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Saurer Melco EMC 10 Technical Manual

Multi-head embroidery machine
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Technical manual for
the EMC 10/12
multi-head embroidery
machine
Part Number 110248-01, Revision A
•
Twelve Melco Embroidery Heads
•
10 Needles with automatic color change
•
Automatic Trimmers
•
Caps, Tubular, Sash Frame

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Summary of Contents for Saurer Melco EMC 10

  • Page 1 Technical manual for the EMC 10/12 multi-head embroidery machine • Twelve Melco Embroidery Heads • 10 Needles with automatic color change • Automatic Trimmers • Caps, Tubular, Sash Frame Part Number 110248-01, Revision A...
  • Page 2 1575 West 124th Avenue Denver, Colorado 80234 United States of America E-mail via the Internet: publications@melco.com Copyright © Melco Embroidery Systems, 1995. 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.

  • Page 3: Table Of Contents

    Table of Contents 1. Introduction Scope Of Manual Conventions Used In Manual Glossary Of Terms Maintenance Philosophy Static Electricity And Grounding Strap Use Warranty Considerations System Overview Physical/Functional Arrangement 2. Service Adjustments General Drive Belt Tensions The SEEM C.Tronic 87 Type 105 Belt Tension Gauge Carriage Section X and Y Drive Belt Tensions Under Carriage Section...
  • Page 4 Table of Contents Center Index 2-27 Cap Frame Limits 2-27 Flats Limits 2-28 Trimmer System 2-30 Sequence of Trim Events 2-30 Trimmer Setup And Adjustments 2-31 Spring Knife 2-32 Under Thread Presser 2-34 Movable Knife Adjustment 2-36 Movable Knife Home Position 2-36 Trimmer Cam Position 2-38...
  • Page 5 Table of Contents Embroidery Heads 3-22 Arm and Bed Assemblies 3-22 Z Motor Replacement 3-22 Tensioner Assembly Panel Removal 3-24 Pre-Tensioner 3-25 Replacing An Individual Thread Tensioner 3-25 Changing A Check Spring 3-26 Replacing Other Thread Tensioner Parts 3-27 Replacing A Thread Break Contact Post 3-28 Replacing The Thread Break Contact Brush 3-29...
  • Page 6 Table of Contents This page intentionally left blank EMC 10/12 Technical Manual...

  • Page 7: Introduction

    1 - 1 1. Introduction Scope Of Manual The EMC 10/12 Technical Manual is designed to provide the user with the information necessary to perform repairs and adjustments beyond routine operator maintenance. This technical manual is presented in three basic sections: 1) an overview of general information found in this introductory section, 2) service adjustments, and 3) mechanical disassembly and replacement of the major components of the machine.

  • Page 8: Glossary Of Terms

    1 - 2 Glossary Of Terms NOTE: This term is used when additional information is required beyond the routine process for communicating the information. It may be used to clarify certain portions of text or to call attention to other items previously mentioned or mentioned later in the procedure.

  • Page 9: System Overview

    Physical/Functional Arrangement 1 - 3 System Overview The EMC 10/12 Embroidery Machine is a twelve head machine assembled with Melco’s ten needle, cylinder arm embroidery heads. The machine is designed for embroidering on flat goods, as well as with cap frames, cylinder hoops, and a sash frame.
  • Page 10 1 - 4 System Overview This page intentionally left blank EMC 10/12 Technical Manual Melco Embroidery Systems...

  • Page 11: Service Adjustments

    Drive Belt Tensions 2 - 1 2. Service Adjustments General This section of the manual provides detailed information for performing machine adjustments required during maintenance or parts replacement. The procedures are guidelines for personnel practicing good maintenance and repair techniques. It is recommended that some procedures in this section be performed by factory-trained personnel in order to obtain the best results.

  • Page 12: Carriage Section

    2 - 2 Carriage Section 3. Check that the tensioning plunger marked "S" is installed in the top of the gauge housing, then rotate this plunger clockwise into the gauge until it is fully seated. 4. Attach the power cable to 120 Volts AC and observe the reading on the gauge indicator box.
  • Page 13 X and Y Drive Belt Tensions 2 - 3 6. Refer to the procedure for attaching the SEEM C.Tronic 87, Type 105 belt tension gauge on page 2-1 and attach the gauge to the belt midway from the edge of the outer belt clamping block to the center of the drive shaft pulley (see Figure 2-2).

  • Page 14: Under Carriage Section

    2 - 4 Under Carriage Section 8. Refer to Figure 2-4, and loosen the hex bolt lock and the four set screws locking the dowels. hex bolt lock inner belt clamping block locking dowel locking dowel (1 of 2) set screws (4 ea.) belt clamp socket head cap screws (1 of 4) outer belt...

  • Page 15: Attach Motor And Belt

    X and Y Motor Belt Tensions 2 - 5 Attach Motor and Belt 1. Put the motor belt in place and attach the motor to the motor mounting bracket. Tighten the motor bolts securely. 2. Snug the motor mounting bracket to the frame, allowing for movement within the slotted holes.

  • Page 16: Power Supply

    2 - 6 Under Carriage Section 9. If the two readings vary by more than 2 units on the indicator box, align the motor pulley to the shaft pulley until both sides read within 2 units. 10. Tighten the motor mounting bracket bolts securely. Power Supply The power supply assembly is made of two independent supplies, the system voltage and and logic voltage.
  • Page 17 4. The closest 2 positions have red wires in them and the 4th, 5th, and 6th Blue positions have black wires (see Figure 11 PIN 2-7). Yellow CONNECTOR Orange 5. Attach your digital voltmeter leads between one of the red wires and one of the black wires to measure Install meter Black...

  • Page 18: Embroidery Heads

    2 - 8 Embroidery Heads 12. Turn the EMC 10/12 back on. 13. With an insulated screw driver, rotate the potentiometer clockwise to increase or counter-clockwise to decrease the voltage. 14. Monitor the voltage at the red and black wires on the connector as you adjust the potentiometer until the voltage reads between +4.90 and +5.10 Volts DC.
  • Page 19 Setting The Shaft Couplings and Thrust Bearings 2 - 9 Before you make any other adjustments to the Z drive system, you must first check that each of the Z shaft sections are securely coupled together and that the thrust bearings are set properly.

  • Page 20: Synchronizing The Heads

    2 - 10 Embroidery Heads Synchronizing The Heads "FACTORY SERVICE ADVISED" NOTE: This procedure requires the use of a special Melco service tool: the Melco 10 needle head up fixture (p/n 995673-01). Head synchronization is very critical in maintaining proper stitch timing for all the embroidery heads.

  • Page 21: Shaft Drive Gear Mesh

    Synchronizing The Heads 2 - 11 6. Position the head up fixture into the head up alignment hole. 7. Loosen the socket head cap screw in the locking collar of the bevel gear on the Z drive shaft associated with the head to be synchronized (see Figure 2-11). This will loosen the grasp of the Z drive shaft on the head.

  • Page 22: Z Encoder System Introduction

    2 - 12 Embroidery Heads Z Encoder System Introduction The ability to place stitches precisely at high speed is dependent on the accurate operation of the electronics and electromechanical assemblies. The "key" to this is the Z encoder. The information provided to the CPU and other PCBs by the Z encoder is the basis for all the embroidery head activity.
  • Page 23 Z Encoder Inspection 2 - 13 The first red LED on the CPU, can be used by the technician to see if the CPU is in fact receiving an index, or head up pulse from the encoder (indicating that the encoder and associated cables are functional).

  • Page 24: Z-Axis Encoder Calibration

    2 - 14 Embroidery Heads Z-Axis Encoder Calibration "FACTORY SERVICE ADVISED" The Z-axis encoder position is set at the factory and most likely will not require any adjustment unless the Z motor is replaced. Should calibration become necessary, refer to the following procedure. 1.

  • Page 25: Thread Tensioner Check Spring Adjustment

    Thread Tensioner Check Spring Adjustment 2 - 15 9. Carefully retighten the encoder mounting screws. 10. To verify the correct encoder position, click on 1 Rev or To Headup. 11. Use the dial indicator to return to the "half stroke" position. The display should read 257.0 ±...

  • Page 26: Cross Roller Bearing Centering

    2 - 16 Embroidery Heads Note 2: If you exceed 1/4 turn, you may start to see a possible deterioration of overall embroidery quality and trimmer reliability. A trimmed thread may start having short tails or ’sling shot’ (thread flies out of the needle when trimmed).
  • Page 27 Cross Roller Bearing Centering 2 - 17 3. Slide the retainer plate assembly left to the point where the left edge of the retainer plate is aligned with the center of the needle bar guide shaft felt pad (see Figure 2-15). 4.

  • Page 28: Retainer Plate Bearing Adjustment

    2 - 18 Embroidery Heads Retainer Plate Bearing Adjustment Note: This procedure requires the use of a special service tool: the V-Rail Adjustment fixture (p/n 995675-01). To adjust without the fixture, refer to the Alternate Method at the end of this procedure. 1.

  • Page 29: Alternate Method

    Retainer Plate Bearing Adjustment 2 - 19 7. Push the retainer plate assembly left and right as far as possible without the bearings coming off the end of the embroidery head v-rail. While moving the retainer plate assembly try to hold the bearings from rotating (one at a time) with your fingers.

  • Page 30: Lower Rail Retainer Adjustment

    2 - 20 Embroidery Heads Lower Rail Retainer Adjustment This adjustment affects the forward and backward movement of the bottom of the needle case. Do not make the adjustment so tight that you preload the roller bearing in the head so it wears prematurely. Do not have so much free play that the needle has excessive movement.

  • Page 31: Jump Stitch Solenoid

    Jump Stitch Solenoid 2 - 21 Jump Stitch Solenoid If a jump stitch solenoid has been replaced, you may have to perform one or more of the adjustment procedures below: NOTE: The needle case must be removed to perform the adjustment procedures in this section.

  • Page 32: Bracket Positioning

    2 - 22 Embroidery Heads Bracket Positioning When attaching the jump stitch solenoid and bracket, it is not only necessary to place the plunger correctly, but you must also position the assembly in the proper forward to backward relationship. There are three concerns in positioning the solenoid and bracket assembly: The solenoid and bracket assembly should be far enough forward so the plunger Bracket...

  • Page 33: Color Change Motor Belt Tension

    Color Change Motor Belt Tension 2 - 23 Color Change Motor Belt Tension The color change belt tension should cause the color change cam to rotate with minimum backlash. CAUTION! The belt should be tensioned with some amount of slack so it is not so tight that it wears the color change shaft and bushings needlessly.
  • Page 34 2 - 24 Embroidery Heads 2. With the needle case in place attach the color change link bars (refer to Figure 2-21. Tighten the top socket head cap screws on the bar clamps but do not fully torque them down. (Note that the lower cap screw holds the clamp to the needle case;...

  • Page 35: Thread Break Brush Adjustment

    Thread Break Brush Adjustment 2 - 25 10. Turn the head mode switch to AUTO. 11. Go to the Advanced Features menu and select Head Timing. 12. Select Bottom Dead Center to extend all needles. 13. Visually check the needle alignment within the needle plate hole. If the alignment is not correct, repeat steps 5 through 9.

  • Page 36: And Y Stop/Limit Encoder Adjustments

    2 - 26 Embroidery Heads X and Y Stop/Limit Encoder Adjustments "FACTORY SERVICE ADVISED" A stop/limit encoder assembly is associated with the X and Y axes. The purpose of these assemblies is to stop the movement of the sash frame (or cap frames) at specified locations and limits.

  • Page 37: Center Index

    X and Y Stop/Limit Encoder Adjustments 2 - 27 Center Index The right hand disk inside the encoder assembly housing is the center index disk. One half of the disk is missing and the other half consists of the fully extended material.

  • Page 38: Flats Limits

    2 - 28 Embroidery Heads CAUTION! Incorrect move values used in the following steps may cause damage to the cap frame mechanism. 4. At the middle disk locations inside the encoder assembly housings for both the X and Y axes, loosen the set screws that secure the cap frame limit disks and open the disk gap slightly at both edges.
  • Page 39 X and Y Stop/Limit Encoder Adjustments 2 - 29 CAUTION! Incorrect move values used in the following steps may cause movement into the mechanism limits of the machine. 3. At the left hand disk locations inside the encoder assembly housings for both the X and Y axes, loosen the set screws that secure the flats limit disks and close the disk gap slightly at both edges.

  • Page 40: Trimmer System

    2 - 30 Trimmer System Trimmer System Although the trimmer system for the EMC 10/12 is assembled and thoroughly tested before the machine is shipped, there are a few things to be aware of to help prevent problems. • Dirt, dust, and thread lint may build up and prevent the movable knife from actuating correctly.

  • Page 41: Trimmer Setup And Adjustments

    Trimmer Setup And Adjustments 2 - 31 Trimmer Setup And Adjustments "FACTORY SERVICE ADVISED" CAUTION! If these adjustments are attempted without using the proper procedures and tools (and without proper training in some cases), machine components may be damaged and operation of the trimmers may become inconsistent.

  • Page 42: Spring Knife

    2 - 32 Trimmer System Spring Knife Poor trimming quality and non trimming may be caused by the condition of the spring knife. This situation may result if the spring knife is worn or is not parallel to the trimming action of the movable knife.
  • Page 43 Spring Knife 2 - 33 You may check the thread cutting ability in much the same way as the ink wipeoff test by performing actual thread cuts at several locations across the cutting range of the blade. To do this follow the steps below: 1.

  • Page 44: Under Thread Presser

    2 - 34 Trimmer System Under Thread Presser The under thread presser, shown in Figure 2-27, holds the bobbin thread after a trim. This permits a loop of bobbin thread for the next stitch. While the under thread presser holds the bobbin thread there should only be enough pressure applied to hold the thread in place under the movable knife.
  • Page 45 Spring Knife 2 - 35 The second part of checking under thread presser is to check if the bobbin thread is in fact being held in place. 1. While the machine is still turned off, remove the front bed cover and disconnect the connecting link from the movable knife drive arm by lifting it from the front pin (see Figure 2-24.) 2.

  • Page 46: Movable Knife Adjustment

    2 - 36 Trimmer System Movable Knife Adjustment Each movable knife is connected to the camming mechanism via a series of levers, rods and pivots. During a trim operation the cam follower is engaged and this in turn activates the trimmer reciprocator arm which provides back and forth movement to the trimmer rod (refer to Figure 2-29).
  • Page 47 Movable Knife Adjustment 2 - 37 5. If all 12 knives are in the same relative position, but not in the home position, adjust all knife positions simultaneously as described in Steps 6 and 7. 6. Refer to Figure 2-29 and loosen the set screws at point A. To Camming Mechanism Short Link...

  • Page 48: Trimmer Cam Position

    2 - 38 Trimmer System 11. Turn the power ON. In the Control Panel window, click the Advanced button, then click the Service button in the resultant Advanced Features dialog box. Trimmer Cam Position 12. In the Service dialog box click the Cutter Timing button. This takes the Z rotation to the position for setting the trimmer cam.
  • Page 49 Movable Knife Adjustment 2 - 39 17. Rotate the Z-axis shaft by hand at the trimmer cam pulley until all three of the pins in the fixture drop into the holes as indicated in Figure 2-30. The middle pin must be securely in positioned in the cam index hole. 18.

  • Page 50: Select Position

    2 - 40 Trimmer System Select Position 30. Engage the cam follower into the cam groove (refer to Figure 2-30) and hold the follower in place with a small block of wood (or other similar jamming device). 31. In the Service dialog, click the Release check box to enable manual rotation of the Z-axis shaft.
  • Page 51 Movable Knife Adjustment 2 - 41 39. Remove the select position fixture from the last head and then remove the jamming device from the cam follower. 40. Click the Trim button several times in the Do Now section of the Advanced Features dialog box.

  • Page 52: Picker Finger Center Position

    2 - 42 Trimmer System Picker Finger Center Position If the cap frame option is not part of your system, you may follow the procedure below to center the picker fingers, should it become necessary. If your EMC 10/12 has the cap frame option, you must give centering priority to the cap frame driver.

  • Page 53: Picker Home Position

    Picker Home Position 2 - 43 Picker Home Position The picker home position should be set so there is no interference between the picker and the table top when the table is lowered. To set this position, adjust the end of the picker fingers approximately 1/8 inch (3 to 4mm) from the edge of the rotary hook support (UTC body).

  • Page 54: Picker Engaged Position

    2 - 44 Trimmer System Picker Engaged Position The picker engagement performs best if adjusted so the end of the picker fingers are positioned .060 to .080 inches (1.5 to 2mm) from paper bobbin spool when set to the proper height. 1.

  • Page 55: Under Thread Control (Utc) Adjustments

    Under Thread Control (UTC) Adjustments 2 - 45 vicinity of grabber blade set screw wiper screw on front of grabber mount Figure 2 - 35 Grabber Setup 6. Go to the Thread Grabber menu and select Full Extended. If any blades are not centered in the wiper, loosen the set screw and push the grabber blade side to side until the correct centering alignment has been achieved (refer to Figure 2-35 for location of the set screw).

  • Page 56: Rotary Hook Retaining Finger Positioning

    2 - 46 Trimmer System It is very important that you follow these instructions any time the rotary hook retaining finger or UTC is loosened or moved. Please follow the instructions in the order they occur. Rotary Hook Retaining Finger Positioning 1.

  • Page 57: Utc Detection Arm To Needle Position

    Under Thread Control (UTC) Adjustments 2 - 47 UTC Detection Arm To Needle Position 7. Turn ON the machine and from the Service dialog in the Advanced Function menu select Bottom Center. 8. With the UTC Combination gauge finger, check the distance between the UTC detection arm and the needle (see Figure 2-37).
  • Page 58 2 - 48 Trimmer System 0.003 to 0.005" UTC detection arm connecting link upper thread trimmer movable lift connecting knife link here Figure 2 - 38 15. Manually position the movable knife directly under the UTC detection arm as shown in Figure 2-38. 16.

  • Page 59: Embroidery Test

    Under Thread Control (UTC) Adjustments 2 - 49 18. Reattach the connecting link to the movable knife (see Figure 2-38). Embroidery Test We now want to actually embroider onto properly hooped material to prove the adjustment is proper. A special design named UTCTEST comes on a disk with your machine.
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