Mitsubishi PLK-E0504 User manual

A180E517P01
MITSUBISHI
Industrial Sewing Machine
TECHNICAL MANUAL
MECHANICAL VERSION
Electronic Pattern Sewing Machine
Model PLK-E0504

FOR YOUR SAFETY !
If you operate the sewing machine first time, please make sure to read the following
instructions for your safety and proper operation.
In this technical manual, the notice CAUTION is mentioned at some paragraph to attract your
attention for the safety. Please keep it in mind whenever you work with the sewing machine.
Explanations for the warning signs
No Warning sign Meanings of warning sign
1
Caution for sewing machine operation:
Warning to operate the sewing machine without safety
guards and to prohibit doing any operation except sewing
while the power is turned ON.
2 Caution for a wound on the fingers:
Warning to a possible danger to cause a wound on the
fingers under the specified operation.
3
Caution for the fingers to be caught in the machine:
Warning to a possible danger to be caught the fingers in the
machine under the specified operation.
4
Direction of pulley rotation:
Indicating the proper rotating direction of the sewing
machine pulley.
CAUTIONis used as the notice to warn a possible danger to cause a wound.
This technical manual explains the instructions how to operate and maintain the sewing
machine.
All information in this technical manual are subject to change without notice.
MITSUBISHI ELECTRIC CORPORATION has all the copy rights on this technical manual.
Reprinting the parts or all of this technical manual is not allowed without permission.

ENVIRONMENT STANDARD
(1) Temperature and humidity
(a) During operating : The atmosphere temperature should not exceeded more 35ºC
(95ºF) or less 5ºC(41ºF).
(b) During transportation : The atmosphere temperature should not exceeded more
55ºC (131ºF) or less -10ºC (18ºF).
(c)
The relative humidity in the atmosphere should not exceeded more 85% or less
45%.
(2) Atmosphere for the machine operation
(a) In the atmosphere filled with dust or corrosive gas.
(b) In the atmosphere filled with flammable or explosive gas.
(3) Power source voltage
(a) In the place where the power fluctuation exceeds more or less 10 % of the fixed
power voltage.
(b) In the place where the power source can not supply enough voltage to keep the
motor running.
(4) Power source voltage
(a) In the place where the power fluctuation exceeds more or less 10 % of the fixed
power voltage.
(b) In the place where the power source can not supply enough voltage to keep the
motor running.
(5) Noise
(a) In the place near a high frequency transmitter or a high frequency welder.
(b) In the place filled with strong electromagnetic radiation or magnetic field.
For avoiding the sewing machine from the troubles, please do not operate the sewing
machine under the following conditions.
Caution

CONTENTS
1. STRUCTURE OF THE MACHINE ････････････････････････････････････････
･
1
2. SPECIFICATION ･･･････････････････････････････････････････････････････ 2
3. INSTALLATION ････････････････････････････････････････････････････････ 3
3-1. Preparation of the table ･･････････････････････････････････････････････ 3
3-2. Preparation for the steel stand ････････････････････････････････････････ 3
3-3. Installation of the motor ･･････････････････････････････････････････････ 3
3-4. Installation of the control 3
3-5. Connection of the operation panel ･････････････････････････････････････ 3
3-6. Installation of the power switch ････････････････････････････････････････ 4
3-7. Connection of the foot switch ･････････････････････････････････････････ 4
3-8. Installation of the oil 5
3-9. Installation of the sewing machine head ････････････････････････････････ 5
3-10. Putting across the V-belt ････････････････････････････････････････････ 6
3-11. Connection of the electric cables ･････････････････････････････････････ 7
3-12. Installation of the belt 8
3-13. Installation of the thread stand ･･･････････････････････････････････････ 9
3-14. Functioning the work holder pedal ････････････････････････････････････ 9
4. LUBRICATION ･････････････････････････････････････････････････････････ 10
4-1. Filling the oil 10
4-2. Oiling ･･････････････････････････････････････････････････････････････ 10
5. PROPER OPERATION ･･････････････････････････････････････････････････ 11
5-1. Loading the system software to the control box ･･････････････････････････ 11
5-2. Installation of the needle ･････････････････････････････････････････････ 11
5-3. Threading the upper thread ･･･････････････････････････････････････････ 12
5-4. Winding the bobbin read ･････････････････････････････････････････････ 12
5-5. Setting the bobbin ･･･････････････････････････････････････････････････ 14
5-6. Setting the bobbin case ･･････････････････････････････････････････････ 14
6. PROPER SEWING ･････････････････････････････････････････････････････ 15
6-1. Operation of the halt switch ･･･････････････････････････････････････････ 15
6-2. The sewing operation ････････････････････････････････････････････････ 16
6-3. Adjustment of the thread tension ･･････････････････････････････････････ 18

7. STANDARD ADJUSTMENT ･････････････････････････････････････････････
･
19
7-1. Adjustment of the needle bar position ･･････････････････････････････････ 19
7-2. Adjustment of the position between the needle and the shuttle 20
7-3. Adjustment of the clearance between the shuttle hook and the needle ･･････ 21
7-4. Adjustment of the clearance between the driver and the 21
7-5. Adjustment of the thread guide ････････････････････････････････････････ 22
7-6. Adjustment of the presser foot ････････････････････････････････････････ 22
7-6-1. Adjustment of the presser foot position ･･･････････････････････････ 22
7-6-2. Adjustment of the presser foot lift during the sewing ････････････････ 24
7-6-3. Adjustment of the presser foot timing ･････････････････････････････ 25
7-7. Adjustment of the wiper ･･････････････････････････････････････････････ 26
7-8. Adjustment of the bobbin 27
7-9. Adjustment of the work 27
7-10. Adjustment of the trimmer cam follower ･･･････････････････････････････ 28
7-11. Adjustment of the position for movable knife 28
7-12. Adjustment of the fixed knife 29
7-13. Adjustment of the thread take up spring stroke ･････････････････････････ 29
7-14. Adjustment of the thread take up spring tension ････････････････････････ 29
7-15. Adjustment of the thread tail after the trimming ･････････････････････････ 30
7-16. Cancellation of the trimming 30
7-17. Adjustment of the upper thread 30
7-18. Adjustment of the 31
7-19. Adjustment of the mechanical home position ･･･････････････････････････ 32
7-19-1. Shifting the mechanical home position X 33
7-19-2. Shifting the mechanical home position Y 33
7-20. Adjustment of the X-Y contact pressure ･･･････････････････････････････ 34
7-21. Adjustment of the X-Y driving gear clearance ･･････････････････････････ 34
7-21-1. Adjustment of the X stepping motor 34
7-21-2. Adjustment of the Y stepping motor 35
7-22. Adjustment of the V belt tension ･･････････････････････････････････････ 35
8. MAINTENANCE ････････････････････････････････････････････････････････ 36
8-1. Cleaning ･･･････････････････････････････････････････････････････････ 36
8-2. Disposing of oil waste ････････････････････････････････････････････････ 36
9. BAD SEWING CONDITION & ITS CAUSE AND 37
APPENDIX ････････････････････････････････････････････････････････････････ 40
Ref.1. Table cut-out for PLK-E0504 machine ････････････････････････････････ 41
Ref.2. Table and stand ･･･････････････････････････････････････････････････ 41
Ref.3. Stand 42

－1－
1. STRUCTURE OF THE SEWING MACHINE
PLK-E0504 electronic bar tack machine is constructed with the following main parts.
9
6
4
3
2
1
5
7
8
Work holder foot switch
Machine head
Half switch
Table top
Thread Stand
Operation panel
Servo-motor
Steel stand
Control
box
Start foot switch
Work holder
pedal

－2－
2. SPECIFICATION
(1) Specification of mechanism
Sewing area : X-Direction (left/right) Y-Direction (fore/backward)
: 50mm 40mm
Maximum sewing speed : 2,500 rpm
Sewing speed : 10 steps variable from 200 to 2,500 rpm
Stitch length : 0.1 to 12.7 mm
: Adjustable from 0.1mm to 12.7mm by 0.1mm resolution)
Stitch type : Single needle lock stitch
Needle bar stroke : 41.2 mm
Thread take up lever stroke : 68 mm
Class of needle : DP ×17 # 18 (the standard specification)
Wiper system : Back to forward wiping system
Presser foot lift *1 : 15 mm (18mm max.)
Presser foot stroke *2 : Variable from 4mm to 10mm (4mm is standard)
Work holder lift : 25 mm
Hook : Shuttle hook
Bobbin case : With non racing spring
Bobbin : Large size 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 : White machining oil
X-Y drive system : Stepping motor and Gear drive
: Intermittent or continuous feeding
Machine dimension : 1,200mm(W) ×773mm(L) ×1,220mm(H)
Weight : TOTAL 116Kg
Type of controller : PLK-E-CU-20
Steel stand : T-shape steel stand for the standing or the sitting operation
(2) Specification of main motor
Type of motor : XL-554-20
*1：Stepping foot lift means the clearance between the bottom of the stepping foot and the surface
of the sliding plate when the sewing machine is stopped running.
*2：Stepping foot stroke means the vertical movement of the stepping foot during the sewing operation.

－3－
The machine should be installed by the specialists who have enough experience for the
sewing machine installations.
All the necessary electric wiring should be done by electric engineers who are qualified for
the electric wiring.
If any damage or fault is found on the machine at the installation, please do not operate until
it is repaired.
Please do not operate the sewing machine with excessive modifications from the standard
specification.
Caution
3. INSTALLATION
3-1. Preparation of the table
If the table is not MITSUBISHI original, the thickness of the table is required to have 40mm
more.
And please refer to the cut out table drawing for your own preparation.
The cut out drawing is shown on the last page of this technical manual as APPENDIX drawing.
3-2. Preparation for the steel stand
If the steel stand is not MITSUBISHI original, please refer to the assembling drawing for your
own preparation.
The assembling drawing is shown on the last page of this technical manual as Ref.1 to Ref.3.
If the steel stand is MITSUBISHI original, please assemble the steel stand with the assembling
instructions enclosed in the packing.
3-3. Installation of the motor
If the motor is purchased without assembling to the table, the motor has to be installed
underneath the table.
Please install the motor with the instructions explained in the paragraph [Installation of the
Motor] on the other CONTROL UNIT technical manual.
3-4. Installation of the control box
If the control box is purchased without assembling to the table, the control box has to be
installed underneath the table.
Please install the control box with the instruction explained in the paragraph [Installation of the
control box] on the other CONTROL UNIT technical manual.
3-5. Connection of the operation panel
Please connect the operation panel with the instructions of Operation Panel technical
manual enclosed in the packing.

－4－
3-6. Installation of the power switch
If the power switch is purchased without assembling to the table, the power switch has to be
attached with the following procedure.
(1) Mount the power switch (NO.1) with the wood screw (NO.2) underneath the table as shown
on the figure.
(2) Fix the electric cords with the staples (NO.3) underneath the table.
(3) Hook up the connector (NO.4) of the power switch (NO.1) to the connector (NO.5) of the
control box.
(4) Attach the power plug (NO.7) to another end of the power switch cord (NO.6).
NOTE Connect the connector with the instructions in the paragraph [P.8 < Back side view of the
Control box >] .
3-7. Connection of the foot switch
Connect the foot switch (NO.8) to the connector (NO.9).
The foot switch is enclosed in the accessory box.
NOTE Connect the connector with the instructions in the paragraph [P.8 < Back side view of the
Control box >].
1
3
5
4
7
6
9
2
8

－5－
For the safety, please make sure to carry the sewing machine head by more than two people.
Caution
3-8. Installation of the oil pan
Insert the oil pan (NO.1) which is enclosed in the accessory box. And settle to the table top by
the staples (NO.2).
3-9. Installation of the sewing machine head
(1) Make sure to hold the machine table with the caster stopper.
(2) Fit the rubber cushion pads (NO.3) into the each hole (NO.4) on the tabletop. The rubber
cushion pads (NO.3) are enclosed in the accessory box.
(3) Put the sewing machine head on the table top and set the each leg (NO.5) to the each
rubber cushion pad (NO.3).
(4) Attach two hinges (NO.6) temporarily to the screw hole (NO.7) on the left side surface of
the machine head by the bolt (NO.8).
At this time, take notice that the each direction of two hinges (NO.6) are set correctly as
shown in below figure. All these parts are enclosed in the accessory box.
(5) Fit the screw holes (NO.10) of the hinges (NO.6) to the bolt setting holes (NO.9) on the
table top then, pass the bolt (NO.11) through these holes and fasten the bolt (NO.11) to fix
the hinges (NO.6) with the flat washers (NO.12), the spring washers (NO.13) and the nuts
(NO.14).
(6) Fasten firmly the Bolt (NO.8), which set the hinges (NO.6) temporarily at above procedure
(4) then, fix the hinges (NO.6) perfectly.
(7) Insert the headrest (NO.15) into the hole (NO.16) on the tabletop.
10
6
912
14
13 3
4
16
15
5
1
2
8
11
7
E-type
retaining ring

－6－
For safety purposes, tilting or raising of the sewing machine must always be carried out by
two or more workers. Apply a stopper on the leg casters to prevent the table from moving,
and then securely support the bed base and the sewing machine head.
Hold the work holder frame to prevent it from dropping down when tilting the sewing
machine
Caution
3-10. Putting across the V-belt
(1) Tilt the sewing machine head to the left, and hold it with the head rest.
(2) Put the V-belt (NO.4) across the sewing machine pulley and the motor pulley with passing it
through the slit on the tabletop.
(3) Raise the tilted sewing machine head to the original position.
(4) Push the center portion of V-belt by the finger with the presser of about 1Kg.
If the V-belt tension is proper, it should be yielded about 10mm.
If the V-belt tension is not proper, please adjust it as follows.
(5) Loosen two nuts (No.2,3) on the motor position adjust bolt (No.1). Fix the motor (No.5)
position with putting the tension to the V belt by its weight and firstly, tighten the upper nut
(No.2) then secondly, tighten the lower nut (No.2).
Please make sure to fasten the nuts (NO.5) firmly after the adjustment.
(6) Put the motor pulley cover on the motor with the set screws.
NOTE The V-belt becomes loose after along period machine running.
If the looseness is recognized definitely, firstly turn the power OFF then, adjust the
V-belt tension again as the above procedure (4).
4
1
235
10mm

－7－
3-11. Connection of the electric cables
(1) Connect the white color cable (NO.1) and the black color cable (NO.2) across the printed
circuit board unit connectors (NO.4) on the sewing machine head (NO.3) rear face and the
connectors (NO.5) on the control box. These cables are enclosed in the accessory box.
(2) Remove the stepping motor cover (NO.6) from sewing machine head (NO.3).
(3) Pass upward the cable (NO.7) which is attached two connectors at the end, through the
cut-out hole on the table top then, connect it to the X-stepping motor connector (No.9) and
to the Y-stepping motor connector (No.10). At this time, fix this cable with the nylon clip
(NO.11) and setscrew (No.12), which are provided on the sewing machine head. And also,
connect the other end of the cable (NO.7) to the connector (NO.8) on the control box. The
cable (NO.7) is enclosed in the accessory box.
NOTE Please confirm X or Y stepping motor connector position carefully.
(4) Pass downward the another cable (NO.13) which is extended from the sewing machine
head through the cut-out hole on the table top then, connect it to the cable (NO.15)
extended from the motor (NO.14).
(5) Connect the last cable (NO.16) to the other extended cable (NO.17) from the motor then,
hook up the other end of the cable (NO.16) to the connector (NO.18) on the control box.
(6) Attach two binders (NO.19) underneath the table with the wood screws (NO.20) then,
bundle and fix all the connected cables with the binders (NO.19) and the staples (NO.21).
The binders (NO.19), the wood screws (NO.20) and the stables (NO.21) are enclosed in
the accessory box.
5
4
3
21
7
11 12
8
10
9
13 15 16211920
17
14
18
22
6

－8－
< Back side view of the Control box >
Fig Con Connect with
1 A Main motor cable
2 B Power supply cable
3 C Stepping motor cable
4 D Solenoid output cable
5 E RS-232C (optional use)
6 F Operation panel cable
7 G Extension I/O cable
8 H Input signal cable
9 I Foot switch cable
3-12. Installation of the belt cover
(1) Put the small belt cover (NO.1) on the sewing machine head with the setscrew (NO.2)
temporally.
(2) Put the large belt cover (NO.3) with the setscrews (NO.4, 5, 6, 7).
(3) Fasten these the setscrew (NO.2) securely. All the necessary parts are enclosed in the
accessory box.
7
8
5
3
6
1
12
3
4
5
6
8
7
9

－9－
3-13. Installation of the thread stand
(1) Assemble the thread stand with the instructions enclosed in the packing.
(2) Fit the thread stand (NO.1) in the thread stand hole on the tabletop.
(3) Fix the thread stand (NO.1) firmly from the rear side of the table with tightening the nut
(NO.4) and the washers (NO.2, 3).
3-14. Functioning the work holder pedal
(1) Connect the chain (NO.1) across the
lever (NO.2) located at the left side of
the sewing machine head and the
work holder pedal (NO.3) mounted on
the steel stand bottom beam. The
chain (NO.1) is enclosed in the
accessory box.
(2) Put the stepping motor cover (NO.4)
back on the sewing machine head with
the screw (NO.5) after the chain
(NO.1) connection.
1
2
3
4
1
3
2
4
5

－10－
Please make sure to turn power switch OFF before oiling.
Please make sure to put some oil before starting the operation of the brand new machine or
when the sewing machine is resumed the operation after along interval.
Caution
4. LUBRICATION
NOTE Please use high quality white machining oil.
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. Move the
work holder by hand to the right end then, pour the oil through the oil hole (NO.4) to the oil tank
(NO.5) on the machine bed. Please fill with the oil over level mark (NO.6) of the oil tank.
4-2. Oiling
Put some oil to the red marked oil holes (NO.7 ~ 13).
8910
11
6
1
2
4
53
7
12
13

－11－
5. PROPER OPERATION
5-1. Loading the system software to the control box
When the brand new machine is operated first time or when the control box is adjusted for the
repairing, the system software has to be loaded to the control box.
For this loading, please take the following procedure.
(1) Insert the system floppy disc printed
[ F1 ] (NO.2) into the disc drive (NO.3)
of the control box. The system floppy
discs are enclosed in the accessory
box.
(2) While holding down the F key on
the setting panel of the control box,
turn the power switch (NO.1) ON.
(3) Load the system software with
following the instructions [System
installation method] on the technical
manual CONTROL UNIT .
(4) After loading the system software,
keep the system floppy disks with in
care.
5-2. Installation of the needle
(1) Loosen the needle set screw (NO.1) then,
insert the new needle (NO.2) until the needle
head is reached the end of the hole of the
needle bar (NO.3).
(2) Fasten the setscrew (NO.1) with facing the
needle groove (NO.4) to the front.
★Please make sure to turn the power switch OFF before installing or replacing the needle.
★Please pay attention for the fingers not to be wounded by the needlepoint.
Caution
4
2
1
3
OFFON
1
2
3

－12－
Please make sure to pull the upper thread out of the needle before winding the bobbin
5-3. Threading the upper thread
Please thread the upper thread with referring to the below figures.
5-4. Winding the bobbin thread
(1) Turn the power switch ON.
(2) Press the key on the operation panel
to enter the second operation window.
(3) Pass through the thread from the thread
stand (NO.1) as shown on the below figure
then, wind the thread to the empty bobbin
(NO.2) in the arrow mark “a” direction
couple times and insert the bobbin (NO.3)
into the bobbin winder (NO.4).
(4) Push the adjust lever (NO.6) in the arrow
mark “b” direction.
(5) Step on the black color foot switch (NO.5)
then work holder goes down.
(6) Press the key, then work holder
moves to home position.
★Please make sure to turn the power switch OFF before threading the upper thread.
Caution

－13－
(7) Press key on the operation panel.
Then presser foot goes down automatically,
and wind mode window will be appeared.
(8) Step on the black color foot switch (NO.5)
again to make work holder down.
(9) Step on the gray color start foot switch
(NO.6). The thread is kept winding to the
bobbin (NO.2) while the gray color start
switch is stepping on.
(10) When the bobbin becomes full of
the thread, the adjust lever (NO.4) is
returned to the original position.
(11) Stop to step the gray foot switch
and press
the key to exit winding mode, and
press the key, to back to the
standard operation windows will be
appeared.
(12) To wind the bobbin thread during
the sewing operation, carry out above (3)
and (4) procedure then, the bobbin winding
is performed automatically.
(13) Regarding the adjustment for the bobbin thread winding volume, please refer to
the instructions in the paragraph [7-8 Adjustment of the bobbin winder] in the following
page.
b
a
321
4
6
5

－14－
5-5. Settling the bobbin
(1) Set the bobbin (NO.2) into the bobbin case (NO.1).
(2) Pull the bobbin thread (NO.3) into the slit (NO.4) and pass the thread through the thread
hole (NO.5).
(3) At this time, pull the bobbin thread (NO.3) then, check with the bobbin (NO.2) if it is rotated
to the arrow direction. If it is not, set the bobbin (NO.2) into the bobbin case (NO.1) over
again to get the proper rotation.
5-6. Setting the bobbin case
(1) Set the needle bar to its highest position then, open the cylinder cover (NO.1).
(2) Open the bobbin case latch lever (NO.2) fully then, fit it securely in the inner hook (NO.3).
NOTE Please pull the bobbin thread about 25mm out of the thread hole (NO.4) of the bobbin
case.
1
3
5
4
2
3
1
2

－15－
6. PROPER SEWING
6-1. Operation of the halt switch
If an incident such as a thread breakage, needle breakage and any other incidents are
happened during the sewing operation, please hit immediately the halt switch. The sewing
machine running is stopped instantly.
(1) Press the HALT switch (NO.1). All operations will stop, and the sewing machine will stop at
the needle UP state without trimming the thread.
(2) Remove the cause of the abnormality.
(3) To continue sewing, turn the HALT switch (NO.1) to the right, and unlock the switch.
Next, when the start switch (NO.3) (gray foot switch) is pressed again, the operation will
resume from the halted position.
(4) To cancel sewing, turn the HALT switch (NO.1) to the right, and unlock the switch.
Then, press the key on the operation panel (NO.2).
The work holder (NO.4) will return to the home position from the stopped position and will
stop.
★Before start the sewing operation, please make sure the location of the halt switch and keep
it in mind the function and how to use it.
★Please keep away the hands and the face from the needle during the sewing operation.
Caution
2
4
3