Mitsubishi Electric PLK-G4030 Technical Manual
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Mitsubishi Electric PLK-G4030 Technical Manual

Industrial sewing machine
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INDUSTRIAL SEWING MACHINE
MODEL
PLK-G4030
PLK-G6030
TECHNICAL MANUAL
SEWING MACHINE HEAD
A180E682P03

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Summary of Contents for Mitsubishi Electric PLK-G4030

  • Page 1 INDUSTRIAL SEWING MACHINE MODEL PLK-G4030 PLK-G6030 TECHNICAL MANUAL SEWING MACHINE HEAD A180E682P03...
  • 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 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: 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 6 7-8. Adjustment of the presser foot height position·············································· 7-9. Adjustment of the presser foot position······················································· 7-10. Adjustment of the presser foot walk during the sewing································· 7-11. Adjustment of the presser foot spring pressure··········································· 7-12. Adjustment of the wiper········································································· 7-13. Adjustment of the work holder pressure···················································· 7-14.

  • 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. <1> <2> <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 - 1 - From the library of Superior Sewing Machine &...

  • 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 2,000 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 - From the library of Superior Sewing Machine & Supply LLC - www.supsew.com...

  • 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: 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 Shuttle Hook

    7-2. Adjustment of the position between the needle and the shuttle hook (1) Turn the power switch off. Move up the needle bar (No.1) from the lowest position then, stop the needle bar at the position where the needle bar timing mark C is matched to the needle bar bushing (No.2) bottom line.

  • Page 22: Adjustment Of The Clearance Between The Shuttle Hook And The Needle

    7-3. Adjustment of the clearance between the shuttle hook and the needle (1) Take the same procedure described in (1) to (4) of above paragraph 7-2. (2) Set the clearance between the shuttle hook (No.1) point and the needle (No.2) in 0 to 0.05 mm, standard position.

  • Page 23: Adjustment Of The Shuttle Race Thread Guide

    7-5. Adjustment of the shuttle race thread guide (1) Remove the ring-E type (No.3) which is engaging the movable knife (No.2) and the trimmer link (No.1). (2) Loosen the set screw (No.4) and remove the sliding plate (No.5) so that the shuttle race thread guide (No.6) shown on the figure appears.

  • Page 24: Adjustment Of The Presser Foot Timing

    7-6. 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

    7-7. 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 7-8. 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

    7-10. 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 the sewing machine stores.

  • Page 28: Adjustment Of The Wiper

    7-12. 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 Bobbin Winder

    <1>：Adjusting knob <1> <2>：Air regulator <2> 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 30: 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 31: Adjustment Of The Trimmer Cam Follower

    7-16 Adjustment of the trimmer cam follower (1) Turn the power switch off and remove the top cover. <5> <3> <1> (2) Loosen the arm set screw (No.3) to adjust the cam <4> follower (No.1) with a cam groove clearance of about 1mm between the cam follower and the trimmer cam (No.2).

  • Page 32: Adjustment Of The Position For The Movable Knife Point

    7-17.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

    7-19. Adjustment of the fixed knife position (1) Open the cylinder cover (No.1) and remove the ring-E type (No.4), which engages the movable knife (No.2) and the thread trimmer link (No.3). (2) Loosen the screw (No.5) then, remove the slide plate (No.6). (3) Adjust the fixed knife (No.7) position to be positioned for the blade edge to have the clearance 0.5mm from the edge of the needle plate (No.8), which is standard position.

  • Page 34: Adjustment Of The Thread Tail After The Trimming

    7-21. 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. When turning the nut counterclockwise, the thread tail becomes <1> longer. <1>: Pre-tension 7-22.

  • Page 35: Adjustment Of The Mechanical Home Position

    7-24. 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 36: Adjustment Of The X Direction

    7-24-1. 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 37: Adjustment Of The Y Direction

    7-24-2. 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 38: Adjustment Of The X-Y Timing Belt Tension

    7-25. 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. 7-25-1. Adjustment of the X timing belt tension (1) Remove the covers and shutters on the top of the sewing machine bed.

  • Page 39: Adjustment Of The Y Timing Belt Tension

    7-25-2. 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 40: 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 41: Troubleshooting

    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 Upper thread is broken.
  • Page 42 Trimming is not Movable knife is at wrong Adjust position of movable 7-17 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 43 MEMO From the library of Superior Sewing Machine & Supply LLC - www.supsew.com...
  • Page 44 Printed in Japan From the library of Superior Sewing Machine & Supply LLC - www.supsew.com...

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Plk-g6030

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