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AMF Reece S-4000 CAED Omron Parts And Service Manual

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S-4000 CAED Omron
MODEL
CUT AFTER EDGE
PARTS AND SERVICE MANUAL
MACHINE SERIAL No.:
PART NUMBER 97.2430.1.001
T his manual is valid from the machine serial number M241429
AMF is trademark of AMF Group, Inc.
01/2010

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Summary of Contents for AMF Reece S-4000 CAED Omron

  • Page 1 S-4000 CAED Omron MODEL CUT AFTER EDGE PARTS AND SERVICE MANUAL MACHINE SERIAL No.: PART NUMBER 97.2430.1.001 T his manual is valid from the machine serial number M241429 AMF is trademark of AMF Group, Inc. 01/2010...
  • Page 2 Authorized Distributor) will have the limited material warranty only. Only the defective material will be covered. Any charges associated with the use of an AMF Reece Technician or that of a Distributor to replace the defective part will be the customer’s responsibility.

  • Page 3: Warranty Registration Card

    Warranty Registration Card (Please Fax or Mail immediately after installation) Note: All Warranty Claims Void, unless Registration Card on file at AMF Reece HQ Machine model number: (S100, S101, S104, S105, S 311, Deco, S4000 , EBS Mark II, ES505, etc) Manufacturer‘s serial or production number:...

  • Page 5: Table Of Contents

    S4000 CAED Omron TABLE OF CONTENTS A - INTRODUCTION 1. Basic information .................... 1-1 2. Safety device and labels ................1-2 3. General machine parts description ..............1-3 4. Specifications ....................1-4 5. Instructions for operator safety and maintenance ........1-5 6.
  • Page 6 S4000 CAED Omron TABLE OF CONTENTS E - MACHINE ADJUSTMENTS 9. Looper adjustments ..................1-31 10. Home position of the clamp plate ............... 1-34 11. Clamp plate adjustment ................1-35 12. Trimming mechanism adjustment ..............1-35 13. Adjustment of the clamp plate change-over ..........1-36 14.

  • Page 7: A - Introduction

    WA R N I N G ! Possible serious injury or machine damage. N OT I C E ! Possible injury or machine damage. We recommend that service workers from AMF Reece oversee the installation and initial training of your mechanics and operators.

  • Page 8: Safety Device And Labels

    S-4000 CAED Omron INTRODUCTION 2 . S A F E TY D E V I C E A N D L A B E L S ž ž ž ž ž — — — — — š š š š š ˜...

  • Page 9: General Machine Parts Description

    S-4000 CAED Omron INTRODUCTION 3 . G E N E R A L M AC H I N E PA RT S D E S C R I P T I O N      › › › › › œ...

  • Page 10: Specifications

    S-4000 CAED Omron INTRODUCTION 4 . S P E C I F I C AT I O N S Machine type S 4000 CAED electronical sewing machine for clothing parts Description stitching with cutting after Sewing speed 1500-3800 stitches/min Stitch density 3-14 stitches/cm Machine clamp foot height 12.7 mm (1/2")

  • Page 11: Instructions For Operator Safety And Maintenance

    S-4000 CAED Omron INTRODUCTION 5 . I N S T RU C T I O N S F O R O P E R ATO R S A F E TY A N D M A I N T E NA N C E When installing the machine we recommend the minimum clearances noted above around the machine.

  • Page 12: Special Accessories

    S-4000 CAED Omron INTRODUCTION CAUTION! Perform all regular service as described in this manual. If there is any problem with the power supply, turn off the main power switch. Do not remove, paint over, damage or in any way change safety labels. If a safety label cannot be easily read, replace it.
  • Page 13 S-4000 CAED Omron INTRODUCTION – C o n n e c t o r Ø order it if the connecting tube has the inner diameter 8 mm. The connector 10 is supplied with the machine. Ø – — part number is 12.0008.3.607 ˜...

  • Page 14: B - Machine Assembly

    S-4000 CAED Omron B - MACHINE ASSEMBLY 1 . C O N T E N T O F T H E S H I P P I N G B OX – The shipment contains one box. There is a carton with accessories, service manual with –...

  • Page 15: Power And Air Connection

    S-4000 CAED Omron B - MACHINE ASSEMBLY 3 . P OW E R A N D A I R C O N N E C T I O N ™ š for inner ∅ of the The machine is equipped with a quick coupler required with connector tube 10.
  • Page 16 S-4000 CAED Omron B - MACHINE ASSEMBLY H E A D P N E U M AT I C J0I1  – — š œ › ˜ – — cutting › — changing the direction of sewing — — clamping feet œ...

  • Page 17: Installation Of Thread Holder

    S-4000 CAED Omron B - MACHINE ASSEMBLY 5 . I N S TA L L AT I O N O F T H R E A D H O L D E R Put the thread holder together as per the drawing.

  • Page 18: C - Proper Application

    S-4000 CAED Omron C - PROPER APPLICATION 1 . P OW E R U P / H O M E P O S I T I O N – Turn the main power switch on by turning clockwise to the I position. The display is illuminated for a moment and the screen shows the model number.

  • Page 19: Needle Installation

    S-4000 CAED Omron C - PROPER APPLICATION 2 . N E E D L E I N S TA L L AT I O N WARNING! Before doing this adjustment, switch the machine off and let the remaining compressed air from the machine out.

  • Page 20: Threading

    S-4000 CAED Omron C - PROPER APPLICATION 3 . T H R E A D I N G WARNING! Switch the main machine power off to prevent accidental starting of the machine. Disconnect the air supply and dissipate any stored energy. –...

  • Page 21: D - Machine Controls

    S-4000 CAED Omron D - MACHINE CONTROLS 1 . PROGRESS OF SEWING Bring the machine to the home position according to the section C1. Be certain that the machine is threaded correctly according to the section C3 and insert the work under the clamp feet.

  • Page 22: Operator Control Panel Push Buttons And Switches

    S-4000 CAED Omron D - MACHINE CONTROLS 2 . O P E R ATO R C O N T RO L PA N E L P U S H BU T TO N S A N D S W I T C H E S Indicator signaling that the Emergency stop button is activated.

  • Page 23: Control Panel Information

    S-4000 CAED Omron D - MACHINE CONTROLS 3 . C O N T RO L PA N E L I N F O R M AT I O N ( M A I N S C R E E N ) H Ready index on Display messages: H Emerg.
  • Page 24 S-4000 CAED Omron D - MACHINE CONTROLS Example: To change the sewing speed from 2000 to 3450 Display Press Display Press ¬ ¬ ¬ (3x) ¬ ¬ ¬ (4x) ¬ ¬ ¬ (5x) ¬ ¬ ¬ Display Max Speed 3500 maximal speed.
  • Page 25 S-4000 CAED Omron D - MACHINE CONTROLS Display C y c l e d e l a y setting the delay between the sewing cycles. Cycling parameter must be (500-2500 ms) activated. It is possible to set it in range 500-2500 ms. C y c l in g activation of the machine cycling.

  • Page 26: Tests

    S-4000 CAED Omron D - MACHINE CONTROLS Display Press - Counter of total number of cycles Counter: 4538 - Setting up number of stitches sewn over Di re cti o n (0-10 stitches) the edge of fabric / workpiece. Return onto the main screen 5 .
  • Page 27 S-4000 CAED Omron D - MACHINE CONTROLS Em Stop Em Stop O f f After pressing button, appears on the O f f O f f Clamp Button Clamp Button display. After releasing the button appears on the display. This parameter checks the switch SA1.
  • Page 28 S-4000 CAED Omron D - MACHINE CONTROL Knife Knife key ¬ To activate thread trimming, press Trim Trim Knife ¬ confirm . This parameter tests the YV3 Trim valve. To activate clamping plate shift, press key ¬ Shift ¬ , confirm Shift Shift the clamp plate is shifted.
  • Page 29 S-4000 CAED Omron D - MACHINE CONTROL 7 . PA R A M E T E R C H E C K L I S T PARAMETER RANGE SETTING 1000-3800 rpm MAX SPEED 3500 SLOW STITCH 500-1000 rpm SLOW SPEED 1000 0-600 imp NDL UP POS...

  • Page 30: Needle Bar

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 1 . M AC H I N E H O M E P O S I T I O N Needle bar is in the upper position. When making the first stitch, the needle – must go into the right side throatplate groove —.
  • Page 31 S-4000 CAED Omron E - MACHINE ADJUSTMENTS 4 . N E E D L E B A R Position of the bell-shaped eccentric Turn the hand wheel š and loose the fastening screw – 1 in the bell-shaped eccentric —. Keep turning the hand wheel until the needle bar reaches upper position.

  • Page 32: Bite,

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 5 . B I T E Before setting up the bite, dismantle pulley cover — and head – – – – – — — — — — cover –. Bite cam Check that the machine is in home position. Tilt the machine head onto the support pin œ...
  • Page 33 S-4000 CAED Omron E - MACHINE ADJUSTMENTS Setting up the width of the bite Tilt the machine head from the support pin back into the sewing position. The width of the bite is set up from the rear side of the machine head from the space below the motor.

  • Page 34: Feeding

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 6 . F E E D I N G Tilt the machine head onto the support pin. ž ž ž ž ž Adjustment of feeding wheels Turn the hand wheel counter-clockwise until the guiding spring snaps into the shifter left arm notch.

  • Page 35: Clutch

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 7 . C L U T C H Clutch pressure is set up by the manufacturer. Under normal circumstances, it is not necessary to adjust it. The correct torque is 0,42 Nm. Hold the nut – and tighten the adjusting screw — with a torque wrench. Adjust the torque so that is even on both sides of the clutch.
  • Page 36 S-4000 CAED Omron E - MACHINE ADJUSTMENTS 9 . L OO P E R S A D J U S T M E N T Before the adjustment, follow the instructions below: – · Turn the hand wheel and see carefully the position of the connecting rod on both extreme —...
  • Page 37 S-4000 CAED Omron E - MACHINE ADJUSTMENTS Adjustment of the first looper With the machine being in the home position,  loosen the looper cam screws and set it to the lowest position. Loosen the adjusting screw and turn the looper so that it is vertically towards the opening in the holder.
  • Page 38 S-4000 CAED Omron E - MACHINE ADJUSTMENTS Adjustment of the second looper 1 0 . Insert the second looper onto the looper shaft. Loosen the looper holder screw and move the holder so that the needle goes through the centre of looper opening.

  • Page 39: Home Position Of The Clamp Plate

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 1 0 . H O M E P O S I T I O N O F T H E C L A M P P L AT E Home position of the clamp plate before sewing: –...
  • Page 40 S-4000 CAED Omron E - MACHINE ADJUSTMENTS 1 1 . C L A M P P L AT E A D J U S T M E N T – — If the distance between the clamp plate cover and the throatplate edge is too large, proceed as instructed in items 2 and 3.
  • Page 41 S-4000 CAED Omron E - MACHINE ADJUSTMENTS › Secure the correct position of the mechanism with the stopper in the upper dead centre and the œ stopper in the plate in the bottom dead centre. › Correct adjustment of the stop screw ...
  • Page 42 S-4000 CAED Omron E - MACHINE ADJUSTMENTS 1 4 . A D J U S T M E N T O F M AC H I N E H E A D C L A M P I N G F OOT —...
  • Page 43 S-4000 CAED Omron E - MACHINE ADJUSTMENTS 1 6 . T H R E A D T E N S I O N Correct thread tension affects the final appearance of sewing. The tension changes with the change of material sewn. The thinner and the more elastic material is, the wider the thread tension must be opened. When replacing any part affecting the thread passing, check the smooth finish of surfaces getting in touch with thread.
  • Page 44 S-4000 CAED Omron E - MACHINE ADJUSTMENTS Adjustment of the trimming hook – — press the piston of the trimming cylinder down to the maximal limit and loosen the screw ž Ÿ of the trimming actuator Ÿ turn the trimming actuator and set the 1.0 mm play between the throatplate and the trimming hook tip.

  • Page 45: Adjustment Of Stop Sensor Position

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 1 9 . T H R E A D B L OW O F F ( S P E C IA L AC C E S S O RY ) Thread blow off is ensured by a pipe placed in the bedplate under the throatplate and air forced into the pipe. Regulation of airflow The airflow can be regulated with a choke placed on YV8 branch.

  • Page 46: Replacement Of The Belt

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 2 1 . R E P L AC E M E N T O F T H E B E LT – — Dismantle the pulley cover by loosing the screws M4 ˜ ™...

  • Page 47: Protection During Voltage Fluctuation (Special Accessory)

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 2 2 . P ROT E C T I O N D U R I N G VO LTAG E F L U C T UAT I O N ( S P E C IA L AC C E S S O RY ) The special accessory, guard voltage relay HRN-35 (VC1), is placed in the machine control box.

  • Page 48: Optical Sensor - Adjustment

    S-4000 CAED Omron E - MACHINE ADJUSTMENTS 23. OPTICAL SENSOR - ADJUSTMENT Loosen the holder of the optical sensor by loosing the screew M4 and adjust it in such way so that the ray of the optical sensor projected by the sensor meets the glass eye in throat plate and returns back to sensor. The sensor is switched on.

  • Page 49: F - Machine Maintenance

    S-4000 CAED Omron F - MACHINE MAINTENANCE Caution: Check the condition of electric cables; whether they are not damaged. Check that all safety covers are in good condition. Replace any damaged covers! Do not put your fingers in the sewing needle area in any cases! Do not modify the machine in any way, which interfere the safety factors.
  • Page 50 S-4000 CAED Omron F - MACHINE MAINTENANCE › œ Take out the filter cover with the cleaning pad Beat or hoover the pad. In case of severe fouling, wash the pad in washing liquid. Do the same maintenance with the back filter. Maintenance of the filter and regulator ...

  • Page 51: List Of Regular Services

    S-4000 CAED Omron F - MACHINE MAINTENANCE 2 . L I S T O F R E G U L A R S E RV I C E S 1x day (8 hours) cleaning sewing devices and machine frame Lubrication of mechanisms – see section F4. 1x week (40 hours) visual checking of internal and external mechanisms Filling the oil tank with oil...

  • Page 52: Schema Of Group Lubrication

    S-4000 CAED Omron F - MACHINE MAINTENANCE 3 . S C H E M E O F G ROU P L U B R I C AT I O N The machine is mainly equipped with needle bearings and ball bearings, which together with a single-circuit lubrication reduce the maintenance requirements.

  • Page 53: Machine Lubrication

    S-4000 CAED Omron F - MACHINE MAINTENANCE 4 . M AC H I N E L U B R I C AT I O N Before the machine is switched on for the first time, or after a long time without any operation, it is necessary to lubricate all areas said below.
  • Page 54 S-4000 CAED Omron F - MACHINE MAINTENANCE Tilt the machine head onto the support pin and lubricate the areas shown in the picture. œ loppers shaft feeding cam  feeding shaft bite cam ž gearwheel trimming shaft Ÿ looper cam Bring the machine head back into the operation position.

  • Page 55: Disposal Measures

    S-4000 CAED Omron F - MACHINE MAINTENANCE 5 . D I S P O S A L M E A S U R E S To ensure correct disposal of the machine following environmental measures, it is important to remove non-metal parts from the machine.

  • Page 56: Pneumatic Diagram

    S-4000 CAED Omron G - PNEUMATIC DIAGRAM Revised 10/2009 1-50 e-mail: service@amfreece.cz; parts@amfreece.cz; website: www.amfreece.com Phones: +420 582 309 146 (Service), +420 582 309 286 (Spare Parts); Fax: +420 582 360 606...

  • Page 57: Electrical Diagram

    S-4000 CAED Omron H - ELECTRICAL DIAGRAM Revised 10/2009 1-51 e-mail: service@amfreece.cz; parts@amfreece.cz; website: www.amfreece.com Phone: +420 582 309 146 (Service), +420 582 309 286 (Spare Parts); Fax: +420 582 360 606...
  • Page 58 S-4000 CAED Omron H - ELECTRICAL DIAGRAM Revised 10/2009 1-52 e-mail: service@amfreece.cz; parts@amfreece.cz; website: www.amfreece.com Phones: +420 582 309 146 (Service), +420 582 309 286 (Spare Parts); Fax: +420 582 360 606...
  • Page 59 S-4000 CAED Omron H - ELECTRICAL DIAGRAM Revised 10/2009 1-53 e-mail: service@amfreece.cz; parts@amfreece.cz; website: www.amfreece.com Phone: +420 582 309 146 (Service), +420 582 309 286 (Spare Parts); Fax: +420 582 360 606...
  • Page 60 S-4000 CAED Omron H - ELECTRICAL DIAGRAM Revised 10/2009 1-54 e-mail: service@amfreece.cz; parts@amfreece.cz; website: www.amfreece.com Phones: +420 582 309 146 (Service), +420 582 309 286 (Spare Parts); Fax: +420 582 360 606...

  • Page 61: Released

    S-4000 CAED Omron TROUBLESHOOTING TROUBLESHOOTING - TABLE OF CONTENTS 1. MECHANICAL FAULTS ....................2-2 2. CONTROL PANEL DISPLAY ERROR MESSAGES ............. 2-5 3. SERVO ERROR MESSAGES .................... 2-6 4. ELECTRICAL FAULTS ..................... 2-7 Released 10/2009 e-mail. service@amfreece.cz; parts@amfreece.cz; website: www.amfreece.com Phones: +420 582 309 160 (Service), +420 582 309 286 (Spare Parts);...

  • Page 62: Thread Tension

    S-4000 CAED Omron TROUBLESHOOTING 1 . MECHANICAL FAULTS PROBABLE SOLUTION SYMPTOM POSSIBLE CAUSE Needle, looper, throat plate Change damaged parts Thread breakage damaged Incorrect needle and sewing Check the adjustment of the mechanism adjustment mechanisms Thread tension is too tight Adjust correct tension Incorrect threading See section C3 for checking.

  • Page 63: Troubleshooting

    S-4000 CAED Omron TROUBLESHOOTING POSSIBLE CAUSE SYMPTOM PROBABLE SOLUTION Needle, looper, throat plate Change damaged parts Stitch skip at the beginning of sewing damaged Needle thread end is too short See section E15, point 1 Incorrectly adjusted needle bar See section E4, point 2 height Incorrectly adjusted clearance See section E5, point 3...
  • Page 64 S-4000 CAED Omron TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE PROBABLE SOLUTION Thread not trimmed at the Trimming knife damaged Replace end of the cycle Low air pressure at trimming Check supply pressure cylinder Incorrect loopers timing See section E9 Incorrect setting of trimming delay Change Trim delay parameter-D4 Trimming length incorrectly set Change Trim time parameter-D4...
  • Page 65 S-4000 CAED Omron TROUBLESHOOTING 2. E R R O R M E S S A G E S O F T H E C O N T R O L PA N E L D I S P L AY PROBABLE SOLUTION POSSIBLE CAUSE SYMPTOM...
  • Page 66 Replace contactor 12.0008.4.833 Contactor KM1 switched on. Contactor KM1 damaged Call AMF Reece service or Servo U1 error or filter Z2 error replace servo U1 (page 2-9) or filter Z2 (page 2-9) Switch the machine off for 1...
  • Page 67 Replace the sensor Sensor BQ1 failure 06.2400.0.009 To set the servo amplifier - call Check the servo amplifier and AMF Reece service, alternatively servomotor replace motor (page 2-9) and servo amplifier (page 2-9) Fork is not fitted properly into Check the connector X3...
  • Page 68 S-4000 CAED Omron TROUBLESHOOTING Notes: Released 10/2009 e-mail: service@amfreece.cz; parts@amfreece.cz; website: www.amfreece.com Phones: +420 582 309 146 (Service), +420 582 309 286 (Spare Parts); Fax: +420 582 360 606...

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