Mitsubishi Electric PLK-J4040RH Technical Manual Download Page 53

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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

Cause

Corrective action

Reference

Upper thread is broken.

Upper thread tension is too
tight.

Adjust thread tension.

5-10

Strength of thread take up
spring is inappropriate.

Adjust thread take up spring.

6-6-2

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.

5-1

Thread melts with heat.

Slow down the sewing speed

Operation
panel
section

Use needle cooler.

Bobbin thread is broken.

Bobbin thread tension is too
tight.

Adjust thread tension.

5-9

Parts on needle plate and
presser foot touching thread
are damaged.

Buff parts or change parts.

Upper thread is pulled
from needle hole when
starting sewing.

Thread take up spring tension
is too much.

Adjust thread take up spring
tension.

6-6-2

Sewing speed is inappropriate
when starting sewing

Use [e-stitch] function.
(Program mode > Sewing
speed group > OPLC is ON)

Operation
panel
section

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com

Summary of Contents for PLK-J4040RH

Page 1: ...INDUSTRIAL SEWING MACHINE MODEL PLK J4040RH TECHNICAL MANUAL SEWING MACHINE HEAD A180E823P02 ...

Page 2: ...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 ...

Page 3: ... 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 in...

Page 4: ...ing 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 m...

Page 5: ... 5 7 How to operating the jig eject system 5 8 Operation of the halt switch 5 9 Adjustment of the thread tension 5 10 Adjustment of upper thread tension 7 8 9 10 11 11 12 13 14 14 6 STANDARD ADJUSTMENT 15 6 1 Adjustment of the needle bar position 6 2 Adjustment of the position between the needle and the rotating hook 6 2 1 Adjustment of the clearance between the hook point and the needle 6 2 2 Adj...

Page 6: ...n 7 5 Adjustment of the thread trimmer 7 5 1 Adjustment of the movable knife 7 5 2 Adjustment of the fixed knife 7 5 3 Adjustment of the trimmer cam detector position 7 6 How to remove the XY cover 7 7 Adjustment of the XY table detector 7 7 1 Adjustment of X direction 7 7 2 Adjustment of Y direction 7 8 Adjustment of the Y timing belt tension 27 29 32 35 36 36 37 38 39 40 41 42 43 8 MAINTENANCE 4...

Page 7: ...g machine consists of the following main parts 1 Sewing machine head 2 Halt switch 3 Control box 4 Operation panel 5 Work holder switch 6 Start switch 7 Thread stand 8 Sewing machine table 1 2 3 4 5 6 7 8 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 8: ...ing motor Presser foot lift 15 0 mm max 30 0 mm Variable in 0 1 mm step Presser foot stroke Digital adjustment stroke 0 0 to 10 0 mm Upper thread tensioner Manual automatic Setting on pattern switchover Oil lubrication Spray method Spray time adjustment Operation panel 6 5 inch color LCD touch panel with USB port External device I F USB port Terminal I O 16 input 16 output Thread trimmer system Ho...

Page 9: ...epaired 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 L The foot switch is enclosed in the accessory box NOTE Refer to the instructions in the paragraph 4 Name of each part wiring and grounding in the CONTROL UNIT technical manual CON L Foot sw...

Page 10: ...and as shown on the figure 2 Fit the thread stand into the hole at the far right on the machine arm with the nut No 14 and the washer No 12 and cushion No 13 1 Air tube 8mm Diameter 2 Filter regulator 3 Intake air fitting 4 Air coupling 4 3 1 2 1 Upper column pipe 2 Lower column pipe 3 Spool stand base 4 Spool mat 5 Spool holder 6 Spool shaft 7 Spring washer 8 Nut 9 Thread hunger 10 Spool holder 1...

Page 11: ... in accessory box For the other three rubber cushions the procedure is same 2 Screw the adjust foot No 2 in the direction of b arrow and adjust the adjust foot height so that the each hour caster No 3 is to be raised from the floor by several millimeters After adjustment please check if there is no inclination about the machine table 1 Eye guard unit 2 Screw 1 2 b a 3 1 Rubber cushion 2 Adjust foo...

Page 12: ... 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 to the oil tank No 2 on the machine arm Pour the oil through the oil hole No 3 which has machine table to the oil tank No 4 Please fill with the oil over level mark No 5 of the oil tank 2 1 5 3 4 5...

Page 13: ... the needle point 1 Attach the needle holder No 2 to the needle bar No 1 then insert a new needle No 3 until the needle head is reached the end of the guide groove of the needle bar No 1 2 Tighten the set screw No 5 with facing the needle groove No 4 to the front 1 Needle bar 2 Needle holder 3 Needle 4 Needle groove 5 Set screw 1 3 4 5 2 From the library of Superior Sewing Machine Supply LLC www s...

Page 14: ...eading the needle thread CAUTION 1 Please turn the power switch off when threading a needle 1 Thread the needle thread as shown on the figure From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 15: ...is stepped on 4 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 Adjust the amount of the winding thread with the subsidiary arm No 4 5 To wind the bobbin thread during the sewing operation carry out the procedure 2 above then the bobbin winding is performed automatically For the bobbin...

Page 16: ...front lower side of the table The bobbin access door opens when opening switch No 2 becomes state in B showing in below figure 2 When closing the bobbin access door No 1 turn the opening switch No 2 in the opposite direction from state in B NOTE When start the sewing unless the bobbin access door No 1 is opened the start prohibition signal is valid 1 Bobbin access door 2 Opening switch 2 A 閉状態 B 開...

Page 17: ... Setting the Inner hook 1 Pull the bobbin thread about 30 mm out of the thread hole of the inner hook No 1 2 Open the bobbin access door 3 Open the hook holding arm No 2 in the arrow direction 4 By Inserting the top of inner hook No 1 between the hook positioner No 3 and hook No 4 set the inner hook No 1 securely 5 Close the hook holding arm No 2 for preventing come off the inner hook No 1 1 Inner...

Page 18: ...he work holder is fixed securely after step on the foot pedal The work holder is not fixed due to the insufficient actuation of locate pin No 4 when either or both cassette jig are not installed enough NOTE Please make sure if the bottom surface of cassette jig A and lower plate No 5 are in same level If different loosen the each four of Jig eject system install screws No 6 and adjust the jig ejec...

Page 19: ...s 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 Halt switch 1 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 20: ...hread 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 NOTE It is possible to adjust the upper thread tension automatically Please refer to the instructions OPERATION PANEL technical manu...

Page 21: ...w and stop the needle bar No 5 at the lowest position NOTE The needle shaft and the hook shaft are controlled by synchronous operation only when the power switch is on In this reason there is a risk that the needle may collide with hook when down the needle bar without removing the needle 3 Make sure the clearance between the bottom of needle bar No 5 and top of the needle plate is 23 5 mm 4 If it...

Page 22: ...pin witch have driving lever No 3 into the trimmer lever No 4 hole When remove the trimmer lever No 4 hold the trimmer lever No 4 by hand as in the below drawing and lift the sliding plate No 1 The trimmer link No 4 is removed from the driving lever No 3 smoothly 4 To entering the locate pin witch have driving lever No 3 into the trimmer lever No 4 hole smoothly aligning the center of the trimmer ...

Page 23: ...ter line of the needle No 7 7 Loosen the three of the hook set screw No 9 then move the hook by hand and adjust the clearance between the hook point and the needle to be about 0 05 mm 8 Hold the hook and tighten the three of hook set screws No 9 securely 6 Hook point 7 Needle 9 0 05mm 6 6 7 Detail of the hook point 7 4 5 mm 9 Hook set screw From the library of Superior Sewing Machine Supply LLC ww...

Page 24: ...detector cover No 5 2 Insert the hexagon wrench from the detector cover No 5 opening and loosen the set screw No 3 which has detector plate No 2 3 Remove the all of any parts tools and screws on the sliding table After make sure the work environment safety Turn the power switch on At this time do not press the home position return icon 6 5 2 1 7 3 4 a 1 Main shaft detector 2 Detector plate 3 Set s...

Page 25: ...ctor plate No 2 little by little in the direction of arrow from the state of A as showing in below drawing Stop the detector plate No 2 and tighten the screw No 3 at the position where the detection lamp lighted which has main shaft detector No 1 In this state the detector plate No 2 is in the state of B 7 After adjustment attach the detector cover and continue the adjustment according to the next...

Page 26: ...ing information is stored This timing information cannot be overwritten when the power switch turned on In this reason please operate this adjustment before press the home position return icon 1 Press the icon from the function mode 2 Input the pass word and press the icon NOTE If press the home position return icon the icon is displayed with shading and cannot display the next setting screen 3 Pr...

Page 27: ...ent of the main shaft detector set the needle bar upper position After the completion of setting press the icon and then press the icon 5 Press the sub motor hook position setting icon From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 28: ...urn operation press the on the standard screen Turn the hand pulley by hand and make sure the timing between hook and needle motion is performed sufficiently as described above 8 After adjustment turn the power switch off 9 After adjustment put the sliding plate and bobbin case to the original locations and close the bobbin access door 10 When put the sliding plate back on the sewing machine in or...

Page 29: ...t screw No 5 and adjust the hook positioner No 1 position 5 After the adjustment put the sliding plate back on the sewing machine NOTE When put the sliding plate back on the sewing machine in order for the needle to come into the right center of the needle hole of the needle plate make sure that the needle plate hole center matches with the needle point Refer to the previous paragraph 6 2 3 10 1 H...

Page 30: ...second for every five hundred stitches NOTE1 Please adjust the oiling amount for each sewing condition For example increase the OL1C OL2C value or shorten the oil injection time OL1T OL2T when much oil is consumed However it is necessary to note the machine seizing when limit the oiling amount NOTE2 When shorten the oil injection time OL1T OL2T set the value to 3 5 as a guide 2 It is also possible...

Page 31: ...1 6 PF motion setting 3 Adjustment of the presser foot lift Please refer to 17 Easy setting 3 5 PF rising position adjustment 6 6 Adjustment of the thread take up spring 6 6 1 Adjusting movable range of the thread take up spring 1 To adjust the movable range of the thread take up spring No 3 loosen the set screw No 2 and turn the whole thread take up spring unit No 1 2 Adjust the thread take up sp...

Page 32: ...t bushing No 2 and reduce the tension of take up spring to 0 then tighten the adjust bushing No 2 from that position 6 7 Adjustment of the air 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 Air pressure is provided from an air source Lift and turn the air regulator s adjustment knob No 1 loca...

Page 33: ... others back on the initial position after the sewing machine adjustment 7 1 How to exchanging the tension spring of the needle thread tensioner unit According to following procedures exchange the tension spring No 1 NOTICE It is required to use the factory original tension spring 1 Turn the thumb screw No 2 and decrease the tension spring pressure 2 Loosen the set screw No 4 and then remove the s...

Page 34: ...TE 1 Bearing No 6 is consist of three parts Please taking care not to make misassembling by referring following figure NOTE 2 Locate the groove of the tension disc No 9 to the thread release pin No 11 when removed tension disc No 9 No 10 1 Tension spring 2 Thumb screw 3 Set screw 4 Set screw 5 Tensioner shaft 6 Bearing 7 Bearing holder 8 Washer 9 Tension disc 10 Tension disc 11 Thread release pin ...

Page 35: ...sser foot movement is based on the origin detection position To prevent the sewing trouble and parts breaking adjust the detector position exactly 1 Remove the eye guard No 1 by referencing the previous paragraph 3 4 Installation of the eye guard 2 Remove the three of fixing screws No 2 and remove the face cover No 3 3 Remove the needle No 4 1 Eye guard 2 Fixing screw 3 Face cover 4 Needle 2 3 1 4...

Page 36: ...dard screen and check if the presser foot lifting value is 15 0 mm If different please change to the initial set value 15 0 mm c Press the Presser foot ZNPP Distance from PF sensor edge to the top surface of slide plate Check if the value is 300 30 0 mm If different please change to the initial set value 300 d For prevent the detection error please use the factory default presser foot 4 Detector 5...

Page 37: ...e downward the detector bracket No 7 and tighten the screw again and press the origin return icon NOTICE Please be careful not to step on the foot switch by mistake 8 Continue the above adjustment up to be a correct distance 15 mm NOTICE 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 posit...

Page 38: ...eded it is necessary to change the ZNPP Distance from PF sensor edge to the top surface of needle plate from default value For example to using a special presser foot which length is 2 mm longer change the value to 280 28 0 mm from default value 300 30 0 mm as showing in the following figure According to the following procedures change the ZNPP value 1 Press the PF position adjustment from standar...

Page 39: ... foot to the top of the needle plate In this time set the gap between bottom of presser foot and top of needle plate to be 0 to 0 2 mm The screen indicates ZNPP default value Upper and current value Lower NOTE The ZNPP value can be set every 0 1 mm 30 0 28 0 15 0 15 0 15 0 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 40: ...press the memory icon and then press the icon NOTE The ZNPP value is flickering until press the icon 6 Following the screen indication put the power switch off 30 0 28 0 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 41: ...tment make sure if the presser foot No 7 is remaining on the sliding plate On the other hand adjust the presser foot hole position to the needle No 8 with turning the presser bar 5 Then tighten the each of set screws No 5 securely while holding the block No 9 by both presser foot holders No 3 No 4 and make sure if there are no gap between both presser foot holders No 3 No 4 and block No 9 1 Bottom...

Page 42: ...surface of sliding plate No 4 as below figure In this time keep aligning the center of the trimmer link hole No 2 and the reference hole No 3 4 If different loosen the screw No 6 and adjust the tip of movable knife No 5 position by moving in the arrow direction In this time keep aligning the center of the trimmer link hole No 2 and the reference hole No 3 too 5 After adjustment tighten the screw N...

Page 43: ...dle plate No 2 is 1 5 mm 2 If different loosen the screw No 3 and adjust the clearance NOTE If the clearance is smaller than 1 5 mm it may cases any trimming failure or unstable trimming length 1 Fixed knife 2 Edge of the needle plate 3 Screw 3 1 1 5mm 2 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 44: ...creen 3 After finish the origin movement please check the clearance from A direction between trimmer cam No 1 and cam roller No 5 is 0 5 mm or less NOTE It is necessary readjust the detector position when the trimmer cam No 1 contact with cam roller No 5 In this case movable knife position may different 4 Turn the machine power off and loosen the two of the screws No 3 and change the detector brac...

Page 45: ...rom machine right side 2 Remove the two of the screws No 2 from machine left side 3 Lift up the XY cover No 1 up to the bottom of machine arm and move in the arrow direction XY cover No 1 can be removed Please operate more than one person and pay attention to XY table and flexible tube 2 3 1 1 2 1 1 4 5 1 XY cover 2 Screw 3 Screw 4 Machine arm 5 Flexible tube From the library of Superior Sewing Ma...

Page 46: ...ea Before adjusting it is necessary to remove the XY cover Please refer to the previous paragraph 7 6 NOTE When modify the home positon somewhere other than the center of sewing area please refer to the instructions OPERATION PANEL technical manual 17 Easy setting 3 8 Home position Detecting positon 5 2 4 1 3 5 400 400 200 200 400 400 200 200 1 X detect plate 2 X detector 3 Y detect plate 4 Y dete...

Page 47: ...g in hatched area is 210 mm If different loosen the two screws No 8 of the X detector No 2 and adjust the detectors position When above distance is more than 210 mm move the X detector No 2 in arrow b direction When less than 210 mm move the X detector No 2 in arrow a direction 4 After adjustment tighten the screw No 8 and check again above 1 to 3 procedures 5 Confirm the clearance between detecto...

Page 48: ...e the Y detector No 4 in arrow a direction 4 After adjustment tighten the screw No 8 and check again above 1 to 3 procedures 5 Confirm the clearance between detector and detect plate is in the range of 1 to 1 5 mm If it has any damage with detector or the detect plate this clearance may different NOTICE For the safety turn the power switch off every time NOTE XY table mechanical home position is t...

Page 49: ...lley bracket 3 Tighten the adjust screw No 2 the timing belt No 3 tension will be increased 4 After the adjustment tighten the screws No 1 Reference Y timing belt tension has been adjusted by 440 N 1 Screw 2 Adjust screw 3 Timing belt 1 2 3 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 50: ...y lowers the slide guide running life Remove the dust and the thread waste sticking regularly and greasing every six months 2 For the guide rail grease to the both side of guide groove For the spline shaft and ball screw shaft grease to the surface of shaft After greased apply the grease uniformly by moving the XY table by hand NOTE This operation required to removing the XY cover and shutter 1 X ...

Page 51: ...ar mechanism NOTE Remove the face cover and motor cover in advance 5 Rack gear which has presser foot unit 6 Gear of the needle thread tensioner drive unit Recommended grease Molybdenum disulfide grease 5 6 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 52: ...osing 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 1 Oil bottle From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 53: ...parts The needle size is bigger than the thread size Change the needle size to suitable size 5 1 Thread melts with heat Slow down the sewing speed Operation panel section Use needle cooler Bobbin thread is broken Bobbin thread tension is too tight Adjust thread tension 5 9 Parts on needle plate and presser foot touching thread are damaged Buff parts or change parts Upper thread is pulled from need...

Page 54: ...fe or change fixed knife Movable knife is dull Sharpen Movable knife or change fixed knife Movable knife home position is not proper Adjust movable knife home position 7 5 1 Setting of trimming timing is not proper Adjust the trimming timing Operation panel section Trimming setting is off Turn trimming setting on Operation panel section Stitch forming is loose Upper thread tension is too loose Adj...

Page 55: ...s Put slip stopper on presser plate Sewing material is too heavy Slow down sewing speed Operation panel section Y timing belt tension is loose Adjust timing belt tension properly 7 8 Returned home position is changed Ambient temperature is out of use range Use sewing machine in ambient temperature in 5 degrees to 35 degrees Clearance between detector and detecting subject is too wide Adjust cleara...

Page 56: ...From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 57: ...From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 58: ...MEMO From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 59: ...MEMO From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 60: ...Printed in Japan From the library of Superior Sewing Machine Supply LLC www supsew com ...

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