Related Manuals for JUKI PLK-G4030R
Summary of Contents for JUKI PLK-G4030R
- Page 1 INDUSTRIAL SEWING MACHINE MODEL PLK-G4030R PLK-G6030R TECHNICAL MANUAL SEWING MACHINE HEAD A181E080P01...
- Page 3 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 4 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 5 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.
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Page 6: Table Of Contents
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 7 7-7. Adjustment of the presser foot height position············································ 7-8. Adjustment of the presser foot position····················································· 7-9. Adjustment of the presser foot walk during the sewing································· 7-10. Adjustment of the presser foot spring pressure········································· 7-11. Adjustment of t the wiper······································································ 7-12. Adjustment of the thread trimmer··························································· 7-12-1 Structure of the thread trimmer mechanism··········································...
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Page 8: Structure Of The Sewing Machine
1. STRUCTURE OF THE SEWING MACHINE PLK-G4030R/G6030R industrial sewing machine consists of the following main parts. <2> <1> <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... -
Page 9: Specification
2. SPECIFICATIONS Model PLK-G4030R PLK-G6030R 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 2,000 rpm Stitch length 0.1 to 20.0 mm... -
Page 10: 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 11: 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 12: 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 13: 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 14: 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 15: 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 16: 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 17: Setting The Bobbin
5-5. Setting the bobbin (1) Set the bobbin (No.2) into the bobbin case (No.1). (2) Pull the bobbin thread (No.3) into the slit (No,4) and pass the through the thread hole (No.5). At this time, pull the bobbin thread (No.3) then, check with the bobbin (No.2) if it is rotated to the arrow direction. -
Page 18: 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 19: Operation Of The Halt Switch
6-2. Operation of the halt switch <1> (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 20: 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 21: Adjustment Of The Position Between The Needle And The Rotating Hook
7-2 Adjustment of the position between the needle and the rotating hook (1) Turn the power switch OFF. (2) Open the cylinder cover (No.1). (3) Remove the bobbin case (No.2). (4) Remove the sliding plate (No.3). (5) Loosen the hook three set screws (No.4). (6) Turn the sewing machine pulley (No.5) by hand in the direction of the arrow then, move up the needle bar (No.6) from the lowest position and stop it at the position (No.7) where the needle bar timing mark C is matched to the needle bar bushing bottom line. -
Page 22: Adjustment Of The Hook Positioner's Position
<1>: Cylinder cover <2>: Bobbin case <3>: Sliding plate <4>: Hook set screw <5>: Pulley <6>: Needle bar <7>: Lowest position of needle bar <8>: Hook point <9>:Needle <10>: Needle hole 7-3 Adjustment of the hook positioner’s position (1) Remove the sliding plate. (2) Loosen the hook positioner set screw (No.4) and adjust the hook positioner (No.1) position to align the right side of the projection (No.3) with the right side of the needle (No.2) as shown on the figure. -
Page 23: Adjustment Of The Lubrication For The Rotating Hook
7-4 Adjustment of the lubrication for the rotating hook (1) Open the cylinder cover (No.1). (2) Tighten the oil flow adjusting screw (No.2) lightly by fingers or a screw driver until it is stopped the turn. NOTE Do not tight the oil flow adjusting screw (No.2) too much. (3) Adjust the oil flow in the range of one reverse turn from the deadlock position of the oil flow adjusting screw (No.2). -
Page 24: Adjustment Of The Presser Foot Timing
7-5. 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 25: Adjustment Of The Presser Foot Lift
7-6. Adjustment of the presser foot lift The presser foot lift can be returned factory default setting at 15mm as the procedure shown below. Also, if the presser foot does not move after changing the presser foot correction value and the stroke, carry out the procedure below. -
Page 26: Adjustment Of The Presser Foot Height Position
<9> <3> <7> <8> <4> <3> 41mm <3>: Gauge <4>: Presser foot bar holder <7>: Detector plate set screw <8>: Detector plate <9>: Presser foot drive motor 7-7. Adjustment of the presser foot height position The height of presser foot can be returned factory default setting as the procedure shown below. (1) Turn the power switch on, and set the correction value at 0. -
Page 27: Adjustment Of The Presser Foot Walk During The Sewing
7-9. Adjustment of the presser foot walk during the sewing (1) The presser foot walk during the sewing can be adjusted with the walk at zero or the walk of 2 to 10mm. The walk at zero requires the exclusive parts (Option). Please feel free to contact your dealer. (2) When turning the set position of the shoulder bolt (No.1) to the direction “a”, the presser foot walk becomes bigger, and when turning the set position to the direction “b", the presser foot walk becomes smaller. -
Page 28: Adjustment Of T The Wiper
7-11. Adjustment of the wiper (1) Loosen the wiper set screw (No.3) and adjust the wiper (No.1) to be positioned where the wiper (No.1) passes under the needle (No.2) point with a clearance of about 2mm right after the sewing machine stops at the needle upper position. -
Page 29: Adjustment Of The Thread Trimmer
7-12 Adjustment of the thread trimmer 7-12-1 Structure of the thread trimmer mechanism The thread trimmer mechanism of sewing machine is shown on the figure. <4> <7> <5> <8> <6> <3> <9> <10> <2> <11> <12> <1> <1>: Knife mounting unit <2>: Knife bracket <3>: Trimming cam <4>: Air cylinder <5>: Stopper <6>: Cam follower crank 2 <7>: Cam follower crank 1 <8>:Knife driving shaft <9>:Driving crank <10>: Movable knife <11>: Stationary knife <12>: Thread guide CAUTION... -
Page 30: 7-12-2.2 Mutual Relation Among The Movable And Stationary Knife Edge
<1>: Knife bracket <3> <2>: Bushing <3>: Set screw <2> <1> (2) Knife mounting unit Under the condition that the rotating hook and the hook positioner are removed, attach the knife mounting unit (No.1) with the set screw (No.2). <1>: Knife mounting unit <2>... -
Page 31: 7-12-2.3 Connection Of The Knife Bracket And The Driving Crank
7-12-2.3 Connection of the knife bracket and the driving crank (1) Connect the knife bracket (No.1) and the driving crank (No.2) with the link (No.3). (2) Loosen the driving crank set screw (No.4) and adjust the attaching position of the driving crank (No.2) in the right and left direction so that the link (No.3) can contact with the same flat surface of the knife bracket (No.1) and the driving crank (No.2) without any distortion. -
Page 32: 7-12-2.5 Adjustment Of The Mounting Position Of The Air Cylinder
7-12-2.5 Adjustment of the mounting position of the air cylinder (1) Attach the thread trimmer air cylinder (No.1) by fixing with the bolt (No.2). When the thread trimmer air cylinder (No.1) is released, there will be a clearance of approx. 1mm at section A. To adjust this clearance, loosen the set screw (No.4) for the mounting plate (No.3), and move the entire mounting plate (No.3). - Page 33 (1) Loosen 2 set screws (No.9) of the thread trimmer cam (No.8).Remove the slide plate and place the 4mm thickness gauge (No.10) on the top of sewing machine bed. Slide the gauge (No.11) in between the needle bar and the 4mm thickness gauge (No.10). Use the 26.2mm part of T side. (2) Make the air cylinder activated condition, then turn the thread trimmer cam (No.8) in the arrow B direction by hand.
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Page 34: 7-12-2.7 Adjustment Of The Knife Engagement
7-12-2.7 Adjustment of the knife engagement (1) The standard position for the movable and stationary knife <3> <2> The standard mutual position for the movable 5.5～ <1> 2.5mm (No.1) and stationary (No.2) knife is as shown on the figure. (2) Adjustment of the amount for the knife engagement Activate the thread trimmer air cylinder, and rotate the upper shaft. -
Page 35: Adjustment Of The Work Holder Pressure
(4) Adjustment of the attaching position of the protector. Attach the protector (No.6) underneath the movable <7> knife (No.1) and fix it with the same set screw (No.7) for the movable knife (No.1) at the position where the point of the protector (No.6) is off 0.5mm left from the <1>... -
Page 36: Adjustment Of The Bobbin Winder
7-14. 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 37: Changing The Work Holder
7-15. Changing the work holder (1) Before changing the work holder (No.1), remove the holder block (No.4) that is secured with the screw (No.3). It will come off by pressing the work holder (No.1) down from the area engaged with the pin (No.6) of the work holder arm (No.5). -
Page 38: Adjustment Of The Thread Tail After The Trimming
7-17. Adjustment of the thread tail after the trimming (1) Adjust the thread tail with the pre-tension (No.1). (2) When turning the nut clockwise, the thread tail becomes shorter. <1> When turning the nut counterclockwise, the thread tail becomes longer. <1>: Pre-tension 7-18. -
Page 39: Adjustment Of The Mechanical Home Position
7-20. Adjustment of the mechanical home position The mechanical home position (No.1) is fixed at the center of the sewing area when the sewing machine is shipped from the factory. However, it can be moved within the area covered with diagonal lines (No.2). -
Page 40: Adjustment Of The X Direction
7-20-1. 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 41: Adjustment Of The Y Direction
7-20-2. 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 42: Adjustment Of The X-Y Timing Belt Tension
7-21. 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. 7-21-1. Adjustment of the X timing belt tension (1) Remove the covers and shutters on the top of the sewing machine bed. -
Page 43: Adjustment Of The Y Timing Belt Tension
7-21-2. 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. (4) After the adjustment, tighten the set screws (No.2) securely. -
Page 44: 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 45: 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 46 Refer to the condition Trimming is not Skip stitching happens in “Frequent skip stitching functioned. trimming. happens”. Operation Trimming setting is off. Turn trimming setting on. panel section Stitch forming is Upper thread tension is too Adjust upper thread tension. loose.
- Page 48 Printed in Japan...
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