Melco Bravo User manual
Technical Manual
Rev 082115
2 of 271
Contents
Copyright Notice 9
About This Manual 10
Scope of Manual 11
Standard Conventions and Denition of Terms 12
Regulatory Notices 13
Best Maintenance Repair Practices 14
Maintenance Philosophy: 14
Grounding and Static Electricity 17
Machine Orientation 19
Safety Issues 20
Warranty Considerations 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
LED Indicator 30
Specications 31
Technical Specications 33
Torque Specications 34
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Software Maintenance Menus 36
Special Tools and Fixtures 37
General Maintenance 38
Cleaning 38
Lubrication Schedule and Specications 40
Maintenance Schedule 40
Daily Maintenance 42
Weekly Maintenance 43
Monthly Maintenance 45
Quarterly Maintenance 51
Thread Cutter Blade Replacement 61
Centering The Needle Plate 62
Head Up Position Adjustment 63
Mechanical Head-Up Position 63
Adjusting Head-Up (Z-Home) Position: 64
Hook Timing Inspection/Adjustment 65
Rotational Hook Timing Inspection Procedure 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 Specications 81
Adjusting an X-Cable that is Tensioned Outside the Required Specications 82
Y-Axis Timing Belt Tensioning 84
Y-Axis Belt Tension Inspection 84
Y-Axis Belt Tension Adjustment 85
When Belt Tensions are Correct 85
Y-Motor Timing Belt Tensioning 86
Inspection and Adjustment 86
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Z-TIMING: Bottom Center & Head-Up 87
Bottom Center (Z Timing) 87
Z-Drive Belt Tensioning 92
Inspection and Adjustment 92
Z-Home Adjustment 94
Procedure to Identify the Closest Needle 95
Needle Case Calibration 98
Fine calibration procedure: 98
Rough Calibration Process: 99
Rotary Hook Support Adjustment 101
Inspection Procedure 101
Adjustment Procedure 103
Color Change, Take-Up, Feeder Housing Assembly 105
Replacement Procedure for Entire Color Change/Take-Up/Feeder Assembly: 105
Color Change 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 Cluster PCB Replacement 118
Presser Foot Assembly Replacement 119
Reciprocator 122
Replacement Procedure 122
Take-Up Lever Cam Replacement 124
Replacement Procedure 124
Z-Drive Repair and Adjustment 127
Z-Drive Belt Replacement and Tensioning 127
Z-Home Sensor PCB Replacement 129
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Z-Belt Idler Assembly Replacement 131
Z-Motor Assembly 132
Clearing Thread from Thread Feeder Roller 135
Color Change Spindle Mounting Bracket Replacement 137
Grabber Blade Replacement 139
Needle Case Removal 142
Needlecase Installation 144
Grabber Stepper Motor Replacement 146
Take Up Lever Replacement 147
Thread Feeder (replacement and adjustment) 149
Thread 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
Grabber/Threadfeed/CC Home Harness 179
Laser Harness 182
LED Cluster Harness 184
Replacement Procedures: 184
Thread Break Harness 188
Z Home Harness 191
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User Interface Harness 193
X/Y Home Harness 195
Bearing Block Assemblies 197
X-Beam Assembly 199
X-Carriage Assembly 201
X-Drive Cable Removal 203
X-Drive Cable Installation 205
X-Drive Motor Replacement 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
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Test Designs 235
Thread Tension Test 236
Belt Tension Test 237
Long Stitch Test 237
Looping Test 237
Orientation Test 238
Registration Test 238
Small Alphabet Test 238
Thread Break Sensor Test 239
Thread Break Test 239
Trimmer Test 240
Electrical Failures 241
AC Power Failure 241
Color Change Failures 241
LED Cluster Assembly Failures 242
Machine Initialization Failure 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 Error 257
Hoop Center Error 257
Stepper Motor Time Out and Index Errors 257
E-Stop Engaged 258
Servo Motor Errors (Move Time Out, Tracking, and Over Current Errors) 260
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Critical Measurements 262
Introduction 262
Needle Drive Stud to Reciprocator Fit 263
Hook Timing 263
Upper Arm to Lower Bed Alignment 263
Needle to Hook Gap 264
Hook to Rotary Support Gap 264
Take-Up Lever Stroke 264
Take-Up 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 Moving Parts 271
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Copyright Notice
© Copyright Melco, 2014
ALL RIGHTS RESERVED. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise)
without prior written approval from the author. The author reserves the right to revise this publication
and to make changes in it at any time without obligation of the author to notify any person or organiza-
tion of such revisions or changes.
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. 6,823,807
• U.S. 5,603,462
• U.S. 5,832,853
• U.S. 6,445,970 B1
• U.S. 6,732,668 B2
• U.S. 6,729,255
• U.S. 6,871,605
• U.S. D 474,785 S
• U.S. 6,736,077 B2
• CH 693569 A5
• EP 0 666 351 B1
• more patents pending
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About This Manual
This manual contains instructions on repairs and adjustments to the embroidery machine, in addition to
other technical information.
If you do not fully understand any information in this manual, you are advised to contact your local au-
thorized technical support provider for assistance.
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