AMF S-4000 Quick start guide

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

([phone]
([phone]
servi[email protected]
Prostejov, Czech Republic
Phone:
Fax:
e-mail:
LIMITEDWARRANTYONNEWAMFREECEEQUIPMENT
Warrantyprovisions:
A ninety (90) day limited service labor warranty to correct defects in installation, workmanship, or material without charge for
labor. This portion of the warranty applies to machines sold as ”installed” only.
Aone (1) year limited material warranty on major component parts to replace materials with defects. Any new part believed
defective must be returned freight prepaid toAMF Reece, Inc. for inspection. If, upon inspection, the part or material is deter-
mined to be defective,AMF Reece, Inc. will replace it without charge to the customer for parts or material.
Service labor warranty period shall begin on the completed installation date. Material warranty shall begin on the date the
equipment is shipped fromAMF Reece, Inc.
Exclusions:
Excludedfrom both servicelabor warranty andmaterial warranty are: (1)Consumable parts whichwould be normallyconsidered
replaceable in day-to-day operations. These include parts such as needles, knives, loopers and spreaders. (2) Normal adjustment
and routine maintenance. This is the sole responsibility of the customer. (3) Cleaning and lubrication of equipment. (4) Parts
found to be altered, broken or damaged due to neglect or improper installation or application. (5) Damage caused by the use of
non-GenuineAMF Reece parts. (6) Shipping or delivery charges.
There is no service labor warranty for machines sold as ”uninstalled”.
Equipment installed without the assistance of a certified technician (either anAMF Reece Employee, a Certified Contractor, or
that of anAuthorized 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.
NOOTHERWARRANTY,EXPRESSORIMPLIED,ASTODESCRIPTION,QUALITY,MERCHANTABILITY,andFITNESSFOR
APARTICULARPURPOSE,ORANYOTHERMATTERISGIVENBYSELLERORSELLER’SAGENTINCONNECTIONHERE-
WITH. UNDERNOCIRCUMSTANCESSHALLSELLERORSELLER’SAGENTBELIABLEFORLOSSOFPROFITSORANY
OTHERDIRECTORINDIRECTCOSTS,EXPENSES,LOSSESORDAMAGESARISINGOUTOFDEFECTSINORFAILUREOF
THEEQUIPMENTORANYPARTTHEREOF.
WHATTODOIFTHEREISAQUESTIONREGARDINGWARRANTY
If a machine is purchased through an authorizedAMF Reece, Inc. distributor, warranty questions should be first directed to that
distributor. However, the satisfaction and goodwill of our customers are of primary concern toAMF Reece, Inc. In the event that
a warranty matter is not handled to your satisfaction, please contact the appropriate AMF Reece office:

Warranty Registration Card
(Please Fax or Mail immediately after installation)
Note:All Warranty ClaimsVoid,unlessRegistrationCard onfile atAMF ReeceHQ
Machinemodelnumber:
(S100, S101, S104, S105, S 311, Deco, S4000 , EBS Mark II, ES505, etc)
Manufacturer‘sserialorproductionnumber:
Installation Site Information:
Customer‘sName:
Customer‘sMailing Address:
Customer‘sTelephoneNumber:
SupervisingMechanic‘sorTechnician‘sName:
SignatureofSupervisingTechnician:
AMFReeceTechnician‘sName:
AMFReeceTechnician‘sSignature:
Typeof garmentproducedatthislocation?
AverageDailyProductionExpectedfromthismachine?
(number of buttonholes, jackets sewn, pants produced, buttons sewn, etc)
Anyspecialrequirementsrequiredatthislocation?
WhatotherAMF ReeceMachines areat thislocation?
Howcanweserveyoubetter?
Tovární 837, 798 11 Prostejov, Czech Republic
Fax: [phone], e-mail: [email protected], website: www.amfreece.com

Released 10/2009
e-mail: [e-mail]; [e-mail], website: www.amfreece.com
Phones: [phone] (Service), [phone] (Spare Parts); Fax: [phone]
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. Special accessories.......................................................................................... 1-6
B - MACHINE ASSEMBLY
1. Content of the shipping box .......................................................................... 1-8
2. Accessories ...................................................................................................... 1-8
3. Power and air connection .............................................................................. 1-9
4. Head pmeumatic............................................................................................. 1-10
5. Installation of thread holder .......................................................................... 1-11
C - PROPER APPLICATION
1. Power Up/ Home position ............................................................................. 1-12
2. Needle installation .......................................................................................... 1-13
3. Threading ......................................................................................................... 1-14
D - MACHINE CONTROLS
1. Progress of sewing.......................................................................................... 1-15
2. Operator control panel push buttons and switches .................................... 1-16
3. Control panel information .............................................................................. 1-17
4. The programming menu ................................................................................. 1-17
5. Tests.................................................................................................................. 1-20
6. Program version .............................................................................................. 1-22
7. Schema of programming ................................................................................ 1-23
8. Parameter checklist ......................................................................................... 1-24
E - MACHINE ADJUSTMENTS
1. Machine home position .................................................................................. 1-25
2. Adjustment of the shifter ............................................................................... 1-25
3. Principles for machine adjustment ................................................................ 1-25
4. Needle bar ....................................................................................................... 1-26
5. Bite ................................................................................................................... 1-27
6. Feeding ............................................................................................................. 1-29
7. Clutch ............................................................................................................... 1-30
8. Stitch Density .................................................................................................. 1-30

S4000 CAED Omron
Released 10/2009
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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. Adjustment of machine head clamping foot .............................................. 1-37
15. Thread draw off ............................................................................................ 1-37
16. Thread tension............................................................................................... 1-38
17. Thread trimming............................................................................................ 1-38
18. Cuts-off blow off .......................................................................................... 1-39
19. Thread blow off (special accessory) .......................................................... 1-40
20. Adjustment of stop sensor position ........................................................... 1-40
21. Replacement of the belt ............................................................................... 1-41
22. Protection during voltage fluctuation (special accessory) ....................... 1-42
23. Optical sensor - Adjustment ........................................................................ 1-43
F - MACHINE MAINTENANCE
1. Cleaning and maintenance of the machine .................................................. 1-44
2. List of regular services ................................................................................... 1-46
3. Schema of group lubrication ......................................................................... 1-47
4. Machine lubrication ........................................................................................ 1-48
5. Disposal measures .......................................................................................... 1-50
G - PNEUMATIC DIAGRA
Pneumatic diagram .............................................................................................. 1-51
H - ELECTRICAL DIRAGRAM
Electrical diagram ................................................................................................ 1-52

S-4000CAEDOmron
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Revised 10/2009
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A- INTRODUCTION
The sewing machines S-4000 CAED are designed and produced to be very reliable. Important design goals
have been achieved to provide a safe machine that is simple and inexpensive to maintain.
The patented rotary needle bar shaft drive, a major benefit, delivers longer needle bar life. The added
benefits of lower vibration and less noise, translate into less operator fatigue.
Simple buttonhole length adjustment located outside the machine, eliminates the need for tilt back, while the
quick stop repair function delivers safety and makes repairs easier.
A halogen work light is included with the S-4000 CAED and LS, to enhance operator safety and product
quality.
Special electronic and mechanical safety devices protect the operator and the machine. There is a special
power lock out switch that permits the machine to be locked in the off position, so that it cannot be cycled
accidentally. There is an emergency off switch. There is a low air pressure detector that will not permit
machine operation if air pressure is dangerously low.
There are safety-warning labels on the machine in all areas that require special care. These must not be
removed. If they are lost replace them immediately.
You are the most important safety equipment of all. Be sure you understand the proper operation of the
machine. Never remove safety mechanisms or labels. We have made every effort to provide the safest
possible machine, but without complete knowledge of how this machine operates, and the use of proper care
by the operator, this machine can cause serious injury or death. That is why there are safety warnings
throughout these instructions that carry one of these messages.
DANGER! Possible loss of life.
WARNING! Possible serious injury or machine damage.
NOTICE! Possible injury or machine damage.
We recommend that service workers from AMF Reece oversee the installation and initial training of your
mechanics and operators.
The most effective safety precaution is a well-managed safety program. Be sure those who use this machine
are properly trained. Never disable safety equipment.
Always wear safety goggles when operating or servicing the machine.
1. BASIC INFORMATION

S-4000CAEDOmron
1-2 Revised 10/2009
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A- INTRODUCTION
2. SAFETY DEVICE AND LABELS
Warning
Covers removed, possible injury
Grounding
Rotational direction
Standard Label
Needle bar cover
➑
➐
➏
➎
➍
➌
➋
➊
➓
➒
Eye guard
Head cover
Fan cover
Manometer with pressure sensor
Machine head
Table Frame















➓➓
➓➓
➓
➍➍
➍➍
➍➌➌
➌➌
➌
➎➎
➎➎
➎
➋➋
➋➋
➋
➒➒
➒➒
➒
Ì

S-4000CAEDOmron
1-3
Revised 10/2009
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3. GENERAL MACHINE PARTS DESCRIPTION
A- INTRODUCTION
Control box
Hand wheel
Emergency Stop Button
Motor
Table Top
Thread Stand
Control Panel
Main switch
Foot pedal
Clamps Up/Down button
Air pressure regulator
Air pressure adjustment knob
Halogen Lamp
Rest Pin
Warning: when opening the cover, mind
your eyes!
27
➐➐
➐➐
➐
➏➏
➏➏
➏
➑➑
➑➑
➑
➊➊
➊➊
➊

S-4000CAEDOmron
1-4 Revised 10/2009
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A- INTRODUCTION
4. SPECIFICATIONS
Sewing length
S 4000 CAED
electronical sewing machine for clothing parts
stitching with cutting after
Knife length 55 mm
Machine type
Air pressure
Machine db level
Machine head dimension
Machine head length
Description
Sewing speed
Stitch density
Machine clamp foot height
1NPE~60Hz 230V/TN-S (according to EN 60204-1)
1NPE~50Hz 230V/TN-S (according to EN 60204-1)
10A charakteristic C (according to EN 60947-2)
16A charakteristic B (according to EN 60947-2)
340 mm (height) x 470 (width) x 250 mm (length)
62 kg
700 mm (height) x 600 mm (width) x 1100 mm (length)
Angle adjustable
semi-automatic
according to IEC 364-3, IEC 364-5-51 temperature from +5°C to 40°C,
relative air humidity from 30 to 80 %
0.55 MPa (80 PSI)
Laeg = 74dB; LWA = 87dB; LpC, peak = 103dB
Line Circuit Breaker
1500-3800 stitches/min
3-14 stitches/cm
12.7 mm (1/2")
to 4 mm (5/32")
7-50 mm
1,7 - 3,0 mm
thread size 80, 100, 120 (Tex 40-60)
Needle 750 SC 90/14, 70/10 (it is possible to order 80/12)
Table dimension
Table type
Electrical Requirements
Maximum work thickness
Bite size
Recommended thread
Needle system
Lubrication
Operating Conditions

S-4000CAEDOmron
1-5
Revised 10/2009
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A- INTRODUCTION
5. INSTRUCTIONS FOR OPERATOR SAFETY AND MAINTENANCE
When installing the machine we recommend the minimum clearances noted above around the machine.
Read all of the instructions that follow. DO NOT PUT THE MACHINE INTO OPERATION UNTIL YOU
ARE COMPLETELY FAMILIAR WITH ALL INSTALLATION AND OPERATING INSTRUCTIONS.
DANGER!
-Before connecting the machine to the power supply, be positive that all safety covers are correctly
installed.
-Always engage the power lockout switch, or disconnect the main power supply, before removing
any safety covers.
WARNING!
-Locate the Emergency Stop button. Be sure you know how to use it.
-Be sure that you have a reliable and uniform power supply.
-Be sure that all electrical supply lines are in good condition and have no signs of damage to avoid
electrical shock.
-If any covers become damaged, they must be repaired or replaced immediately.
-Do not touch moving parts of the machine while it is operating.
-Keep clear of the needle.
-Always switch off the main power before changing the needle.
-Before cleaning the machine or performing service to the machine, engage the power lock out switch
or disconnect the main power supply.
-When the machine is not in use engage the power lock out switch or disconnect the main power supply.
-When this machine is used incorrectly, or is incorrectly maintained, it can be dangerous.
Everyone who uses this machine, or maintains this machine, must be completely familiar with this
manual.

S-4000CAEDOmron
1-6 Revised 10/2009
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A- 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.
-Long hair and loose clothing may be dangerous near any machinery. Always contain long hair
and avoid loose clothing, so that it cannot be caught by machinery and cause injury.
-Never use this machine while under the influence of drugs or alcohol.
-If anything seems to be operating incorrectly in the machine call for maintenance assistance
immediately.
-Be sure that there is adequate light for safe operation. A normal minimum light level is 750 lux.
6. SPECIAL ACCESSORIES
-machine device, which is not included in the standard equipment of the machine and can be ordered by
the customer
Voltage guard - relay HRN 35 06.2400.0.004
The machine operation is ensured when the power supply is in range AC 230V
± 10 % (EN 60204-1). It is possible to equip the machine with the relay HRN-35 in case
of larger fluctuation of power supply.
It prevents the machine from damage and in case of large decrease of power supply, the
operator is informed by error message.
If the power supply range is exceeded - max 255V and min 185V the voltage guard -
relay HRN-35 which ensures that machine does not start. After the power supply is in
required range, it is possible to start the machine.
The manufacturer recommends to use the external stabilizer in case of large fluctuation of power supply.
Needles750 SC 80/12, 90/14
-the manufacturer recommends to use these needles when sewing thin material
-part numbers 02.0750.2.100 (80/12), 02.0750.2.110 (90/14)

S-4000CAEDOmron
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Revised 10/2009
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A- INTRODUCTION
Connector Ø8 Ê
-order it if the connecting tube has the inner diameter 8 mm.
The connector Ø10 is supplied with the machine.
-part number is 12.0008.3.607
Reduction Ë
-place an order in case you use connections with inch threads
(order number 12.0008.3.081)
Hand valve Ì
-to dissipate any air from the machine, order it (air circuit is bled). It is necessary to order the
connectors (see below) to the hand valve for connection to the air tubes.
-part number 12.0008.3.463
Connectors
➍12.0008.3.464 Ø8 for connection to the tube with inner Ø8 mm
➎12.0008.3.466 Ø10 for connection to the tube with inner Ø10 mm
Ï12.0008.3.467 Ø12 for connection to the tube with inner Ø12 mm*
Ð12.0008.3.465 Ø16 for connection to the tube with inner Ø16 mm*
*To connect the tube with inner Ø12 and Ø16, it is also necessary to order Ø10.
Thread Draw - Off Kit 03.5524.0.004
-order this device if
you would like to use
the machine for both,
sewing and trimming.







without
trimming with trimming
Thread Blow - Off Kit 03.5524.0.023
-the device enables thread tail at
the needle to be caught above the clamping
feet

S-4000CAEDOmron
1-8 Revised 10/2009
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B - MACHINE ASSEMBLY
1. CONTENT OF THE SHIPPING BOX
1. The shipment contains one box.
2. There is a carton with accessories, service manual with
parts section and thread stand ➊in the box.
3. During unpacking the shipment, follow the labels which are on a
cover.
CAUTION: If the machine or crate was damaged in shipment inform
the freight company immediately. Check the contents of the crate
immediately and report any damage or missing items to the
manufacturer immediately, late reports will not be considered!
Ê
2. ACCESSORIES
A package of accessories is supplied with the machine,
please refer to page 3-48 for detailed descriptions.
The height of the working area is normaly set in range 830 -
850 mm from the manufacturer. When using this height of
the working area, recommended height of the operator seat
is in range 430 - 460 mm. The height of the table can be set
in range 670 - 880 mm by screws Ì.
* It is possible to tilt the operator’s head up to 5°.
Remove the shipping strap Ëafter 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).
STANDARD ACCESSORIES
➋➋
➋➋
➋

S-4000CAEDOmron
1-9
Revised 10/2009
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B - MACHINE ASSEMBLY
3. POWER AND AIR CONNECTION
1. The machine is equipped with a quick coupler ➍required with connector ➎for inner ∅of the
tube 10. The connector for inner ∅of the tube 8 is not
supplied with the machine, a customer has to order it. The
manufacturer recommends to use connector ➏for
customers who requires to connect the tube with
connector NPT.
If a customer needs to use a shut off valve ➊, which allows
fast releasing of the air from the circuit, he must order it.
A variety of connectors ➋can be used separately or in
combination to adapt to the available input supply hose. It
depends on type of the tube which is used by a customer.
These connectors are not included in the accessories. A
tubing clamp ➌is provided.
NOTE: Parts ➊, ➋, ➎, ➏are included in Extra Parts - see 3-48.
2. After air connection check the set air pressure on the dial of the regulator. It should be in range
0.5 - 0.6 MPa. The green pointer ➐indicates the lowest working air pressure 0.5 MPa, which is set
from the manufacturer on the regulator ➑. If the air pressure is lower than 0.5 MPa after connecting
the machine to the power supply, „Low Pressure“ message appears on the control panel display. To
adjust the working pressure, loosen the regulator cap lock ➓and turn the regulator cap clockwise to
increase the pressure. Push the regulator cap ➓down. The LED is for setting the minimal operation
air pressure.
3. Power supply must be 230 volts. Receptacle plug must meet requirements of IEC standard 364-4-41,
its circuit breaker must be minimal 10A with characteristic C according to the EN 60947-2 (or 16A with
characteristic B). No other devices must not be connected to the circuit breaker of the socker. The
hand wheel must turn counter clockwise.
The machine is equipped with a filters which contain capacitors which generate an high frequency
leakage current. In order to prevent nuisance tripping, residual current protection device must be
protected against these high frequency currents: this is the case for industrial residual current
device (example „S“ type).

S-4000CAEDOmron
1-10 Revised 10/2009
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J6A
J6B
J5A
B - MACHINE ASSEMBLY
4. HEAD PNEUMATIC
Ê— cutting
Ë — clamping feet
Ì — thread trimming
Η shifting clamping plate
Ï— changing the direction of sewing
З blowing off the cut material
Ñ— loopers, thread blow off (*Extra parts)
J0I1; J0I2 — air supply
BQ2 - manometer with pressure sensor
MARKING
OFHOSES JXXX
BQ2
J0I1
J0I2
Ê
Ë
Ì
Ñ
Ï
ÐÎ
*
air supply
1, 2 — X => marking of pneumatic cylinder
1, 2 — X => auxiliary line
A= supply; B= return line; I= valve supply

S-4000CAEDOmron
1-11
Revised 10/2009
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B - MACHINE ASSEMBLY
5. INSTALLATION OF THREAD HOLDER
1. Put the thread holder together as per
the drawing.
2. Position of the ring ➊enables
assembly of the complete holder onto
tables with different thickness of the
tabletop. The end of the rod with
threads ➏shall not overtop the nut
more than 1 mm.
3. Once the ring ➊is positioned, insert
the mat ➋with the groove towards
the ring; place the rod into the opening
in the tabletop ➌(on the right at the
back). Tighten the nut ➎with the mat
➍underneath.

S-4000CAEDOmron
1-12 Revised 10/2009
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C - PROPER APPLICATION
1. POWER UP/HOME POSITION
1. Turn the main power switch on ➊by turning clockwise to the I position.
2. The display is illuminated for a moment and the screen shows the model number.
3. The machine is ready for operation when the Ready message appears on the display and the green
LED lights.
The machine must be in the home position before starting to sew (to be certain, press the foot treadle
and sew one buttonhole).
4. It is possible to install the power voltage control (Voltage monitoring relay HRN 35) into the machine
control system. This power voltage control cautions a machine operator if the supply voltage is not in
the required range (185V - 255V) and the machine could be damaged - see section E19.
Note: The power voltage guard is installed in the machine only if a customer has ordered it with the
machine.
➊

S-4000CAEDOmron
1-13
Revised 10/2009
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C - PROPER APPLICATION
2. NEEDLE INSTALLATION
WARNING! Before doing this adjustment, switch the machine off and let the remaining compressed air from
the machine out.
For thin fabrics the machine uses needles order number 02.0750.2.109 (750 SC 70/10— Groz-Beckert) as
standard and for thicker fabrice needles order number 02.0750.2.110 (750SC 90/14— Groz-Beckert) – see
accessories. I tis possible to use needles order number 02.0750.2.100 (750 SC 80/12 - Groz-Beckert) for
thin fabrice – these needles are not in a standard accessory kit.
1. Using the screwdriver push the latch ➊and open the needle bar cover ➋.
Note: The accessories contain the lever ➎(part number 22.0213.0.000) and screw (part number
08.6000.4.005) with washer (08.6850.4.000) ➏, which is possible to fit to the latch. It allows
opening of the cover without using the tool.
2. Loosen the screw ➌and remove the needle.
3. Insert the new needle so that the long thread
groove ➍is in the rear and the spot for the
clamping screw ➌is in line. Do not install a
bent or broken needle. Roll the needle on a flat
surface to check for straightness.
4. Tighten the screw ➌well.
ÊÊ
Ê
Ê
Ê
ËË
ËË
Ë
➎
➏
Ê
Ê
ÊÊ
Ê

S-4000CAEDOmron
1-14 Revised 10/2009
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3. THREADING
WARNING! Switch the main machine power off to prevent accidental starting of the machine. Disconnect
the air supply and dissipate any stored energy.
When threading, see the pictures below. Change the thread tension by nut ➊according to the sewing
conditions. To increase the thread draw off (for example sewing on the thin fabrics) there is an arm ➋
installed on the thread draw off lever.
C - PROPER APPLICATION
The appearance and quality of the sewing may be affected by one or more of the following:
- clamping of the material
- thread tension
- type of thread (size etc.)
- sewn material (thickness, density)