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AMF S 4000 TKF Parts And Service Manual

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S-4000 TKF, LS
MODEL
Omron
TACKER AND LABEL SEWER
PARTS AND SERVICE MANUAL
MACHINE SERIAL No.:
PART NUMBER 97.2441.1.001
This manual is valid from the machine serial number M241428
AMF is trademark of AMF Group, Inc.
07/2012
www.promelectroavtomat.ru

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  • Page 1 S-4000 TKF, LS MODEL Omron TACKER AND LABEL SEWER PARTS AND SERVICE MANUAL MACHINE SERIAL No.: PART NUMBER 97.2441.1.001 This manual is valid from the machine serial number M241428 AMF is trademark of AMF Group, Inc. 07/2012 www.promelectroavtomat.ru...
  • 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 (Please Fax or Mail immediately after installation) Note: All Warranty Claims Void, unless Registration Card on file at AMF Reece HQ Machine model number: (S101, S100, S104, S105, S311, Decostitch, S4000 BH, EBS Mark II, etc) Manufacturer‘s serial or production number: Installation Site Information: Customer‘s Name:...
  • Page 4 www.promelectroavtomat.ru...

  • Page 5: Table Of Contents

    S4000 TKF, LS 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. Table type ......................1-5 6. Instructions for operator safety and maintenance ........1-6 7.
  • Page 6 S4000 TKF, LS Omron TABLE OF CONTENTS E - MACHINE ADJUSTMENTS 9. Looper adjustments ..................1-33 10. The clamp plate home position ..............1-37 11. Clamp plate to the center of the throat plate adjustment ......1-38 12. The sewing length change ................1-38 13.

  • 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 TKF, LS 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 TKF, LS Omron INTRODUCTION 3 . G E N E R A L M AC H I N E PART S D E S C R I P T I O N      › › › › › œ...

  • Page 10: Specifications

    S-4000 TKF, LS Omron INTRODUCTION 4 . S P E C I F I C AT I O N S Machine type S 4000 TKF S4000 LS electronic controlled machine for electronic controlled machine for Description sewing the tacks on various clothes...
  • Page 11 S-4000 TKF, LS Omron INTRODUCTION 5 . TA B L E TY P E – PARALLEL Parallel – — Crosswise ˜ Crosswise embedded ™ Universal - possible adjustable: parallel/crosswise TKF, LS CROSSWISE — ˜ CROSSWISE EMBEDDED TKF, LS ™ UNIVERSAL UNIVERSAL PARALLEL CROSSWISE...

  • Page 12: Instructions For Operator Safety And Maintenance

    S-4000 TKF, LS Omron INTRODUCTION 6 . 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 13: Special Accessories

    S-4000 TKF, LS 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 14 S-4000 TKF, LS 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 Ø 10 is supplied with the machine. – — part number is 12.0008.3.607 ˜...
  • Page 15 S-4000 TKF, LS Omron INTRODUCTION Clamping-bite 1,5 - 2 mm possible to order, for TKF (order no. 03.5524.0.032) Clamping foot-bite 4 mm possible to order, for TKF 24.3211.0.000 Clamp foot 1 1/2 24.3212.0.000 Clamp foot 3/4 24.3213.0.000 Clamp foot 3/8 Throat plate-bite 4 mm possible to order, for TKF 24.3214.0.000...

  • Page 16: B - Machine Assembly

    S-4000 TKF, LS 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 17 S-4000 TKF, LS Omron B - MACHINE ASSEMBLY — Remove the shipping strap after unpacking the machine, the use of this strap is recommended anytime the machine is transported (This is valid for all types of tables - parallel, crosswise, universal).

  • Page 18: The Display Position Change When The Head Position Is Change

    S-4000 TKF, LS Omron B - MACHINE ASSEMBLY 3 . T H E D I S P L AY P O S I T I O N C H A N G E W H E N T H E H E A D P O S I T I O N I S C H A N G E (the universal table only) To ch a n g e t h e c r o s s w is e t a b l e t o t h e p a r a l l e l t a b l e –...
  • Page 19 S-4000 TKF, LS Omron B - MACHINE ASSEMBLY To c h a n g e t h e p a r a l l e l t a b l e t o t h e c r o s s wis e t a b l e š...

  • Page 20: Power And Air Connection

    S-4000 TKF, LS Omron B - MACHINE ASSEMBLY 4 . P OW E R A N D A I R C O N N E C T I O N ™ required with connector for inner ∅ of the tube 10. The machine is equipped with a quick coupler The connector for inner ∅...
  • Page 21 S-4000 TKF, LS Omron B - MACHINE ASSEMBLY Head Pneumatic – ˜ - thread draw-off, tension release - thread trim — J0I1 - air input - clamp feet BQ2 - regulator with air pressure switch air distribution 0, 1, 2 — X => distribution from a regulator Tubes J X X X 0, 1, 2 —...

  • Page 22: Thread Stand Installation

    S-4000 TKF, LS Omron B - MACHINE ASSEMBLY 5 . T H R E A D S TA N D I N S TA L L AT I O N Put the thread stand together according to the drawing. – Position of the locking ring allows assembly of the thread stand for various thickness of...

  • Page 23: C - Proper Application

    S-4000 TKF, LS 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 and the screen shows the model number.

  • Page 24: Needle Installation

    S-4000 TKF, LS Omron C - PROPER APPLICATION 2 . N E E D L E I N S TA L L AT I O N WARNING! Before performing this adjustment, switch the main machine power off to prevent accidental starting of the machine.

  • Page 25: Threading

    S-4000 TKF, LS 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 26: D - Machine Controls

    S-4000 TKF, LS 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 27: Operator Control Panel Push Buttons And Switches

    S-4000 TKF, LS Omron D - MACHINE CONTROLS 2. OPERATOR CONTROL PANEL PUSH BUTTONS AND SWITCHES Red LED - activated when the Emergency Stop button is activated Green LED - activated when the machine is Ready for sewing Next - scrolling down key Previous - scrolling up key Key for setting the parameter value Key for setting the parameter value...

  • Page 28: Control Panel Information

    S-4000 TKF, LS 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 H Ready Display message: H Emerg. Stop Standard messages: H Service mode H Wait please H Ready F1 Service F6...

  • Page 29: The Programming Menu

    S-4000 TKF, LS Omron D - MACHINE CONTROLS 4 . T H E P R O G R A M M I N G M E N U Main screen - press appears on the display. To enter the programming menu, press appears on the display.
  • Page 30 S-4000 TKF, LS Omron D - MACHINE CONTROLS 1. Max speed - maximal speed. Range 1000-3800 spm. 2. Slow stitch - selecting the number of stitches in slow start. Range 0-3. 3. Slow speed - setting the slow start speed at the beginning of the sewing cycle. Range 500-1000 spm.

  • Page 31: Tests

    S-4000 TKF, LS Omron D - MACHINE CONTROLS 5. TESTS WARNING! ONLY PROFESSIONAL SERVICE TECHNICIANS SHOULD PERFORM THESE TESTS! The main screen appears on the display. Press appears on the display. To enter the tests menu, press key. The follwing screen appears on the display . To scroll this menu down, press key, to scroll this menu up, press key.
  • Page 32 S-4000 TKF, LS Omron D - MACHINE CONTROLS OUTPUTS The following parameters can be tested only in case the air supply is connected to the machine. After pressing key, appears on tehe display. To selected the line press key used for change.

  • Page 33: Program Version

    S-4000 TKF, LS Omron D - MACHINE CONTROL 6. PROGRAM VERSION Home screen appears on the display. Press appears on the display. To find out loaded program version into the machine. press the key. appears on the display. Press again key to return back to main screen.

  • Page 34: E - Machine Adjustments

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 . M AC H I N E H O M E P O S I T I O N – The needle bar is in the upper position. The needle descends to the right side of the throat plate —...

  • Page 35: Needle Bar

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 4 . N E E D L E B A R Needle bar crank position š – Turn the handwheel and loosen the screw in the — needle bar crank . Turn the handwheel until the ˜...

  • Page 36: Bite

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 5 . B I T E – – – – – — — — — — — Before the bite adjustment, remove the pulley cover – the head cover B it e c a m Check if the machine is in the home position.
  • Page 37 S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS B it e w id t h a d j u s t m e n t To adjust the bite width, first remove the head cover for access to adjustments. The S-4000 is fitted with a regular bite throat plate , that allows a bite range of 1.5 mm (1/16“) to 2.3 mm (3/31“).

  • Page 38: Feeding

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 6 . F E E D I N G Tilt the sewing head onto the rest pin. ž ž ž ž ž Bevel Gear Adjustments Manually turn the handwheel counter clockwise until the drive spring in the main cam engages with a indent .

  • Page 39: Slip Clutch

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 7 . S L I P C L U T C H The slip clutch pressure is factory set and under normal conditions will not need adjusting. The correct clutch torque setting is 0.43 Nm (60 to 65 inch ounces). –...

  • Page 40: Looper Adjustments

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 9 . L OO P E R A D J U S T M E N T S Before making this adjustment, follow the points described below: – Turn the handwheel and observe the position of the connecting link at both ends of the —...
  • Page 41 S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS T h e f ir s t l o o p e r a d j u s t m e n t Bring the machine to the home position and  loosen the screws of the looper cam adjust the looper cam to the lowest position.
  • Page 42 S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS T h e s e c o n d l o o p e r a d j u s t m e n t 1 0 . Insert the second looper on the looper shaft.

  • Page 43: The Clamp Plate Home Position

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 0 . T H E C L A M P P L AT E H O M E P O S I T I O N The home position of the clamp plate before sewing is: –...

  • Page 44: Clamp Plate To The Center Of The Throat Plate Adjustment

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 1 . C L A M P P L AT E TO T H E C E N T E R O F T H E T H ROAT P L AT E A D J U S T M E N T –...

  • Page 45: Head Clamp Foot Adjustment

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 3 . H E A D C L A M P F OOT A D J U S T M E N T A d j u s t m e n t fo r c l a m p h e ig h t Be sure that air supply is switch on and the clamp foot is opened.

  • Page 46: Thread Draw-Off

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 4 . T H R E A D D R AW- O F F A d j u s t m e n t o f t h e D r a w - O f f L e ve r Po s itio n The correct adjustment ensures a long enough thread tail for starting the next sewing.

  • Page 47: Thread Tension

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 5 . T H R E A D T E N S I O N The thread tension influences the appearance of the sewing. A thread tension change may be needed if the thread and fabric change.
  • Page 48 S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS T h e c o r r e c t p o s it io n o f t h e t e n s io n m e c h a n is m ˜...

  • Page 49: Thread Trimming

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 6 . T H R E A D T R I M M I N G The trimming mechanism ensures the correct thread trimming after sewing the last stitch. The trimming hook moves in the direction of the arrow, both thread loop legs A and B are pulled forward.

  • Page 50: The Hold Down Adjustment

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 7 . T H E H O L D D OW N A D J U S T M E N T (S4000 LS modification only) ˜ It is necessary to adjust the hold down –...

  • Page 51: Adjustment Of The Stopping Sensor Position

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 8 . A D J U S T M E N T O F T H E S TO P P I N G S E N S O R P O S I T I O N Follow the steps described below to set the position of the sensor.

  • Page 52: Changing The Drive Belt

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 1 9 . C H A N G I N G T H E D R IV E B E LT – — Remove the pulley cover after loosening the M4 screws ˜...

  • Page 53: Voltage Guard

    S-4000 TKF, LS Omron E - MACHINE ADJUSTMENTS 2 0 . VO LTAG E G UA R D The voltage guard - relay HRN-35 (VC1) as an extra accessories is placed in the machine control box. It is adjusted and sealed from a manufacturer. If the supply voltage is in the required range, the green LED Un indicates it on the voltage monitoring relay.

  • Page 54: F - Machine Maintenance

    S-4000 TKF, LS Omron F - MACHINE MAINTENANCE Warning: Check for damage to electrical cables Check safety covers for damage and replace immediately if needed Keep your hands out of the sewing area Do not modify the machine in any way, which could eliminate safety parts Do not attach external lights or other devices to the machine´s electrical system Do not neglect periodic maintenance.
  • Page 55 S-4000 TKF, LS Omron F - MACHINE MAINTENANCE › œ Remove the filter cover with cleaning pad Remove the dust from the cleaning pad or in case of considerable dirt, wash it using a mild detergent. Perform the same cleaning on the rear fan . The filter and regulator maintenance ...

  • Page 56: Periodic Maintenance

    S-4000 TKF, LS Omron F - MACHINE MAINTENANCE 2 . P E R I O D I C M A I N T E N A N C E once a day (8 hours of operation) - cleaning of the sewing mechanism area and inner frame of the - machine - lubrication of mechanisms - see area F4.

  • Page 57: Lubrication Diagram

    S-4000 TKF, LS Omron F - MACHINE MAINTENANCE 3 . L U B R I C AT I O N D IAG R A M The machine is mainly equipped with needle and ball bearings, which in combination with a single lubrication circuit decrease the requirements for maintenance.

  • Page 58: Machine Lubrication

    S-4000 TKF, LS Omron F - MACHINE MAINTENANCE 4 . M AC H I N E L U B R I C AT I O N It is necessary to lubricate the places shown below before the machine is switched on for the first time or after a long idle period.
  • Page 59 S-4000 TKF, LS Omron F - MACHINE MAINTENANCE Tilt the machine head onto the rest pin and lubricate the places shown in the picture. œ looper shafts feed cam surfaces  shifter bite cam surfaces ž bevel gears trimmer shaft Ÿ...

  • Page 60: Machine Disposal

    S-4000 TKF, LS Omron F - MACHINE MAINTENANCE 5 . M AC H I N E D I S P O S A L To ensure machine ecelogical disposal, it is neccesary to remove nonmetallic parts from the machine. To take these parts out, it is necessary to perform the partial dismantling of the machine, remove covers, dismantle the machine arm and remove the frame.

  • Page 61: G - Pneumatic Diagram

    S-4000 TKF, LS Omron G - PNEUMATIC DIAGRAM Released 12/2009 1-55 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 www.promelectroavtomat.ru...

  • Page 62: H - Electrical Diragram

    S-4000 TKF, LS Omron H - ELECTRICAL DIAGRAM Released 12/2009 1-56 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 www.promelectroavtomat.ru...
  • Page 63 S-4000 TKF, LS Omron H - ELECTRICAL DIAGRAM Released 12/2009 1-57 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 www.promelectroavtomat.ru...
  • Page 64 S-4000 TKF, LS Omron H - ELECTRICAL DIAGRAM Released 12/2009 1-58 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 www.promelectroavtomat.ru...
  • Page 65 S-4000 TKF, LS Omron H - ELECTRICAL DIAGRAM Released 12/2009 1-59 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 www.promelectroavtomat.ru...
  • Page 66 S-4000 TKF, LS Omron H - ELECTRICAL DIAGRAM Released 12/2009 1-60 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 www.promelectroavtomat.ru...
  • Page 67 S-4000 TKF, LS Omron Released 12/2009 1-61 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 www.promelectroavtomat.ru...
  • Page 68 www.promelectroavtomat.ru...
  • Page 69 S-4000 TKF, LS 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 12/2009 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 70 S-4000 TKF, LS 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 71 S-4000 TKF, LS Omron TROUBLESHOOTING POSSIBLE CAUSE SYMPTOM PROBABLE SOLUTION Change damaged parts Needle, looper, throat plate Stitch skip at the beginning of sewing damaged See section E14, point 2 Needle thread end is too short Incorrectly adjusted needle bar See section E4 height Incorrectly adjusted clearance...
  • Page 72 S-4000 TKF, LS Omron TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE PROBABLE SOLUTION Thread not trimmed at the Trimming knife damaged Replace the knife end of the cycle Low air pressure at trimming Check supply pressure cylinder Flow control valve to tension See section E15 point 3 cylinder closed Incorrect loopers timing See section E9...
  • Page 73 S-4000 TKF, LS 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 74 The following messages can be seen on the servo display, which is placed inside the control box. In order to eliminate these messages, switch off the machine for 5 minutes. Then switch the machine on again. The error message should not appear on the display. If the message appears - call AMF Reece service.
  • Page 75 Replace contactor 12.0008.4.833 operate. Contactor KM1 Contactor KM1 damaged switched on. Call AMF Reece service or Servo U1 error or filter Z2 error replace servo U1 Switch the machine off for 1 Error in sewing motor circuit...
  • Page 76 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 servo replace 12.0010.4.177 and 24.8001.2.005 Fork is not fitted properly into Check the connector X3...

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