Saurer Melco EMC 1 Installation guide

Basic Maintenance
for Melco
Sewing Peripherals
A Company of Saurer Textile Systems
Part Number 110207-01, Revision B
•Cleaning
•Lubrication
•Hook Timing
For the following peripherals:
•EMC 1
•EMC 6, 6M, 6ML, 6MLT
•EMC 6/4, 6/4M, 6/4MT
•EMC 10, 10T, 10/4, 10/4T
•CH 1
•Advantage 18

1575 West 124th Avenue
Denver, Colorado 80234
United States of America
© Copyright 1995 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
First Printing: February 1995
Revision B: April 1995

Table of Contents
1. Cleaning
General 1 - 1
Exterior Surfaces 1 - 2
Behind the Electronic Covers 1 - 3
EMC 1, EMC 6M, 6ML, 6MLT, EMC 10, EMC 10T,
CH 1, ADV 18: 1 - 3
EMC 6: 1 - 3
End Cap Removal 1 - 4
EMC 1, EMC 6, 6M, 6ML, 6MLT, EMC 10, EMC 10T
CH 1, ADV 18: 1 - 4
Removing the Rear Covers 1 - 5
EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T: 1 - 5
Removing the Table Tops 1 - 6
EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T: 1 - 6
Cleaning the Y-Rails 1 - 7
EMC 1, EMC 6, 6M, 6ML, 6MLT, EMC 10, EMC 10T
CH 1, ADV 18: 1 - 7
EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T: 1 - 8
Power Supply Fan 1 - 10
EMC 1, EMC 6, 6M, 6ML, 6MLT, EMC 10, EMC 10T
CH 1, ADV 18: 1 - 10
EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T: 1 - 10
Trimmer Blade and Knife 1 - 11
110207-01, Rev. B
i
Table of Contents

EMC 1, EMC 6MTL, EMC6/4MT, EMC 10T,
EMC 10/4T, ADV 18: 1 - 11
Bobbin Case and Rotary Hook 1 - 12
All Units Except CH 1: 1 - 12
Thread Break Contact Posts 1 - 13
EMC 6, 6M, 6ML, 6MLT, EMC6/4M, EMC6/4MT: 1 - 13
EMC 10, EMC 10T EMC 10/4, EMC 10/4T: 1 - 14
Replacing Other Thread Tensioner Parts 1 - 15
2. Lubrication
General 2 - 1
Lubricating The Sewing Head 2 - 2
Rotary Hook 2 - 3
Needle Bar 2 - 4
EMC 1, ADV 18: 2 - 4
EMC 6: 2 - 5
Basic Maintenance
ii
Melco Embroidery Systems

EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M,
EMC 6/4MT: 2 - 6
EMC 10, EMC 10T EMC 10/4, EMC 10/4T: 2 - 7
Needle Bar Driver 2 - 9
EMC 1, ADV 18: 2 - 9
EMC 6: 2 - 10
EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M,
EMC 6/4MT: 2 - 11
EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: 2 - 12
Upper Connecting Rod 2 - 13
EMC 1, ADV 18: 2 - 13
EMC 6, EMC 6/4: 2 - 13
EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M,
EMC 6/4MT: 2 - 14
EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: 2 - 15
Lower Connecting Rod 2 - 16
All Units Except CH 1: 2 - 16
Take-Up Lever Cam 2 - 18
EMC 1, EMC 6M, EMC 6ML, EMC 6MLT,
EMC 6/4M, EMC 6/4MT: 2 - 18
EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: 2 - 19
Linear Bearing 2 - 20
EMC 6, EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: 2 - 20
The Color Change Cam 2 - 21
110207-01, Rev. B
iii
Table of Contents

EMC 6, EMC 6M, EMC 6ML, EMC 6MLT,
EMC 6/4M, EMC 6/4MT, EMC 10, EMC 10T,
EMC 10/4, EMC 10/4T: 2 - 21
The Pantograph 2 - 22
EMC 1, EMC 6, EMC 6M, EMC 6ML, EMC 6MLT,
EMC 10, EMC 10T, CH 1, ADV 18: 2 - 23
The Pulley Assembly 2 - 24
The X-Carriage Rollers 2 - 26
The Y-Rails 2 - 27
Trimmers 2 - 28
General 2 - 28
EMC 6MLT, EMC 6/4MT: 2 - 29
EMC 10T, EMC 10/4T: 2 - 30
The Rear of Head Trimmer Parts 2 - 31
The Front Of Head Trimmer Parts 2 - 32
EMC 6MLT, EMC 6/4T, EMC 10T, EMC 10/4T 2 - 32
3. Hook Timing
General 3 - 1
Head Timing 3 - 2
Machine Out Of Timing 3 - 3
Setting Timing 3 - 4
General 3 - 4
EMC 10, EMC 10T, EMC 10/4, EMC 10/4T, ADV 18: 3 - 4
Needle Depth Check/Adjustment 3 - 5
Basic Maintenance
iv
Melco Embroidery Systems

Hook Timing 3 - 8
Checking Hook Timing 3 - 9
Adjusting Hook Timing 3 - 11
Under Thread Control (UTC) Adjustments 3 - 14
When To Call For Service 3 - 16
110207-01, Rev. B
v
Table of Contents

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Basic Maintenance
vi
Melco Embroidery Systems

1. Cleaning
General
Regular maintenance will prolong the life of any embroidery peripheral, as well as
also minimize down-time and lost production time. A properly maintained machine
will perform better, last longer, and help to create a higher-quality product.
To maintain the machine’s operating condition, certain cleanings must be performed
on a regular basis. This section will cover all routine cleaning that is required prior to
any lubrication. Lubricating a dirty machine will only make a mess.
For further information on adjustments and repairs that are not covered in
this basic manual, consult your particular machine’s technical manual or call
your local area service representative for advice.
1-1
110207-01, Rev. B 1. Cleaning

Exterior Surfaces
Cleaning of the outer surfaces, while not important to the machine’s operation, is an
aesthetic consideration for the looks of the equipment. DO NOT use strong, harsh
detergents such as powdered cleansers or "all-purpose cleaners" for cleaning the
plastic or painted parts of your machine. You MAY use mild cleaners like "Fantastik
Spray Cleaner" or a mild detergent soap solution. Use a soft, clean cloth to wipe the
surfaces. Wring out any excess liquid from the cloth before using.
WARNING! Do Not Apply Any
Cleaning Fluids While The Machine Is
Running Or The Power Is On!
CAUTION! If an accidental spill should occur,
mop up the fluid with a clean cloth and allow
the machine to dry before turning the power
ON. If any fluid entered either the controller or
computer, it will require removing the covers to
gain access to the interior. Contact your local
service representative for recommendations
before proceeding.
Multi-head machines will also benefit from a regular application of
automotive wax to the tabletop surfaces. Not only will this help to maintain
a cleaner surface, it will also allow the hoops and garments to slide more
easily.
1-2 Exterior Surfaces
Basic Maintenance Melco Embroidery Systems

Behind the Electronic Covers
EMC 1, EMC 6M, 6ML, 6MLT, EMC 10, EMC 10T,
CH 1, ADV 18:
There are two covers at the rear of the machine, the electronics cover and the
keyboard cover (see Figure 1-1 below). These covers are attached to the machine
with cover catches in the rear and angled tabs in front. The front angle tabs slip into
slots at the rear edge of the sewing area. The rear cover catches lock the covers in
place.
To remove either cover, place a small bladed screw driver under the center of, first
one locking tab at the rear, and then the other, and pry up. The cover comes off in
one motion toward the front.
EMC 6:
The electronics cover and the keyboard cover look similar, but instead of using a
screwdriver to release the locking tabs, merely push the back of the covers toward
the front of the machine, then lift upward.
Caution: When the electronics cover is removed,
the CPU, the 4 axis driver, and the backplane
boards are exposed. DO NOT TOUCH THE BOARDS
WITHOUT USING ANTI STATIC PRECAUTIONS.
Electronics
Cover
Keyboard Cover
Figure 1-1
Behind the Electronic Covers 1-3
110207-01, Rev. B 1. Cleaning

End Cap Removal
EMC 1, EMC 6, 6M, 6ML, 6MLT, EMC 10, EMC 10T
CH 1, ADV 18:
The 2 end caps (or side panels) of the are removable to gain access to the areas
covered by each.
There are 3 cap head screws that must be removed, and 2 cap head screws that
must be loosened to remove each end cap (refer to Figure 1-2).
Remove the 3 horizontal cap head screws first, then loosen the 2 outer cap head
screws.
Use a small brush or can of compressed air to clean any dust or accumulated lint
from inside the caps themselves, as well as the electronic components.
CONTROLLER
SECTION
right end cap
CARRIAGE
SECTION
HEAD
SECTION
cap head
screw (1
each per
end cap,
loosen only)
cap head screw
(1 each per end
cap, loosen only)
front of
machine
left end cap
Keyboard
cover
Electronics
cover
cap head screw
(3 each per end
cap, remove
completely)
KEYBOARD
SECTION
Figure 1-2
1-4 Exterior Surfaces
Basic Maintenance Melco Embroidery Systems

Removing the Rear Covers
EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T:
The rear covers are attached to the peripheral frame with plastic tabs in the front of
the covers and with machine screws on the backside of the covers.
All covers are removed and reinstalled in the same manner, however, they must
follow a specific sequence since some of the covers overlap others.
Rear cover #4 covers the Controller Section which houses the EMI (Electro-Magnetic
Interference) box and its printed circuit boards. As with other covers, it is attached
with screws at the rear and tabs on the front. Cover #4 overlaps covers #3 and #5,
and is the first of the 5 covers to be removed and becomes the last cover installed.
After removing cover #4 you will remove cover #5, which covers the Z motor and
encoder area; then remove covers #3, #2, and then #1 in that order in the other
direction. (Refer to the figure below for an illustration of the covers and their
removal/installation sequence.
Use a small brush or can of compressed air to clean any dust or accumulated
lint from inside the caps themselves, as well as the electronic components.
Cover #3 Cover #4
Cover #2Cover #1
PERIPHERAL REAR COVERS AS
VIEWED FROM THE REAR
Cover #5
rear screws (2
for each cover)
Figure 1-3
Removing the Rear Covers 1-5
110207-01, Rev. B 1. Cleaning

Removing the Table Tops
EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T:
Remove the table top inserts in the order shown in Figure 1-4.
Use a small brush or can of compressed air to clean any dust or accumulated
lint from underneath the table tops themselves. Look for any foreign objects
(scissors, pens, needles, etc.) that may have fallen inside the channels.
Remove these
sections first
Remove these
sections second
Figure 1-4
1-6 Exterior Surfaces
Basic Maintenance Melco Embroidery Systems

Cleaning the Y-Rails
EMC 1, EMC 6, 6M, 6ML, 6MLT, EMC 10, EMC 10T
CH 1, ADV 18:
Use alcohol or an electronic cleaner that dries or evaporates without leaving a film or
residue. Apply the cleaning fluid to a soft cloth and wipe the full length of both left
and right side Y-rails. Push the pantograph back and forth several times, then wipe
the Y-rails again. Repeat a third time if necessary.
NOTE: Never spray an electrical cleaner direct onto the Y-rails. If the cleaner
contacts the peripheral chassis or covers, it may cause damage to
the composite materials.
Once the Y-rails have been thoroughly cleaned, apply fresh sewing machine oil as
shown in Figure 1-5. Push the pantograph back and forth to it’s full extremes to
distribute the oil along the Y-rails.
This would also be a good time to check the belt tensions before replacing
the end caps.
Right side Y-rail
Y-rail bearing
Apply sewing
machine oil here
Apply sewing
machine oil here
Figure 1-5
Cleaning the Y-Rails 1-7
110207-01, Rev. B 1. Cleaning

EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T:
Use alcohol or an electronic cleaner that dries or evaporates without leaving a film or
residue. Apply the cleaning fluid to a soft cloth and wipe the full length of both left
and right side Y-rails. Push the pantograph back and forth several times, then wipe
the Y-rails again. Repeat a third time if necessary.
NOTE: Never spray an electrical cleaner direct onto the Y-rails. If the cleaner
contacts the peripheral chassis or covers, it may cause damage to
the composite materials.
The right,
rear Y-rail.
The right,
front Y-rail.
The right end of the
pantograph with the
table top removed.
Figure 1-6
1-8 Exterior Surfaces
Basic Maintenance Melco Embroidery Systems

Once the Y-rails have been thoroughly cleaned, replace the tabletop sections, then
apply fresh sewing machine oil as shown in Figure 1-7. Push the pantograph back
and forth to it’s full extremes to distribute the oil along the Y-rails.
This would also be a good time to check the belt tensions before replacing
the end caps.
The Y-rail can be
lubricated with the
table top in place by
inserting the oiler
tube through the slot.
Place 1 to 2 drops
of oil on both the
front and rear of
the Y-rail. Repeat
on the left Y-rail.
Figure 1-7
Cleaning the Y-Rails 1-9
110207-01, Rev. B 1. Cleaning

Power Supply Fan
EMC 1, EMC 6, 6M, 6ML, 6MLT, EMC 10, EMC 10T
CH 1, ADV 18:
Use a small vacuum and/or a lint brush to remove any accumulated dust from the
power supply fan. Figure 1-8 shows the location of the power supply fan.
EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T:
The power supply fan features a foam filter element that may be removed as shown
in the figure below. Clean the filter by rinsing with ordinary tap water and allow it to
dry completely before reinstalling. Use a small vacuum and/or a lint brush to remove
any accumulated dust from the fan assembly and surrounding area.
Power Supply Fan
Figure 1-8
Unsnap this cover
to remove the
filter element
located behind it.
Figure 1-9
1-10 Exterior Surfaces
Basic Maintenance Melco Embroidery Systems

Trimmer Blade and Knife
EMC 1, EMC 6MTL, EMC6/4MT, EMC 10T, EMC 10/4T, ADV 18:
Occasionally, thread dust and lint will build up in the trimmer and areas. It is a good
idea to check these areas at least once a week to prevent any accumulation of debris
from affecting the performance of the trimmer . A well-cleaned trimmer will make
much better cuts than one that is clogged with lint.
NOTE: It is extremely important to clean away all thread debris prior to oiling
the trimmer blade and knife. Adding oil to uncleaned parts will
only make a mess, and the lubrication will be less effective
Use a small brush to clear away any threads, or use a small can of compressed air to
blow away dust or debris. A small vacuum may also be used.
Clean all around the
Trimmer Knife Arm
Front Pin
Clean all around
the Trimmer Knife
Drive Arm Shaft
Figure 1-10
Trimmer Knife
Drive Arm Shaft,
side view
Clean both
locations
Figure 1-11
Trimmer Blade and Knife 1-11
110207-01, Rev. B 1. Cleaning

Bobbin Case and Rotary Hook
All Units Except CH 1:
Remove the bobbin and bobbin case and clean all parts. Use a small brush to clear
away any threads, or use a small can of compressed air to blow away dust or debris.
Asmall vacuum may be used instead of compressed air.
NOTE: If your machine is equipped with under thread control (UTC) it is not
necessary to remove the UTC sensor for cleaning.
Bobbin Bobbin Case
Figure 1-12
Clean all around the post and
inside of the rotary hook
NOTE: the UTC sensor is
shown removed for clarity. It
is not necessary to remove
the sensor for cleaning.
Figure 1-13
1-12 Exterior Surfaces
Basic Maintenance Melco Embroidery Systems