Mitsubishi Electric PLK-G1010 User manual

Industrial Sewing Machine
TECHNICAL MANUAL
SEWING MACHINE HEAD
Electronic Pattern Sewing Machine
Model PLK-G1010
A180E593P03

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.
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.
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.
4
Indication of pulley rotation direction:
Indicates a normal pulley rotation direction of sewing machine.
(For sewing machine with pulley)

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) When tilting the sewing machine, please stand at the hinge side and hold the sewing machine with
both hands. Also, please lock the caster on the steel stand
(7) When tilting the sewing machine, the work clamp slides toward the hinges. Remember to move the
work clamps Fully to the right side of the casting before placing the sewing head in the sewing
position.
(8) Please lock the caster on the steel stand to prevent the machine from moving before tilting the
sewing machine.

(9) 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.
(10) If the table and the steel stand are not MITSUBISHI original, the table and the steel stand have to
be strong enough to withstand the weight and Vibration of the sewing machine.
(11) When fitting the caster to the steel stand that are not MITSUBISHI original, the caster with locking
function has to be strong enough to withstand the weight and Vibration of the sewing machine.
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.
(5) Please make sure to lock the caster on the table when tilting the sewing machine.

CONTENTS
1. STRUCTURE OF THE SEWING MACHINE···································· 1
2. SPECIFICATION······································································· 2
3. INSTALLATION········································································ 3
3-1. Preparation of the table··········································································
3-2. Preparation of the steel stand··································································
3-3. Installation of the control box···································································
3-4. Installation of the operation panel·····························································
3-5. Installation of the power switch and foot switch············································
3-6. Installation of the oil pan·········································································
3-7. Installation of the machine head·······························································
3-8. Installation of the tilting detect switch·························································
3-9. Installation of the eye guard····································································
3-10. Connection of the electric cables····························································
3-11. Installation of the thread stand································································
3-12. Installation of the chain for manual work holder presser·······························
3-13. Installation of the spindle motor······························································
3
4
4
4
4
5
5
6
6
7
8
8
9
4. LUBRICATION········································································· 10
5. PROPER OPERATION······························································ 10
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··········································································
10
11
11
12
13
13
6. SEWING················································································· 14
6-1. The sewing operation············································································
6-2. Operation of the halt switch·····································································
6-3. Adjustment of the thread tension······························································
14
15
15

7. STANDARD ADJUSTMENT························································ 16
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·····························································
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 (the adjustment for holding thick sewing
material) ····························································································
7-14. Adjustment of the trimmer cam follower····················································
7-15. Adjustment of the position of movable knife···············································
7-16. Adjustment of the fixed knife position·······················································
7-17. Adjustment of the thread take up spring···················································
7-18. Adjustment of the thread tail after the trimming··········································
7-19. Adjustment of the upper thread tension release (the width between thread
tension discs) ·····················································································
7-20. Adjustment of opening time of the upper thread tension release disks·············
7-21. Adjustment of the X-Y mechanical home position·······································
7-21-1. Adjustment of the X direction····························································
7-21-2. Adjustment of the Y direction····························································
7-22. The X-Y drive timing belt tension····························································
16
16
17
17
18
19
20
21
21
22
22
23
23
24
24
25
25
26
26
26
27
27
28
28
8. MAINTENANCE······································································· 29
8-1. Cleaning·····························································································
8-2. Disposing of oil waste············································································
29
29
9. TROUBLESHOOTING······························································· 30
APPENDIX················································································· 32

- 1 -
1. STRUCTURE OF THE SEWING MACHINE
PLK-G1010 electronic pattern 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> Work holder pedal
<9>: Steel stand <10>: Thread stand <11>: Gas spring (Option)
<1>
<2>
<4>
<5>
<7>
<9>
<11>
<10>
<6>
<8>
<3>

- 2 -
2. SPECIFICATIONS
Sewing area : X-direction (left/right) 100 mm, Y-direction (front / back) 100 mm
Maximum sewing speed : 2,800 rpm *1
Setting speed : 10 speed levels in 200 rpm to 2,800 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 : 512 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 : Back to front wiping system
Presser foot lift *2 : 15 mm (12 mm as factory default setting)
Presser foot stroke *3 : In 4 mm to 10 mm (4 mm as factory default setting)
Work holder lift : 25 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 : 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
Machine dimensions : 1,200 mm (W) ×867 mm (L) ×1,289 mm (H)
Weight : Total 133 Kg
Type of motor : XL-K756-20
Type of controller : PLK-G-CU-20
Type of operation panel : PLK-G-PAL
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：when sewing at speeds of over 2,500rpm, use an anti-noise protective equipment as needed.
*2：Presser foot lift is the height of the presser foot after the sewing has stopped.
*3：Presser foot stroke is the up and down movement of the presser foot while sewing.

- 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.
(5) If the table and the steel stand are not MITSUBISHI original, the table and the steel stand have to be
strong enough to withstand the weight and Vibration of the sewing machine.
(6) When fitting the caster to the steel stand that are not MITSUBISHI original, the caster with locking
function has to be strong enough to withstand the weight and Vibration of the sewing machine.
3-1. Preparation of the table
(1) If the table is not MITSUBISHI original, the thickness of the table is required to have 40mm and that is
strong enough to withstand the weight and Vibration of the sewing machine.
(2) Manufacture the table as shown on the figure below.

- 4 -
3-2. Preparation of the steel stand
(1) If the steel stand is not MITSUBISHI original, please refer
to the dimensions shown on the figure at the right.
(2) When fitting the caster to the steel stand, the steel stand
has to be strong enough to withstand the weight and Vibration
of the sewing machine.
(3) If the steel stand is MITSUBISHI PLK-G1010 original,
assemble the steel stand with the assembling instructions
enclosed in the packing.
3-3. Installation of the control box
Install the control box with the instructions in the paragraph “[3] Installation” in the CONTROL UNIT
technical manual.
* For connector location see page 7, Section 3-10 of this catalog.
3-4. Installation of the operation panel
Connect the operation panel PLK-G-PAL with the CON A on the rear of the control box.
* See page 7 for the location.
3-5. Installation of the power switch and foot switch
(1) Mount the power switch (No.1) with the wood screw (No.2) at the position as shown on the figure.
(2) Hook up the connector (No.3) of the power switch to the control box CON B.
(3) Attach the power plug (No.5) to the incoming electrical cable (No.4).
(4) Fix the electric cables with the staples (No.6) to prevent the cables from hanging down.
(5) Hook up the connector (No.8) of the foot switch (No.7) to the control box CON H.
(6) As for the control box connector, refer to the instructions in the paragraph “3-10.Connection of the
electric cables” in this manual.
<1>: Power switch
<2>: Wood screw
<3>: Power switch connector
<4>: Electrical cable
<5>: Power plug
<6>: Staple (six staples)
<7>: Foot switch
<8>: Foot switch connector
<1>
<2>
<3>
<6>
<8>
<5>
<7>
<4>

- 5 -
3-6. Installation of the oil pan
(1) Remove the oil pan A (No.1) from the accessory box then, set the oil bottle (No.2) to the oil pan A
(No.1).
(2) Put the oil pan at the position shown on the figure then, fix the oil pan with staples (No.3).
(3) Set the damper cushions (No.4) to the table.
3-7. Installation of the machine head
CAUTION
(1) The sewing machine is heavy. For the safety, please make sure to install the sewing machine head by
more than one person.
(2) When tilting the sewing machine, please stand at the hinge side and hold the sewing machine with
both hands. Also, please lock the caster on the steel stand.
(3) When tilting the sewing machine, the work clamp slides toward the hinges. Remember to move the
work clamps Fully to the right side of the casting before placing the sewing head in the sewing
position.
(1) Put the machine head carefully on the damper cushion.
(2) Insert the hinge shafts (No.1) into the hole on the machine then, fix it to the machine with set screws
(No.2).
(3) Fit the hinge rubbers (No.4) and the support plates (No.5) into the holes of the hinges (No.3) then, set
the hinges to the hinge shafts.
(4) Fit the screw holes of the hinges (No.3) to the bolt setting holes then, fix the machine with the socket
bolts (No.6) and the flat washers (No.7).
(5) Fix the head rest (No.8) with safety socket bolts (No.9).
Upside
<4>
<2>
<1>
<3>
<4> <1>: Oil panA
<2>: Oil bottle
<3>: Staple (seven staples)
<4>: Damper cushion
(sixcushions)

- 6 -
3-8. Installation of the tilting detect switch
(1) Install the switch units (No.1) with the SW-MW screws (No.2) so that the switch turns on when the
machine head in initial position is pushed by the machine table.
[Notice] if the switch is not turned on, error [M-038] will occur.
3-9. Installation of the eye guard
(1) Loosen the SW-MW screws (No.2) on the eye guard unit (No.1) then, mount the SW-PW 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 SW-MW screws (No.2).
<1>: Hinge shaft (two shafts)
<2>: Set screw (two screws)
<3>: Hinge (two hinges)
<4>: Hinge rubber (two rubbers)
<5>: Support plate (two plates)
<6>: Socket bolt (four bolts)
<7>: Flat washer (four washers)
<8>: Head rest
<9>: Safety socket bolt (four bolts)
<3>
<5>
<7>
<6>
<1>
<2>
<8>
<9>
<4>
<1>
<2>
<3>
<1>: Eye guard unit
<2>: SW-MW screw
<3>: SW-PW screw (two screws)
Snap!
<1>
<2>
<1>: Switch units
<2>: SW-MW screw (two screws)

- 7 -
3-10. Connection of the electric cables
CAUTION
(1) Please make sure to ground the place where there is a mark. Failure to do so may cause electric
shock and/or malfunction.
(1) Connect the machine head and the control box with cables as shown on the figure.
(2) Hold the dangling cables under the table with accessory tie holders (MB60A0420) and cord ties
(MB60A0201). At this time, please check whether the cables are not pulled when tilting the sewing
machine.

<1>
<3>
<6> <7>
<5>
<4>
<2>
CON A
CON E
CON F
CON G
CON H
CON J
CON B
CON C
CON D
CON K
<1>: Solenoid cable
<2>: Solenoid power cable
<3>: Spindle encoder cable
<4>: Spindle motor cable
<5>: X-Y spindle encoder cable
<6>: X-Y spindle motor cable
<7>: P-F spindle motor cable
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

- 8 -
3-11. 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).
3-12. Installation of the chain for manual work holder presser
(1) Remove the X-Y motor cover.
(2) Link the machine head arm (No.1) and the pedal (No.2) on the stand side with the chain (No.3).
[Notice] Please make sure to unfasten the chain when tilting the machine. Tilting the machine head linked
with the chain causes the chain to be burst or the like.
<1>
<12>
<3>
<4>
<6>
<7>
<8>
<9>
<2>
<10>
<11>
<5>
<13>
<1>: Upper column pipe
<2>: Lower column pipe
<3>: Spool stand base (two stand bases)
<4>: Spool mat (two mats)
<5>: Spool holder (two holders)
<6>: Spool shaft (two shafts)
<7>: Spring washer (two washers)
<8>: Nut (four nuts)
<9>: Thread hunger
<10>: Spool holder
<11>: Column joint
<12>: Washer
<13>: Nut
<1>: Arm
<2>: Pedal
<3>: Chain
<2>
<3>
<1>

- 9 -
3-13. 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 UP position when reinstalling the coupling to the machine
top shaft.
(4) 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>: Spindle motor <2>: Motor mark <3>: Pin <4>: Coupling <5>: Gauge <6>: Bolt A
<7>: Bolt B
<1>
<5>
<3>
<2>
<4>
<7>
<6>
<5>
50.1mm
7mm

- 10 -
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.
(1) The oil tanks are set at three places of the machine. Pour oil through the oil holes of (No.1 to No.3) to
the oil tanks.
(2) The oil tanks have level marks (at the center of the tank). Running out the oil may cause the machine
to make abnormal noise and seize up. When the amount of oil decreases to one-third or less than
one-third, make sure to fill the tank with oil.
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.
<1>
<3>
<2>
Level mark

- 11 -
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.
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.
<3>
<1>
<2>
<4>
<1>: Set screw
<2>: Needle
<3>: Needle bar
<4>: Needle groove

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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. Adjust the amount of the winding
thread with the subsidiary arm (No.4).
(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.
a
<1>
<2>
<3>
<4>
<1>: Bobbin <2>: Bobbin winder <3>: Bobbin presser arm <4>: Subsidiary arm

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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.
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).
<4>
<2>
<1>
<3>
<5>
<1>: Bobbin case
<2>: Bobbin
<3>: Thread
<4>: Bobbin case slit
<5>: Bobbin case thread hole
<2>
<1>
<3> 2.5cm
<1>: Cylinder cover
<2>: Bobbin case latch
<3>: Shuttle hook

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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 also can switch the target.)
Press the 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.