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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 A Company of Saurer Textile Systems Part Number 110207-01, Revision B...
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.
Exterior Surfaces 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.
Behind the Electronic Covers 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.
Exterior Surfaces 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).
Removing the Rear Covers 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.
Exterior Surfaces 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. Remove these sections first Remove these sections second 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.
Cleaning the Y-Rails 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.
Exterior Surfaces 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.
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Cleaning the Y-Rails 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. The Y-rail can be lubricated with the table top in place by...
1-10 Exterior Surfaces 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. Power Supply Fan Figure 1-8 EMC 6/4, 6/4M, 6/4MT, EMC 10/4, EMC 10/4T:...
Trimmer Blade and Knife 1-11 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 .
1-12 Exterior Surfaces 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. A small vacuum may be used instead of compressed air.
Thread Break Contact Posts 1-13 Thread Break Contact Posts Clean the thread break contact posts using a cotton swab dipped in alcohol. If deeper cleaning is necessary, refer to Figure 1-14 and the following procedure: EMC 6, 6M, 6ML, 6MLT, EMC6/4M, EMC6/4MT: In order to clean the base of the thread break contact posts, the PCB must be removed.
1-14 Exterior Surfaces EMC 10, EMC 10T EMC 10/4, EMC 10/4T: Each thread tensioner assembly is secured by a set screw against the thread tensioner shaft inside the thread tensioner bracket. The set screw is accessible through a slot at the top of the tensioner bracket. 1.
Thread Break Contact Posts 1-15 Replacing Other Thread Tensioner Parts The individual thread tensioners may be disassembled by turning the knurled adjustment knob counter-clockwise until it comes free. Underneath the adjustment knob is a ribbed plastic disk and a tension spring. The knob, disk, and spring all nest within a large outer housing that, in turn, rests against a felt washer and the two-piece, notched thread wheel.
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1-16 Exterior Surfaces This page intentionally left blank. Basic Maintenance Melco Embroidery Systems...
2 - 1 2. Lubrication General Regular lubrication will prolong the life of any embroidery peripheral, as well as also minimize down-time and lost production time. A properly lubricated machine will perform better, last longer, and help to create a higher-quality product. To maintain the machine’s operating condition, certain lubrication must be performed on a regular basis.
2 - 2 Lubricating The Sewing Head Lubricating The Sewing Head The areas in the sewing head that require lubrication are the needle bar, the needle bar driver and connecting rod, and the rotary hook. NOTE: The CH 1 does not use a bobbin or rotary hook. Refer to your Ch 1 Operation Manual for a full lubrication schedule.
Rotary Hook 2 - 3 Rotary Hook NOTE: This procedure applies to all models except the CH 1. 1. Slide out the table insert to gain access to the rotary hook area. 2. Remove the bobbin case and bobbin from the hook assembly. 3.
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2 - 4 Lubricating The Sewing Head Needle Bar EMC 1, ADV 18: The needle bar must be lubricated at both its upper and the lower ends. The needle bar is accessed from the front of the needle case. There you will see the slot that holds the take-up lever.
Needle Bar 2 - 5 EMC 6: Refering to Figure 2-3, oil each needle bar at the point where it goes thru the upper felt pad. The felt pad may be accessed by placing the oiler tube thru the take-up lever slots.
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2 - 6 Lubricating The Sewing Head EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M, EMC 6/4MT: Remove the needle case cover. Refering to Figure 2-4, locate the upper and lower needle bar oil pads. These two oil pads are placed to supply oil in proper amounts to the needle bars during operation Lubricate the needle bars just above the two pad locations on each needle bar every 80 operation hours.
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Needle Bar 2 - 7 EMC 10, EMC 10T EMC 10/4, EMC 10/4T: The needle bars must be lubricated at both the upper and lower ends. The needle bars for each sewing head are accessed from the front of the needle case. There you will see the slots that hold the take-up levers.
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2 - 8 Lubricating The Sewing Head 2. To lubricate the lower area, first use the keypad and press the [ALT][ ⇒ ] keys to move the needle case to needle #10 (full right position). 3. From behind the needle case, place the oiler tube thru through the slot and through the spring, near the bottom of the bar.
Needle Bar Driver 2 - 9 Needle Bar Driver EMC 1, ADV 18: The needle bar driver is located inside the head casting, directly behind the needle bar. It can be accessed through the slot of the take-up lever and is identified but a spiral groove on its shaft.
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2 - 10 Lubricating The Sewing Head EMC 6: The needle bar driver is located behind the needle case. Move the needle case to the right-most position and place 2-3 drops of oil in the puddle slot as shown in Figure 2-8.
Needle Bar Driver 2 - 11 EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M, EMC 6/4MT: Move the sewing head to the left-most position. Place 3-5 drops of sewing machine oil in the puddle slot shown in Figure 2-9. Do this every 80 operating hours. Location of the puddle slot Figure 2-9...
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2 - 12 Lubricating The Sewing Head EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: 1. Using the keypad, press the [ALT][ ⇐ ] keys to move the needle case to needle #1 (full left position). 2. Remove the cover panels on either side of the sewing head. 3.
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Upper Connecting Rod 2 - 13 Upper Connecting Rod EMC 1, ADV 18: To lubricate the upper connecting rod from the front, follow these steps and refer to Figure 2-11. Upper Connecting Rod lubrication hole Cutaway of the plastic guide to show the lubrication hole.
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2 - 14 Lubricating The Sewing Head EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M, EMC 6/4MT: The following steps and Figure 2-12 describe how to lubricate the upper connecting rod. Lubrication Access Hole Oiler Tube Position of the upper lubrication hole when the sewing head is aligned with access...
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Upper Connecting Rod 2 - 15 EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: The upper connecting rod is accessed near the lower right side of the needle case, follow these steps and refer to Figure 2-13. Place oil here. This area is behind the Needle Case Cover.
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2 - 16 Lubricating The Sewing Head Lower Connecting Rod All Units Except CH 1: The lower connecting rod is accessed on the left side of the sewing head. Follow these steps and refer to Figure 2-14: NOTE: The lubrication hole is located on the opposite side of the sewing head for EMC 6 and EMC 6/4 units.
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Lower Connecting Rod 2 - 17 6. Locate the lubrication hole for the connecting rod. It is behind the access hole on the left side of the sewing head as shown in Figures 2-14 and 2-15. Lower Connecting Rod lubrication hole Hole in casting for lubrication access NOTE: The lubrication hole is located on...
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2 - 18 Lubricating The Sewing Head Take-Up Lever Cam EMC 1, EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M, EMC 6/4MT: Place a dollop of grease on the take-up lever cam groove once a year. You may need to remove the needle case and/or the thread saddle to gain access to this area. Top View of the Needle Case.
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Take-Up Lever Cam 2 - 19 EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: Place a dollop of grease on the take-up lever cam groove once a year, as shown in Figures 2-17 and 2-18. Place grease here. This area is behind the Needle Case Cover.
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2 - 20 Lubricating The Sewing Head Linear Bearing NOTE: This procedure does not apply to the following peripherals: EMC 1, EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M, EMC 6/4MT, CH 1. EMC 6, EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: Although the linear bearing assemblies used in the sewing heads require very little maintenance, it is advisable to lubricate them approximately once every six months.
The Color Change Cam 2 - 21 The Color Change Cam NOTE: This procedure does not apply to the following peripherals: EMC 1, CH 1, ADV 18. EMC 6, EMC 6M, EMC 6ML, EMC 6MLT, EMC 6/4M, EMC 6/4MT, EMC 10, EMC 10T, EMC 10/4, EMC 10/4T: The color change cam moves the needle case during a color change.
2 - 22 Lubricating The Sewing Head The Pantograph The beam moves the hoop left/right (the X-axis) and forward/backward (the Y-axis). To keep the beam assembly in good condition, you must lubricate it with sewing machine oil regularly as described in the following schedule. Placing a clean, soft cloth under the lubrication points when possible will help keep the machine clean.
The Pantograph 2 - 23 EMC 1, EMC 6, EMC 6M, EMC 6ML, EMC 6MLT, EMC 10, EMC 10T, CH 1, ADV 18: Refer to Figure 2-21 for the pantograph locations that require lubrication Idler Pulley Right Rollers Left Rollers Right Y Rail, Front and Rear Front &...
2 - 24 Lubricating The Sewing Head The Pulley Assembly Referring to Figure 2-22, proceed with the following steps: Drive Cover Locking Tab X-Drive Cover X-Carriage Cover Screws Beam Figure 2-24 1. Turn the power switch to OFF. 2. Remove the X-drive cover. All Other Peripherals EMC 6 ONLY Figure 2-22...
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The Pantograph 2 - 25 3. Move the X-carriage manually all the way to the left. 4. Insert the tube of the oil bottle through the access hole and place one drop of oil on top of the pulley shaft. Oil access hole Place one drop of oil at each location Figure 2-25...
2 - 26 Lubricating The Sewing Head The X-Carriage Rollers Use the same procedure to lubricate the four X-carriage rollers that you used with the drive pulleys. Place one drop of oil on each roller as shown in Figures 2-27, 2-28., and 2-29. Lubricate this area once every 160 Figure 2-27 machine operating hours.
The Pantograph 2 - 27 The Y-Rails The two Y-carriages are on either side of the beam. You must lubricate the Y-rails that they ride on. The Y-rails are accessed through the slots on either side of the beam. Refer to Figure 2-28 for the specific points of lubrication. 1.
2 - 28 Lubricating The Sewing Head Trimmers General The optional trimmer assembly is located under the sewing bed, as indicated in Figure 2-33. It trims the thread below the needle plate when a color change or trim immediate command is performed. To insure reliable performance, the trimmer assembly must be lubricated on a regular schedule as indicated in the following chart: Lower Trimmer Lubrication Schedule Lubrication Point...
Trimmers 2 - 29 EMC 6MLT, EMC 6/4MT: Remove the trimmer cam box cover, located at the left end of machine, as shown in Figure 2-31. Place a dollop of grease on the trimmer cam groove every six months. Z-Drive Motor Bed Assemblies Trimmer Linkage Trimmer Cam Box...
2 - 30 Lubricating The Sewing Head EMC 10T, EMC 10/4T: Remove the rear bed cover shown in Figure 2-33. Locate the trimmer cam shown in Figure 2-34. Place a dollop of grease on the trimmer cam groove every six months. Rear Bed Cover Needle Plate Figure 2-33...
Trimmers 2 - 31 The Rear of Head Trimmer Parts Remove the rear bed cover to access the trimmer areas shown in Figures 2-34 and 2-35. Lubricate these areas by placing a drop of sewing machine oil in the indicated locations every 40 operating hours. Figure 2-34 shows that both the cam follower bracket and the cam follower bracket lever have two locations that need oil.
2 - 32 Lubricating The Sewing Head The Front Of Head Trimmer Parts EMC 6MLT, EMC 6/4T, EMC 10T, EMC 10/4T Remove the needle plate to access the trimmer areas shown in Figures 2-36, 2-37, and 2-38. Lubricate these areas sparingly by placing a drop of sewing machine oil in the indicated locations every 40 operating hours.
3 - 1 3. Hook Timing General Regular adjustments will prolong the life of any embroidery peripheral, as well as also minimize down-time and lost production time. A properly adjusted machine will perform better, last longer, and help to create a higher-quality product. To maintain the machine’s operating condition, certain adjustments must be performed on a regular basis.
3 - 2 Head Timing Head Timing Head Timing covers these related topics. • Headup • Needle Depth • Hook Timing • Hook Gap To make a stitch, the rotary hook point, which holds the bobbin case, passes behind the needle just as the needle is beginning to rise from its lowest point. As the needle rises, a small loop of thread is created behind it as shown in Figure 3-1.
3 - 3 Machine Out Of Timing It is rare for the machine to go out of timing, but the most frequent cause is spiking the hoop. Spiking means that the needle strikes or is embedded in the hoop while sewing.
3 - 4 Machine Out Of Timing Setting Timing General When you time the sewing head, you perform the procedures listed below. Detailed illustrations and instructions for each procedure will follow: Adjust the Needle Depth if necessary. The correct needle depth is that point where the needle reaches the lowest point in its cycle and approximately the bottom of the eye of the needle is just visible inside the bobbin cavity of the rotary hook.
Needle Depth Check/Adjustment 3 - 5 Needle Depth Check/Adjustment Setting needle depth is one of the basic operator adjustments required to achieve good sewing quality. The needle depth setting is the relationship between the eye of the needle and the hook when the needle is at its lowest point. Because of the wide range of acceptable needle types, the distance between the blunt end and the eye of the needle may vary enough to cause missed stitches or cut threads if the needle depth is not absolutely correct.
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3 - 6 Machine Out Of Timing 10. Look directly into the hook to compare the needle’s position to the illustrations in Figure 3-3. Figure 3-3 If the eye of the needle is within the limits shown in the illustrations, then your needle bar setting is correct and no adjustments are required.
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Needle Depth Check/Adjustment 3 - 7 If the needle’s eye is not in the acceptable range, adjust it as described here: 11. Remove the needle case lower cover. Refer to Figure 3-4. 12. Use a 2.5mm hex driver to loosen the needle bar connecting stud. 13.
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3 - 8 Machine Out Of Timing Hook Timing The Hook Timing adjustment should not change when adjusting the needle depth position, but it would be a good idea to check it and make sure. Figures 3-5 and 3-6 show the proper hook/needle relationship. Needle Rotary Hook Point Figure 3-5...
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Checking Hook Timing 3 - 9 Checking Hook Timing 1. Install a new needle so that the needle/hook point positioning can be better evaluated. 2. Remove the table insert and bobbin case, if not already removed. 3. Remove the two screws that secure the needle plate and lift the needle plate.
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3 - 10 Machine Out Of Timing 9. Press the [ALT][ ⇒ ] keys and the LCD will display: HOOK POSITION. The hook point, as shown in Figure 3-8, should have a gap between it and the needle approximately the thickness of the thread being used. The gap can be checked by positioning a length of sewing thread below the hook, between it and the needle.
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Adjusting Hook Timing 3 - 11 Adjusting Hook Timing Hook timing may be adjusted wrong if the needle depth is incorrect, so always check the needle depth first. The following steps presume that the rotary hook is installed in the approximate position for sewing. Refer to Figures 3-10 and 3-11. If you have not already done so, remove the needle plate and the bobbin case.
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3 - 12 Machine Out Of Timing 6. UTC-equiped peripherals only: check to make certain the UTC retaining tab is still securing the inner basket of the rotary hook as shown in Figures 3-12 and 3-13. If the inner basket moves, it could cause a broken needle or a damaged hook.
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Adjusting Hook Timing 3 - 13 9. When the gap is correct, tighten all the screws. You can press the [ ⇒ ] key to move the rotary hook to make the screws more accessible. It is easy for the hook position to slip, so tighten the screws slowly. 10.
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3 - 14 Machine Out Of Timing Under Thread Control (UTC) Adjustments NOTE: This section is intended for machines that feature UTC sensors. Sensor Arm The primary purpose of the UTC, shown in Figures 3-14, 3-15, and 3-16, is to signal when the bobbin thread runs out or breaks.
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Under Thread Control (UTC) Adjustments 3 - 15 UTC Sensor Arm UTC Retaining Tab. It is properly placed in the indentation of the rotary hook inner basket Front of the UTC. This should be mounted flush with the edge of the needle plate.
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3 - 16 Machine Out Of Timing When To Call For Service Although this basic manual covers many service adjustments and procedures, there will be times when the work may be more technically oriented than you are comfortable with. Your local area service representative will be able to handle all types of diagnostics and repairs that are needed to keep your embroidery peripheral running in peak shape.
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