JUKI PLK-G4030R User manual

INDUSTRIAL SEWING MACHINE
MODEL
PLK-G4030R
PLK-G6030R
TECHNICAL MANUAL
SEWING MACHINE HEAD
A181E080P01

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.
CAUTION
Indicates that incorrect handling may cause hazardous conditions, resulting
in medium or slight personal injury or physical damage. Note that 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.
Caution indication
Description
1
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.

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.

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.

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··················································································
4-2. Oiling·································································································
6
6
5. PROPER OPERATION······························································
7
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··········································································
7
7
8
9
10
10
6. SEWING·················································································
11
6-1. The sewing operation············································································
6-2. Operation of the halt switch·····································································
6-3. Adjustment of the thread tension······························································
11
12
12
7. STANDARD ADJUSTMENT·······················································
13
7-1. Adjustment of the needle bar position·······················································
7-2. Adjustment of the position between the needle and the rotating hook··············
7-3. Adjustment of the hook positioner’s position···············································
7-4. Adjustment of the lubrication for the rotating hook·······································
7-5. Adjustment of the presser foot timing························································
7-6. Adjustment of the presser foot lift·····························································
13
14
15
16
17
18

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··········································
7-12-2 Assembling and readjustment of the thread trimmer mechanism···············
7-12-2.1 Attaching the knife bracket and the knife mounting unit·······················
7-12-2.2 Mutual relation among the movable and stationary knife edge··············
7-12-2.3 Connection of the knife bracket and the driving crank·························
7-12-2.4 Adjustment of the component parts of the knife driving mechanism········
7-12-2.5 Adjustment of the mounting position of the air cylinder························
7-12-2.6 Adjustment of the mounting position of the thread trimmer cam·············
7-12-2.7 Adjustment of the knife engagement···············································
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 thread take up spring··················································
7-17. Adjustment of the thread tail after the trimming·········································
7-18. Adjustment of the upper thread tension release (the width between thread
tension discs)···················································································
7-19. Adjustment of the opening time of the upper thread tension release disks·······
7-20. Adjustment of the mechanical home position············································
7-20-1. Adjustment of the X direction····························································
7-20-2. Adjustment of the Y direction ···························································
7-21. Adjustment of the X-Y timing belt tension················································
7-21-1. Adjustment of the X timing belt tension················································
7-21-2. Adjustment of the Y timing belt tension···············································
19
19
20
20
21
22
22
22
22
23
24
24
25
25
27
28
29
30
30
31
31
31
32
33
34
35
35
36
8. MAINTENANCE·······································································
37
8-1. Cleaning·····························································································
8-2. Disposing of oil waste············································································
37
37
9. TROUBLESHOOTING·······························································
38

- 1 -
1. STRUCTURE OF THE SEWING MACHINE
PLK-G4030R/G6030R industrial sewing machine consists of the following main parts.
<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>
<2>
<3>
<4>
<5>
<6>
<7>
<8>

- 2 -
2. SPECIFICATIONS
Model
PLK-G4030R
PLK-G6030R
Sewing area
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
40.0 mm
Thread take up lever stroke
73.0 mm
Class of needle
DPX17#18 (at standard installation)
Wiper system
Back to front wiping system
Presser foot lift *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 rotating hook
Bobbin case
With non racing spring
Bobbin
Large size steel 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
Stepping motor feedback control
Timing belt drive system. Intermittent or continuous feeding
Machine dimensions
(W)x(L)x(H)
1,185mm x 1,572mm x
1,234mm
1,350mm x 1,572mm x
1,234mm
Weight
Total 420 Kg
Total 440Kg
Type of motor
XL-K756-20
Type of controller
PLK-G-CU-20
Type of operation panel
PLK-G-PAL-2
Power
In 200V to 240V single-phrase or three-phrase
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.

- 3 -
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.
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
②
<2>
<1>
<1>: Intake air fitting
<2>: Air coupling
<
3
>
:
S
p
o
o
l
CON A : Operation panel
CON B : Power supply
CON C : Various solenoid DC power
CON D : Spindle motor
CON E: Various solenoid
CON F : Spindle encoder
CON G : X-Y spindle encoder
CON H : Foot switch
CON J : X-Y spindle stepping motor
CON K : P-F spindle stepping motor
CON A
CON E
CON F
CON G
CON H
CON J
CON B
CON C
CON D
CON K