E M T 1 0 T   T r o u b l e   S h o o t i n g   G u i d e

Welcome to EMT10T troubleshooting guide. This guide was written for the domestic version of the EMT10T embroidery machine. The information in this guide is divided into 4 major sections.

1. Section 1, The machine does... , contains items that the EMT10T might do or might not do.
2. Section 2 contains a list of error messages the EMT10T might display. Both of these sections can be used as a starting point in determining what might be wrong with the EMT10T. In both sections under each item is an example of things that might cause the problem. Use these sections to help get an idea of where the problem might be.
3. Section 3 gives a description of the LED's on the front of the machine. Sections 1, 2, and 3 can be used by anyone to get an idea of what is going on with the EMT10T. This may helpful when you need to talk to a Melco representative or technician.
4. Section 4 is the troubleshooting portion of the guide and was written for someone that has a technical background and is comfortable troubleshooting the EMT10T. Please note that not all of the possible failures are listed in this guide. As new problems and solutions come to light they will be added to this guide. If you have any ideas or any solutions that are not listed in this guide, please let us know.

SECTION 1

THE MACHINE DOES...
This is a list of the most common "the machine will do this" problems. Below each one are examples of what could correct the problem. These solutions are what have been found during build and testing of the EMT10T. Not all of the possible solutions are listed and should not be taken as gospel. Troubleshooting should be done to determine the correct solution for the problem.

CC run away -- Color change mechanism runs the needle case left or right and off the head. The encoder is "out of phase" with the motor (See Troubleshooting Section)

	CC cable has bent pins
	CC cable disconnected
	CC motor encoder cable connected backwards
	CC motor connected wrong
	CC flag broke on the cc cam

Disk problems -- (See Troubleshooting Section)

Won't boot off the boot disk - The embroidery machine will not boot off the boot disk.

	Wrong boot disk
	Not a boot disk
	Defective boot disk

No download from disk or read disk -- When a disk is inserted into the disk drive and then an disk error comes up or won't read disk at all

	Bad disk
	Is it HD? should be a low density disk
	Blank
	Disk is bad
	Disk is not inserted properly in disc drive.
	Is the machine configured properly? Ref pg 1-13 in the Ops manual
	Check +5V is above 4.92V when the disk drive is on (green LED on drive)
	Disconnected disk drive cable
	Defective disk drive cable
	Bad disk drive
	Defective CPU PCB

E-stop problem -- E-stop switch is not engaged and the display says "E-STOP ENGAGED" (See Troubleshooting Section)

	Defective E-stop cable
	Loose E-stop cable at E-stop switch
	Loose E-stop cable at power supply assembly
	Defective E-stop fuses
	Defective Estop PCB

Grabber -- does not operate. It will not do a grab function (See Troubleshooting Section)

	Grabber blade hung up any where?
	Grabber guides to tight.
	Grabber guides not aligned properly
	Cable loose or disconnected
	Bent pin in cable connector
	Wire loose on motor
	Grabber sensor or blade mis-adjusted
	LV Driver PCB defective

Grabber noise -- Grabber motor is making noise at idle or when moving (See Troubleshooting Section)

	Wrong configuration?
	Grabber blade hung up any where?
	Loose grabber blade guides ?
	Grabber sensor or blade mis-adjusted
	Defective grabber motor
	LV driver PCB defective

Jump stitch firing at all times -- Jump stitch solenoid stays engaged holding the needle up

	Manual jump stitch lever engaged
	Jump stitch solenoid not adjusted properly
	Jump stitch solenoid plunger stuck
	Pinched or defective cable
	Bad ribbon cable from CC PCB to the tensioner or between tensioners
	LV driver PCB defective
	CPU PCB defective

Loosing configuration -- The embroidery machine cannot remember what it is

	Old software
	Old/down rev CPU
	Defective battery on CPU

Loosing origin -- The sew field seems to drift in any direction while the machine is running

	Old PCB revision
	Defective interface PCB
	Defective motor driver PCB
	Defective X motor
	Noise problem - check for damaged connectors and cabling

No power -- When the machine is turned on nothing happens (See Troubleshooting Section)

	Not plugged in
	Blown fuse in power entry
	Customers circuit breaker is tripped
	Power supplies dead

Keyboard display does not change -- The keyboard display will not accept any keystrokes, Its locked up

	Keyboard switch stuck
	Loose power connector at the display PCB
	Defective keyboard display PCB
	Defective CPU PCB

Trimmer on head will not work -- The trimmer on the head will not fire when a trim function is performed (See Troubleshooting Section)

	Machine is configured wrong
	Trimmer is turned OFF
	A birds nest has occurred
	Head switch is in the OFF position
	Trimmer wiring pinched
	Cable not connected
	Harness not plugged into backplane
	Defective LV PCB
	Defective cutter solenoid

Voltages wrong -- When measured at the test points, the machine voltages are not measuring right (See Troubleshooting Section )

	110/220 switch in 220 position (International machines only)
	Power supplies bad

X home sensor not working -- The X home sensor is not functioning properly. Machine may have a problem setting home (See Troubleshooting Section)

	6volt ISO voltage low or absent
	X home sensor dirty
	X home sensor loose
	X home sensor not adjusted properly
	X home sensor not connected
	X flex cable not connected or defective
	X beam/rack PCB bad
	Interface PCB defective
	CPU PCB defective
	Mother board PCB bad

X run away -- The X rack will jog to one side and hit a hard stop (See Troubleshooting Section)

	Encoder on X motor not connected
	Encoder not connected properly
	Pinched wire on encoder
	Loose wire on encoder
	Encoder cable loose
	X flex cable loose
	X flex cable not connected properly

Y run away -- The Y rack will jog to one side and hit a hard stop (See Troubleshooting Section)

	Encoder on Y motor not connected
	Encoder not connected properly
	Pinched wire on encoder
	Loose wire on encoder
	Encoder cable loose
	Encoder cable not connected at backplane or loose

Z run away -- The needle will start moving up and down quickly with out being told to do so (See Troubleshooting Section )

	Encoder on Z motor not connected
	Encoder not connected properly
	Pinched wire on encoder
	Loose wire on encoder
	Encoder cable loose
	Encoder defective

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SECTION 2

DISPLAYED ERROR MESSAGES
This section contains some of the most common displayed errors, what they are and what may cause them. Like section 1, not all of the solutions are listed. These solutions were found during build and test of the EMT10T and provide an idea of what to look for. Complete troubleshooting of the problem needs to be done to determine the correct solution.

Bad Design Name -- The machine could not find the design name when the start key is pressed

Auto delete ON

Boot Disk Error -- When a boot disk is inserted and this message is displayed

	Bad disk
	Wrong disk HD vs. SD/DD

Cap Driver In error -- Displayed when NO cap driver is in

	Cap driver wire under head shorted to ground
	Bad interface PCB

CC move timeout -- Machine didn't complete a color change in 5 seconds (See Troubleshooting Section )

	Mechanical bind in color change assembly
	Bad LV driver PCB
	Bad cc PCB
	Interface PCB bad

Check Bobbin -- (See Troubleshooting Section )

	UTC not adjusted properly
	Bad UTC
	Interface PCB bad

Color Change Axis Current Limit -- Color change electronics detect excessive current draw (See Troubleshooting Section)

	Mechanical bind in color change assembly
	Bad LV driver PCB
	Bad cc PCB
	Interface PCB bad

DSP command error -- Motor controller received an invalid command sequence.

Bad CPU PCB

Disk Dir. Error --

	Disk is bad
	Disk is wrong format

Disk Load Error --

	Disk is bad
	Try cleaning drive with disk drive cleaning kit

E-Stop engaged error -- E-stop switch is not engaged but this error is displayed (See Troubleshooting Section )

	Bent pin on connector to E-stop PCB
	Fuse F1 blown on e-stop PCB
	Cable not connected at E-stop PCB
	E-stop switch wired wrong
	F3 missing
	CPU bad

Grabber Axis Current Limit -- Grabber electronics detect excessive current draw (See Troubleshooting Section )

	Grabber binding
	Grabber motor bad
	LV driver PCB bad

Grabber not home -- (See Troubleshooting Section )

	Flag not adjusted properly
	Grabber hung up in Velcro
	Encoder connected backwards

Not at head up error -- Machine is not at head up while trying to perform a X, Y, color change, or trim function (See Troubleshooting Section )

	Shorted trimmer solenoid
	Z encoder mis-adjusted
	Z encoder coupler broke

Off color index -- (See Troubleshooting Section )

	Loose pulley
	Cc motor encoder backwards
	Cabling not connected or bad
	Bad CC motor
	Bad LV driver
	Bad CC PCB

Thread break -- (See Troubleshooting Section )

	Loose tension - upper
	Loose tension - lower
	Check spring wrong side of post
	Defective interface PCB

Trimmer not home -- (See Troubleshooting Section)

	Mis-adjusted sensor
	Sensor wired wrong
	Loose wire
	Defective sensor or PCB

X axis limit -- (See Troubleshooting Section )

	Mechanical bind
	Pinched wires
	Winding shorted out in motor
	Defective motor driver PCB

Y axis limit -- (See Troubleshooting Section )

	Mechanical bind
	Pinched wires
	Winding shorted out in motor
	Defective motor driver PCB

Z axis limit -- (See Troubleshooting Section)

	Mechanical bind
	Pinched wires
	Winding shorted out in motor
	Defective motor driver PCB

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SECTION 3

LED STATUS

LEDS STATUS REMARKS

Yellow LED's

	CUT HD#1 OFF Will come ON when trimming
	CUT HD#2 OFF Not used on EMT10
	CUT HD#3 OFF Not used on EMT10
	CUT HD#4 OFF Not used on EMT10
	UTC #1 OFF UTC installed ( blinks when sewing )
	UTC #2 ON Not used on EMT10
	UTC #3 ON Not used on EMT10
	UTC #4 ON Not used on EMT10
	CAP OFF Not installed (ON when installed)
	WA CAP OFF Not installed (ON when installed)

Green LED's

	X HOME *** ON or OFF depending where the X rack is
	Y HOME *** ON or OFF depending where the Y rack is
	GRABBER HOME OFF when at HOME, ON when not at HOME
	XYZ MOTOR BREAKS On until motors are initiated, then they are off
	COLOR CHANGE & GRABBER MOTOR BREAKS On until motors are initiated, then they are off
	X HALL ON Motor hall switches good
	Y HALL ON Motor hall switches good
	Z HALL ON Motor hall switches good
	WATCH DOG (WD) ON Watch dog timer on the CPU
	Z INDEX *** ON or OFF depending where Z axis is (Headup =ON)

Red LED's (all red LED's are normally off)

	X HOME OFF X limit PCB problem
	Y HOME OFF Y limit PCB problem
	X MOTOR CURRENT LIMIT  OFF
	Y MOTOR CURRENT LIMIT  OFF
	Z MOTOR CURRENT LIMIT  OFF
	COLOR CHANGE MOTOR CURRENT LIMIT  OFF
	GRABBER MOTOR CURRENT LIMIT  OFF
	Bobbin fuse bad
	Light fuse bad
	ESTOP OFF Comes ON when Estop switch is engaged.

Green LED's

	+5(+24V) ON
	+5(+12V) ON
	+12V ON
	-12V ON
	+24V ON
	+36V ON
	+6V (ISO) ON
	+5V (PG) ON
	CONTROL FPGA ON (CPU configured OK at startup)
	I/O FPGA ON (CPU configured OK at startup)

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SECTION 4

TROUBLESHOOTING SECTION
This section contains troubleshooting information for the major sections of the EMT10T. Common troubleshooting technics are used and where applicable, a block diagram is shown.

AC POWER TROUBLESHOOTING

NO AC POWER

No AC power to the EMT10 machine. Nothing happens when the power switch is turned ON.

1) Check - Is the machine plugged in?

2) Check - Fuses in power entry module

	Good - Continue to the next Check item.
	Bad - One or both fuses blown, there is a short somewhere is the machine. Go to BLOWN AC FUSE.

3) Check - Fuses on the E-stop PCB.

	Good - Continue to the next Check item.
	Bad - Go to E-STOP PCB PROBLEMS.

WARNING -- AC voltage present in next step, use caution.

4) Check - On the E-stop PCB, disconnect the black and white wires going to ES1-L1 and ES1-L2 (AC IN). Plug the machine in and set the power switch to the ON position. Measure AC voltage in the terminals of the cable (010412-02) that was just disconnected.

	Good - AC power is present when the machine is turned ON. AC power is going to the E-stop PCB. Problem is on the E-stop PCB. Go to E-STOP PCB PROBLEMS.
	Bad - No AC power present when machine is turned ON. Continue to the next check item.

WARNING -- AC voltage present in next step, use caution.

5) Check - Remove side cover ( side with power switch ). Unplug the AC power cord. On power switch, disconnect the wires labeled P1 and P2 ( red and black wires typically on the bottom 2 terminals of the power switch ). Plug the machine in and measure AC voltage at P1 and P2.

Good - AC power is present when machine is plugged in. AC power is coming from the AC outlet but not making it through the power switch to the E-stop PCB. 2 things could be wrong at this point. Either the power switch is bad or the 010412 cable has an open wire. To troubleshoot this further, check the switch function, replace it if its bad. Also perform a continuity check on the 010412 cable, replace it if its bad.

Bad - No AC power present when machine is plugged in. Go to next check item.

WARNING -- AC voltage present in next step, use caution.

6) Check - Unplug AC power cord form the machine and with cord plugged in the AC outlet, measure AC voltage in the power cord.

	Good - AC power present at power cord. AC power is making it to the power entry module but not to the power switch. Check the fuses and replace them if bad. Perform a continuity check on the 010412 cable, replace if its bad. If fuses blow again after they are replaced go to BLOWN AC FUSE.
	Bad - No AC power present at power cord. 2 things could be wrong at this point. Either the power cord is bad or the AC outlet is not working. Perform a continuity test on the power cord and replace it if it's bad. Measure the voltage at the AC outlet. Have an experienced electrician fix the AC power outlet problem.

BLOWN FUSE TROUBLESHOOTING

BLOWN AC FUSE

No AC power to the EMT10 machine. Nothing happens when the power switch is turned ON. One or more of the fuses are blown in the power entry module.

WARNING --Make sure the power cord is disconnected and the power switch is in the OFF position.

1) Check - On the E-stop PCB, disconnect the black and white wires going to ES1-L1 and ES1-L2 (AC IN). Connect the DVM up to the terminals of the cable (010412-02) that was just disconnected and measure the resistance between the two.

	Good - Greater than 1K ohms. The two wires are not shorted together. Continue to next check item.
	Bad - Less than 1 ohm. There is a short in the 010412-02 harness or the power switch. Replace the defective component.

2) Check - Set the power switch to the ON position. Measure the resistance between the two wires.

	Good - Greater than 1K ohms. The two wires are not shorted together. Continue to next check item.
	Bad - Less than 1 ohm. There is a short in the 010412-02 harness, the power switch, or the power entry module. Replace defective component.

3) Check - On the E-stop PCB, Connect the DVM up to the terminals ES1-L1 and ES1-L2 (AC IN) and measure the resistance between the two.

	Good - Greater than 1K ohms. The two terminals are not shorted together. Replace the fuses in the power entry module and reconnect the 010412-02 harness to the E-Stop PCB.
	Bad - Less than 1 ohm. There is a short present between the two terminals. Continue to next check item.

4) Check - Disconnect the computer power supply from the E-stop PCB. On the E-stop PCB, Connect the DVM up to the terminals ES1-L1 and ES1-L2 (AC IN) and measure the resistance between the two.

	Good - Greater than 1K ohms. The two terminals are not shorted together. The SHORT exists in the computer power supply. Replace the defective power supply.
	Bad - Less than 1 ohm. There is an AC short present on the E-Stop PCB. Replace the defective E-Stop PCB.

BLOWN E-STOP FUSE

The E-stop switch does not function and the 24/36 volt power supply does not work. The E-stop fuse is blown.

1) Check - Disconnect the E-stop cable from the E-stop PCB. Replace the fuse and turn ON the machine. Using a DVM, check to see if AC power is present ON the E-stop PCB, ES1A and ES1B.

	Good - AC power present at the terminals on the PCB. Continue to next check item.
	Bad - No AC power present at the terminals on the PCB. Go to AC POWER TROUBLESHOOTING.

2) Check - Turn OFF the machine and check the E-stop fuse.

	Good - The fuse is good. No shorts are present on the E-stop PCB. Go to next check item.
	Bad - The fuse is blown. A short exists on the E-stop PCB. Replace defective E-stop PCB.

3) Check - Plug the E-stop cable back into the E-stop PCB. Power up the machine and check the function of the E-stop switch.

	Good - The E-stop switch works properly.
	Bad - The E-stop switch will not work. The E-stop fuse is blown again. A short exists in the E-stop cable or the E-stop switch. Replace the defective component.

BLOWN BOBBIN WINDER FUSE

The bobbin winder does not function and the bobbin winder fuse is blown.

1) Check - Disconnect the bobbin winder cable from the E-stop PCB. Replace the fuse and turn ON the machine. Using a DVM, check to see if AC power is present ON the E-stop PCB, ES1A and ES1B.

	Good - AC power present at the terminals on the PCB. Continue to next check item.
	Bad - No AC power present at the terminals on the PCB. Go to AC POWER TROUBLESHOOTING.

2) Check - Turn OFF the machine and check the bobbin winder fuse.

	Good - The fuse is good. No shorts are present on the E-stop PCB. Go to next check item.
	Bad - The fuse is blown. A short exists on the E-stop PCB. Replace defective E-stop PCB.

3) Check - Plug the bobbin winder cable back into the E-stop PCB. Power up the machine and check the function of the bobbin winder.

	Good - The bobbin winder works properly.
	Bad - The bobbin winder will not work. The bobbin winder fuse is blown again. A short exists in the cable or bobbin winder. Replace the defective component.

BLOWN 6V-ISO FUSE

The X and Y limits and color change do not function and the 6V-ISO fuse is blown.

1) Check - Disconnect the backplane power cable from the E-stop PCB. Replace the fuse and turn ON the machine. Using a DVM, check to see if AC power is present ON the E-stop PCB, ES1A and ES1B.

	Good - AC power present at the terminals on the PCB. Continue to next check item.
	Bad - No AC power present at the terminals on the PCB. Go to AC POWER TROUBLESHOOTING.

2) Check - Turn OFF the machine and check the 6V-ISO fuse.

	Good - The fuse is good. No shorts are present on the E-stop PCB. Go to next check item.
	Bad - The fuse is blown. A short exists on the E-stop PCB. Replace defective E-stop PCB.

3) Check - Plug the backplane power cable back into the E-stop PCB. Power up the machine and check the function of the X and Y limit and/or the color change.

	Good - The limits and/or the color change work properly.
	Bad - The limits and/or color change will not work. The 6V-ISO fuse is blown again. A short exists in the 6V-ISO circuit. Replace the defective component.

BLOWN LIGHT FUSE

The light does not function and light fuse is blown.

1) Check - Disconnect the light cable from the E-stop PCB. Replace the fuse and turn ON the machine. Using a DVM, check to see if AC power is present ON the E-stop PCB, ES1A and ES1B.

	Good - AC power present at the terminals on the PCB. Continue to next check item.
	Bad - No AC power present at the terminals on the PCB. Go to AC POWER TROUBLESHOOTING.

2) Check - Turn OFF the machine and check the light fuse.

	Good - The fuse is good. No shorts are present on the E-stop PCB. Go to next check item.
	Bad - The fuse is blown. A short exists on the E-stop PCB. Replace defective E-stop PCB.

3) Check - Plug the light cable back into the E-stop PCB. Power up the machine and check the function of the light.

	Good - The light works properly.
	Bad - The light will not work. The light fuse is blown again. A short exists in the light assembly. Replace the defective component.

BLOWN 12 VOLT FUSE

The 12 LED is not lit and/or there is no +12 volts at the test points.

1) Check - Disconnect the backplane power cable from the E-stop PCB. Replace the fuse and turn ON the machine. Using a DVM, check to see if AC power is present ON the E-stop PCB, ES1A and ES1B.

	Good - AC power present at the terminals on the PCB. Continue to next check item.
	Bad - No AC power present at the terminals on the PCB. Go to AC POWER TROUBLESHOOTING.

2) Check - Turn OFF the machine and check the 12 Volt fuse.

	Good - The fuse is good. No shorts are present on the E-stop PCB. Go to next check item.
	Bad - The fuse is blown. A short exists on the E-stop PCB. Replace defective E-stop PCB.

3) Check - Plug the backplane power cable back into the E-stop PCB. Power up the machine and check the voltage and LED.

	Good - The voltage and LED are good.
	Bad - The voltage and LED are not working. A short exists in the 12Vdc circuit. Replace the defective component.

BLOWN 24/36 POWER SUPPLY AC POWER FUSE

See 24V/36V Power Supply Troubleshooting.

EMT10 FUSE REPLACEMENT CHART

BOBBIN DETECT (UTC) TROUBLESHOOTING
As the machine embroiders, bobbin thread activates the bobbin sensor by moving its arm. This electrical signal travels thru the bed cable, the head cable, thru the backplane, to the interface PCB, and then finally to the CPU. Note: UTC and Bobbin

NO BOBBIN DETECT

The bobbin detect is not working.

1) Check - Under the configuration menu, check the following:

	BOBBIN DETECT: should be ON. (0=ON and - = OFF)
	BOBBIN DETECT COUNT: should be 1 or greater, if it is set to 0 it will disable the bobbin detect.
	Good - Both items are correct. Continue ON to next check item.
	Bad - One or both items are not set correctly. Correct the setting.

2) Check - Remove the needle plate and inspect the UTC for damage.

	Good - UTC is not damaged. Continue ON to next check item.
	Bad - UTC is damaged. Replace defective UTC and adjust properly.

3) Check - Under the diagnostics menu, go to the BOBBIN CONTROL TEST. A beep should sound when the bobbin sensor arm is moved.

	Good - Beeps when arm is moved. The sensor is working properly. The bobbin sensor is not adjusted correctly.
	Bad - No beep. Continue ON to next check item.

4) Check - Is the UTC installed LED lit ( yellow LED ) on the front of the machine?

	Good - LED is lit and will go ON and OFF when are is moved. Signal is making it to the Interface PCB but not to the CPU. Replace the CPU.
	Bad - LED is not lit and will not go on. UTC signal is not getting to the interface PCB. Check the cabling for damage, if none exists replace the interface PCB.

CARD CAGE TROUBLESHOOTING
The cage has a short some where internal causing one or more of the power supplies to short out.

NOTE: TURN OFF MACHINE

1) Check - Connect the DVM up to the voltage test points on the front of the card cage for the power supply or voltage that is shorted out. If the 5vdc power is shorted out, connect to the 5vdc test points. Set the DVM on the resistance scale and verify that the short exists.

	Good - short exists. Go on to next check item.
	Bad - No short present. Check DVM connections and check all other voltage test points for shorts.

2) Check - Remove the CPU PCB from the card cage. Check the reading on the DVM.

	Good - On the DVM the short goes away. The CPU has a short on it. Replace the defective PCB.
	Bad - On the DVM the short is still present. Continue ON to the next check item.

3) Check - Remove the Interface PCB from the card cage. Check the reading on the DVM.

	Good - On the DVM the short goes away. The Interface has a short on it. Replace the defective PCB.
	Bad - On the DVM the short is still present. Continue ON to the next check item.

4) Check - Remove the LV DRIVER PCB from the card cage. Check the reading on the DVM.

	Good - On the DVM the short goes away. The LV DRIVER has a short on it. Replace the defective PCB.
	Bad - On the DVM the short is still present. Continue ON to the next check item.

5) Check - Remove the Motor Driver PCB from the card cage. Check the reading on the DVM.

	Good - On the DVM the short goes away. The Motor driver has a short on it. Replace the defective PCB.
	Bad - On the DVM the short is still present. Continue ON to the next check item.

6) Check - Remove the Network PCB from the card cage (if applicable). Check the reading on the DVM.

	Good - On the DVM the short goes away. The Network PCB has a short on it. Replace the defective PCB.
	Bad - On the DVM the short is still present. Continue ON to the next check item.

7) Check - Remove, one by one, each cable from the card cage. Check the reading on the DVM.

	Good - On the DVM the short goes away. The cable has a short in it. Troubleshoot further to determine the problem.
	Bad - On the DVM the short is still present. Continue ON to the next check item.

8) Check - Every cable and every PCB is removed from the card cage. The reading on the DVM still shows a short. The backplane PCB has a short on it. Replace the defective PCB.

COLOR CHANGE TROUBLESHOOTING
The color change PCB has the sensors for color change position and needle index. These signals go thru a head cable, thru the backplane, to the interface PCB, and finally to the CPU. The color change motor is controlled by the motor driver PCB. The motor encoder signals and motor power go thru a motor harness, thru the backplane, to the motor driver PCB, and then to the CPU.

CC AXIS CURRENT LIMIT

The machine will display a CC axis current limit while performing a color change sequence.

1) Check - Turn OFF the machine. Using a screw driver, rotate the color change assembly thru all needles and check for a bind.

	Good - No bind in color change assembly. Continue on to the next check item.
	Bad - Bind in the color change assembly. Grease color change cam or repair defective component in color change assembly.

2) Check - Disconnect motor power cable from motor. Using a DVM, measure the resistance of the motor.

	Good - Resistance is greater than 10 ohms. Continue on to next check item.
	Bad - Motor has a short. Replace defective CC motor and perform the next check item. Need to check to see if LV driver PCB is shorted also.

3) Check - Using the DVM, measure the resistance between the motor power cable connections.

	Good - The resistance is greater than TBD ohms. Power up machine. If problem returns, replace defective LV driver PCB.
	Bad - There is a short between the motor leads. Continue on to next check item.

4) Check - Disconnect cable at the card cage and measure the resistance between the motor power cable connections.

	Good - The resistance is greater than 1M ohms., replace defective LV driver PCB.
	Bad - There is a short between the motor leads. Replace defective cable.

COMPUTER POWER SUPPLY TROUBLESHOOTING

NO +5Vdc

No +5Vdc when measured at the front voltage test points on the EMT10.

CAUTION -- When making the following measurements, be careful not to short the pins together.

1) Check - Disconnect backplane power cable, 009970, from card cage and measure +5Vdc at Pin 8 (+) to Pin 15 (-). Measure +5Vdc at Pin 7 (+) and Pin 14 (-). Is there between 4.92Vdc to 5.18Vdc?

	Good - 5Vdc is present at both points in the 009970 cable. There is a short in the card cage. Go to CARD CAGE PROBLEMS - SHORT.
	Bad - No + 5Vdc measured at the 009970 cable. Continue to the next check item.

2) Check - Verify that there AC power going to the computer power supply.

	Good - AC power is present at power supply. Go to next check item.
	Bad - No AC power to PS. Go to NO AC POWER.

3) Check - Disconnect P8 and P9 (coming from the computer power supply) from ES-4 on the E-stop PCB. Measure + 5vdc at P9 red (+) and P9 black (-).

	Good - 5vdc is present at P9. Short exists on E-stop PCB. Replace E-stop PCB.
	Bad - No 5Vdc at P9. Power supply is not working. Replace Computer power supply.

NO +12Vdc

No +12Vdc when measured at the front voltage test points on the EMT10.

CAUTION --When making the following measurements, be careful not to short the pins together.

1) Check - Disconnect backplane power cable, 009970, from card cage and measure +12Vdc at Pin 6 (+) to Pin 15 (-). Is there between 11Vdc to 13Vdc?

	Good - 12Vdc is present at both points in the 009970 cable. There is a short in the card cage. Go to CARD CAGE PROBLEMS - SHORT.
	Bad - No +12Vdc measured at the 009970 cable. Continue to the next check item.

2) Check - Verify that there AC power going to the computer power supply.

	Good - AC power is present at power supply. Go to next check item.
	Bad - No Ac power to PS. Go to NO AC POWER.

3) Check - Disconnect P8 and P9 (coming from the computer power supply) from ES-4 on the E-stop PCB. Measure + 12vdc at P8 yellow (+) and P8 black (-).

	Good - 12vdc is present at P8. Short exists on E-stop PCB. Replace E-stop PCB.
	Bad - No 12Vdc at P8. Power supply is not working. Replace Computer power supply.

NO -12Vdc

No -12Vdc when measured at the front voltage test points on the EMT10.

CAUTION --When making the following measurements, be careful not to short the pins together.

1) Check - Disconnect backplane power cable, 009970, from card cage and measure -12Vdc at Pin 5 (+) to Pin 15 (-). Is there between -10Vdc to -13Vdc?

	Good - -12Vdc is present at both points in the 009970 cable. There is a short in the card cage. Go to CARD CAGE PROBLEMS - SHORT.
	Bad - No -12Vdc measured at the 009970 cable. Continue to the next check item.

2) Check - Verify that there AC power going to the computer power supply.

	Good - AC power is present at power supply. Go to next check item.
	Bad - No Ac power to PS. Go to NO AC POWER.

3) Check - Disconnect P8 and P9 (coming from the computer power supply) from ES-4 on the E-stop PCB. Measure + 12vdc at P8 blue (+) and P8 black (-).

	Good - -12vdc is present at P8. Short exists on E-stop PCB. Replace E-stop PCB.
	Bad - No -12Vdc at P8. Power supply is not working. Replace Computer power supply.

24V/36V POWER SUPPLY TROUBLESHOOTING

NO +24Vdc

No +24Vdc when measured at the front voltage test points on the EMT10.

CAUTION --When making the following measurements, be careful not to short the pins together.

1) Check - Is E-stop switch engaged?

	Good - E-stop switch is engaged, disable E-stop switch.
	Bad - E-stop switch is not engaged, continue to next check item.

2) Check - Disconnect low voltage cable, 009961-XX, from the EMT10 Motor driver PCB (009419-XX) and measure +24Vdc at Pin 3 (+) to Pin 5 (-). Is there between 22Vdc to 25Vdc?

	Good - 24Vdc is present in the 009961-XX cable. There is a short in the card cage. Go to CARD CAGE PROBLEMS - SHORT.
	Bad - No +24Vdc measured at the 009961-XX cable. Continue to the next check item.

3) Check - Verify the 24 VDC fuse is good.

	Good - Continue to the next check item.
	Bad - Replace the fuse.

4) Check - Verify that there AC power going to the 24/36 volt power supply.

	Good - AC power is present at power supply. Replace defective power supply.
	Bad - No Ac power to PS. Go to NO AC POWER.

NO +36Vdc

No +36Vdc when measured at the front voltage test points on the EMT10.

CAUTION --When making the following measurements, be careful not to short the pins together.

1) Check - Is E-stop switch engaged?

	Good - E-stop switch is engaged, disable E-stop switch.
	Bad - E-stop switch is not engaged, continue to next check item.

2) Check - Disconnect low voltage cable, 009961, from card cage and measure +36Vdc at Pin 5 (+) to Pin 1 (-). Is there between 32Vdc to 38Vdc?

	Good - 36Vdc is present at both points in the 009961 cable. There is a short in the card cage. Go to CARD CAGE PROBLEMS - SHORT.
	Bad - No 36Vdc measured at the 009961 cable. Continue to the next check item.

3) Check - Verify that there AC power going to the power supply.

	Good - AC power is present at power supply. Replace defective power supply.
	Bad - No Ac power to PS. Go to NO AC POWER.

E-STOP PCB TROUBLESHOOTING
The E-stop PCB controls a variety of functions. It supplies AC power directly to the computer power supply and switched AC power to the 24/36V power supply. When the E-Stop switch is engaged, AC power to the 24/36 volt power supply is cut off. The E-stop PCB supplies DC voltages from the computer power supply to the backplane PCB, supplies +12Vdc to the light and bobbin winder, and also supplies the +6Vdc ISO voltage. Finally, a majority of the machine fuses are located on the PCB.

GRABBER TROUBLESHOOTING

GRABBER NOT HOME

Grabber not home error. The grabber has not fully retracted to its home position.

1) Check - See if the grabber is caught up on the thread or the Velcro strip.

	Good - Grabber is not caught up and appears to be home. Continue on to next check item.
	Bad - Grabber is caught up. Free up grabber and resume sewing.

2) Check - Manually move grabber to see if its binding up anywhere in its travel.

	Good - Grabber moves freely. Continue on to next check item.
	Bad - Grabber binds. Inspect the grabber blade and grabber blade guilds. Correct the defective parts.

3) Check - Manually move the grabber to the home position. Check LED Grabber Home on front of machine. When the grabber is home the LED will be OFF. When it is not home, it will be ON.

	Good - The LED is OFF when home and ON when not home. Continue ON to the next check item.
	Bad - The LED is ON when the grabber is home or the LED doesn't work at all. If the LED is ON the grabber flag needs to be adjusted. It the LED doesn't work, the Interface PCB needs replacing.

4) Check - From the last step, the LED works properly but the grabber not home error still exists. The CPU is not reading the signal from the Interface PCB. Replace the CPU.

GRABBER AXIS CURRENT LIMIT

This error is caused by the electronics detecting excessive current draw by the grabber motor.

1) Check - See if the grabber is caught up on the thread, the Velcro strip or is binding anywhere in its travel.

	Good - Grabber is not caught up and appears to be free. Continue on to next check item.
	Bad - Grabber is caught up. Free up grabber and resume sewing.

2) Check - Remove the grabber cover and disconnect the motor connector. Measure the resistance of the grabber motor. S/B 9.0 ohms or greater.

	Good - Resistance of motor is 9.0 ohms or greater. (Will vary as grabber is moved in and out) Continue on to next check item.
	Bad - Resistance is low. Motor is shorted out. Replace defective motor.

3) Check - A failure has occurred on the LV driver PCB. Replace LV driver.

THREAD BREAK TROUBLESHOOTING
The thread break electronics work by sensing the stitching motion of the thread. This motion is sensed by the check spring. As the machine stitches, the check spring moves up and down against the check spring post which causes an electrical signal. This signal goes thru the CC PCB, thru the Interface PCB, and finally to the CPU PCB.

REAL

The thread is constantly breaking as the machine sews.

1) Check - The design for short or dense stitches.

	Good - The design is OK. Continue ON to the next check item.
	Bad - The design is wrong. Edit design to correct.

2) Check - The needles. Are they correct for the thread size? Is the needle bent, damaged, or dull? Is the needle position correct?

	Good - The needle is OK. Continue ON to the next check item.
	Bad - The needle has a problem. Correct the defective part.

3) Check - Upper bobbin tension.

	Good - Upper tension OK. Continue ON to the next check item.
	Bad - Upper tension not correct. Adjust the tension.

4) Check - The rotary hook function. Does it rotate smoothly?

	Good - The rotary hook is OK. Continue ON to the next check item.
	Bad - The rotary hook does not rotate smoothly. Clean, oil, or replace defective rotary hook.

5) Check - Is the gap between the rotary hook and the UTC retaining finger correct.

	Good - The gap is OK. Continue ON to the next check item.
	Bad - The gap is too narrow. Widen the gap.

6) Check - Is the hook timing correct?.

	Good - Hook timing correct. Continue ON to the next check item.
	Bad - Hook timing wrong. Adjust hook timing.

7) Check - Is the bobbin damaged?

	Good - The bobbin is OK. Continue ON to the next check item.
	Bad - The bobbin is damaged. Replace the bobbin.

8) Check - Is the needle depth correct?

	Good - Needle depth correct. Continue ON to the next check item.
	Bad - Needle depth is wrong. Adjust needle depth.

9) Check - Does the thread path have any scratches or burrs on the thread path?

Bad - Remove scratches and burrs with emery cloth.

FALSE THREAD BREAKS

The electronics think that there is a thread break and displays "THREAD BREAK..." when there is no thread break.

1) Check - Is the upper bobbin tension loose?

	Good - Upper tension OK. Continue ON to the next check item.
	Bad - Upper tension not correct. Adjust the tension.

2) Check - Is the lower bobbin tension loose?

	Good - Lower tension OK. Continue ON to the next check item.
	Bad - Lower tension not correct. Adjust the tension.

3) Check - Is the check spring on the wrong side of the post?

	Good - The check spring is OK. Continue ON to the next check item.
	Bad - Correct the check spring.

4) Check - Is the cabling connected properly and not damaged?

	Good - The cabling is OK. Continue ON to the next check item.
	Bad - Cabling is damaged or not connected. Correct the defective component or reconnect the cable.

5) Check - The electrical signal is not getting to the CPU PCB. Replace the interface PCB.

TRIMMER TROUBLESHOOTING
The trimmer assembly is controlled by the electronics. The trimmer and picker solenoids are controlled by the CPU PCB. The CPU sends a trim and pick signal to the LV driver PCB. The LV Driver PCB converts these signals into solenoid drive signals and sends them to the trim and pick solenoids. The home sensor signal is sent to the Interface PCB. This signal is then sent to the cutter home LED on the backplane and to the CPU PCB.

TRIMMER NOT HOME

The display show a "Trimmer NOT Home " error message and the machine won't sew.

1) Check - Is the yellow CUT HD#1 LED on the backplane OFF?

	Good - The LED is OFF. Skip to check item 6.
	Bad - The LED is ON. Continue ON to the next check item.

2) Check - Verify that all the cabling is plugged in and not damaged or pinched in anyway.

	Good - All cables are plugged in and not damaged. Continue ON to the next check item.
	Bad - Cables not plugged or damaged. Replace defective components.

3) Check - Remove the needle plate and check if any thread is caught up in the trimmer blade, preventing it from moving home.

	Good - There is nothing caught in the trimmer blade. Continue ON the next check item.
	Bad - Stuff caught in trimmer blade. Clean out all obstructions, replace needle plate, and continue sewing.

4) Check - Remove the bed plate cover and inspect the trimmer assembly. Is the trimmer assembly in the home position and the trimmer home flag in the sensor?

	Good - The trimmer assembly is in the home position and the trimmer home flag is in the sensor. The flag is adjusted properly. Replace the defective Interface PCB.
	Bad - The trimmer assembly is NOT in the home position. Push the trimmer assembly into its home position. Continue ON to the next check item.

5) Check - Readjust the trimmer home flag. Does the cut home LED work properly when flag is moved in and out of the sensor?

	Good - LED works properly. Perform a trim immediate function, lubricate as needed, and button up the machine.
	Bad - LED does not work properly. replace defective Interface PCB.

6) Check - LED is OFF from check item 1. Verify that all the cabling is plugged in and not damaged or pinched in anyway.

	Good - All cables are plugged in and not damaged. Continue ON to the next check item.
	Bad - Cables not plugged or damaged. Replace defective components.

7) Check - Remove the bed plate cover and inspect the trimmer assembly. Does the LED work when the trimmer assembly is moved? (LED will come ON when the flag leaves the sensor)

	Good - The LED works properly. The interface is processing the signal but the CPU does not see it. Replace the defective CPU.
	Bad - LED does not work properly. replace defective Interface PCB.

TRIMMER WILL NOT WORK AT ALL

The trimmer will not function at all.

1) Check - Under the configuration menu, is the trimmer enabled?

	Good - The trimmer is enabled. Continue ON to the next check item.
	Bad - Enable the trimmer and continue sewing.

2) Check - Verify that all the cabling is plugged in and not damaged or pinched in anyway.

	Good - All cables are plugged in and not damaged. Continue ON to the next check item.
	Bad - Cables not plugged or damaged. Replace defective components.

3) Check - Perform a Trim immediate function. Do both solenoids work?

	Good - Both solenoids function properly. Check that the trim on stitch length is greater than 0 or check the design.
	Bad - One or both solenoids do not work properly. Replace the LV driver PCB.

X AXIS TROUBLESHOOTING
The X axis motion is controlled by the electronics. The CPU will send commands to the motor driver PCB. The motor driver PCB will send these commands to the X motor. Feedback to the CPU is provided by the encoder and home sensor. These tell the CPU where the X motor is during sewing.

X AXIS CURRENT LIMIT

The X axis motor driver has detected a excess amount of current going to the X axis motor.

1) Check - Move the X beam back and forth and check for binding.

	Good - X beam moves freely. Continue ON to next check item.
	Bad - Beam is bound up. Replace defective components.

2) Check - Verify all of the cabling is not damaged or pinched any where.

	Good - Cabling is OK. Continue ON to next check item.
	Bad - Cabling is damaged. Replace the defective cable.

3) Check - Remove the X-PCB cover off the beam. Inspect the cover to see if there is evidence of electrical arcing or the PCB touching this cover.

	Good - No evidence of arcing or PCB touching cover. Continue ON to next check item.
	Bad - Evidence of arcing or PCB touching the cover. Trim PCB leads touching cover or replace PCB. Need to continue ON to next check item and see if any other components are damaged.

4) Check - Disconnect the motor connector from the X rack PCB. Using a DVM, measure the resistance of the motor windings using the following chart.

	Good - The resistance of the windings are OK. Continue ON to the next check Item.
	Bad - One or more of the windings are shorted. Low resistance. Replace the defective X motor. Need to continue ON to next check item and see if any other components are damaged.

5) Check - On the X axis PCB measure resistance between the following points looking for a short circuit. (less that .1 ohms)

	Good - No shorts. Nothing else damaged. Reconnect and sew.
	Bad - One or more shorts exist. Continue ON to the next check Item.

6) Check - Disconnect the X axis collector harness from the motor driver PCB and perform check item number 5. See if the short goes away.

	Good - The short goes away. Replace the defective motor driver PCB.
	Bad - The short is still present. Continue ON to the next check Item.

7) Check - Inspect the X-axis flex cable and X axis collector harness going to the motor driver PCB for damage, pinched, or bent pins in the any of the connectors.

Bad - Problems found with the cabling. Replace the defective component.

X AXIS RUN AWAY

The X beam runs away and hits a hard stop. This is commonly a problem with the encoder not being connected up or functioning properly. The motor controller has no idea where the X beam is without the feedback the encoder provides. That is why the X beam runs away.

1) Check - Remove the X beam PCB cover and inspect the motor encoder cable for damage.

	Good - No damage to the cable. Continue ON to the next check Item.
	Bad - Encoder cable damaged. Replace X motor.

2) Check - Disconnect the encoder cable from the X beam PCB. On the X beam PCB measure, using a DVM, the encoder +5Vdc at X3 pin1 (+) and X3 pin 2 (-).

	Good - There is +5Vdc at X3 pin 1 and 2. Continue ON to the next check Item.
	Bad - There is NO +5Vdc. This +5Vdc is supplied to all the encoders thru a poly switch on the backplane. Inspect the cabling for damage, pinched wires, or bent pins. If cabling is OK, suspect the poly switch on the backplane.

3) Check - Plug back the encoder into the PCB and measure the +5Vdc on the PCB again.

	Good - There is +5Vdc at X3 pin 1 and 2. Continue ON to the next check Item.
	Bad - There is NO +5Vdc. The motor encoder is shorting out the +5Vdc. replace the defective motor.

4) Check - All the cabling for pinched wires, damage, or bent pins in the connectors.

	Good - The cabling is OK. Continue ON to the next check Item.
	Bad - Replace the defective cable.

5) Check - Disconnect the X motor encoder from the X beam PCB. Disconnect the X, Y, Z encoder cable from the card cage. Using the DVM, verify continuity of the following encoder lines.

	Good - The continuity of the two encoder lines is good. The encoder signals are not getting to the CPU. Replace the CPU PCB.
	Bad - Troubleshoot further to determine which cable is defective. Replace the defective cable.

Y AXIS TROUBLESHOOTING
The Y axis motion is controlled by the electronics. The CPU will send commands to the motor driver PCB. The motor driver PCB will send these commands to the Y motor. Feedback to the CPU is provided by the encoder and home sensor. These tell the CPU where the motor is during sewing.

Y AXIS CURRENT LIMIT

The Y axis motor driver has detected a excess amount of current going to the Y axis motor.

1) Check - Move the Y beam back and forth and check for binding.

	Good - Y beam moves freely. Continue ON to next check item.
	Bad - Beam is bound up. Oil or replace defective components.

2) Check - Verify all of the Y axis cabling is not damaged or pinched any where.

	Good - Cabling is OK. Continue ON to next check item.
	Bad - Cabling is damaged. Replace the defective cable.

3) Check - Disconnect the XYZ motor interface cable from the motor driver PCB. Using a DVM, measure the resistance, looking for a short circuit, of the motor windings using the following chart.

	Good - The windings are OK. None of them are shorted. Continue ON to the next check Item.
	Bad - One or more of the windings are shorted. Low resistance. Replace the defective Y motor. Need to continue ON to next check item and see if any other components are damaged.

4) Check - Disconnect the Y motor from the XYZ interface cable. Using a DVM, measure the resistance, looking for a short circuit or an open circuit. This will determine if the cable is damaged. Use the chart from Check item 3 above.

	Good - The cable wiring is OK. None of them are shorted or have an open. Continue ON to the next check Item.
	Bad - One or more of the wires are shorted or are open. Replace the defective cable. Need to continue ON to next check item and see if any PCB components are damaged.

5) Check - Remove the motor driver PCB form the machine. On the PCB measure resistance between the following points looking for a short circuit or an open circuit.

	Good - No shorts or opens on PCB. Nothing else damaged. Reconnect and sew.
	Bad - One or more shorts or open exist. Replace defective motor driver PCB.

Y AXIS RUN AWAY

The Y beam runs away and hits a hard stop. This is commonly a problem with the encoder not being connected up or functioning properly. The motor controller has no idea where the Y beam is without the feedback the encoder provides. That is why the Y beam runs away.

1) Check - Remove the cover and inspect the motor encoder cable for damage, if it came off motor, or is not connected properly.

	Good - No damage to the cable. Continue ON to the next check Item.
	Bad - If encoder cable is damaged, replace Y motor. If encoder connector came off or is not connected properly, reseat connector and sew.

2) Check - Disconnect the encoder cable from the Y motor. On the encoder cable measure, using a DVM, the encoder +5Vdc at J3 pin 4 (+) and J3 pin 1 (-).

	Good - There is +5Vdc at J3 pin 1 and 4. Continue ON to the next check Item.
	Bad - There is NO +5Vdc. This +5Vdc is supplied to all the encoders thru a poly switch on the backplane. Inspect the cabling for damage, pinched wires, or bent pins. If cabling is OK, suspect the poly switch on the backplane.

3) Check - Plug back the encoder into the motor and measure the +5Vdc on the cable again.

	Good - There is +5Vdc at J3 pin 1 and 4. Continue ON to the next check Item.
	Bad - There is NO +5Vdc. The motor encoder is shorting out the +5Vdc. replace the defective motor.

4) Check - All the cabling for pinched wires, damage, or bent pins in the connectors.

	Good - The cabling is OK. Continue ON to the next check Item.
	Bad - Replace the defective cable.

5) Check - Disconnect the Y motor encoder from the Y motor. Disconnect the Y, Z axis cable from the card cage. Using the DVM, verify continuity of the following encoder lines.

	Good - The continuity of the two encoder lines is good. The encoder signals are not getting to the CPU. Replace the CPU PCB.
	Bad - Troubleshoot further to determine which cable is defective. Replace the defective cable.

Z AXIS TROUBLESHOOTING
The Z axis motion is controlled by the electronics. The CPU will send commands to the motor driver PCB. The motor driver PCB will send these commands to the Z motor. Feedback to the CPU is provided by the encoder and home sensor. These tell the CPU where the motor is during sewing.

Z AXIS CURRENT LIMIT

The Z axis motor driver has detected a excess amount of current going to the Z axis motor.

1) Check - Rotate the Z axis and check for binding.

	Good - Z axis moves freely. Continue ON to next check item.
	Bad - Z axis is bound up. Oil or replace defective components.

2) Check - Verify all of the Z axis cabling is not damaged or pinched any where.

	Good - Cabling is OK. Continue ON to next check item.
	Bad - Cabling is damaged. Replace the defective cable.

3) Check - Disconnect the XYZ motor interface cable from the motor driver PCB. Using a DVM, measure the resistance, looking for a short circuit, of the motor windings using the following chart.

 

	Good - The windings are OK. None of them are shorted. Continue ON to the next check Item.
	Bad - One or more of the windings are shorted. Low resistance. Replace the defective Z motor. Need to continue ON to next check item and see if any other components are damaged.

4) Check - Disconnect the Z motor from the XYZ interface cable. Using a DVM, measure the resistance, looking for a short circuit or an open circuit. This will determine if the cable is damaged. Use the chart from Check item 3 above.

	Good - The cable wiring is OK. None of them are shorted or have an open. Continue ON to the next check Item.
	Bad - One or more of the wires are shorted or are open. Replace the defective cable. Need to continue ON to next check item and see if any PCB components are damaged.

5) Check - Remove the motor driver PCB form the machine. On the PCB measure resistance between the following points looking for a short circuit or an open circuit.

 

	Good - No shorts or opens on PCB. Nothing else damaged. Reconnect and sew.
	Bad - One or more shorts or open exist. Replace defective motor driver PCB.

Z AXIS RUN AWAY

The Z axis runs away. This is commonly a problem with the encoder not being connected up or functioning properly. The motor controller has no idea where the Z axis is without the feedback the encoder provides. That is why the Z axis runs away.

1) Check - Remove the cover and inspect the motor encoder cable for damage, if it came off motor, or is not connected properly.

	Good - No damage to the cable. Continue ON to the next check Item.
	Bad - If encoder cable damaged, replace encoder cable. If encoder connector came off or is not connected properly, reseat connector and sew.

2) Check - Disconnect the encoder cable from the Z motor. On the encoder cable measure, using a DVM, the encoder +5Vdc at pin1 (+) and pin 4 (-).

	Good - There is +5Vdc at pin 1 and 4. Continue ON to the next check Item.
	Bad - There is NO +5Vdc. This +5Vdc is supplied to all the encoders thru a poly switch on the backplane. Inspect the cabling for damage, pinched wires, or bent pins. If cabling is OK, suspect the poly switch on the backplane.

3) Check - Plug back the encoder into the motor and measure the +5Vdc on the encoder again.

	Good - There is +5Vdc at pin 1 and 4. Continue ON to the next check item.
	Bad - There is NO +5Vdc. The motor encoder is shorting out the +5Vdc. Replace the defective motor.

4) Check - All the cabling for pinched wires, damage, or bent pins in the connectors.

	Good - The cabling is OK. Continue ON to the next check Item.
	Bad - Replace the defective cable.

5) Check - Disconnect the Z motor encoder. Disconnect the Y, Z encoder cable from the card cage. Using the DVM, verify continuity of the following encoder lines.

	Good - The continuity of the two encoder lines is good. The encoder signals are not getting to the CPU. Replace the CPU PCB.
	Bad - Troubleshoot further to determine which cable is defective. Replace the defective cable.

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