange of pieces 4 and
5will be placed together in the mid-
dle of the cart assembly. Insert the
necessary screws (M5 phillips head
screw with a flat washer between the
screw and the cart piece) securing
them tightly.
Figure 1-11
1
2
4
3
5
Figure 1-9
1
2
3
x
Stand here
Grasp here
Figure 1-10
Straight flange
1
Bent flange
Straight Flange

Assembly 1-7
11817 Rev. A 1. Installation
Mounting the EMT 10T on the cart
1. Remove the main tabletop.
2. Remove the side covers; there are 5 screws holding each
side cover in place (see Figure 1-12). Use the #2 Phillips
head driver included in the operator kit to remove the
screws.
Caution! The side panels are heavy; if
dropped, damage may occur.
3. Lift the EMT 10T (2 people are required) and carefully place the machine on the “pillars” of
the cart. The 4 holes where the feet attach should be aligned with the 4 holes on the cart’s
pillars. If the holes do not match up then slightly loosen all of the cart screws for flexibility.
4. Secure the machine to the cart using the M6 socket-head cap screws, a flat washer, and a
lock washer (provided with the cart). Refer to Figure 1-13.
Install the flat washer, then the lock washer, then the bolt.
5. Make sure the cart is standing straight, tighten all screws.
6. Replace the side covers.
7. Replace the tabletop (if desired).
Installing the feet
If you have purchased the Foot option with your EMT 10T, refer to these steps to install the feet.
1. Remove the main tabletop.
2. Remove the side covers; there are 5 screws holding each side cover in place (see Figure 1-12).
Use the #2 Phillips head driver included in the operator kit to remove the screws.
Caution! The side panels are heavy; if dropped, damage may occur.
3. Working on one side at a time, raise the machine and support it securely. The machine should
be lifted approximately 4" (10cm).
4. Install the 4 “feet” on the peripheral (see Figure 1-14). Turn
the indicated flat section of the stem with an adjustable
wrench to install or remove the foot on to the peripheral.
5. Place the machine on the surface where you intend to use it,
and level the machine. Adjust the appropriate feet by turning
the stem up or down and sequre with the lock nut against
the peripheral.
Figure 1-12
Screws
Figure 1-14
Turn at
the flats
to adjust
Figure 1-13
lock nut

1-8 Tabletop
Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems
Installing the tabletop (EMT 10/4 Only)
You only need to install the tabletop on the EMT 10/4 if you are going to embroider flat goods or
use the sash frame. To install the tabletop, refer to the instructions below.
The tabletop is shipped in five parts (see Figure 1-15). The two ends and the center section slide
into place in the positions shown in Figure 1-15. The remaining two sections slide into place as
shown in Figure 1-16. This design makes it easy to remove the tabletop to embroider tubular
goods, to embroider with a cap frame, or to perform routine maintenance.
1. Using four thumb screws for each section, slide the right, left, and center sections into the
metal channels on the table. The screws are inserted from the underside of each piece.
2. There is a 2-section shelf and a covering mat that comes with the table top assembly (see Fig-
ure 1-15). Place the shelf pieces on top of the brackets located in the base of the machine and
lay the mat on top of the shelf pieces.
Figure 1-15
2-piece shelf
Rubber
mat
Left section
Center section
Right section

3. Slide the last two pieces into place (see Figure 1-16). They fit on the table support tabs on the
end and center sections.
4. Tighten the thumb screws under the table to secure the pieces.
Special note on the tabletops
You MUST remove all 5 tabletop inserts before embroidering tubular goods or caps
on the EMT 10/4 or 10/4T. Failure to do so may result in damage to the equipment or
bodily injury. You may use parts Aand Bof the tabletop (in Figure 1-16) in the LOW-
ERED POSITION to support heavy garments during tubular embroidery only.
Tabletop 1-9
11817 Rev. A 1. Installation
Figure 1-16
A
B

1-10 Connecting cables
Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems
Connecting cables
Power requirements
Melco suggests using a dedicated line with a line conditioner (available from Accessory Resource
Corporation). Do not use any power cable that appears to be damaged. If your power cable
appears to be damaged, order a new power cable from your Melco representative.
EMT 10T
1. Figure 1-17 shows the power in the ON position. Turn
the power OFF before connecting ANY cables.
2. If your peripheral is equipped with a voltage selector
switch, set it to the correct position for your area.
3. Plug the power cable to the rear of the unit as shown in
Figure 1-18.
4. Plug the other end of the cable into the line conditioner.
5. Connect the line conditioner to the power source.
Note: The fuses have been installed for the voltage in your area; if you use a voltage other than
the factory preset, make sure you replace the factory fuses with appropriately rated fuses.
Refer to Chapter 4 for more information about fuses.
Figure 1-18
Net-
work cable Voltage
selector switch (if
applicable)
Rear of peripheral
Power cable plug
Figure 1-17
ON
(green)
OFF
(red)

Connecting cables 1-11
EMT 10/4
1. Figure 1-17 shows the power in the ON position. Turn the power OFF before connecting ANY
cables.
2. If your peripheral is equipped with a voltage selector switch, set it to the correct position
(115VAC or 220VAC) for your area.
3. Plug the power cable to the leg of the unit as shown in Figure 1-19.
4. Plug the other end of the cable into the line conditioner.
5. Connect the line conditioner to the power source.
Note: The fuses have been installed for the voltage in your area; if you use a voltage other than
the factory preset, make sure you replace the factory fuses with appropriately rated fuses.
Refer to Chapter 4 for more information about fuses.
11817 Rev. A 1. Installation
Figure 1-19
Voltage
selector switch
Power
cable

1-12 Connecting cables
Operation Manual for the EMT 10T, 10/4, and 10/4T Melco Embroidery Systems
Attaching the peripheral to a network
The EMT product line is compatible with Ethernet network technology. With Ethernet, peripherals
connect to a wiring hub, and the hub connects to an EDS III or Wilcom computer. The hub is a
small electronic device that contains a number of cable jacks and diagnostic lights. The peripher-
als, EDS III computers, and Wilcom computers can plug into any port on the hub. You can connect
as many peripherals or computers as your hub can hold. If you have more peripherals or comput-
ers than your hub has ports, you can daisy-chain 2 (or more) hubs together.
Refer to Figure 1-20 for a sample Ethernet network.
*Note: You may have as many licensed EDS III systems operating on an Ethernet network as you
choose. Each computer running EDS III on the network must have a licensed EDS System
(including the dongle) installed to operate properly.
Ethernet hub
EMT 10/12
EMT Products
EDS III
Computer*
EDS III
Laptop*
Each cable may be up to 100 meters (327 feet) long. Hubs may be daisy-chained
for more capacity or distance.
Figure 1-20