Mitsubishi PLK-G6030 Technical Manual
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Mitsubishi PLK-G6030 Technical Manual

Sewing machine head. electronic pattern sewing machine
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Industrial Sewing Machine
TECHNICAL MANUAL
SEWING MACHINE HEAD
Electronic Pattern Sewing Machine
Model PLK-G4030
PLK-G6030
A180E646P01

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Summary of Contents for Mitsubishi PLK-G6030

  • Page 1 Industrial Sewing Machine TECHNICAL MANUAL SEWING MACHINE HEAD Electronic Pattern Sewing Machine Model PLK-G4030 PLK-G6030 A180E646P01...
  • Page 2 FOR SAFE USE Before the installation, operation, and inspection for this product, read the “FOR SAFE USE” and the technical manuals carefully. Also read the other technical manuals, “Control Unit” and “Operation Panel” describing some instructions, which are not in this manual, and use the sewing machine properly. SAFETY INDICATIONS Indicates that incorrect handling may cause hazardous conditions, resulting DANGER...

  • Page 3: Safety Precautions

    SAFETY PRECAUTIONS DANGER To prevent from receiving an electric shock, always turn off a power switch and unplug power supply when opening a control box, and then open after ten minutes passes. CAUTION USAGE ENVIRONMENT Please do not operate the sewing machine under the following conditions. (1) In the ambient temperature of 35 degrees (95°F) or more than 35 degrees, or the ambient temperature of 5 degrees or less than 5 degrees (41°F).
  • Page 4 SEWING (1) Please make sure to turn the power switch off before installing or replacing needles. (2) Please pay attention for the fingers not to be injured by the needle point. (3) Please make sure to turn power switch off before lubricating. (4) Please pay attention that oil does not get on your skin or in your eyes as it may cause an inflammation.
  • Page 5 CONTENTS 1. STRUCTURE OF THE SEWING MACHINE···································· 2. SPECIFICATION······································································· 3. INSTALLATION········································································ 3-1. Installation of the foot switch···································································· 3-2. Connection of the air tube······································································· 3-3. Installation of the thread stand································································· 3-4. Installation of the eye guard···································································· 3-5. Installation of the spindle motor································································ 4.
  • Page 6 7. STANDARD ADJUSTMENT························································ 7-1. Adjustment of the needle bar position························································ 7-2. Adjustment of the position between the needle and the shuttle hook················ 7-3. Adjustment of the clearance between the shuttle hook and the needle·············· 7-4. Adjustment of the clearance between the driver and the needle······················ 7-5.

  • Page 7: Structure Of The Sewing Machine

    1. STRUCTURE OF THE SEWING MACHINE PLK-G4030/G6030 electronic pattern sewing machine consists of the following main parts. <2> <1> <9> <8> <3> <5> <4> <7> <6> <1>: Sewing machine head <2>: Main shaft motor <3>: Halt switch <4>: Control box <5>: Operation panel <6>: Work holder foot switch <7>: Start foot switch <8>: Thread stand <9>: Presser foot 2-stage lifting device - 1 -...

  • Page 8: Specification

    2. SPECIFICATIONS Model PLK-G4030 PLK-G6030 X-direction (left/right) 400 mm X-direction (left/right) 600 mm Sewing area Y-direction (front / back) 300 mm Maximum sewing speed 2,000rpm Setting speed 10 speed levels in 200 rpm to 2,800 rpm Stitch length 0.1 to 20.0 mm...

  • Page 9: Installation

    3. INSTALLATION CAUTION (1) Please have some specialists, who have enough experience for the sewing machine installations, install the sewing machine. (2) Please have a Qualified Electrician perform necessary electric wiring. (3) Please do not operate until the sewing machine is repaired when any damage or fault is found on the sewing machine at the installation.

  • Page 10: Installation Of The Thread Stand

    3-3. Installation of the thread stand (1) Assemble the parts (No.1 to No.11) of the thread stand as shown on the figure. (2) Fit the thread stand into the hole at the far right on the table stand with the nut (No.13) and the washers (No.12).

  • Page 11: Installation Of The Spindle Motor

    3-5. Installation of the spindle motor (1) If the spindle motor (No.1) has been removed from the machine for the adjustment or the like, fix the spindle motor as the procedure described below. (2) Set the pin (No.3) position of the bushing to the motor mark (No.2). (3) Adjust the clearance between the motor and the coupling (No.4).

  • Page 12: Lubrication

    4. LUBRICATION CAUTION (1) Please make sure to turn power switch off before lubricating. (2) Please pay attention that oil does not get on your skin or in your eyes as it may cause an inflammation. (3) Please make sure to keep oil out of the reach of children who may drink oil by mistake. [Notice] Please make sure to lubricate when operating for the first time after the installation.

  • Page 13: Proper Operation

    5. PROPER OPERATION 5-1. Initial setting of the control box When using the sewing machine for the first time, the model and the language of the sewing machine in use have to be set. Refer to the instructions in the paragraph “[6] Initial Setting of System (Model/language Setting)” in the CONTROL UNIT technical manual.

  • Page 14: Threading The Upper Thread

    5-3. Threading the upper thread CAUTION (1) Please turn the power switch off when threading a needle. Thread the upper thread as shown on the figure. - 8 -...

  • Page 15: Winding The Bobbin Thread

    5-4. Winding the bobbin thread CAUTION (1) Please do not touch the rotating part during winding thread. Doing so may cause injury and/or the machine failure. [Notice] Please make sure to pull the upper thread out of the needle before winding the bobbin thread. (1) Route the thread as shown in the below figure then, wind the thread to the bobbin (No.1) in the direction of “a”...

  • Page 16: Setting The Bobbin

    5-5. Setting the bobbin (1) Insert a full Bobbin (No.2) into the bobbin case (No.1). (2) Pull out the bobbin thread (No.3) from the slit (No.4) and pass the thread through the thread hole (No.5). When the bobbin thread is pulled, the pin rotates in the arrow direction shown on the figure. If the pin starts rotating to the opposite direction, turn the bobbin over and reset the bobbin.

  • Page 17: Sewing

    6. SEWING CAUTION (1) Before starting the sewing, please make sure the position and the function of the halt switch. (2) Please do not touch the operating parts during sewing operation. (3) It is very dangerous to operate the sewing machine without safety guards (eye guards, belt covers, link covers, finger guards or the others).

  • Page 18: Operation Of The Halt Switch

    6-2. Operation of the halt switch (1) If accidents such as a thread breakage, needle breakage and others happened during the sewing, press the halt switch immediately. The sewing machine stops instantly. (2) To cancel the halt state, press the halt switch again. (3) When continuing sewing, step on the grey foot switch to restart at the halted position.

  • Page 19: Adjustment Of The Thread Tension

    6-3. Adjustment of the thread tension (1) Adjustment of bobbin thread tension <1> Adjust the bobbin thread tension with the thread tension <2> adjusting screw (No.2) on the bobbin case (No.1). The thread tension becomes loose when loosening the thread tension adjusting screw (No.2) counterclockwise, and the thread tension becomes tight when tightening the thread tension adjusting screw clockwise.

  • Page 20: Operation Of The Presser Foot 2-Stage Lifting Device

    6-4. Operation of the presser foot 2-stage lifting device To operate the Presser Foot 2-Stage Lifting Device, use the Function Code 2 (FUN2) in the process of pattern input. ＜Example＞ An example of operations to add function code 2 using the operation panel is explained below. This section describes the methods for input the code data with the input mode when newly creating a pattern, Please refer to the technical data "Operation Panel Section"...
  • Page 21 (4)The screen for selecting the codes will open, so select , and then press Input the subsequent pattern data after that. (5) Press the ( ) after inputting the pattern data. And then check that the "FUN2" code has been input. 6-5.

  • Page 22: Standard Adjustment

    7. STANDARD ADJUSTMENT CAUTION (1) Please make sure to turn the power switch off before adjusting the sewing machine. (2) When adjusting the sewing machine with the power switch on, please be careful not to step on the foot switch by mistake. (3) Please be careful not to be injured by a sharp part such as the needle and the shuttle hook point.

  • Page 23: Adjustment Of The Clearance Between The Shuttle Hook And The Needle

    (6) If the shuttle hook point is not matched with the center line of the needle, loosen the driver (No.9) set screw (No.10) then, turn the shuttle hook and the driver for the adjustment. (7) For the needle class DP×5, move the needle bar to the position where the needle bar timing mark D is matched to the needle bar bushing bottom line then, carry out the same procedure as described above.

  • Page 24: Adjustment Of The Clearance Between The Driver And The Needle

    7-4. Adjustment of the clearance between the driver and the needle (1) Please take the same procedures as above paragraph 7-2. from (1) to (5). (2) Please make sure the clearance between the shuttle hook point and the needle has been adjusted 0.05~0.1mm at above procedure 7-3 Adjustment of the clearance between the shuttle hook and the needle.

  • Page 25: Adjustment Of The Shuttle Race Thread Guide

    7-5. Adjustment of the shuttle race thread guide (1) Remove the E-shaped snap ring (No.3) which is engaging the movable knife (No.2) and the link (No.1) then, loosen the setscrews (No.4) and remove the sliding plate (No.5). (2) Loosen the setscrews (No.10) and move the thread guide (No.6) to the position where the needle center line (No.8) divides the needle groove (No.7) evenly and the rear side line (No.9) of the needle is aligned with the shoulder (No.9) of the thread guide (No.6).
  • Page 26 (1) Turn the power switch OFF. (2) Remove the face plate (No.1) and the cover (No.2). (3) Turn the sewing machine pulley by hand and stop the needle bar (No.3) at the lowest position. At this time, make sure the setscrew (No.5) of the eccentric cam (No.4) is positioned right beside the center line of the upper shaft.

  • Page 27: Adjustment Of The Presser Foot Lift During The Sewing

    NOTE If the thickness of the sewing material changes very often, it is recommended to take the easy way for the adjustment of the presser foot position with the method that change only the fixed position of the presser foot after fixed the presser foot bar at higher position. For this adjustment, loosen the setscrew (No.16) then, move the presser foot (No.12) up and down.

  • Page 28: Adjustment Of The Presser Foot Timing

    7-6-3. Adjustment of the presser foot timing NOTE The presser foot up and down movement during the sewing synchronizes with the needle up and down movement. With changing this synchronized timing to the sewing materials, the skip stitches can be prevented or the seam tightness can be improved. For example, the delay of the presser foot timing against the needle movement prevents the skip stitches especially to the thin materials, and the advance of the presser foot timing can improve the seam tightness especially to the thick materials.

  • Page 29: Adjustment Of The Wiper

    7-7. Adjustment of the wiper (1) Loosen the wiper setscrew (No.3) and adjust the wiper (No.1) to be positioned where the wiper (No.1) passes under the needle point (No.2) with about 2mm clearances right after the sewing machine is stopped running at the needle upper position (the thread take up lever's highest position). NOTE When the presser foot position or the presser foot lift is changed, the wiper (No.1) may collide with the presser foot (No.4).

  • Page 30: Adjustment Of The Bobbin Winder

    7-8. Adjustment of the bobbin winder (1) Adjustment of the winding volume Adjust the amount of the winding thread with the subsidiary arm (No.1). The winding volume is adjusted 80% of the full volume when the sewing machine is shipped from the factory.

  • Page 31: Adjustment Of The Trimmer Cam Follower

    Marked parts are only used for PLK-G6030. 7-10. Adjustment of the trimmer cam follower (1) Turn the power switch OFF and remove the top cover. (2) Under the sewing machine regular stop condition (the needle stop position is upper and the take up lever stop position is highest), loosen the setscrew (No.5) of the cam follower lever (No.4) and...

  • Page 32: Adjustment Of The Blade Drive Arm Spring Force

    7-11. Adjustment of the position for the movable knife point (1) Proceed as below to adjust the movable knife so that its end coincides with the front of the hook retainer (No.2). (2) Remove then slide plate, and open the cylinder cover. (3) Check with the point (No.1) of the movable knife whether it is located at the position apart 0.5mm from the front face of the hook retainer (No.2).

  • Page 33: Adjustment Of The Fixed Knife Position

    7-13. Adjustment of the fixed knife position (1) Open the cylinder cover (No.1). (2) Remove the E-shaped snap ring (No.4), which engages the movable knife (No.2) and the link (No.3). (3) Loosen the setscrews (No.5) then, remove the sliding plate (No.6). (4) Turn the sliding plate (No.6) upside down and loosen two setscrews (No.9) then, adjust the fixed knife (No.10) position to be positioned for the blade edge (No.7) to have the clearance 0.5mm from the edge of the needle plate (No.8).

  • Page 34: Adjustment Of The Thread Take Up Spring Swing Stroke

    7-14. Adjustment of the thread take up spring swing stroke Loosen the setscrew (No.2) and turn the whole thread tension regulator (No.3) then, adjust the thread take up spring swing stroke to be become 9~10mm. After the adjustment, tighten the setscrew (No.2) securely. 7-15.

  • Page 35: Adjustment Of The Upper Thread Tension Release

    7-17. Adjustment of the upper thread tension release NOTE (a) The upper thread tension release works when the upper thread is trimmed automatically or the presser foot is lifted during the work holder feeding. (b) If the upper thread tension release does not work properly when the upper thread is trimmed automatically, the thread tail from the needle becomes shorter then, it induces the skip stitch happening or pulling the thread tail out of the needle at the start of the sewing.

  • Page 36: Adjustment Of The Mechanical Home Position

    (No.2). [Rear side] Original home position Adjustable [Front side] ) For PLK-G6030 (1) After canceling the sewing area limit, change the mechanical home position. (2) Press the on the standard screen to open the MENU mode. (3) Press the >...

  • Page 37: Adjustment Of The X Direction

    7-18-1. Adjustment of the X direction (1) Turn the power switch off. (2) The mechanical home position of the X direction is the position where the detector (No.2) can detect the edge of the detector plate X (No.1). (3) For the adjustment of the X direction mechanical home position, loosen the detector plate set screws (No.3) at the left and right side then, move the detector plate X in the arrow direction as shown on the figure.

  • Page 38: Adjustment Of The Y Direction

    7-18-2. Adjustment of the Y direction (1) Turn the power switch off. (2) Remove the covers and shutters on the top of the sewing machine bed. (3) For the adjustment of the Y direction mechanical home position, loosen the detector set screw (No.1) then, move the detector (No.2) to the arrow direction as shown on the figure.

  • Page 39: Adjustment Of The X-Y Timing Belt Tension

    7-19. Adjustment of the X-Y timing belt tension NOTE The proper condition of the X-Y timing belt tension is standing that they will not be got any yield even it is slightly pushed by hand. 7-19-1. Adjustment of the X timing belt tension (1) Remove the covers and shutters on the top of the sewing machine bed.

  • Page 40: Adjustment Of The Y Timing Belt Tension

    7-19-2. Adjustment of the Y timing belt tension (1) Remove the covers and shutters on the top of the sewing machine bed. (2) Loosen set screws (No.2) of the brackets (No.1). (It’s located right and left side) (3) Tighten the adjust screw (No.3) of right and left side, the Y timing belt (No.4) tension will be increased.

  • Page 41: Maintenance

    8. MAINTENANCE CAUTION (1) Please make sure to turn the power switch off before cleaning the sewing machine. (2) Please pay attention to that staining your skin or eyes with oil may cause an inflammation. 8-1. Cleaning (1) Remove the dust and the thread waste sticking the threading parts or the hooks area regularly.

  • Page 42: Troubleshooting

    9. TROUBLESHOOTING CAUTION (1) Please make sure to turn the power switch off before adjusting the sewing machine. (2) If the adjustment is required while the power switch on, do not step on the foot switch by mistake. Condition Cause Corrective action Reference Upper thread tension is too...
  • Page 43 Trimming is not Movable knife is at wrong Adjust position of movable 7-11 functioned. position. knife properly. Refer to the condition Skip stitching happens in “Frequent skip stitching trimming. happens”. Operation Trimming setting is off. Turn trimming setting on. panel section Upper thread tension is too Stitch forming is loose.
  • Page 44 FACTORY AUTOMATION SYSTEM GROUP 2-7-3, Marunouchi Chiyoda-ku Tokyo 100-8310, Japan Fax : +81-3-3218-6821 New publication, effective APR.2011 Contents subject to change without notice...

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Plk-g4030

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