AMAYA Lubrication Schedule and Specifications

Tools and supplies needed for these procedures are provided in your operator's kit.

Using the correct lubricants properly and when specified by scheduled maintenance is critical to the operation of the AMAYA. Failure to use the proper lubricants as specified can shorten the usable life of internal components and can void the warranty. Using the wrong lubricants can adversely affect your machine. The recommended and authorized lubricants to be used on the AMAYA are specified below:

Melco Part Number:	Part Name	Comments
761003-01	Oiler, 3/4 oz. bottle	sewing machine oil (order from Melco Mart)
32078	Grease, EMB-Polymer, 8 oz bottle	polymer light grease
32079	Grease, Multi-purpose (Lithium), 8 oz bottle	heavy grease

Maintenance Schedule

The following table summarizes the lubrication points and schedule for your machine. The table also lists which type of lubrication you should use for each lubrication point.

Please note that these schedules are meant to be used as guidelines. Depending on many circumstances (such as environment, garment types sewn on, etc.), you may need to lubricate your machines more or less frequently. Follow a lubrication schedule that best fits your needs to take care of your machine(s).

WARNING! Do not attempt to lubricate the machine while it is in operation.

Important: The color change lead screw is lubricated for life and should NEVER be lubricated by the user or a technician.

Every 200,000 Stitches:

Item	Lubricant
*Rotary Hook (uncoated)*	Sewing Machine Oil (1 drop)

Every 600,000 Stitches:

Item	Lubricant
*Rotary Hook (coated)*	Sewing Machine Oil (1 drop)

Every 2,000,000 Stitches:

Item	Lubricant
Needle Drive:
Reciprocator Guide, Cam Follower Shaft, Connecting Rod Pin	Sewing Machine Oil (25 drops)
Needle Case (Upper V-Rail)	Clean Only
Cap Frame Driver Guide Shafts	Clean Only

Every 4,000,000 Stitches:

Item	Lubricant
Needle Case (Needle Bar)	Sewing Machine Oil (1 drop)
Trimmer and Selector Lubrication	Sewing Machine Oil (1 drop)
Thread Feeder Rollers (Inspection, Cleaning, and Lubrication)	EMB-Polymer Grease

Every 10,000,000 Stitches:

Item	Lubricant
Take-Up Lever Cam and Cam Follower	EMB-Polymer Grease

Every 20,000,000 Stitches

Item	Lubricant
X-Drive Carriage Rail Guide	Multi-purpose (Lithium) Grease
Y-Drive Bearing Block Assembly	Sewing Machine Oil (4-5 drops)
Grabber Drive Eccentric	Sewing Machine Oil (1 drop)
Presser Foot Cam Follower Lubrication	EMB-Polymer Grease

Every 50,000,000 Stitches

Item	Lubricant
Y-Drive Bearing Block Assembly	Sewing Machine Oil (100 drops)

Every 100,000,000 Stitches:

Item	Lubricant
Presser Foot Cam	EMB-Polymer Grease

Once a Year

The following belts should be checked once a year: X-Cable, Y-Axis Timing Belt, and Z-Drive Belt. You can either have a Melco Service Technician check these belts for a charge (contact Melco Service-303.457.2025), or you can perform these checks yourself. To perform these checks, you will need to purchase the following tools / fixtures from the Melco Parts Department (800.877.4272), and follow the procedures in the AMAYA Technical Manual.

Fixture, Y-Belt Tensioning (PN: 32108)
Force Gauge (0-10 lbs.) (PN: 995591-01)
Universal Force Gauge Adapter (PN: 32498)

See the AMAYA Technical Manual, see X-cable Tensioning , Y-axis timing belt Tensioning , Z-drive Belt Tensioning

CAUTION! Some of the lubrication procedures instruct you to remove the right/left front covers. Do not turn the AMAYA machine off, then on again when either of these covers is removed. This will cause the machine to color change, which will cause the needle bars to fall out. Do not move the needlecase at all when either of the front covers is removed. If you proceed without this cover damage to your machine will occur and a service call will be necessary.

Disclaimer: Melco will not be held responsible for any damage to the machine from not performing this step.

Maintenance Timers

As long as you have maintenance timers enabled (see Timers Tab), you will be guided through the lubrication of your machine with maintenance timers (see example below).

Each time a maintenance timer reaches zero, a dialog box pops up indicating that you need to perform that maintenance. To perform the maintenance, click the Step button. You will then be guided through performing the maintenance step by step. (These step-by-step procedures are condensed versions of the lubrication procedures in this section; these step-by-step procedures also perform the machine commands, such as head up, for you.) If you successfully complete the maintenance, the timer will reset when you are finished. If you receive an error while you are performing the maintenance that prevents you from successfully completing the procedures, the timer will not reset. You will need to restart the step by step procedure and complete it successfully.

If you click the Reset button, the stitch count for that timer will be reset to zero. However, it is strongly recommended that you do not reset timers without performing the required maintenance. Neglecting the maintenance of your machine could damage your machine. You can click the View All button to display all of the maintenance timers (displayed on the Timers Tab). If you click the Ignore button, the dialog box will be displayed again after each successive design is completed.

You can perform the step through procedures at any time for any timer interval. To do this, open the Settings menu and click the Timers tab. Click the Step button for the timer interval to step through the lubrication for that interval. If you successfully complete the maintenance, the timer will reset when you are finished. You can click on any of the pictures in the step through procedures and they will enlarge.

You can perform the step-through procedures provided by the timers without using the procedures below (unless you want to refer to the pictures). If for some reason you are lubricating without using the step-through procedures, follow the procedures below.

Maintenance Procedures- 200,000 Stitches (Uncoated Hook), 600,000 Stitches (Coated Hook)

Rotary Hook

Follow these steps for rotary hook lubrication:

Remove the bobbin case from the hook assembly.
Clean the rotary hook area with a brush (or canned or compressed air). While the bobbin case is out of the machine, you may want to clean it as well (click here for instructions).
Select the Maintenance menu in AMAYA OS.
Click on the Head Timing tab.
If performing maintenance on all machines in a flex cluster, check the All Machines box. If performing maintenance on a single machine in the cluster, uncheck the All Machines box, and click the machine in the Machine List.
Click the Oil Hook button.
Place one drop of sewing machine oil in the rotary hook as shown in the image below. Be careful not to over oil.

If you do squeeze too much oil, then you may need to run a sewout on some scrap fabric. This will prevent the excess oil from getting all over your garment.
Click the Spin Hook button in the Head Timing tab and the hook rotates for several seconds to spread the oil.
Replace the bobbin case in the machine, and thread the needle if required.

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Maintenance Procedures- 2,000,000 Stitches

Needle Drive

Reciprocator Guide, Cam Follower Shaft, Connecting Rod Pin

Color change to Needle 16 (press and hold , then press until you reach needle 16.)
Select the Maintenance menu in AMAYA OS.
Select the Head Timing tab.
If performing maintenance on all machines in a cluster, check the All Machines box. If performing maintenance on a single machine in a cluster, uncheck the All Machines box, and click the machine in the Machine List. These options will be grayed out if performing maintenance on Flex machines.
Click the Top Center button to take the head to the upper top position.
Put 25 drops of sewing machine oil in the oiling channel located on the left take-up lever rail next to the left side of the needle case assembly. (See image below).

Allow the machine to sit without running for 2-3 minutes. This will allow the oil to seep through the felt onto the assemblies intended to be lubricated in this process (Reciprocator Guide, Cam Follower Shaft, Connecting Rod Pin).
Click the Head Up button.

Needle Case - Upper V-Rail

Color change to Needle #1 or Needle #16 (press and hold , then press or ).
Using a clean, dry cloth, wipe the surface of the upper v-rail clean as shown in the photograph (IMPORTANT: Make sure there is no oil or grease is applied to the upper v-rail).

Color change all the way all the way to the other side (press and hold , then press or ).
Repeat step 2 for the other side.

Cap Frame Driver - Guide shafts

Perform maintenance on the wide angle cap frame driver after 2,000,000 stitches have been sewn using the cap frame driver.

Move the x-carriage all the way to the back of the machine (press and hold , then press ). (If the driver is installed on the machine).
Wipe any lint off the driver shafts and use compressed air to blow any dust off the entire assembly.

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Maintenance Procedures- 4,000,000 Stitches

Needle Case - Needle Bar

Remove the needlecase access cover (between the middle thread guide and lower thread guide) by gently pulling it off the machine.
Add 1 drop of sewing machine oil to each needle bar (at the bottom of the needlecase).
Replace the needlecase access cover.
Apply 1 drop of sewing machine oil directly to each needle bar (between each of the take-up levers and the middle thread guide) as shown in the image to the right.

Trimmer and Selector Lubrication

If there is a hoop installed on the machine, remove it.
Press the Emergency Stop button to prevent accidental starting of the machine.
Remove the Rotary Hook Guards by loosening the screws as shown below.

NOTE: These screws do NOT need to be removed in order to remove the guards.

Remove the Needle Plate by removing the two screws from the bottom of the extrusion.

Clean the exposed areas with compressed or canned air.
Apply one drop of oil on the pin as indicated in the image below.

Reinstall the Needle Plate and the Rotary Hook Guards.
Disengage the emergency stop button by twisting it.

Thread Feeder Roller Inspection, Cleaning, and Lubrication

For this maintenance procedure, you will need to inspect each thread feed roller. Repeat the following procedure for each roller:

(This section provides part numbers for the parts you may need to replace. Please note that it is possible for part numbers to change after the release of this help system).

See the Thread Feeder Roller Troubleshooting section for more in-depth information about thread feeder rollers.

Lift the thread feeder lever.
Remove the thread feeder front cover, carefully using your fingernails or a screwdriver.
Using two thin-bladed flat screwdrivers, carefully pry the thread feed roller out of the assembly.
Rotate the roller, inspecting it for wear, nicks, or grooves. Also check the roller for dust, lint, oil, or grease accumulation.
Using a clean, dry cloth thoroughly clean the entire surface of the thread feed roller. NOTE: A small amount of alcohol may be used to remove any oil or grease.
Visually inspect each red pinch roller. If you detect a line in the center of any of the pinch rollers, run a fingernail across each of these rollers to check for grooves. Please note that lines on the surface of the rollers are normal but deep grooves can affect the operation of the thread feed system.
If you detect a groove in a roller and the thread fits into the groove such that the top of the thread is lower than the surface of the roller then the roller needs to be replaced (Melco P/N 30619-01). The picture shows a front view of a grooved pinch roller that needs to be replaced.
Using a clean cloth, lightly covered with alcohol, clean all the old grease and residue from the thread feeder arm.
Using the photograph as a guide, apply a small amount of EMB polymer grease to the hubs on each side of the thread feed wheel with a flat-blade screwdriver or a cotton swab.
To re-install the thread wheel, align the wheel in place as shown in the photo and push it all the way in until it snaps into place.
Using the photograph as a guide, apply a small amount of EMB polymer grease to the surface of the thread feeder arm.
Snap the red pinch roller wheel back onto the pinch roller arm. Check to make sure that there is no grease on the surface of the pinch roller or the thread feed roller below.
To re-install the cover, move the thread out of the way. Insert the top of the cover into the slot at the top of the thread feeder assembly. Push until it snaps into place.
Rethread the machine if necessary. Make sure the thread is centered in the grooves on the thread feeder front cover. When you are finished lower the thread feed arm.

Maintenance Procedures - 10,000,000 Stitches

Take-Up Lever - Cam and Cam Follower

Color change to Needle #1 (press and hold , then press ).
Using a 2.5 mm metric hex wrench, remove the 3 screws attaching the left color change drive cover to the machine; then remove the cover from the machine.
Select the Maintenance menu in AMAYA OS. Select the Head Timing tab. Click the Head Up button. If performing maintenance on all machines in a cluster, check the All Machines box. If performing maintenance on a single machine in a cluster, uncheck the All Machines box, and click the machine in the Machine List. These options will be grayed out if performing maintenance on Flex machines.
Type 235 in the Set Position box, then click the Goto Position button.
Locate the take-up lever cam. If you look through the back, right side of the needle case, you will be able to see the portion of the cam that needs to be lubricated.
Using the brush provided in the Operator’s Kit, apply EMB polymer grease to the portion of the cam that is accessible.
Click the Head Up button several times to spread the grease around the outside surface of the cam. Reinstall the left color change drive cover by replacing the screws.

Maintenance Procedures - 20,000,000 Stitches

X Drive - Carriage Rail

Move the x-beam all the way forward (press and hold , then press ), and all the way to one side (press and hold , then press or ).
Using a clean cotton rag, wipe off any dust/lint accumulation from both of the carriage rails (see the image below for the location of these rails).
Again using a cotton rag, apply a very thin layer of multi-purpose lithium grease to both carriage rails (one in the front and one in the back of the beam) from underneath the beam. If you can see clumps of the white grease after you have applied it, then you have put too much. Wipe off excess grease before proceeding.
Move the beam all the way to the other side (press and hold , then press or ) and repeat step 2 on the other end of the carriage rails.

Y Drive - Bearing Block Assembly

CAUTION: DO NOT APPLY GREASE TO THE Y-RAILS. If you do so, machine performance will be impaired. Grease will attract dust, which will serve as an abrasive against the bearings and the shaft.

If you follow the procedure as described below, it is not necessary to remove the machine’s red transparent covers. If desired, the red covers can be removed to make the oiling holes easier to access.

Move the x-carriage to the center of the y-rails.
Use the image below to locate the oiling hole on the top center of each bearing block assembly.
As shown in the image below, place the oiler under the red transparent cover so that the tip touches the oiling hole on the bearing block assembly. (You may find it helpful to bend the oiler tip). Add five drops of sewing machine oil to the oiling hole. Repeat for the oiling hole on the other side of the machine.

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Grabber Drive (Eccentric)

Color change to Needle #1 (press and hold , then press ).
Using the image to the right, locate the grabber drive eccentric on the back of the needle case.
Apply 2 drops of sewing machine oil to the grabber drive eccentric in the location shown in the image to the right.

Presser Foot Cam Follower Lubrication

Color change to Needle #1 (press and hold , then press ). Turn Hoop Limits off. Move the x-beam all the way back (press and hold , then press ). Set needle to bottom, dead center.
Using a 3mm and a 2.5mm metric Allen wrench, remove the right upper arm front cover by removing the five screws attaching it to the machine.
Lift the presser foot up and continue to hold as shown in the photo.
Using the photograph as a guide, locate the presser foot cam follower. NOTE: The presser foot cam follower is the black plate located directly below the white, plastic pad on the presser foot shaft.
Use the brush provided in the Operator's Kit to apply EMB polymer grease to the surface of the presser foot cam follower. When you are finished, release the presser foot.
Reinstall the right upper arm front cover.

Maintenance Procedures - 100,000,000 Stitches

Presser Foot Cam

Color change to Needle #1 (press and hold , then press ). Turn Hoop Limits off. Move the x-beam all the way back (press and hold , then press ).
Set needle to bottom, dead center.
Using a 3mm metric Allen wrench, remove the left upper arm front cover by removing the four screws attaching it to the machine.
Facing the machine, locate the presser foot cam.
Using the brush, apply grease to the top, right surface of the presser foot cam. NOTE: The cam shown in this photograph is white. Newer machines may have a brown presser foot cam.
Reinstall the left upper arm front cover.

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