JUKI PLK-J4040 Bedienungsanleitung

INDUSTRIAL SEWING MACHINE

MODEL

PLK-J4040

TECHNICAL MANUAL

SEWING MACHINE HEAD

A181E032P01

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

Prec

aution for sewing machine operation:

Indicates that removing the safety and operating

the sewing

machine for some other purposes with power-on

are prohibited.

zPlease do not operate the sewing machine

without

protective

equipment such as a needle guard, an eye guard,

a belt cover or the others.

zPlease turn off the

power switch when threading, changing

a needle and a bobbin, cleaning, and lubricating.

Caution

for fingers injury:

Indicates a possibility of fingers (hands) injury in a certain

condition.

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 danger

ous 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····································

2. SPECIFICATIONS·····································································

3. INSTALLATION········································································

3-1. Installation of the foot switch···································································

3-2. Connection of the air tube·······································································

3-3. Installation of the thread stand·································································

3-4. Installation of the eye guard····································································

3-5. Installation of the rubber cushion······························································

4. LUBRICATION·········································································

4-1. Filling the oil tank··················································································

5. PROPER OPERATION······························································

5-1. Installation of the needles·······································································

5-2. Threading the needle thread···································································

5-3. Winding the bobbin thread······································································

5-4. How to opening the bobbin access door·····················································

5-5. Setting the bobbin·················································································

5-6. Setting the bobbin case··········································································

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·························································

6. S

TANDARD ADJUSTMENT···························

·····························

6-1. Adjustment of the needle bar position·······················································

6-2. Adjustment of the position between the needle and the shuttle hook···············

6-2-1. How to remove the sliding plate························································

6-2-2. Adjustment of the driver position························································

6-2-3. Adjustment of the clearance between the shuttle hook and the needle ·····

6-2-4. Adjustment of the clearance between the driver and the needle ··············

6-2-5. Adjustment of the shuttle race thread guide·········································

6-2-6. Adjustment of the timing between the hook and the needle motion···········

6-4. Adjustment of the oil lubrication······························································

6-5. Setting of the pressor foot movement·······················································

6-6. Adjustment of the wiper·········································································

6-7. Adjustment of the thread take up spring····················································

6-7-1. Adjusting movable range of the thread take up spring····························

6-7-2. Adjusting intensity of the thread take up spring·····································

6-8. Adjustment of the thread tail after the trimming···········································

6-9 Adjustment of the air pressure·································································

VARIOS ADJUSTMENT······································

·······················

7-1. How to exchanging the tension spring of the needle thread tensioner unit·······

7-2. Adjustment of the detector position of the presser foot unit···························

7-3. How to replace with a special pressor foot················································

7-4. Adjustment of the pressor foot holder position············································

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·····················································

8. MAINTENANCE·······································································

8-1. Cleaning····························································································

8-2. Greasing····························································································

8-3. Disposing of oil waste···········································································

9. TROUBLESHOOTING·······························································

. APPENDIX

10-1. The positional relationship between the sewing area and jig eject system

10-2. Air piping drawing

-1-

1. STRUCTURE OF THE SEWING MACHINE

PLK-J4040 Industrial sewing 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>

- 2 -

2. SPECIFICATIONS

Model



PLK

-J4040

Stitch type



Single needle lock stitch



Hook



Large

size shuttle hook

Class of needle



DPX17#18



Sewing area



-direction (left/right) 400 mm

-direction (front / back) 400 mm

Maximum sewing speed

*1

000rpm (Continuous feeding) 2,000rpm (M3 feeding)

Maximum sewing speed



10 speed levels in 200 rpm to 2,0

00 rpm (M3 feeding)

Stitch

length

0.1 to 20.0 mm

(min. resolution 0.1 mm)

Maximum number of needles

20,000 per pattern



Storable sewing data item



9,000

patterns*2

Data memory



USB memory



Type of motor (Needle side)

750W direct servo motor

Type of motor (Hook side)



0W direct servo motor

Work holder

Jig eject system

eedle bar stroke

41.2

Thread take up lever stroke



68.0

Presser foot drive

Direct drive by stepping motor

resser foot lift

18.0

mm (max. 24.0 mm) Variable in 0.1 mm step

Presser foot

stroke

Digi

tal adjustment stroke: 0.1 to 10.0 mm

Upper thread tensioner

Manual / automatic / Setting on pattern (switchover)

Wiper

system

Back to front wiping system

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



Horizontal engagement with fixed knife and movable knife



Machine dimensions

(W)x(L)x(H)



1,350mm x 1,570mm x1,205mm

Weight



0kg

Power



In 200V to 240V single-phase or three-phase



*1: Sewing speed may be limited by the operation or sewing condition.

*2: The max. patterns may be limited depending on the number of stitches of each pattern in the memory.

*3: Standard value is 8.0 mm.

-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 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 switch

-4-

3-2. Connection of the air tube

Insert the one end of the air tube (8mm Diameter) into the intake air fitting (No.3) of the filter regulator

(No.2) 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.4) is enclosed in the accessory box.

3-3. Installation of the thread stand

(1) Assemble the parts of the thread stand 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

<11>: Column joint

<12>: Washer

<13>: Cushion

<14>: Nut

<15>: Bracket (large)

<16>: Bracket (small)

<17>: Holder

<18>: Thread guide

<1>

<12>

<3>

<4>

<6>

<7>

<8>

<9>

<2>

<10>

<11>

<5>

<14>

<13>

<12>

<17>

<16>

<18>

<15>

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