Mitsubishi PLK-G6030 User manual

Industrial Sewing Machine
TECHNICAL MANUAL
SEWING MACHINE HEAD
Electronic Pattern Sewing Machine
Model PLK-G4030
PLK-G6030
A180E646P01

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
41. Filling the oil tank···················································································
42. 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······························································
6-4. Operation of the presser foot 2-stage lifting device·······································
6-5. Adjustment of the lifting volume································································
11
12
13
14
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·································································
7-6-1. Adjustment of the presser foot position·················································
7-6-2. Adjustment of the presser foot lift during the sewing································
7-6-3. Adjustment of the presser foot timing····················································
7-7. Adjustment of the wiper··········································································
7-8. Adjustment of the bobbin winder······························································
7-9. Adjustment of the work holder·································································
7-9-1. Adjustment of the work holder pressure················································
7-9-2. Changing the work holder··································································
7-10. Adjustment of the trimmer cam follower····················································
7-11. Adjustment of the position of movable knife···············································
7-12. Adjustment of the blade drive arm spring force··········································
7-13. Adjustment of the fixed knife position·······················································
7-14. Adjustment of the thread take up spring swing stroke··································
7-15. Adjustment of the thread take up spring tension·········································
7-16. Adjustment of the thread tail after the trimming··········································
7-17. Adjustment of the upper thread tension release ·········································
7-18. Adjustment of the mechanical home position·············································
7-18-1. Adjustment of the X direction····························································
7-18-2. Adjustment of the Y direction····························································
7-19. Adjustment of the X-Y timing belt tension··················································
7-19-1. Adjustment of the X timing belt tension················································
7-19-2. Adjustment of the Y timing belt tension················································
16
16
17
18
19
19
19
21
22
23
24
24
24
24
25
26
26
27
28
28
28
29
30
31
32
33
33
34
8. MAINTENANCE······································································· 35
8-1. Cleaning·····························································································
8-2. Disposing of oil waste············································································
35
35
9. TROUBLESHOOTING······························································· 36

- 1 -
1. STRUCTURE OF THE SEWING MACHINE
PLK-G4030/G6030 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>: Thread stand
<9>: Presser foot 2-stage lifting device
<1>
<2>
<3>
<4>
<5>
<6>
<7>
<8>
<9>

- 2 -
2. SPECIFICATIONS
Model PLK-G4030 PLK-G6030
X-direction (left/right) 400 mm X-direction (left/right) 600 mm
Sewing area Y-direction (front / back) 300 mm
Maximum sewing speed 2,000rpm
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 520 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 *1 15 mm (12 mm as factory default setting)
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
Stepping motor feedback control
X-Y drive system
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
The power in 110V to 120V or in 380V to 415V is compatible with
Power 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 -
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.
CON A
CON E
CON F
CON G
CON H
CON J
CON B
CON C
CON D
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
①
②
<2>
<1>
<1>: Intake air fitting
<2>: Air coupling

- 4 -
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).
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>: Screw
<3>: Screw (two screws)
<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>
<12>
<3>
<4>
<6>
<7>
<8>
<9>
<2>
<10>
<11>
<5>
<13>
<1>
<3>
<2>

- 5 -
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>: Spindle motor <2>: Motor mark <3>: Pin <4>: Coupling <5>: Gauge <6>: Bolt A
<7>: Bolt B <8>: Pulley
<1>
<5>
<3>
<2>
<4>
<7> <6>
<5>
2.0～3.2mm
<8>
7

- 6 -
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 ~ 14).
<2>
<7>
<6>
<5>
<4>
<3>
<1>
<8> <9>
<10>
<12>
<11> <13>
<14>

- 7 -
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>
<2>
<4>
<1>: Set screw
<2>: Needle
<3>: Needle bar
<4>: Needle groove

- 8 -
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.

- 9 -
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>: Bobbin <2>: Bobbin winder <3>: Bobbin presser arm
1
2
3
4
6
5
<1>
<2>
<3>

- 10 -
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

- 11 -
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.

- 12 -
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>: Halt switch
<1>

- 13 -
6-3. Adjustment of the thread tension
(1) Adjustment of bobbin thread tension
Adjust the bobbin thread tension with the thread tension
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.
(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>
<2>
<1>: Thread tension adjusting nut
<1>: Bobbin case
<2>: Thread tension adjusting screw
<1>

- 14 -
6-4. Operation of the presser foot 2-stage lifting device
To operate the Presser Foot 2-Stage Lifting Device, use the Function Code 2 (FUN2) in the
process of pattern input.
＜Example＞
An example of operations to add function code 2 using the operation panel is explained below.
This section describes the methods for input the code data with the input mode when newly
creating a pattern, Please refer to the technical data "Operation Panel Section" enclosed with the
operation panel for details.
(1) Press the on the standard screen.
(2) Press the and open the Input Mode
screen.
(3) Input the dry feed data and stitching data, etc.,
and press at the position where the
"presser foot two-step changeover unit" is to be
activated (the position where the FUN2 code is
to be input).