[amayausers] Re: Thread Breaks

When you see oil soaked 'fuzzies' on your hat brim, or falling into  
the sewout area in a hoop, then you know it is way past time to clean  
up above the needles...our problem hasn't been with excess oil as Rob  
gets-we were still only oiling the 'ten' drops recommended until we  
had a needle shaft get 'stuck' once. Service tech told us to add  
extra oil up in the V slot, and also go take off the magnetic cover  
and put 2 drops of oil on each shaft directly when it started to get  
noisy. Problem was caused by running the same colors all the time on  
the same needles-right next to each other. We had black, white, red,  
gold, blue as the first 5 needles and were doing a ton of fire dept  
or school mascots-all using the same colors. This was causing the  
shafts to over heat, suck up more oil, and then run out of oil long  
before the service timer called for more. Now with the upgrade  
calling for 25 drops, big difference! Also, we no longer put the most  
used colors next to each other-we have them separated and also move  
the position every time we put a new spool in. Like rotating  
tires...change the location of the ones that get the most use. When  
we do the 2 million service, we add 5-6 drops of oil in the V, then  
when it calls for it, the 25 drops. No more noisy shafts running!
Roland
On Mar 25, 2006, at 2:27 PM, Rod or Sharon wrote:

> Mary,
>
> Sorry if it sounded like I made it sound like you had to oiled the
> reciprocater directly all the time. As you wanted to know what it  
> was ,I
> described how you could get a good look at it and see just how the  
> whole
> system worked. Whenever I have the front covers off,  I do soak up  
> the pads
> with oil directly during the inspection process.
>
> The newest spects on oiling the reciprocator is to add "25" drops  
> of oil in
> the oiling channel when the pop-up for this procedure is required.  
> But once
> again, if the machine is running constantly and/or the machine sits  
> for long
> periods of time and is not used, it is only wise to add a few more  
> drops of
> oil in the channel to keep the system wet with oil..
>
> At the bottom of the reciprocator shaft, there is an oil soaker pad  
> that
> will collect any excess oil to keep it from running out the bottom and
> soiling a garment. Anytime I have the covers off the front of a  
> machine I
> always take a screwdriver and tissue paper, paper towel, etc, and  
> try to
> soak out the oil from this pad by squeezing the paper towel against  
> it with
> the screwdriver. If this is not done periodically and the machine  
> is kept
> well oiled, then there is the possibility that the pad will/could  
> become
> saturated and oil will have no where to go but down and down is  
> toward the
> needle and what ever you are sewing on...
>
> Rod Springer
>
> Embroidery Cottage
> Rod & Sharon Springer
> Melco Amaya Tech & Trainer
> Design Shop Pro+ Digitizing
>
> Boise, ID  83713
> 208-938-3038
>
>
> ----- Original Message -----
> From: "Shuffletown Embroidery" <shuffemb@xxxxxxxxxxxxx>
> To: <amayausers@xxxxxxxxxxxxx>
> Sent: Saturday, March 25, 2006 11:51 AM
> Subject: [amayausers] Re: Thread Breaks
>
>
>
>> Rod,
>> I found the reference to the reciprocator lubrication in the 2 M
>> maintenance. According to my manual, it is lubricated indirectly by
>> putting
>> 24 drops of oil in the v-channel. It sounds like you are talking  
>> about a
>> direct lubrication of the reciprocator. Or is the indirect one all  
>> that is
>> needed?
>> Thanks for taking the time to explain this to me.
>> Mary
>>
>> Mary Buckle
>> Shuffletown Embroidery
>> Charlotte, NC
>> 704-398-1273
>>
>>
>> -----Original Message-----
>> From: amayausers-bounce@xxxxxxxxxxxxx
>> [mailto:amayausers-bounce@xxxxxxxxxxxxx] On Behalf Of Rod or Sharon
>> Sent: Thursday, March 23, 2006 5:47 PM
>> To: amayausers@xxxxxxxxxxxxx
>> Subject: [amayausers] Re: Thread Breaks
>>
>> Mary,
>> Each needle bar has an attached stud that rides along the  
>> alignment groove
>> in the black front cover plates behind the needle case. When a color
>> change
>> is selected by the machine, it moves the needle case to a new  
>> position and
>> selects a new needle bar to be the "active" needle
>>
>> The stud on this needle bar slides into a set of jaws that is  
>> lined up
>> with
>> the groove in the plastic front covers in the center of the  
>> machine behind
>> the needle case. These jaws are called the reciprocator. The  
>> reciprocator
>> assembly is mounted on a hollow metal tube called the reciprocator  
>> shaft.
>> Within the reciprocator assembly is a set of felt oil retaining  
>> pads and a
>> small rubber boot that acts kind like an oil sump. It is critical to
>> maintain proper lubrication of this system.
>>
>> Think about this. The needle case moves and in the process selects a
>> different needle bar/needle for each color change, but each needle  
>> bar
>> aligns up with the same and only one reciprocator jaws and shaft.  
>> This of
>> course means that the reciprocator assembly wears 100% of the time  
>> the
>> machine is running. Failure to maintain proper lubrication in this  
>> area
>> leads to all sorts of problems, especially in the Z axis area with  
>> errors
>> and timeouts, thread breaks, etc.
>>
>> To get a good look at the reciprocator assembly, color change to  
>> needle 16
>> and remove the left front black plastic cover. DO NOT ALLOW THE  
>> NEEDLE
>> CASE
>> TO MOVE or COLOR CHANGE WHILE THE FRONT COVER IS OFF. The needle  
>> bars will
>> drop out of the groove in the right cover and this is a very bad  
>> thing.
>> Removing the front covers one at a time is a normal part of the  
>> internal
>> lubrication and inspection process. Just be careful to not do  
>> anything
>> that
>> would start the needle case to move before the front cover is  
>> replaced.
>>
>> Rod Springer
>>
>> Embroidery Cottage
>> Rod & Sharon Springer
>> Melco Amaya Tech & Trainer
>> Design Shop Pro+ Digitizing
>>
>> Boise, ID  83713
>> 208-938-3038
>> ----- Original Message -----
>> From: "Shuffletown Embroidery" <shuffemb@xxxxxxxxxxxxx>
>> To: <amayausers@xxxxxxxxxxxxx>
>> Sent: Thursday, March 23, 2006 2:45 PM
>> Subject: [amayausers] Re: Thread Breaks
>>
>>
>>
>>> OK, What's a reciprocator? I've never seen a reference to it. Is  
>>> that on
>>> an
>>> Amaya?
>>> Mary
>>>
>>> Mary Buckle
>>> Shuffletown Embroidery
>>> Charlotte, NC
>>> 704-398-1273
>>>
>>> -----Original Message-----
>>> From: amayausers-bounce@xxxxxxxxxxxxx
>>> [mailto:amayausers-bounce@xxxxxxxxxxxxx] On Behalf Of Douglas Parker
>>> Sent: Thursday, March 23, 2006 4:19 PM
>>> To: amayausers@xxxxxxxxxxxxx
>>> Subject: [amayausers] Re: Thread Breaks
>>>
>>> Hi Jeff,
>>>
>>> Tnx for the reply. I too watch maintenance and use the timers as  
>>> a basic
>>> guide. Daily and sometimes multiple times a day when running  
>>> hard, I do
>>> the
>>> hook lubrication. Several times a week, even before the timer comes
>>> around
>>>
>>
>>
>>> I
>>> cycle to needle 16 and do the reciprocator  lubrication, and at  
>>> least 1
>>> time
>>> every two weeks I pull the needle case cover and lube the needle  
>>> bars
>>> upper
>>> and lower pads. If the machine has sat idle for several days  
>>> ( and in
>>> slow
>>> times, this can be up to a couple of weeks or even a month), I  
>>> run the
>>> entire machine lubrication. This takes a couple of hours but I  
>>> find it is
>>> worth it. Oil and grease are cheap as are needles. Replacing  
>>> major parts
>>> are
>>> expensive even with the maintenance agreements.
>>> My machine is an older one (SN: 320821) and has all its original  
>>> parts
>>> except for the rotary hook. It still stitches fine and runs at  
>>> 1200 spm
>>> default speed.
>>>
>>> Regards,
>>>
>>> Doug Parker
>>> JTB Embroidery Services, Inc.
>>> Denver, CO
>>> jtbembsvcinc@xxxxxxxxxxxxx
>>>
>>> On 3/23/06 14:06, "Jeff Banks" <banksje@xxxxxxxxxxx> wrote:
>>>
>>>
>>>> HI Douglas,
>>>>
>>>>  I think you will find it is now 4,000,000 stitches. But, I have  
>>>> to go
>>>>
>>> back
>>>
>>>> to my last post. If 3,900,000 of those stitches were all on one  
>>>> or two
>>>> needles, I am gong to look long and hard at those rollers and  
>>>> associated
>>>> mechanics. It also does not state to replace them unless  
>>>> needed.  It is
>>>> a
>>>> lubrication and cleaning, and replace if needed maintenance.  
>>>> Again, what
>>>>
>>> if
>>>
>>>> the 4,000,000 stitches were done with metallic thread? This is  
>>>> going to
>>>>
>>> show
>>>
>>>> more wear and tear on the parts. What if the 4,000,000 stitches  
>>>> were
>>>> done
>>>>
>>> in
>>>
>>>> a 100 degree heat, in a warehouse with construction next door  
>>>> going on?
>>>>
>>> All
>>>
>>>> the rollers may be dirty, not just the ones used for those 4  
>>>> million
>>>> stitches.  If a particular thread feed mechanics and rollers  
>>>> seem to be
>>>> giving a problem, (thread popping out along one side for  
>>>> instance), then
>>>> doing the maintenance and insuring it is clean and properly  
>>>> lubricated
>>>> is
>>>> the first thing to look at, even if you just did it. The point  
>>>> is, more
>>>> or
>>>> less maintenance may need to be done depending on use and  
>>>> environment.
>>>>
>>>>  Jeff Banks
>>>>  Melco Embroidery Systems
>>>>
>>>>
>>>> ----- Original Message -----
>>>> From: "Douglas Parker" <jtbembsvcinc@xxxxxxxxxxxxx>
>>>> To: <amayausers@xxxxxxxxxxxxx>
>>>> Sent: Thursday, March 23, 2006 1:44 PM
>>>> Subject: [amayausers] Re: Thread Breaks
>>>>
>>>>
>>>>
>>>>> Rod & All,
>>>>> Have been following this thread on thread tracking and new roller
>>>>> lubrication. I recently (December 2005) replaced my black  
>>>>> rollers with
>>>>>
>>> the
>>>
>>>>> new yellow rollers and the knurled pinch rollers. As you  
>>>>> pointed out,
>>>>> it
>>>>> is
>>>>> difficult, following the Melco approved lubrication procedures,  
>>>>> to get
>>>>>
>>> the
>>>
>>>>> roller down in the seat without contaminating the surface with  
>>>>> grease.
>>>>> At the same time I replaced the rollers I upgraded my software  
>>>>> from
>>>>> 4.02.022
>>>>> to 6.08.522. There is in the 6.08.522 a lubrication procedure ( I
>>>>> believe
>>>>> at
>>>>> 2 million stitches) that requires the removal, cleaning,  
>>>>> lubrication
>>>>> and
>>>>> replacement of the feed rollers and pinch rollers. I have had  
>>>>> to do
>>>>> this
>>>>> at
>>>>> least one time since the initial installation.
>>>>>
>>>>> Maybe Jeff Banks can verify this as he is a MELCO guru.
>>>>>
>>>>> Regards,
>>>>> Doug Parker
>>>>> JTB Embroidery Services, Inc.
>>>>> Denver, Colorado
>>>>> jtbembsvcinc@xxxxxxxxxxxxx
>>>>>
>>>>>
>>>>> On 3/23/06 08:35, "Rod or Sharon" <springer37@xxxxxxxxxxxx> wrote:
>>>>>
>>>>>
>>>>>> Beverly,
>>>>>> The new style yellow rollers are a definite improvement over  
>>>>>> the black
>>>>>> ones
>>>>>> but they are critical to a couple of important items. The  
>>>>>> first is
>>>>>>
>>> proper
>>>
>>>>>> lubrication, especially the little red pinch rollers. Both the  
>>>>>> red
>>>>>> pinch
>>>>>> rollers and the yellow thread feed rollers need to be removed
>>>>>> periodically
>>>>>> and cleaned . It is difficult to say just how long between  
>>>>>> cleanings
>>>>>> one
>>>>>> should wait. This would depend on how much one needle is used  
>>>>>> over
>>>>>> another
>>>>>> and the wear each individual roller system would receive. Pop  
>>>>>> off a
>>>>>> couple
>>>>>> of the more used red pinch rollers, black or white thread for  
>>>>>> example
>>>>>> or
>>>>>> the
>>>>>> ones that seem to be giving you the most trouble, and look  
>>>>>> carefully
>>>>>> at
>>>>>> the
>>>>>> axle hub that it rotates on. If  they appear dry  and/or you  
>>>>>> can see a
>>>>>> red
>>>>>> powder looking residue on the axle hub the red pinch roller  
>>>>>> rotates
>>>>>> on,
>>>>>> it
>>>>>> is imperative that they be cleaned and lubricated.
>>>>>>
>>>>>> A good pre-sign that lubrication may be the culprit, is the  
>>>>>> thread
>>>>>> tracking
>>>>>> to the left side of the roller as you indicated in your post.
>>>>>>
>>>>>> The second thing that is critical with the new rollers is that  
>>>>>> if any
>>>>>>
>>> oil
>>>
>>>>>> or
>>>>>> grease gets on the surface of them, the tread will track clear  
>>>>>> off of
>>>>>>
>>> the
>>>
>>>>>> left side of the rollers and cause a bird-nest. They must be kept
>>>>>> clean.
>>>>>> To
>>>>>> clean them, take them out----both the red pinch rollers and  
>>>>>> yellow
>>>>>>
>>> thread
>>>
>>>>>> feed rollers........, and wash them with warm soapy water,
>>>>>> re-lubricate
>>>>>> and
>>>>>> replace them being very careful not to get any lubricating  
>>>>>> grease back
>>>>>>
>>> on
>>>
>>>>>> the surface of the rollers. I always wash my hands after  
>>>>>> applying the
>>>>>> lubricating greas e with a cotton q-tip before re-attaching  
>>>>>> the red
>>>>>> rollers
>>>>>> and inserting the yellow rollers. I apply the grease to the  
>>>>>> axle hub
>>>>>> the
>>>>>> red
>>>>>> roller rotates on and the hub area in the machine that the yellow
>>>>>> roller
>>>>>> rotates in, I do not apply any grease direcly to the rollers
>>>>>> themselves
>>>>>> as
>>>>>> it is very difficult not to transfer grease all over the place.
>>>>>>
>>>>>> Another item worthy of mention, along this same line, is how  
>>>>>> long has
>>>>>> it
>>>>>> been since the needle bar shafts were last oiled? This too can  
>>>>>> create
>>>>>> thread
>>>>>> break problems for the same reason as above. Some needles get  
>>>>>> used
>>>>>> more
>>>>>> often than others and therefore should receive more attention  
>>>>>> in the
>>>>>> lubrication field. How fast are you running your designs?  
>>>>>> Remember
>>>>>> additional speed equals more friction which generates heat  
>>>>>> which means
>>>>>> lubrication is and will be a very critical element in being  
>>>>>> successful
>>>>>> while
>>>>>> using the Amaya..
>>>>>>
>>>>>> Hope this helps
>>>>>>
>>>>>> Rod Springer
>>>>>>
>>>>>> Embroidery Cottage
>>>>>> Rod & Sharon Springer
>>>>>>
>>>>>> Melco Amaya Tech & Trainer
>>>>>> Design Shop Pro+ Digitizing
>>>>>>
>>>>>> Boise, ID  83713
>>>>>> 208-938-3038
>>>>>>
>>>>>> ----- Original Message -----
>>>>>> From: "Beverly Thompson" <beverlyt@xxxxxxxxxxx>
>>>>>> To: <amayausers@xxxxxxxxxxxxx>
>>>>>> Sent: Thursday, March 23, 2006 7:32 AM
>>>>>> Subject: [amayausers] Re: Thread Breaks
>>>>>>
>>>>>>
>>>>>>
>>>>>>> Herb,
>>>>>>>
>>>>>>> thanks for the advice.  I am running anvil rib tees,  using 2
>>>>>>> cutaway,
>>>>>>> and
>>>>>>> mt of 4.  It seems that alot of times when it breaks there's  
>>>>>>> a little
>>>>>>> loop
>>>>>>> of thread behind the roller wheel.  also on some of the  
>>>>>>> rollers it
>>>>>>>
>>> looks
>>>
>>>>>>> like the yellow roller is far to the right and the thread  
>>>>>>> barely on
>>>>>>> it.
>>>>>>> Could that be a problem?
>>>>>>> As far as the needles,  I always check to see if the eye is  
>>>>>>> straight,
>>>>>>>
>>> if
>>>
>>>>>>> not
>>>>>>> i make an adjustment there.  thanks for the magnifer tip,  i  
>>>>>>> find i
>>>>>>>
>>> have
>>>
>>>>>>> trouble seeing even with my glasses.  So your saying go up to  
>>>>>>> 6 mt
>>>>>>> and
>>>>>>> try
>>>>>>> that?
>>>>>>>
>>>>>>> Regards,
>>>>>>> Beverly Thompson
>>>>>>> Perdido Beach Embroidery
>>>>>>>
>>>>>>> ----- Original Message -----
>>>>>>> From: "HK Acree" <hkacree@xxxxxxxxxxxx>
>>>>>>> To: <amayausers@xxxxxxxxxxxxx>
>>>>>>> Sent: Thursday, March 23, 2006 12:16 AM
>>>>>>> Subject: [amayausers] Re: Thread Breaks
>>>>>>>
>>>>>>>
>>>>>>>
>>>>>>>> Bev,
>>>>>>>> After the change in rollers the material thickness you were  
>>>>>>>> used to
>>>>>>>> using
>>>>>>>> changes. Bump it up by 2 to begin with then check your work and
>>>>>>>> adjust
>>>>>>>> accordingly. You should see  far less thread breaks.
>>>>>>>>
>>>>>>>> As for your needles. Rod Springer really helped  me on this  
>>>>>>>> one. Get
>>>>>>>> a
>>>>>>>> magnifier with the light in it. Cheap at Home Depot, $2.50.
>>>>>>>> Look at the groove in the needle. This represents the eye.  
>>>>>>>> Tweak it
>>>>>>>> a
>>>>>>>> hair
>>>>>>>> and the needles are set.
>>>>>>>>
>>>>>>>> Would appreciate some feedback on this.
>>>>>>>>
>>>>>>>> Herb
>>>>>>>> Royal Embroidery
>>>>>>>> ----- Original Message -----
>>>>>>>> From: "Beverly Thompson" <beverlyt@xxxxxxxxxxx>
>>>>>>>> To: <amayausers@xxxxxxxxxxxxx>
>>>>>>>> Sent: Wednesday, March 22, 2006 5:51 PM
>>>>>>>> Subject: [amayausers] Thread Breaks
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>> Hello Everybody,
>>>>>>>>> did the roller upgrade on my machines, not the software.  i am
>>>>>>>>> starting
>>>>>>>>> to
>>>>>>>>> get thread breaks again.  some needles run good others not.  I
>>>>>>>>> don't
>>>>>>>>> think
>>>>>>>>> it was how they were put in or anything because a tech did it.
>>>>>>>>> Can someone tell me again how to clean the rollers in case its
>>>>>>>>>
>>> grease.
>>>
>>>>>>>>>
>>>>>>>>>
>>>>>>>>> Regards,
>>>>>>>>> Beverly Thompson
>>>>>>>>> Perdido Beach Embroidery
>>>>>>>>>
>>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>
>>>>>>>
>>>>>>>
>>>>>>>
>>>>>>
>>>>>>
>>>>>>
>>>>>
>>>>>
>>>>>
>>>>>
>>>>>
>>>>
>>>>
>>>>
>>>
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