Mitsubishi Electric PLK-G4030 Technical Manual

INDUSTRIAL SEWING MACHINE
MODEL
PLK-G4030
PLK-G6030
TECHNICAL MANUAL
SEWING MACHINE HEAD
A180E682P03
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
DANGER
Indicates that incorrect handling may cause hazardous conditions, resulting
in death or severe injury.
Indicates that incorrect handling may cause hazardous conditions, resulting
in medium or slight personal injury or physical damage. Note that CAUTION
CAUTION
level may lead to a serious consequence according to the circumstances.
Always follow the instructions of both levels because they are important to
personal safety.
CAUTION INDICATIONS
No.
1
Caution indication
Description
Precaution for sewing machine operation:
Indicates that removing the safety and operating the sewing
machine for some other purposes with power-on are prohibited.

Please do not operate the sewing machine without
protective equipment such as a needle guard, an eye guard,
a belt cover or the others.

Please turn off the power switch when threading, changing
a needle and a bobbin, cleaning, and lubricating.
2
Caution for fingers injury:
Indicates a possibility of fingers (hands) injury in a certain
condition.
3
Caution for squeezing fingers:
Indicates a possibility of squeezing fingers in a certain condition.
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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).
(2) In the ambient temperature of 55 degrees (131°F) or more than 55 degrees, or the ambient
temperature of -10 degrees or less than -10 degrees (18°F) during transportation.
(3) In the relative humidity exceeding 85% or less than 45%.
(4) In the open-air place or the location that receives direct sunlight.
(5) In the place near heat sources such as heating devices.
(6) In the atmosphere filled with dust, explosive gas, or corrosive gas.
(7) In the place where the fluctuation in the power voltage of 10% or more than 10%, or the power
voltage of -10% or less than -10% of the fixed power voltage.
(8) In the place where the power source cannot supply enough voltage to keep the motor running.
(9) In the place filled with strong electric noises such as high-frequency welders.
INSTALLATION
(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.
(4) Please do not refurbish the sewing machine.
(5) The sewing machine is heavy. For the safety, please make sure to install the sewing machine head
by more than one person.
(6) Please make sure to fit the safety protective equipment (the motor cover or the others) and the
accessory protective equipment (the eye guard) that removed temporarily for installation.
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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.
(5) Please make sure to keep oil out of the reach of children who may drink oil by mistake.
(6) Please make sure to turn the power switch off before threading a needle.
(7) Before starting the sewing, please make sure the position and the function of the halt switch.
(8) Please do not touch the operating parts during sewing operation.
(9) It is very dangerous to operate the sewing machine without safety guards (eye guards, belt covers,
link covers, finger guards or the others).
Please make sure to operate the sewing machine with safety guards.
(10) Please make sure to turn the power switch off when stopping the sewing machine temporarily.
ADJUSTMENT
(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.
(3) Please be careful not to be injured by a sharp part such as the needle and the shuttle hook point.
(4) Please make sure to put the safety guards (eye guards, belt guards, link covers, and finger guards
or the others) back on the initial position after the sewing machine adjustment.
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CONTENTS
1. STRUCTURE OF THE SEWING MACHINE···································· 1
2. SPECIFICATION······································································· 2
3. INSTALLATION········································································
3
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································································
3
3
4
4
5
4. LUBRICATION·········································································
6
4-1. Filling the oil tank··················································································· 6
4-2. Oiling·································································································· 6
5. PROPER OPERATION······························································
5-1. Initial setting of the control box·································································
5-2. Installation of the needle·········································································
5-3. Threading the upper thread·····································································
5-4. Winding the bobbin thread······································································
5-5. Setting the bobbin·················································································
5-6. Setting the bobbin case··········································································
6. SEWING·················································································
7
7
7
8
9
10
10
11
6-1. The sewing operation············································································
6-2. Operation of the halt switch·····································································
6-3. Adjustment of the thread tension······························································
11
12
13
7. STANDARD ADJUSTMENT······················································
14
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. Adjustment of the shuttle race thread guide················································
7-6. Adjustment of the presser foot timing························································
7-7. Adjustment of the presser foot lift······························································
14
15
16
16
17
18
19
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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. Adjustment of the bobbin winder·····························································
7-15. Changing the work holder······································································
7-16. Adjustment of the trimmer cam follower····················································
7-17. Adjustment of the position for the movable knife point··································
7-18. Adjustment of the blade drive arm spring force···········································
7-19. Adjustment of the fixed knife position························································
7-20. Adjustment of the thread take up spring···················································
7-21. Adjustment of the thread tail after the trimming··········································
7-22. Adjustment of the upper thread tension release (the width between thread
20
20
21
21
22
22
23
24
25
26
26
27
27
28
tension discs) ·····················································································
7-23. Adjustment of the opening time of the upper thread tension release disks········
7-24. Adjustment of the mechanical home position·············································
7-24-1. Adjustment of the X direction····························································
7-24-2. Adjustment of the Y direction····························································
7-25. Adjustment of the X-Y timing belt tension··················································
7-25-1. Adjustment of the X timing belt tension················································
7-25-2. Adjustment of the Y timing belt tension················································
28
28
29
30
31
32
32
33
8. MAINTENANCE······································································ 34
8-1. Cleaning···························································································
8-2. Disposing of oil waste··········································································
34
34
9.TROUBLESHOOTING······························································· 35
From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
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-
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2. SPECIFICATIONS
Model
Sewing area
PLK-G4030
PLK-G6030
X-direction (left/right) 400 mm
X-direction (left/right) 600 mm
Y-direction (front / back) 300 mm
Maximum sewing speed
*3
2,000rpm
Setting speed
10 speed levels in 200 rpm to 2,000 rpm
Stitch length
0.1 to 20.0 mm
Stitch type
Single needle lock stitch
Maximum number of needles
20,000 per pattern
Storable sewing data item
900 patterns (internal memory)
Data memory
Internal memory, USB memory
Needle bar stroke
41.2 mm
Thread take up lever stroke
68 mm
Class of needle
DPX17#18 (at standard installation)
Wiper system
Presser foot lift
Back to front wiping system
*1
12 mm (maximum 15 mm )
Presser foot stroke *2
In 4 mm to 10 mm (4 mm as factory default setting)
Work holder lift
30 mm
Hook
Large size shuttle hook
Bobbin case
With non racing spring
Bobbin
Aluminum bobbin
Thread trimmer system
Horizontal engagement with fixed knife and movable knife
Lubrication system
Manual oiling and replenishment with the oil braids from the oil tanks
Lubrication oil
Pulley SF oil
X-Y drive system
Machine dimensions
(W)x(L)x(H)
Stepping motor feedback control
Timing belt drive system. Intermittent or continuous feeding
1,185mm x 1,572mm x
1,350mm x 1,572mm x
1,234mm
1,234mm
Weight
Total 420 Kg
Type of motor
XL-K756-20
Type of controller
PLK-G-CU-20
Type of operation panel
PLK-G-PAL-2
Total 440Kg
In 200V to 240V single-phrase or three-phrase
Power
The power in 110V to 120V or in 380V to 415V is compatible with
power unit (option)
*1：Presser foot lift is the height of the presser foot after the sewing has stopped.
*2：Presser foot stroke is the up and down movement of the presser foot while sewing.
*3：Sewing speed may be limited by the operation or sewing condition.
-2-
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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.
(4) Please do not refurbish the sewing machine.
3-1. Installation of the foot switch
Connect the foot switch to the connector CON H.
The foot switch is enclosed in the accessory box.
CON A : Operation panel
CON A
CON B
CON B : Power supply
CON C : Various solenoid DC power
CON E
CON C
CON D : Spindle motor
CON E: Various solenoid
CON F
CON D
CON F : Spindle encoder
CON G : X-Y spindle encoder
CON G
CON K
CON H : Foot switch
CON J : X-Y spindle stepping motor
CON H
CON K : P-F spindle stepping motor
CON J
3-2. Connection of the air tube
Insert the one end of the air tube (8mm Diameter) into the intake air fitting of the filter regulator (No.1)
then, join the other end of the air tube with the suitable air coupling to be adopted with the air supply
source provided in your factory. One of the air couplings (No.2) is enclosed in the accessory box.
<1>: Intake air fitting
①
<2>: Air coupling
<2>
<1>
②
-3-
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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).
<1>: Upper column pipe
<2>: Lower column pipe
<9>
<3>: Spool stand base (two stand bases)
<6>
<4>: Spool mat (two mats)
<1>
<5>: Spool holder (two holders)
<5>
<6>: Spool shaft (two shafts)
<4>
<7>: Spring washer (two washers)
<3>
<11>
<8>: Nut (four nuts)
<9>: Thread hunger
<7>
<10>: Spool holder
<2>
<8>
<11>: Column joint
<10>
<12>: Washer
<12>
<13>: Nut
<13>
3-4. Installation of the eye guard
(1) Loosen the screws (No.2) on the eye guard unit (No.1) then, mount the screws (No.3) to the flat place
of the sewing machine with the open guard.
(2) Return the open guard to the initial position then, tighten the screws (No.2).
<1>: Eye guard unit
<2>: SW-MW screw
<3>: SW-PW screw (two screws)
<2>
<1>
<3>
-4-
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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). Use the part measuring 7mm on the
gauge (No.5). Position Bolt “A” (No.6) in the below described position when reinstalling the coupling to
the machine top shaft. Make sure the clearance of the coupling is from 2.0 to 3.2mm.
(4) Turn the pulley (No.8) in the direction of the arrow then, slip the gauge (No.5) in between the needle
bar and the needle plate. Use the part of S side (50.1mm) on the gauge.
(5) Be careful not to make the motor turn and fit the coupling to the upper shaft, and then tighten the bolt
A (No.6) first and the bolt B (No.7) second.
<1>
<8>
<6>
<7>
<2>
<3>
<5>
50.1mm
7 mm
<5>
<4>
2.0~3.2mm
<1>: Spindle motor <2>: Motor mark <3>: Pin <4>: Coupling <5>: Gauge <6>: Bolt A
<7>: Bolt B <8>: Pulley
-5-
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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. Also, please
make sure to check the amount of oil when the machine has not been used for a long time.
4-1. Filling the oil tank
Pour the oil through the oil hole (No.1 and 3) to the oil tank (No.2 and 4) on the machine arm. Pour
the oil hole (No.5) to the oil tank (No.6) on the machine bed. Please fill with the oil over level mark
(No.7) of the oil tank.
4-2. Oiling
Put some oil to the red marked oil holes (No.8 ~ 11).
<1>
<3>
<2>
<4>
<8>
<9>
<10>
<11>
<5>
<7>
<6>
-6-
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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.
5-2. Installation of the needle
CAUTION
(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.
(1) Loosen the set screw (No.1) then, insert a new needle (No.2) until the needle head is reached the end
of the hole of the needle bar (No.3).
(2) Tighten the set screw (No.1) with facing the needle groove (No.4) to the front.
<3>
<1>: Set screw
<2>: Needle
<1>
<3>: Needle bar
<4>: Needle groove
<2>
<4>
-7-
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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-
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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” arrow several times. Then fit the bobbin to the bobbin winder (No.2) and push in the
bobbin presser arm (No.3).
(2) With the machine in the Bobbin Wind Mode, step on the work holder foot switch first and then the start
switch second so that the thread continues winding to the bobbin while the start switch is stepped on.
(3) When the bobbin finishes winding a certain amount (80 to 90 % of the outside diameter of bobbin) of
thread, the bobbin presser arm is returned to the initial position.
(4) To wind the bobbin thread during the sewing operation, carry out the procedure (1) above then, the
bobbin winding is performed automatically.
For the bobbin winding mode, refer to the instructions in the paragraph “[3] Explanations of basic
screen, icons and operation “5. The Bobbin Winding screen” is explained below” in the
OPERATION PANEL technical manual.
<1>
<2>
<3>
<1>: Bobbin <2>: Bobbin winder <3>: Bobbin presser arm
-9-
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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.
<1>: Bobbin case
<4>
<2>: Bobbin
<5>
<2>
<3>: Thread
<4>: Bobbin case slit
<5>: Bobbin case thread hole
<3>
<1>
5-6. Setting the bobbin case
(1) Pull the bobbin thread about 2.5cm out of the thread hole of the bobbin case.
(2) Open the cylinder cover (No.1).
(3) Open the bobbin case latch (No.2) and hold it then, fit it securely in the shuttle hook (No.3).
<1>: Cylinder cover
<2>: Bobbin case latch
<3>: Shuttle hook
2.5cm
<2>
<3>
<1>
- 10 -
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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). Please make sure to operate the sewing machine with safety
guards.
(4) Please make sure to turn the power switch off when stopping the sewing machine temporarily.
6-1. The sewing operation
(1) Turn the power switch on.
(2) Press the home position return icon
.
(3) Select a sewing data.
Press the
on the standard screen then, press the
.
(4) Select a target (internal memory/USB memory) to read the data from.
The screen as default setting is set to the reading from internal memory mode.
(The mode display at the left top on the screen is
Press the
.)
,when switching the reading from the internal memory to the reading from USB
memory mode.
(Pressing the
Press the
also can switch the target.)
to switch the page with full of data.
(5) Select a data then, set the data.
Press the target data number then, press the
.
(6) Set the sewing speed.
Set the appropriate sewing speed by selecting
or
. (10 selections of 0 to 9)
(7) Set the sewing material under the work holder.
(8) When the black foot switch is stepped on, the work holder goes down.
(When the sewing material has to be reset, step the black color foot switch again to make the work
holder go up.)
(9) Step on the gray color start switch so that the sewing machine starts sewing,
(10) After the sewing finishes, the work holder is lifted automatically then, the sewing material is released.
- 11 -
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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. (Press the jogging in forward/reverse direction icon so
that the sewing start position will move.)
(4) To cancel sewing, press the home position return icon
.
<1>
<1>: Halt switch
- 12 -
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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.
<1>: Bobbin case
<2>: Thread tension adjusting screw
(2) Adjustment of upper thread tension
Adjust the upper thread tension corresponding to the bobbin
Thread tension. The upper thread tension becomes tight when
tightening the thread tension adjusting nut (No.1) clockwise,
and the upper thread tension becomes loose when loosening
the thread tension adjusting nut counterclockwise.
<1>: Thread tension adjusting nut
<1>
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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.
(4) Please make sure to put the safety guards (eye guards, belt guards, link covers, and finger guards or
the others) back on the initial position after the sewing machine adjustment.
7-1. Adjustment of the needle bar position
(1) Turn the power switch off then, stop the needle bar (No.1) at the lowest position.
(2) Move the needle bar to the position where the needle bar timing mark A is matched to the needle bar
bushing (No.2) bottom line. (For the needle class DP×17)
(3) If the position of the needle bar timing mark A is not matched to the needle bar bushing bottom line,
remove the rubber plug (No.3) from the face cover then, loosen the needle bar holder set screw
(No.4).
(4) For the needle class DP×5, move the needle bar to the position where the needle bar timing mark B is
matched to the needle bar bushing bottom line.
<2>
<1>: Needle bar
<4>
<2>: Needle bar bushing
<3>: Rubber plug
A
<4>: Needle bar holder set screw
B
<1>
Timing mark A: For the needle class DP×17
Timing mark B: For the needle class DP×5
<3>
- 14 -
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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. (For the needle class DP×17)
(2) Open the cylinder cover (No.3).
(3) Remove the bobbin case (No.4).
(4) Turn the hook retainer arm (No.5) then, remove the hook retainer (No.6).
(5) Adjust the shuttle hook (No.7) point to match with the center line of the needle (No.8). The matched
position is standard.
(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.
<2>
D
<4> <6>
<7>
C
<8>
<5>
<9>
<3>
<1>
<10>
<1>: Needle bar <2>: Needle bar bushing <3>: Cylinder cover <4>: Bobbin case <5>: Shuttle hook
retainer arm <6>: Hook retainer <7>: Shuttle hook <8>: Needle <9>: Driver <10>: Set screw
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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.
(3) Loosen the shuttle race set screw (No.3) and turn the eccentric pin (No.4) to move the hook entirely
back and forth for adjustment. Adjust the clearance to be standard, and tighten set screw (No.3). (*1)
(4) After adjusting, check that the pulley can be turned lightly by hand.
*1: Be careful not to tighten the shuttle race set screw (No.3) excessively because a load is applied to the
rotating shaft and it causes trouble.
<1>: Shuttle hook
<2>
<2>: Needle
0 to 0.05mm
<4>
<3>: Shuttle race set screw
<4>: Eccentric pin
<1>
<5>: Cylinder cover
<3>
<5>
7-4. Adjustment of the clearance between the driver and the needle
(1) Take the same procedure as above paragraph 7-2. from (1) to (4).
(2) Check the clearance between the shuttle hook point and the needle has been adjusted in 0 to
0.05mm.
(3) Loosen the lower shaft bushing screw (No.1) and turn the eccentric pin (No.2) so that the driver (No.3)
moves back and forth. Adjust the clearance between the needle (No.4) and the driver (No.3) in 0 to
0.05mm, and tighten set screw (No.1). (*1)
(4) After adjusting, check that the pulley can be turned lightly by hand.
*1: Be careful not to tighten the lower shaft bushing screw (No.1) excessively because a load is applied to
the rotating shaft and it causes trouble.
<4>
0 to 0.05mm
<1>
<2>
<3>
<1>: Lower shaft bushing screw <2>: Eccentric pin <3>: Driver <4>: Needle
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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.
(3) Loosen the set screws (No.10) to match the hole in the shuttle race thread guide (No.6) with the
needle bar center line so that the shoulder (No.9) of the shuttle race thread guide matches with the
rear side line (No.8) of the needle. At this time, make sure that there is a clearance between the hook
retainer (No.13) and the hole of shuttle race thread guide (No.7) at least the thread can be passed
through. (The standard clearance is 0.8mm.) The wide clearance causes the trimming failure.
(4) After the adjustment, assemble the place with the reverse procedure. Make sure to set the sliding
plate (No.5) at this time so that the needle (No.11) comes down to the center of the needle hole
(No.12) of the needle plate.
<1>: Trimmer link
<4>
<7>
<8>
<6>
<3>: Ring-E type
<4>: Set screw
<5>
<2>
<2>: Movable knife
<5>: Sliding plate
<10>
<6>: Shuttle race thread guide
<1>
<7>: Hole of shuttle race thread
0.8mm
<9>
<13>
guide
<8>: Needle bar center line
<11>
<12>
<9>: Shoulder
<10>: Set screw
<11>: Needle
<3>
<12>: Needle hole
<13>: Shuttle hook retainer
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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.
(1) Remove the cover (No.1).
(2) Loosen the set screw "C" of the eccentric cam (No.2).
(3) Turn the sewing machine pulley by hand and stop the needle bar (No.3) at the lowest position. At
this stage, the set screw "A" of the eccentric cam (No.2) is positioned right beside the center line of
the upper shaft. This is the standard position for the eccentric cam (No.2).
(4) Loosen the set screw "A" of the eccentric cam (No.2).
(5) If turn the eccentric cam (No.2) to the arrow direction "D", the presser foot timing is advanced, and
turn the eccentric cam (No.2) to the arrow direction "F", the presser foot timing is delayed.
(6) After the adjustment, tighten the set screw "A" and "C" in turn with slightly pushing the eccentric cam
(No.2) to the arrow direction "E".
(7)Put the cover (No.1) back on the original location.
<1>
Ｆ
<2>
<1>:Cover
<2>:Eccentric cam
- 18 -
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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.
(1) Remove the face cover, the rubber plug (No.1), and the PF motor cover (No.6).
(2) Keep the thread take-up lever at the highest position then, loosen the arm set screw (No.2).
(3) Slide the 24mm part on the gauge (No.3) in between the presser bar holder (No.4) and the arm.
(4) Push down the presser foot lifting lever (No.5) then, tighten the arm set screw (No.2).
<6>
<1>
<3>
24mm
<5>
<2>
<4>
<3>
<1>: Rubber plug <2>: Arm set screw <3>: Gauge <4>: Presser bar holder
<5>: Presser foot lifting lever <6>: PF motor cover
(5) Turn the power switch on then, press the home position return icon
.
(6) Check the clearance between the presser bar holder (No.4) and the arm with the 41mm part on the
gauge (No.3). Refer to the next figure.
(7) If the clearance is less than 41mm, loosen the detector plate set screw (No.7) on the presser foot
drive motor (No.6) and adjust the notch part of detector plate (No.8).
*If it is more than 41mm, turn the detector plate to the direction “a”.
*If it is less than 41mm, turn the detector plate to the direction “b”.
(8) Remove the gauge then, press the home position return icon
and make sure the clearance is
41mm.
[Notice] If it is not 41mm, carry out the same procedure (7) and (8) again.
(9) Put the face cover, the rubber plug (No.1), and the PF motor cover (No.6) back on the original
location.
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<9>
<3>
<7>
<8>
b
a
<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. (*1)
For details, refer to the instructions in the paragraph “[8] Controlling
the Presser Foot” in the OPERATION PANEL technical manual.
(2) Press the
on the standard screen and lower the presser foot.
(3) Turn the hand pulley and place the needle bar at the lowest position.
(4) Loosen the presser foot bar set screw (No.1) and adjust the
clearance between the presser foot and slide plate to be 0mm and
<1>
then, tighten the screw (No.1).
(5) The correction value is set at 3 as the factory default.
*1: When changing the correction value at 0, an error message;
<1>: Presser foot bar set screw
“ M-096: OVER LIMIT OF PRESSER FOOT STROKE “ may show up. This happens when the presser
foot stroke is already set to the sewing data and by changing the correction value, the stroke in sewing
data becomes 0mm or less. In that case, make new sewing data without the presser foot stroke or read
out a sewing data that the stroke does not become 0mm or less.
7-9. Adjustment of the presser foot position
The presser foot lift during the sewing can be adjusted from 0 to 8mm. For details, refer to the instructions
in the paragraph “[8] Controlling the Presser Foot” in the OPERATION PANEL technical manual.
[Notice] When using the long cylinder type of the presser foot, the correction value and the stroke are
restricted.
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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.
(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.
(3) To adjust the walk in 2 to 4mm, connect the link (No.2) with the screw hole A and adjust with the
method (2) described above.
(4) To adjust the walk in 4 to 10mm, connect the link (No.2) shown on the figure and adjust the method
(2) described above.
<2>
<1>: Shoulder bolt
a
<2>: Link
b
<1>
Screw hole A
7-11. Adjustment of the presser foot spring pressure
The presser foot spring pressure can be changed with the
<4>
<5>
following two methods.
(1) To increase the spring pressure, remove the face cover and loosen
the bolt (No.1) then, adjust the spring A (No.3) pressure with the
<2>
adjust screw (No.2). After the adjustment, tighten the bolt (No.1).
<6>
(2) To fine-tune the spring pressure, loosen the nut (No.4) then,
turn the thumb screw (No.5) to adjust the spring B (No.6) pressure.
* If tighten the adjust screw (No.2) spring A (No.3) pressure
<1>
can be increase.
<3>
* If tighten the thumb screw (No.5) spring B (No.6) pressure
can be increase.
<1>: Bolt <2>: Adjust screw <3>: Spring A
<4>: Nut <5>: Thumb screw <6>: Spring B
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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.
(2) When setting the presser foot (No.4) to upper position during the sewing of thick material, the setting
may not leave the clearance of passing wiper. The wiper cannot be used in this case.
(3) The wiper does not work enough, loosen the wiper adjust screw (No.5) and adjust the wiper position.
<5>
<3>
<1>: Wiper
<2>: Needle
<3>: Wiper set screw
<1>
<1>
<4>: Presser foot
<2>
<5>: Wiper adjust screw
<4>
2mm
(4) When the wiper function is not be used (not able to be used), set the following.
Set the wiper function to off.
Press the
(5) Press the
(6) Select the
on the standard screen to open the MENU mode.
>
>
[Wiper ON/OFF] in order.
on the [Wiper ON/OFF] screen, and press the
.
7-13 Adjustment of the work holder pressure
CAUTION
★If the secondary side air pressure is set too high, trouble such as operation faults may occur. Always
set the pressure to within 0.4Mpa.
(1) The work holder pressure is provided from an air source.
Lift and turn the air regulator’s adjustment knob (No.1) located under the table to adjust the air
pressure.
(2) If turn the adjusting knob (No.1) to the clockwise, the air pressure is increased and the work holder
pressure is also increased simultaneously.
(3) If turn the adjusting knob (No.1) to counter clockwise, the air pressure is decreased and the work
holder pressure is also decreased simultaneously.
(4) 0.4Mpa (4kgf/cm2) is the standard air pressure as a normal sewing operation.
- 22 -
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<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.
(2) Adjustment of the proper position of the bobbin winder
Firstly, loosen the set screws (No.2) of the bobbin winder and put the empty bobbin (No.3) on the
rotating shaft (No.4) then, push the adjusting lever (No.5) to the arrow direction "a". Secondary, move
the whole bobbin winder to the arrow direction "b" and stop it at the position where the empty bobbin
is rotated then, tighten the set screws (No.2) of the bobbin winder. This is the proper position of the
bobbin winder.
<3>
<4>
<2>
a
b
<2>
<5>
<1>
<1>: subsidiary arm <2>: Set screw <3>: Bobbin
<4>: Rotating shaft <5>: Adjusting lever
- 23 -
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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).
(2) Prepare another work holder and securely engaged its U shaped ditch (No.2) with the pin (No.6) of
the work holder arm (No.5). At this time, make sure that there is no play in the
 arrow direction.
*
<3>
*
<4>
<5>
<6>
<2>
<1>
* Marked parts are only used for PLK-G6030.
<1>: Work holder <2>: U shaped ditch
<3>: Screw <4>:Holder block
<5>: Work holder arm <6>:Pin
- 24 -
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7-16 Adjustment of the trimmer cam follower
(1) Turn the power switch off and remove the top cover.
(2) Loosen the arm set screw (No.3) to adjust the cam
<5>
<4>
<3>
<1>
follower (No.1) with a cam groove clearance of about
1mm between the cam follower and the trimmer cam (No.2).
(3) Loosen the nut (No.4) for turning the adjust screw (No.5).
(4) Turn the pulley so that the needle bar moves to the
lowest position.
1mm
(5) Push the cam follower arm (No.1) to the arrow direction
“A” and put the cam into the cam groove of the trimmer
cam (No.2).
(6) When tightening the adjust screw (No.5) in the condition
<2>
described above, the cam follower is pushed into the cam
groove then, the cam follower arm (No.1) is not returned
even when releasing the cam follower arm .
A
b
a
B
(7) When loosening the adjust screw (No.5) to the point “a”
shown on the figure, the cam follower arm (No.1) goes
back to the position in the direction “B”
Loosen the nut (No.4) from the point “a” to “b”,
90-degree turns, and then fix the adjust screw (No.5).
<1>: Cam follower arm <2>: Trimmer cam
<3>: Arm set screw <4>: Nut <5>: Adjust screw
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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).
(4) For the adjustment of the movable knife point (No.1), loosen the adjusting screw nut (No.3,4) and
move the rod end (No.5) right and left then, adjust the position of the movable knife point.
(5) After the adjustment, tighten the adjusting screw nut (No.3,4) securely.
<4>
<5>
<2>
<3>
<1>
<1>:Movable knife <2>:Hook retainer <3>:Left screw nut <4>:Right screw nut <5>:Connecting rod
7-18.Adjustment of the blade drive arm spring force
(1) Remove the belt cover at the motor side
and detach the V-belt.
(2) Remove the screw of the oil pan at the
front. And slide the oil pan to front side.
(3) Turn the pulley by hand to needle down
position, Push the cam follower lever by
hand. And turn pulley again to low end
position of thread take-up lever with
pushing the cam follower lever.
(4) Release the cam follower lever and continue
to turn pulley.
(5) Now check whether the cam followeis
returned automatically.
If it is not returned, it is need to adjust as
follows.
(6) Loosen the nut (No.8) and turn the screw
(No.7) in the direction of the arrow, so that
force of the returning spring (No.6) becomes
strong.
(7) Fasten the nut (No.8) securely.
<8>
<6>
<7>
<6>: Returning spring <7>: Screw <8>: Nut
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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.
(4) For the adjustment of the fixed knife (No.7) position, loosen the screw (No.9) and move the knife.
<5>
<1>: Cylinder cover
<6>
<2>: Movable knife
<3>: Thread trimmer link
<4>: Ring-E type
<3>
<5>: Screw
<2>
<8>
<6>: Slide plate
<7>: Fixed knife
<8>: Needle plate
<9>: Screw
0.5mm
<7>
<9>
<4>
<1>
7-20. Adjustment of the thread take up spring
(1) Loosen the set screw (No.2) and turn the whole thread tension regulator (No.3) then, adjust the thread
take up spring (No.1) stroke to be in 9 to 10mm, which is standard stroke.
(2) Insert the screw driver into the slit of the thread tension regulator and adjust the thread take up spring
tension. When tightening the screw driver clockwise, the thread take up spring tension becomes tight,
and when loosening the screw driver counterclockwise, the thread take up spring tension becomes
loose. For the adjustment of the thread take up spring tension, tighten the set screw (No.2) so that the
whole thread tension regulator does not turn.
9~10mm
<1>: Thread take up spring
<1>
<3>
<2>: Set screw
<3>: Thread tension regulator
<2>
- 27 -
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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. Adjustment of the upper thread tension release (the width between thread tension discs)
(1) When the upper thread tension is released, the thread tension discs (No.1) open in 0.8mm to 1.0mm,
which is standard width.
(2) For the adjustment of the upper thread release, loosen the set screw (No.2) and move the whole
upper thread tension release to the arrow direction as shown on the figure. When moving the upper
thread tension release to the direction “A”, the width between the discs becomes bigger and moving to
the “B”, the width between the discs becomes smaller.
<1>
B
A
0.8~1.0mm
<2>
<1>: Thread tension disc <2>: Set screw
7-23. Adjustment of the opening time of the upper thread tension release disks
When the presser foot rises, the thread tension disks are open for a given length of time and close. The
default setting is set at one-minute intervals. To change the set value, carry out the procedure shown
below.
(1) Turn the power switch on.
(2) Press the
on the standard screen to open the MENU mode.
(3) Press the
>
>
[Setting for tension release outputs time length
at presser] in order.
(4) Current set value is “60 sec”.
(5) Change the value from 0 to 10000 then press the
.
If change the value to “0” the thread tension disks closed when the presser foot rises.
(6) Press the
>
. Changing set value has been completed.
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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).
[Rear side]
1 Home position as the factory default
2 Adjustable area
[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
(4) Select the
(5) Press
>
>
[Cancellation of sewing area limit] in order.
on the [Cancellation of sewing area limit] screen, and press the
→ press
.
to return the standard screen.
- 29 -
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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. Set the clearance between the detector plate X and the detector within the range of 1.0 to
1.5mm.
(4) Turn the power switch on. Press the home position return icon
, and check the mechanical
home position.
(5) If the mechanical home position is not the desired position, carry out the same procedure (3) and (4)
again. In that case, turn the power switch off each time.
[Notice] The machine has a function that the motor memorizes the home position at the first home
position returning operation after the switch is turned on. Therefore, from the second home position
returning, it does not use the home position return sensor. Make sure to turn the power switch off to
change the mechanical home position.
To use the sensor from the send returning, press
>
>
[Home
returning method since the second time returning] on the standard screen and set it ON.
<1>: Detector plate X
<2>: Detector
<1>
<3>: Detector plate set screw
1 to 1.5 mm
<3>
<2>
- 30 -
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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.
(4) Turn the power switch on. Press the home position return icon
, and check the mechanical
home position.
(5) If the mechanical home position is not the desired position, carry out the same procedure (3) and (4)
again. In that case, turn the power switch off each time.
[Notice] The machine has a function that the motor memorizes the home position at the first home
position returning operation after the switch is turned on. Therefore, from the second home position
returning, it does not use the home position return sensor. Make sure to turn the power switch off to
change the mechanical home position.
To use the sensor from the send returning, press
>
>
[Home
returning method since the second time returning] on the standard screen and set it ON.
<1>: Set screw <2>:Detector bracket
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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.
(2) Loosen the set screws (No.1) (4 pieces) of the bracket (No.2).
(3) If tighten the tension adjust screw (No.3), the X timing belt (No.4) tension will be increased.
(4) After the adjustment, securely tighten the set screw (No.1) of the bracket (No.2) and put the covers
and shutters on the original locations.
<2>
<4>
<1>
<3>
<1>: Set screw <2>:Pulley bracket <3>:Adjust screw <4>:Timing belt
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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.
(4) After the adjustment, tighten the set screws (No.2) securely.
NOTE Distinct difference of the tension between the right and left timing belt will be possible to cause
undesirable moving of X-Y table. Please adjust the tension of both side timing belt to be same.
<4> <2> <1>
<3>
<1>: Pulley bracket <2>: Set screw <3>: Adjust screw <4>: Timing belt
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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.
(2) The dust or the like sticking the X-Y slide guide absorbs
lubrication oil on the rails and significantly lowers the slide
guide running life.
Clean the slide guide regularly and also pour some grease.
Recommended grease: Multemp PS2 (Produced by Kyodo Yushi Co. Ltd)
(Lithium grease 2)
8-2. Disposing of oil waste
If the waste oil pan is full filled in the oil bottle (No.1), remove the oil bottle then dispose of the waste oil.
<1>:Oil bottle
<1>
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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
Upper thread is broken.
Cause
Corrective action
Upper thread tension is too
tight.
Adjust thread tension.
6-3
Strength of thread take up
spring is inappropriate.
Adjust thread take up spring.
7-20
Parts on needle plate, hook,
and presser foot touching
thread are damaged.
Grind parts or change parts.
-
The needle size is bigger
than the thread size.
Change the needle size to
suitable size.
5-2
Thread melts with heat.
Slow down the sewing speed
6-1
Use needle cooler.
Bobbin thread is
broken.
Bobbin thread tension is too
tight.
Adjust thread tension.
Parts on needle plate and
presser foot touching thread
are damaged.
Buff parts or change parts.
Upper thread is pulled
from needle hole when Thread tail is short.
starting sewing.
Thread take up spring
tension is too much.
Frequent skip stitching
happens.
Trimming is not
functioned.
Reference
6-3
-
Adjust thread tail with
pre-tension.
7-21
Adjust thread take up spring
tension.
7-20
Clearance between needle
and shuttle hook is too big.
Adjust clearance between
needle and shuttle hook
properly.
7-3
Timing of needle and shuttle
hook is not proper.
Adjust position of needle and
shuttle properly.
7-2
Contact between needle and
driver is too tight.
Adjust clearance between
needle and driver properly.
7-4
Needle is bent.
Change needle.
5-2
Needle is at wrong position.
Fix position properly.
5-2
Fixed knife is dull.
Sharpen fixed knife or
change fixed knife.
7-19
Movable knife is dull.
Change movable knife.
7-17
- 35 -
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Trimming is not
functioned.
Movable knife is at wrong
position.
Skip stitching happens in
trimming.
Trimming setting is off.
Stitch forming is loose.
Stitch on back comes
apart.
Work holder does not
fall.
Upper thread tension is too
loose.
Bobbin thread tension is too
loose.
Strength of thread take up
spring is inadequate.
Presser foot position is not
proper.
Presser foot up and down
timing is not proper.
Thread is not divided with
thread guide properly.
Operation
panel section
Adjust upper thread tension.
6-3
Adjust bobbin thread tension.
6-3
Adjust thread guide position.
7-5
Needle thread is too long.
Adjust needle thread with
pre-tension.
7-21
Foot switch is broken.
Change foot switch.
Work holder switch is out of
order
Returned home
position is changed.
-
7-7,7-8
7-9
strong enough
Sewing pattern is
changed.
Turn trimming setting on.
7-17
Adjust strength of thread take
up spring.
Adjust presser foot position
properly.
Adjust presser foot up and
down properly.
Work holder presser is not
Wiper system does not
work.
Adjust position of movable
knife properly.
Refer to the condition
“Frequent skip stitching
happens”.
Increase work holder presser
Change it new work holder
switch
7-20
7-6
7-13
-
Wiper hits needle or presser
foot.
Adjust wiper position.
7-12
Wiper setting is turned off.
Turn wiper setting on.
7-12
Sewing material is not
pressed properly.
Adjust work holder pressure.
7-13
Sewing material in work
clamp slips.
Put slip stopper on presser
plate.
-
Sewing material is too heavy.
Slow down sewing speed.
6-1
X-Y timing belt tension is
loose.
Adjust X-Y belt tension
properly.
7-25
Use sewing machine in
Ambient temperature is out of
ambient temperature in 5
use range.
degrees to 35 degrees.
Clearance between detector
and detecting subject is too
wide.
- 36 -
Adjust clearance in 1 to
1.5mm.
-
7-24
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MEMO
From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
Printed in Japan
From the library of Superior Sewing Machine & Supply LLC - www.supsew.com