Illustrated Parts Manual
for the EMT 10/4
embroidery peripheral
• A Complete Illustrated Parts Manual
• Trimmer and Non-Trimmer Machines
• Tubular
•
Part Number 110278-01, Revision E
1575 West 124th Avenue
Denver, Colorado 80234
United States of America
E-mail: publications@melco.com
© Copyright 1997, 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.
Printed in the United States of America
Revision A, April 1997
Revision B, July 1997
Revision D, January 1998
Revision E, July 1998
110278-01, Rev. E Illustrated Parts Manual
Covers/Table Top (1 of 4) 1-1
Covers/Table Top (2 of 4) 2-1
Covers/Table Top (3 of 4) 3-1
Covers/Table Top (4 of 4) 4-1
Keyboard Panel 5-1
Start/Stop Panel 6-1
Fluorescent Lights 7-1
Sewing Head (Head 1) 8-1
Sewing Head (Heads 2-4) 9-1
Color Change 10-1
Thread Tree 11-1
Gearbox 12-1
Needle Case (1 of 2) 13-1
Needle Case (2 of 2) 14-1
Needle Case Linear Drive 15-1
Thread Tensioner 16-1
Arm and Bed 17-1
Reciprocator 18-1
Bobbin Idler 19-1
Take-Up Drive Lever 20-1
Grabber Blade 21-1
Grabber Motor 22-1
Cutter/Picker 23-1
Trimmer Drive 24-1
X-Beam (1 of 3) 25-1
i-i
Page
Description Number
Table Of Contents
i-ii
X-Beam (2 of 3) 26-1
X-Beam (3 of 3) 27-1
Y-Drive Motor 28-1
Y-Drive 29-1
Z-Drive (1 of 2) 30-1
Z-Drive (2 of 2) 31-1
Z-Drive Mount 32-1
Encoder Plate 33-1
Left Y-Carriage 34-1
Y-Idler Pulley 35-1
Right Y-Carriage 36-1
Center Y-Carriage 37-1
Electronic Cage (1 of 2) 38-1
Electronic Cage (2 of 2) 39-1
Power Supply 40-1
Motor Amplifier 41-1
AC Power Distribution 42-1
Cap Frame Mounts 43-1
Harnesses (1 of 5) 44-1
Harnesses (2 of 5) 45-1
Harnesses (3 of 5) 46-1
Harnesses (4 of 5) 47-1
Harnesses (5 of 5) 48-1
OPTIONS
Melco Cap Frame 49-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Page
Description Number
110278-01, Rev. E Illustrated Parts Manual
Melco Cap Frame Drive 50-1
Melco Cap Frame Gauge 51-1
Wide-Angle Cap Frame (1 of 7) 52-1
Wide-Angle Cap Frame (2 of 7) 53-1
Wide-Angle Cap Frame (3 of 7) 54-1
Wide-Angle Cap Frame (4 of 7) 55-1
Wide-Angle Cap Frame (5 of 7) 56-1
Wide-Angle Cap Frame (6 of 7) 57-1
Wide-Angle Cap Frame (7 of 7) 58-1
Wide-Angle Cap Frame Gauge 59-1
Sash Frame 60-1
Sash Hoops (21cm, 25cm) 61-1
Disk Drive 62-1
Hoop Interface 63-1
Tubular Hoops (44cm x 30cm) 64-1
Index
i-iii
Page
Description Number
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EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
INTRODUCTION
Model and Serial Numbers
The contents of this manual must be understood by the user to ensure that the correct
part for the correct machine model is selected.
Some equipment built by Melco containing the same "common" name may be identified
by more than one model part number. In some cases, a different serial number sequence
is also prevalent between two models of the same machine.
Determine the model number of your machine before you use this manual to order parts.
The machine MODEL number is located on the label that is placed on the front of the
frame, under the table and to right side of the machine.
Remember, although many parts are identical between the various embroidery peripheral
models, this manual should only be used for identifying and ordering parts for the
machines described above.
How To Use This Manual
The manual is divided into several sections, each containing a set of parts most common
to each other, or to a function of the machine.
Figures
Accompanying each section is a figure showing the general area of the machine that is
represented in that section. Parts are identified with letters and numbers in these figures.
Letters contained in circles generally are used to refer the user to a different figure or section of the manual that identifies the assembly with more detail. Part numbers and part
identifications of the numbers inside circles are found on the pages adjacent to the figure.
Item Numbers
All the numbers in circles on a diagram are listed in the first column of the parts listing
accompanying that figure. Each item number in each figure is identified independently in
hopes to help prevent any confusion that may occur by trying to "cross-reference" part
numbers.
Part Numbers
The Melco part number is found in the second column of the parts list, directly in line
with each item number from the first column.
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110278-01, Rev. E Illustrated Parts Manual
Part Descriptions
Each part listed has a descriptive name in the third column of the parts listing. Hardware
(such as screws, washers, etc.) are described by size in order to help the user to identify
common hardware items that can be obtained by local sources if desired.
Special Parts Handling
If care is not taken in handling certain parts of the sewing head, there is a high probability
that the sewing head will not function properly or the parts will fail prematurely.
These parts are to have special handling considerations from the vendor, through quality
control inspection, into spare parts inventories, then on to packaging for shipping, and
finally to installation.
Handling of these parts (and for that matter all parts), is not limited to the considerations
below. Please use common sense, good judgement, and accepted handling practices in
handling all parts. If you have any questions or concerns, please call your area service
department.
General Considerations
* Painted and coated surfaces need to be protected from dirt, other foreign matter,
nicks, and scratches.
* Non-painted and coated surfaces must not be touched by the human hand, to pre-
vent corrosive body oils, dirt, and other foreign matter from contaminating the surfaces.
* Protect all bearings, bushings, cams, rails, gears, rollers, needle bars, pins, studs,
connecting rods, guide shafts, and other surface finishes from dirt, other foreign
matter, marring, scratches, and nicks, etc.
* Bearing surfaces and shaft bore surfaces need to be thoroughly cleaned and mat-
ing parts oiled before assembly.
Printed Circuit Boards
Printed circuit boards are packaged and shipped in anti static bags. The components of
the printed circuit boards are sensitive to static electrical discharges. The use of standard
anti static precautions is recommended.
i-vi
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Special Packaging
Several parts are packaged in specially sealed packages. These packages keep lubricant on
the parts and protect them from contamination during shipment. To install these parts,
clean your hands and place a small amount of sewing machine oil on your fingers to kept
the integrity of the part intact.
Index
Hardware not listed can be found by identifying a related part and refering to that page.
CAUTION: When purchasing hardware from a source other than Melco,
it is the user's responsibility to ensure that such hardware is of sufficient quality and grade to meet or exceed Melco's original equipment
hardware. Melco assumes no liability for the use of inadequate hardware that was purchased by and/or installed by other than an authorized Melco factory representative.
110278-01, Rev. E Illustrated Parts Manual
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1-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Covers/Table Top (1 of 4)
Figure 1
1-2
110278-01, Rev. E Illustrated Parts Manual
Covers/Table Top (1 of 4) Reference Figure 1
Item Part Item
No. Number Description Comments
A 010233-01 Keyboard See Page 5-1
B 010229-01 Disk Drive See Page 62-1
C 010258-01 Start/Stop Panel See Page 6-1
1 010246-01 Cover, Tensioner Bracket, Left
2 010244-03 Cover, Rear, Tensioner
3 010245-02 Cover, Tensioner Bracket, Right
4 009458-01 Cover, Spacer, Lower
5 006802-01 Damper, Spacer Cover
6 343109-01 Grommet, Rubber
7 008495-01 Bushing, Insulating, Miniature
8 010171-08 Screw, Socket Head Cap, M4 x 0.7 x 8mm, Zinc Plate
9 003197-01 Screw, Thread Form, #8 x 1/2"
10 010912-01 Cover, Grabber
11 010171-30 Screw, Socket Head Cap, M4 x 0.7 x 30mm, Zinc Plate
12 690427-04 Washer, Lock, Split, M4
13 690439-04 Washer, Flat, M4
14 010167-04 Washer, External Star, M4
15 011111-01 Cable, Ground, 4.75”, #8
16 009561-04 Nut, Kep, M4
17 10835 Clamp, Cable, X-Axis
18 010171-20 Screw, Socket Head Cap, M4 x 0.7 x 20mm, Zinc Plate
19 010622-02 Bracket, Tube, Thread
20 690811-38 Washer, Lock, Internal Star, #8
2-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Covers/Table Top (2 of 4)
Figure 2
2-2
110278-01, Rev. E Illustrated Parts Manual
Covers/Table Top (2 of 4) Reference Figure 2
Item Part Item
No. Number Description Comments
1 006848-01 Shelf, Half, Frame, Black
2 010171-12 Screw, Socket Head Cap, M4 x 0.7 x 12mm, Zinc Plate
3 011148-01 Screw, Shoulder, 10-32, Modified
4 009167-03 Cover, X-Drive Mounting, Center
5 009859-03 Brace, Table, Left
6 009860-03 Brace, Table, Right
7 009166-04 Cover, Y-Drive Mounting, Right
8 006863-01 Mat, Rubber
9 010604-03 Cover, Y-Drive Mounting, Left
10 690427-04 Washer, Lock, Split, M4
11 010572-04 Washer, Flat, M4
12 010172-16 Screw, Socket Head Cap, M5 x 0.8 x 16mm, Zinc Plate
13 690427-05 Washer, Lock, Split, M5
14 690439-05 Washer, Flat, M5
15 010167-04 Washer, External Star, #4
16 001955-17 Ring, Retainer, External, .25” ID
17* 010954-01 Shim, .020” Thick, End Y-Drive Cover
18* 010955-01 Shim, .032” Thick, End Y-Drive Cover
19* 010956-01 Shim, .020” Thick, Center Y-Drive Cover
20* 010957-01 Shim, .032” Thick, Center Y-Drive Cover
21* 006672-01 Spacer, .401” ID x .75” OD x .015” Thick, Stainless Steel
22 010572-05 Washer, Flat, M5
23 010172-12 Screw, Socket Head Cap, M5 x 0.8 x 12mm, Zinc Plate
Note: *Items 17-21 are used as needed
3-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Covers/Table Top (3 of 4)
Figure 3
3-2
110278-01, Rev. E Illustrated Parts Manual
Covers/Table Top (3 of 4) Reference Figure 3
Item Part Item
No. Number Description Comments
A 010185-02 Table Tops See Page 4-1
1 010008-02 Cover, Left Rear Channel
2 010171-12 Screw, Socket Head Cap, M4 x 0.7 x 12mm, Zinc Plate
3 010007-03 Cover, Z-Drive Motor
4 010006-03 Cover, Right Rear Channel
5 690427-04 Washer, Lock, Split, M4
6 690439-04 Washer, Flat, M4
7 010019-01 Guard, Z-Drive
8 010171-08 Screw, Socket Head Cap, M4 x 0.7 x 8mm, Zinc Plate
9 010496-04 Cover, Under Bed
10 010235-20 Plug, Hole, 1.5”
4-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Covers/Table Top (4 of 4)
Figure 4
4-2
110278-01, Rev. E Illustrated Parts Manual
Covers/Table Top (4 of 4) Reference Figure 4
Item Part Item
No. Number Description Comments
1 10327 Table Top, Left, Front
2 009271-01 Table Top, Center, Drive
3 10328 Table Top, Right, Front
4 010009-01 Insert, Table
5 006840-01 Guide, Table, Insert
6 006839-01 Retainer, Table Insert
7 005340-01 Stiffener, Insert, Table Top
8 006841-01 Guide, Table Insert
9 690034-03 Washer, Flat, #10
10 690033-03 Washer, Lock, Split, #10
11 670038-08 Screw, Socket Head Cap, 10-32 x 1/2"
12 009255-03 Support, Right Y-Drive Table
13 010616-03 Support, Left Y-Drive Table
14 009256-01 Support, Center X-Drive Table
15 009157-01 Knob, Locking, 1/4-20
16 010408-03 Tape, Adhesive, 18-7/8”
5-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Keyboard Panel
Figure 5
5-2
110278-01, Rev. E Illustrated Parts Manual
Keyboard Panel Reference Figure 5
Item Part Item
No. Number Description Comments
1* 009309-02 Panel, Keyboard
2* 009448-04 PCB, Keyboard, Assembly
3 009561-04 Nut, Kep, M4
4 010484-25 Standoff, M/F, M3 x 25mm
5* 009017-02 Keycap, Vertical Arrow
6* 009017-06 Keycap, Color Change
7* 009017-08 Keycap, Enter
8* 009017-03 Keycap, Menu
9* 009017-04 Keycap, Alt
10* 009017-01 Keycap, Horizontal Arrow
11* 009017-05 Keycap, Jog
12* 009017-07 Keycap, Fast/Slow
13 010920-01 Template, Panel (domestic only)
14 004648-01 Washer, Flat, #10, .203” ID x .443” OD x .06” Thick
15 11223 Knob, Extension Pot
Note: The following can be replaced as a factory built assembly:
*010233-01 Keypad, Panel, Assembly
6-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Start/Stop Panel
Figure 6
6-2
110278-01, Rev. E Illustrated Parts Manual
Start/Stop Panel Reference Figure 6
Item Part Item
No. Number Description Comments
1* 010339-01 Switch, Momentary, w/Full Guard
2* 010338-01 Switch, Pushbutton, Momentary
3* 010257-01 Cover, Spacer, Tensioner Bracket
4* 009144-01 Pushbutton, Emergency Stop
5* 009145-01 Block, Contact, Emergency Stop
6* 009143-01 Plate, Emergency Stop
7* 009081-01 Lens, Push Button, White, Start
8* 009081-02 Lens, Push Button, Black, Stop
9* 009081-03 Lens, Push Button, Gray, Frame
10* 010159-01 Switch, Contact Block
11 010919-01 Template, Panel, Start/Stop (domestic only)
Note: The following can be replaced as a factory built assembly:
*010258-01 Panel, Start/Stop, Assembly
7-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Fluorescent Lights
Figure 7
7-2
110278-01, Rev. E Illustrated Parts Manual
Fluorescent Lights Reference Figure 7
Item Part Item
No. Number Description Comments
1 006799-01 Bracket, Support, Light
2 690439-05 Washer, Flat, M5
3 003573-05 Nut, Hex, M5
4 011198-12 Screw, Flat Head Socket, M5 x 0.8 x 12mm, Zinc Plate
5 010172-16 Screw, Socket Head Cap, M5 x 0.8 x 16mm, Zinc Plate
6* 010267-01 Fixture, Set, Light, Fluorescent
7 007059-01 Bumper, Light
8 340743-03 Cable Clamp, 1/4”
9 690427-05 Washer, Lock, Split, M5
10 007068-01 Cable, Cord, Fluorescent Lights
Note: The following can be replaced as a seperate item:
11171 Bulb, Fluorescent, 3 Ft.
8-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Sewing Head (Head 1)
Figure 8
8-2
110278-01, Rev. E Illustrated Parts Manual
Sewing Head (Head 1) Reference Figure 8
Item Part Item
No. Number Description Comments
A -------------- Needle Case See Pages 13-1 & 14-1
B 010261-02 Thread Tensioner See Page 16-1
C 010234-01 Color Change See Page 10-1
D 010231-01 Thread Tree See Page 11-1
1 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6mm
2 006529-01 Set, Cover, Rotary Hook
3 006034-21 Cover, Bed, Rear
4 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8mm
5 007526-01 Cover, Bed, Front
6* 005704-01 Tubing, .125" ID x .187" OD
7 004779-01 Key, Color Change Mount
8* 005702-01 Guide, Thread, Thread Tree
9 010171-20 Screw, Socket Head Cap, M4 x 0.7 x 20mm, Zinc Plate
10 690427-04 Washer, Lock, Split, M4
11 690439-04 Washer, Flat, M4
12 10320 Cover, Drive, Color Change, Right
13 10322 Cover, Drive, Color Change, Left
14 010171-08 Screw, Socket Head Cap, M4 x 0.7 x 8mm, Zinc Plate
15 005707-01 Clip, Tubing
16 009801-01 Clamp, Needle Case Linkage
17 009800-01 Shaft, Needle Case Linkage
18 010171-14 Screw, Socket Head Cap, M4 x 0.7 x 14mm, Zinc Plate
19* 009802-01 Pillar, Head Support
20* 010178-08 Nut, Hex, M8
21 10547-08 Washer, Head
22 690427-08 Washer, Lock, Split, M8
23 690439-08 Washer, Flat, M8
24 690439-03 Washer, Flat, M3
25 010171-20 Screw, Socket Head Cap, M4 x 0.7 x 20mm, Zinc Plate
26 010448-01 Bracket, Wire Loom (position for heads 1&3)
27 001935-10 Screw, Flat Head Phillips, M3 x 0.5 x 10mm
Note: The following can be replaced as a factory built assembly:
*006937-01 Tubing, Thread Tree, 24", Assembly
9-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Sewing Head (Heads 2-4)
Figure 9
9-2
110278-01, Rev. E Illustrated Parts Manual
Sewing Head (Heads 2-4) Reference Figure 9
Item Part Item
No. Number Description Comments
A -------------- Needle Case See Pages 13-1 & 14-1
B 010261-02 Thread Tensioner See Page 16-1
C 010234-01 Color Change See Page 10-1
D 010231-01 Thread Tree See Page 11-1
1 003136-06 Screw, Button Head Socket, M3 x 0.5 x 6mm
2 006529-01 Set, Cover, Rotary Hook
3 006034-21 Cover, Bed, Rear
4 003509-08 Screw, Button Head Socket, M4 x 0.7 x 8mm
5 007526-01 Cover, Bed, Front
6* 005704-01 Tubing, .125" ID x .187" OD
7* 005702-01 Guide, Thread, Thread Tree
8 010171-20 Screw, Socket Head Cap, M4 x 0.7 x 20mm, Zinc Plate
9 690427-04 Washer, Lock, Split, M4
10 005707-01 Clip, Tubing
11 009801-01 Clamp, Needle Case Linkage
12 009800-01 Shaft, Needle Case Linkage
13 010171-10 Screw, Socket Head Cap, M4 x 0.7 x 10mm, Zinc Plate
14 010171-14 Screw, Socket Head Cap, M4 x 0.7 x 14mm, Zinc Plate
15 010167-04 Washer, External Star, M4
16 340743-02 Clamp, Cable, Nylon, 3/16” ID, Black
17 011137-02 Cover, Rear Take-up Lever
18 008129-30 Standoff, M/F, M4 x 0.7 x 30mm
19 010448-01 Bracket, Wire Loom (direction for heads 2&4)
20 011141-01 Cable, Ground, Braided
21 001935-10 Screw, Flat Head Phillips, M3 x 0.5 x 10mm
22 690439-04 Washer, Flat, M4
23 690439-03 Washer, Flat, M3
Note: The following can be replaced as a factory built assembly:
*006937-01 Tubing, Thread Tree, 24", Assembly
10-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Color Change
Figure 10
10-2
110278-01, Rev. E Illustrated Parts Manual
Color Change Reference Figure 10
Item Part Item
No. Number Description Comments
1* 003504-01 Belt, Timing, 39T, 1/5P
2 005034-02 Screw, Set, Cup Point, M4 x 0.7 x 4mm
3* 008059-01 Pulley, Timing, 5.08mmP, 12 Groove
4 008129-35 Standoff, Hex, M-F, M4 x 0.7 x 35mm
5* 009411-02 PCB, EMT, Color Change, Assembly
6 670174-08 Screw, Pan Head Phillips, 6-32 x 1/2"
7 690033-36 Washer, External Star, #6
8* 010243-01 Housing, Drive, Color Change
9 690034-36 Washer, Flat, #6
10* 000465-01 Motor, X-Y Servo
11 008062-01 Clamp, Split-Hub, 8mm ID
12* 006485-01 Shaft, Cam, Color Change
13* 007574-01 Washer, Thrust, 1.00mm Thick
14* 008061-01 Bearing, Thrust, 8mm
15 001927-08 Screw, Set, Socket, Flat Point, M5 x 0.8 x 8mm
16* 008056-01 Cam, Color Change
17* 007573-01 Washer, Thrust, 2.75mm Thick
18* 008060-01 Pulley, Timing, 5.08mmP, 16 Groove
19 702876-08 Spacer, Shaft, 5/16" ID x .016" Thick
20 008129-38 Standoff, Hex, M-F, M4 x 0.7 x 38mm
21 008129-48 Standoff, Hex, M-F, M4 x 0.7 x 48mm
22 005034-01 Screw, Set, Cup Point, M4 x 0.7 x 6mm
Note: The following can be replaced as a factory built assembly:
*010234-01 Color Change, Assembly
11-1
EMT 10/4 Embroidery Peripheral Melco Embroidery Systems
Thread Tree
Figure 11
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