z axis error

[Ian]

Second design today my machine stopped halfway through a design. Z axis error. If I try to change to a different needle I get "Machine not head up". I stumped a couple of techs today any ideas here?

Ian

[levelbest]

Big Red or Amaya XT?

Not to get you worried because it could be something else but the motor could be failing. We had a similar issue with 2 of our machines which in both cases lead to having to replace the original (underpowered) motor with a newer high efficiency motor. It wasn't cheap either... I seem to recall 5 or 6 bones for the motor.

[Ian]

John, Thanks for the input. it's an XT. Got the Machine in feb. and not a heck of a lot of hours and no heavy duty stuff on it, so should be under warantee. Support had me reload OS, check sensors and wiring, still nothing. I can turn the Z shaft and everything goes up and down. No other issues other than false bobbing breaks in the original OS. Running great as of late.

[levelbest]

Given the age, doubt its the motor... though the symptoms are the same. We'd be sewing thru a design, the needle would go down and wouldn't come up. We'd get the error. Would have to restart the machine. It would sew for a bit again, and then die.

Hopefully someone can give you some other stuff to try. Glad to hear you are under warranty!

[Ian]

".......the needle would go down and wouldn't come up"

Yes, thats exactly what happened, except it hasn't sewn since. Talked with Sal and Kevin today. I'll call at first light, schedule the travel charge (GRR) and get Queequeg fixed.

[GF]

My machine was about the same age when I started experiecing the same problem. Turned out to be two things -- the fan blade was broken off inside the mother board area and the board had an error when tested so it needed to be replaced. The other thing was the motor was bad so it too was replaced. Since then, the machines have been running excellent. These problems, before corrected, also caused the gear to crack and that too was replaced. That's the snapping sound which occurs when the needles move from one side to the other. This is exactly why one would purchase the Melco extended warranty. Although when this problem happened the first time, it was under the warranty. But I would never want to have to go through this without Melco's technical expertise. Now they are just a phone call away and I've had no problems getting them on the phone or requesting a service call. Worth the annual fee for peace of mind.

GF

[Christine]

I have had all of these problems over the last two and a half years - but kept being told these are teething problems.... (LOL) Don't know any child of 2 without teeth. I did say when the machine was installed and making noises like a ghost ship from Pirates of the Carribean, but was told that this was the noise that these machines made - really??

Presser foot and needle came down on the hoop and again onto the grabber, loads of z-axis errors, loads of thread breaks, loads of bad registration. I suppose I am lucky really - spent in excess of au$27,000 and made at least $200 over the last two years - though I still have the stock that I couldn't fulfil orders for, because the machine wasn't reliable enough to stitch out a design twice the same way resulting in me cancelling the orders. Cost $100's in giving free service because the machine stuffed up two very expensive customer provided shirts and the story goes on....

I had a "preventative maintenance" (anyone heard of one of those) done 4 weeks ago (it was actually a 6 month late annual service). The machine showed me what it was actually capable of for 14 days after that(and it wasn't making the Davey Jones Black Pearl noises) - but hey hoop - 8 z-axis errors on the 15th day 3 of which was able to fix with the head-up command but the other five required turning the needle shaft, and 5 of the 8 were on the same design - ah well I suppose I could become a Melco engineer after all this - at least I'd be earning something!! I can tell my customers "I'll be there in 4 weeks" when their machine has stopped completely and won't go anywhere. I can tell a few "white" lies by telling them that the machine is in perfect order and that's the way it works - looks good sitting in the corner - very impressive and you won't have any creaking noises if you don't turn it on!!

Oh and it seems that I need to pay for the privilege of storing the machine on my premises - got a bill for the "preventative maintenance" too!

Obviously I am not at all impressed with the machine, engineering, support or Melco.

[Ian]

I played "stump the tech" one more time this morning, and it was decided that I'll get a service call and some new parts. It's either Saturday or next Thusrday. So much for a long relaxing weekend.

Ian
btownpixelprint.com
imprimeo.net

[KERRMINATOR]

Ian,
I had the exact same thing happen to me, twice. I was part way through stitching a design and it just stopped for no apparent reason. The needle was all the way up but the arm thing that moves up and down, was about half way up. I'd hit start and it would just squawk, then I'd try hitting start a few other times and it would toggle the grabber, move slightly and just make brief squawk noises. I was confused the first time it happened because nothing showed up on the screen to say why it stopped. I was also unable to click on maintenance in the tools menu because it was greyed out. The second time this happened I pressed start and it squawked a little then a window popped up saying not at headup. I was then able to click on maintenance and go to the head timing menu. Even after doing the headup thing, it still wouldn't start. Eventually we just turned off the machine, closed OS, started the machine up again, then turned back on OS after (so that the machine would go back to where it stopped and not lose the design). When everything booted back up, I hit start, but then it said z-axis tracking error. I went to headup again and hit start. The design stitched ok, I had a lot of false bobbin breaks but that was most likely due to the design. The machine has been fine now for about 3 days.

It concerned me most the first time because I had no idea why it would do that in the middle of a design and one of the first things I thought of was that something in the machine seized (like an engine in a car, when you don't have enough oil in there to keep it running smoothly, and once it seizes, good luck fixing that :-P) I was afraid something wasn't lubricated properly or something. *sigh......who knows, hopefully it won't happen again, but somehow I doubt it. :-D

[Ian]

update:
it was the main board. Brad (the tech) came by Saturday morning and replaced the board calibrated needle possitions and we ran test designs to make sure the motor was OK. Since this was my first tech call, I picked his brain and he showed me some good maintenance tips that went beyond what was taught in basic training. I applaud Melco for helping me get going... even on this holiday weekend. Thank everyone who chimed in here.

Ian