ÀDvaNcED aNo EVER aDVANCTNG

MÍTSuBlSHl ELECIRIC

MITSUBISHI
lndustrial Sewing Machine
INSTRUCTION MANUAL <Sewing Machine>

Electronic Pattern Sewing Machine

PLK-A1006
PLK.AOSO4F
PLK-AOsPF

lntroduction
Thank you for your purchase of Mitsubishi lndustrial Electronic Sewing Machine.
BeÍore aüempting to operate the unit, please read through these instructions since
they will help you to keep the unit in the best possible working order.
Thesê instructions describe the operations of the mechanical parts, inclusive of the
machine head, of this industrial electronic sewing machine. For details on how to
operate the control unit and how to prepare the sewing pattems, reÍe:rence should
be made to the lnstruction Manual below.
Mitsubishi lndustrial Sewing Machine lnstruction Manual
<Control Unit>: A180E207

4180E180P02
 Precautions ÍoÍ Operation

(1) Seíety
1) Make sure that the sewing machine is grounded in order to safeguard against nois€ and electric
shocks.
2) Do not placê your hand under the needle area or pulley aÍêa when tuming on the poyver.
3) The sewing machine which is opêrating is dangerous and so cere must bê taken not to torrch any
oÍ its moving parts. Also, remember to tum off the power beÍore proceeding with repair woÍk or
inspections.
4) Under no circumstances should the operator bring his or her Íingers near the woÍk holdêr while
the sêwing machine is being operated.
5) Do not operate the sêwing mechine withoú eye guard and protective covers in place.
6) Always tum ofÍ the power switch when not using the sewing machine or when the worker leeves
the sewing machine.
4 Always tum the power switch oÍÍ when tilting the machine head, removing/mounting the V belt or
adiusting/replacing the parts.

(2) Precsúions bêíore sewing machine operation

1) Confirm that lhe voltage and classification of singlêphase, 3-phase on the motor nameplate'rs
correct.
2) Usê a supply voltage within -+10% rangê oÍ the rating.
3) When e single-phase motor is being used, do not peíorm the staÍt opêration immediately bú wait
aboú 10 seconds after the power has been switched on until the motor operetion stabilizes.
4) Bumouts may be caused by insuÍÍicient lubrícation oÍ thê mêchanicel paÍts. BêÍore operation, be
sure to lubricãte and check the parts.
5) When operating the sewing machine Íor the first time, confiÍm the pulley rotating direction by
turning on the power. Cfhe conect rotation dirêction is counterclockwise looking from the pulley
side.)
6) ConÍirm the following before tuming the power on.
@ Confirm that the needle moves through the cênter oÍ the pressure Íoot.
@ Manually move the clamp so that the needle position is within the clemp Írame.
7) Contirm that the floppy disk with the pettems memorted is corÍectly inserted. (Íhe test pdterns
are input in the floppy disk at the Íactory.)

(3) Op€ration
1) Do NOT turn off the oower or remove the flooov disk while the flooDV disk drive is readino or
writino data (while the drivê LED is liohted). This mav cause the data stored to be lost.
2) When sewing a new pattem or enlarging a pattern, be sure to peíorm a test operation and chêck
the relationship between the work holder and pattem.
3) Remove your foot from the staÍt switch (pedal switch) when tuming the power switch on or otÍ.
4) The presser Íoot must be lowered when the pulley is turned manually. lt is lowered when the
poweÍ is oÍÍ so that the wheel can be rotated withoú ÍuÍther edlustment. When the power is on,
it can be lowered by setting the bobbin winder switch to the ON time.
5) The maximum sewing speed ditfers eccoÍding to the stitch lêngth. The maximum speed is
aúomatically limited in accordance with the stitch lengths. ReÍer to section 6 'Chêck points Íor
operation' and it should be set Íor each individual Íabric.
6) A Íetainer method is used Íor thê X-Y table mechanism. To stitch conect patterns, press the work
holder foMerd/backward/lêft and right so that it touches the stopper, and position the retainer
beÍore turning the power on.
7) Avoid using a multimeter to inspect the intemal control circuitry since the voltage Írom such may
damagê the semiconductor paÍts.
8) When an instantaneous power failure occurs, the sewing machine stops in the reset or erÍor
mode. To resume opêÍation, first make sure that the power is off and then switch it back on
again.
(4) Precautions regarding work environment
1) Do not operate the sewing machine at high temperatures (over 4(fC) or low temperatur6 (under
5"C). OtheMise, trouble or malfunctioning may occur in the machine.
2) The sewing machine cannot be used in an atmosphere whêre it will be exposed to explosive
gzlsês, dust, or oily vapors.
3) Avoid using the sewing machine in a location where it will be exposed to excessivê shock or
vibration.
4) Take care not to allow water or any othêr liquids from entering lhe machine head and control unit,
and to keep metal waste and other conductive materials away ÍÍom the sewing machine.
5) When the powêr line is afÍected by surge voltages (noise), the stitch pattem may shift or
malÍunctioning may occur in the sewing machine.
6) Similar efÍects may occur when the sewing machine is operated in the vicinity oÍ any equipment
which generates high noise lêvels (such as a high-Írequency welder). Keep the machine as far
away Írom such equipment is possible and use a separate power line to supply power to Ít.
7) Using a radio orTV sêt near the sewing machlne may cause noise interferencê in the reception
of radio or TV broadcests. ln cases like this, use a diÍÍerent power supply or place the radio or
TV set at a distance Írom the sewing machine.

tNÃ;l
Since PROM control box is available as the optional accessory, it is possible to úllize cunent ROM
cassettes which have been used with the conventional electronic sewing machine.

Data oÍ PROM Cassette

Max. numbêr
Kind oÍ Max, number Max. number Kind oí
ROM
Qlv oÍ stilches
oÍ stitches Min. pitch
oÍ patterns cassette
per pattern
,l '1000 1000 0.2 mm 10

1 2000 2000 0.2 mm 10

2732 PLK-ROM
4000 4000 0.2 mm 10 PLK Series
'I 2000 2000 0.2 mm 10
27324
4000 4000 0.2 mm 10

'16 PLK.A-ROM
1 8000 8000 0.1 mm
PLK-A Series
 Contents

L Unpacking and Check oÍ Conslruction

í.1 Caúions at Unpacking
1.2 Check of Construction
2. Construction
3. Features
4. SpeciÍicetions
4.1 GeneralSpeciÍications
4.2 Replacement Parts for Light and Heavy Fabrics . . .
5. lnstallatlon
5.Í lnsralling the Table
5.2 lnstalling the Machine Head (see Fig. 5.3 and 5.4)
5.3 Connection oÍ Cables
5.4 lnstalling the Control Box
5.5 Work Lamp Leads
5.6 Power Cable Connection
5.7 Changing the Direction oÍ the Motor Rotation
5.8 lnstalling the Work Holder Pedal . . . . .
6. Checkpoinis Íor Operation
7. Handling the Sewing Machine Head
7.1 Lubrication
7.2 lnstallation oÍ Needle (see Fig. 7.8)
7.3 Threading the Needle Thread
7.4 Winding the Bobbin Thread
7.5 lnsítalling the Bobbin . . . .
7.6 lnstalling the Bobbin Case
7.7 Removing the lnner Hook
7.8 Thread Tension
7.9 Lubícetion with Silicone Oil
7.1o Adiusting the Presser Foot
7.'11 Replacement oÍ the work Holder
7.12 Replacement oÍ the Feed Plate
7. 13 Position of the Work Holder and Dimensions
8. Adiustment and Maintenance
8.1 Ad,usting the Bobbin Winder
8.2 Adiusling the Needle Position
8.3 Adiusting the Timing between Driver Motion and lnner Hook Motion
8.4 Adiuíing the Thread Guide (above Hook) (seê Fig. 8.9)
8.5 Height Adjustment oÍ Work Holder .
8.6 Adiusting lhe ]lming oÍ lhe Presser Foot Motion (Except PLK-Ao5PF)
8.7 Adjusting the Veítical SÍoke oÍ the Presser Foot (Except PLK-Ao5PF)
8.8 Adjusting the Lift oÍ Presser Foot at Stitching Stop
8.9 Adjusting the Wiper .
8.1O Adiusting the Home Position
8.11 Adiusting the X-Y Table
8.í2 Ad,usting the Synchronizer
8.13 Adiusting the Thread Trimmer . . .
8.14 Adiusting the Trimmed Thread Tail Lengith
8.15 Adjusting the Thread Release (l-ension Disc Pressure) . . . .
8.16 Adjusting the Stroke oÍ Take-up Spring
8.17 Adjusting the L|M|-STOP Z Motor Belt Tension
8.í8 Sewing Machine DÍive Motor
Troubleshooting (Sewing Machine Mechanism)
 1. Unpacking and Check oÍ ConstÍuctaon
1.1 Caulions at Unpacking
(1) CaÍryiÍrg the mâchine head
1) Since the machine head is very heavy, it must be carried by at least by 2 persons.
2) ln order to pr€vent unexpected deÍorms or damage, do not to hold such vulneÍable sections as
the synchronizer, slide plate, work holder, belt coveÍ, etc. OtheÍwise, it may cause accidents
by Íalling, etc.
3) Fig. 1.1 shows the posture and points to be held when the machine head is canied.

Table
Synchronizer

Slide plate
It

Work holder

Fig. 1.í Fig. 1.2

(2) CaÍrying the table

'Í) A minimum oÍ 2 persons should attend to carry the table.
2) Pleese note that the center of gravity is located at the side where the control panel is mounted.
3) Lever is provided on the caster oÍ leg. lÍ the lever is tumed down, the motion oÍ wheel is
arested. Release this stop mechanlsm when the table is moved.
4) Fig. 1.2 shows the positions to be suppoÍted when the table is held up. Be surê to support the
edges oÍ top plate as shown by lhe sketch.

1.2 Check oÍ ConstÍuction

The standard construction oÍ the sewing machine that you have purch.rsed Íollows that noted in the
parts catalog. Refer to the parts câtalog ÍoÍ optional parts, and purchase as necessary.

2. Construction
The PLK-A compact elec'tronic sewing machine is constructed of the followang parts.
PLK-A0804F/A1006 PLK.AOSPF
Head rest Mâchino head
Cotton stand
Table
--
)'r-
.::4.- Control box
Drawer :1 --/
UMLSTOP Z motor
-
C.anltoller
--.-
Stend

Casteí I
,p í,"u G
ê
| , Trm ,
\\ Turn down: Iock 'l) Podal
- c
STAFT switah (Red) Work holder slvilcà (Black)
BX2. r gJz.2

1
3. Features
(1) Valuablê contribution to incÍeasing productivity
. High-speed sewing
Use oÍ the latest control technology has resulted in a 50% increas€ in sewing speeds and a
doubling oÍ the fabric Íeed rate (compared with the peÍformanc€ oÍ past modob by MitsubishD.
. Adoption of large-sized shunb hook
The adoption oÍ a large-sized shrrttle hook (1,8 times larger than the size Íeatured in past
models by MitsubishD makês it possible to drastically reduce the Írequency with which the
bobbin thread is replaced and it enhances the work emciency as well.
. Widê variety oÍ stitches and pattems
Up to 150 pattems featuring the data Íor 8,000 stitches per pattem can be stored on a single
floppy disk to meet the requirements oÍ fancy stitching or embÍoidery involving large numbers
oÍ stitches.
- Easy adaptability to automatic machine
Extemal inteÍÍace Íunctions Íor use as an application machine or special-puÍpos€ machine are
optionally provided.
(2) Less dependency on skills or tÍaining requiÍêd
. Simple inpú and operation thanks to interactive system
The liquid crystal display (LCD) vastly simpliÍies the pÍeparation oÍ the sewing pattems and the
preparatioÍrs madê Íor operation, and it also displays opeÍating eÍrors in the form oÍ messages.
The teaching playback type of inpú makês it possibls to create s€vving pattems which match
the clamp Írame.
. Easy maintenance
Thê íull line-up of troubleshooting functions make the pinpointing of trouble and 'rts display on
the LCD an easy tÉrsk.
. Adding/subtracting counters provided as a standard Íeature
The subtracting counter uses a buzzer to sound the time at which the bobbing thread should
bê replaced while the adding counter makes it possible to veÍiíy the oúpú.
(3) Eíhêtically pleasing seams and stitchiÍrg
. By bringing the rêsolúion oÍ the fabric Íeêd mechanism accurãtêly dorm to a 0.1 mm pitch, it
is now possible to sêw both smoothly and precisely.
. Maximum stitch length oÍ 12,7 mm (Maximum sewing spêed oÍ 4 mÍn/2,ooo spm)
The variable stitch length accommodates eveÍything Írom stitches wheÍe a delicate touch is
required such as in embroidery to large-pitch sewing oÍ such aÍticles as container bags.
. Home position Íetum function
As the stitching oÍ one pattem is completed, the work holder rêtums to the home position so
that there is no accumulation oÍ mechanical displacement.
. Since the sewing machine drive motor is controlled with PWN (pulse width modulation), stable
sewing machine Íevolúions are obtained.
(4) Abundent optional Íunctions are provided
(DGompressor (Model: MP-AI&AU) - Spacs saving as it is storsd in tàe table.
@Aií driven typê work holder (MP-Â@AO) - Íhê standaÍd work holdeÍ is â solênoid ddvân typê, bú this can
easily bê convoíed to thê air drivên type.
OÀr driwn typê 2-íep clamp - The lsft and right clamp can bs oporated s€paralely.
(MP-ÁO&K2, MP-A1$K2)
(DAÍ drivên type label clamp Handy roí sêwing labels and badges.
(R6vorsô axis type, Model: MP-A&AH) (Ihe compressor is nêcêss&y.)
OEectÍomag neüc díiven labsl damp Handy roí sêwing labels and badges.
(Rovsrsê 6xis type, Modoli MP+O&OH, MP- (Compíessor nol necêssary due to fulty êloclÍic syslem)
AlGDH)
@ROM unit (Model: MP-AI7-BU) Íhe PROM cass€ttes used in ths conventional êlêctíonic sêwing
machines (PLK-Imô, etc.) can bs used.
@YO unit: (Modol: MP-Aí7-|O) This is ân inteíâêo unit to bo used whên linking various
electronic sêwing machine pêripheral equipment to thê system.

2-
4. SpeciÍicataons
4.í General Specilications
(1) Speciíications oÍ mêchanisms
Type oÍ stitching : Single-needle lockstitch
Needle baÍ stroke : 41 .2 mm
Take-up lever stroke: 68 mm
Needle : DP x 17 #18 (standaÍd)
wiper : Lengthwise thread wiping drive (with wiper release switch)
Work holder lift : 22 mm (max.), slÍoke 20 (mm)
Presser Íoot lift : 6 to 12 mm
Presser foot stroke : PLK-41 006/40804F: 0, 4 to l0 mm (4 mm at Íactory shipment)
PLK-Ao5PF :4mm,0mm (Option: 7 mm, 0 mm)
Hook : Large-sized shuttle hook
Bobbin case : With slip pretention spring
Bobbin : Aluminum bobbin Íor large-sized hook
Thread tÍimmer : Combination of Íixed kniÍe and movable knifê (plane scissoíng)
Lubricetion system : Manual oiling and replenishment with oil braid Oank type)
Oil usêd : White spindle oil No.2
Sewing area : PLK-A'1006 : X (left/right) 100 mm Y (ÍorwaÍd/backward) 60 mm
PLK-A0804F: X (lewright) 80 mm Y (Íorward/backward) 40 mm
PLK-AosPF : x (lefvright) 50 mm Y (ÍoMard/backward) 40 mm
Dimensions : PLK-41006/Ao8o4F: W xLxH = 1200 x 565 x 1140
PLK-A0SPF: W x L x H = 1000 x 545 x 1í40
Weight : PLK-Aí 006/40804F: í 50 kg (l-otal weigho
PLK-Ao5PF: 140 kg Ootal weight)
(2) ReÍer to the instÍuction manual control unit section íor the speciÍications on the control unit and
teaching.
(3) LIM|-STOP Z motoÍ speciÍications
i/todel CEZ@E cBz4ü2E CYZ@E
Output lW 400 4@ «)0
Phases Single phase 3 phase 3 phase
Polês 2 2 2

Daive
Voltage M 110 2m 2âlwl415
molor Fíequency (Hz) 50 60 50 60 50 60
Full-load cuííent (A) 5.8 5.6 2.2 2.O 1.911.311.2 '1.711.111.O

Full-load speed (s/min)) 2,870 3.470 2pN 3,500 2,860 3.440

Type approval Obtained
Oulch Oútput lorque (kgtm) 0.13 0.11 0.13 0.11 0.13 0.11

4.2 Replâcement Parts Íor Light and Heavy Fabrics

Table 4.3
SpedficaüoÍl FoÍ lighr hbÍic Foí modiumrrcatay ÍabÍb FoÍ he-ar4y hb{ic
t{8rne oÍ part (Sandard)
Thrêad tension Íegulator For DB standard Foí DB standaíd Foí heavy fabric
MF10E0210 irFr0E0210 M F82E0210
Needlê plate

wJ].-t Needle hole

diametêí )
o1.6
MSOSA0r 01 MS03A110r
a2.6
M30342101

Presser íoot
a3.5 o4.5 64.5
Outêr
(lnneí dia.: 02 0) (lnner dia. o3.0) (lnner dia.: 63.0)
( ) t\^/3041256 lvlV3OA0256 tÍÍ\&)40256

Large-sized MS1740120 MS17AO120 MS1741120

hner hook
Slandard-sized MS0140120 MSo140120 MSO1A1120
Hook retainer Standard MSo1A06Í6 Standard MS1Aml6 Foí heaw íabric MS0141616
Foí laíge MS1740125 MS 174O125 MS17AO12s
Bobbin case
Foí standard MS09E0125 MSO9E0Í 25 MSO9E0125
For large MS1740123 MS17AO 123 MS1740123
Bobbin
Foí standard MSOgAl 123 MSOgA1123 MS09A1 123
Note: Parts Íor light tabriG and heâvy labÍics âre optional
5. lnstallation
5.í lnstalling the Table
(l) Casters can be locked by pressing dorrn the lever of êach caster. To mo\re the sewing machine,
release the lock Írom each caster, by liÍting the lever.
(2) The seu/ing machine should be placed on flat and rigid flooÍ.
(3) The sewing machine can be operated in a standing as well as sitting posture.
Since the tablê has been Íactory-adiusted Íor sitting work, change the table height when th€ sewing
machine is operated in a standing posture as Íollows:
p.o í ÊFú, bofis lÚí
cond box hãrEing
HÍ|9.

SEd ChamrgÍed surÍacê

8 xnge 0A)

Câat6t
I fi

Fig. 5.Í Fig. 5.2

1) Remove each threê left and right stand clamping screws. (See Fig. 5.1)
2) Lift the table and secure it in position with the stand clamping screws.
Notes
'1. Table height should be changed before the machine head is installed.
2. tÍ table height must be changed efter the machine head has been installed,
dismount the head and then adiust (Íor saÍety).
(4) Put each one rubber ped into six holes in the table.
(5) Pú each one hinge (A) into two recesses in the table and securê it with bolt and nú.
+ Each hinge (A) should be placed with its chamÍered suÍface Íaced up, as shown in Fig. 5.2.

5.2 lnstalling the Machinê Head (see Fig. 5.3 and 5.4)
(1) lnseÍt the head rest inlo the conesponding holes in the table.
(2) Atlach two hinges (B) to the unpacked machine head.
(3) Pú the hêad on rhe tâble so that it rests on the six rubber pads and two hinges.
(4) Raise the heed to rest it veÍtically and pass the cords and air tubes through thê holes in the table.
(5) lnstall the oil pan as shown in Fig. 5.4 and drive four staples to secuÍe the oil pan in position.
(6) lnstall the V betts to the machine pulley end the motor pulley and retum the head to hoízontal
position.
(7) Raise the sewing machine to ns normal state. The bett cover must be remo/ed when the head is
titted or the pulley is rotaled by hand. lnstall the belt cover after the standard adjustments are
completed.
(8)lnstall the belt cover (large) to the machine head with screws.
(9)lnstall the belt cover (small) to the table with screws.
(10) InseÍt the vinyl hose intothe oil pan, and insert the other end into the oil bottle. ReÍer to the lower
diagram to install the oil pan onto the leg.
(í1) Assemble the cotton stand, and fx to lhe lop with washers and nús.
Belt cover (large) V belt Pulley
To oil pan

? Y
Hosê
§
§ Oil botüe Hexagonal bolt
Holdêr Rrôbeí spacer
Bêlt covêí (small)
Bubbeí pad lnstallation hole
Stand
Hinge (B)
Hinge (A) or pan Phin washer
SpÍirE washer
Hexagonal nut
CoÍds Hôlê
Fig. 5.3 Fig. 5.4

-4
5,3 Connection oÍ Cables
(1) Pass the connection cable Íor the sewing
Lu
machine head through the holes and
then connect with the relevant leads
(those with the sâme alphabet character) Control box Câble @
on the control box. (ReÍer to Fig. 5.3, (+pin wiih
5.5)
(2) Connect the K display lêad O Írom the
lsâd O
control box to lead with 3-pin connector
@ Írom the sewing machine drive motor.
(ReÍer to Fig. 5.5)
(3) Connect the L display lead Írom the cabte o (12-Pin)

control box to lead with the 2-pin

L display leed
connector @ Írom the sewing machine Foot switch Sêwing machin6
Lead with 2-pin dÍive motoí
drive motor. connactor (D
(4) Connect the cable O (12-pin) from the
control box and the lead (4-pin with male Fig. 5.5
connector) to the power supply unit.
(5) Connect the sewing machine drive motor
cable@ between the power supply unit Table
and sewing machine drive motor.
Lead clamp
(6) Connect the connection cable Ôto the 4-
pin connector on the power supply unit
and 'Switch input' display connector on Screwdriver
the control box.
(4 Connect the Íoot switch to the control
Fig. 5.6
box's 4-pin connector.
(8) Secure the leads in position with lead clamps so that they do come into contact with the belt. The
cord band oÍ lead clamp can be Íeleased by levering it with screwdriver as shown in Fig. 5.7.

Note
Two types of ,unction cords arê used for connection ol the control box to stepping motoÃi
(one is Íor X-axis stepping motor, and other is Íor Y-axis stepping motoÍ). Since the X-axis
cable may not be used for connection oÍ Y-axis stepping motor, and vice versa, though the
connectorsi of both iunction cords are oÍ the same type, identify each cable beÍore the
connêction.

Nylon holdeí
5.4 lnstalling lhe ContÍol panel
Wood scrêw
(1) The control panel can be placed wherever Stand
wasners ir)
operation the switches is easy. Use the enclosed Coíneí fleain
nylon holder to fix the control panel. Clipthe nylon
holdeÍ to the bottom ofthe control panel in two
places. Remove the sheet on the adhesive tape
t
on the back oÍ the nylon holdêr, and stick to the Rubbêr cushion Adhesive tapê
top plate. Remove all dirt and oil on the top Adhesive lape
plate beÍore Íixing the control panel. Fig. 5.7
The control panel can be Íixed more securely when
Íixêd with the enclosed wood screw (3.í x 16) and ContÍol bor cord
washer.
(ReÍer ro Fig. 5.7)
(2) Stick the enclosed rubber cushion onto the table
where the corner of the control box will come into
contact. (Refer to Fig. 5.7) C.ontrol switch panel
Ohe rubber cushion backing is adhesive tape. Conneclor
Real off the label beÍore use.)
Square h
(3) Fit and lock the connector o, the contÍol box cord
into the connector marked'control panel' at the
rear oÍ the control panel. (ReÍer to Fig. 5.8) Fig.5.8 Table

-5-
5.5 Work Lâmp Leâds
(1) When the work lamp (6V15-20W) is epplied, us€
the connecting leads provided at the Íront part oÍ lnsulation Phasê Í€v!Íging
the motor. tape plug

Remove the protecting cover, make the connection Lamp lêâds

and wrap it with insulation tape.
(ReÍer to Fig. 5.9)

Caution
UMI.STOP
Voltage of lemp is only 6V bú the ground Z motor
voltege is nearÍy aboú 10OV. Plêase make
sure to tum off the power bêÍore connec,ting
Fig.5.9
the leads.

(2) When the lamp is not used, the lamp leads must
be insulated as shown by the sketch. lÍ e lnsulation t8p€
shortcircuit occurs, the coil oÍ motor will bum down. Cul stÍiped
(ReÍer to Fig. 5.10) lead
Aboul 10 mm
(oÍ ove0
Caulion l,âmp lêads lâmp lêads
tt is strictly prohibited to connect the work
Iamp and a heating device such as the Íeet
warmer in parallel because it may cause Fig. 5.10 Work lamp lead
overheating due to overload.

5.6PoweÍ Câble Connection

The por ,er supply capecity should bê large enough ÍoÍ the motor rating and the p(n,lrer cable should
be selected with sufricient allowance to the power source requirement.
(1) When a threêphasê motor is used, connêct the po,eÍ supply in cúnect phase sequence as
follo\rc:
'U' phese ....... Red lead
1f phase ....... White lead
'\M phase ....... Black lead
(2) Connect the green lead in the three-phese poweÍ cable to the ground teÍminal. For sdety, do not
Íeil to ground. Be sure to leave the grounding work to a qualified electricien.
(3) When a single-phase motor is used, do not plug the poweÍ cord to e branch sock6t, bú plug to
a wall oúlet.

Notes
1. All leads should be bundled and sec-ured in position so that they cannot come into
contact with the v belt.
2 Securely set the plugs and connectors.
3. Eefore starting connection o, leads, unplug the poyver cable oÍ cord.

b-
5.7 Changing the Oirection oÍ the Motor Botation
lf thê motor oÍ the sewing machine is rotating in the
reverse direction, the Íollowing display appears, and the Direction
machine stops operating. oÍ rotaüon

REVERSE ROTATION )
When this display has appeared, normal rotâtion is
restored by turning the phase-reveÍsing plug through 180"
and inserting it. Be sure to insert it properly as Íar as it will
go. (See Fig. 5.11)
Since it takes aboú 2 minúes Íor e single-phase motor to
stop completely after the power has been tumed olf,
Phasê-
remember to switch on the power after it has stopped.
reve,sing Plug
Ohe direction oÍthe single-phese motor rotation will remain
unchanged iÍ the power is turned on while the motor is Fig. 5.11
running.)

Note
Be sure to set the poweÍ s{ritch to the OFF position when disconnec-ting thê poiveÍ plug.

5.8 lnstâlling the Work Holder Pêdal

To use the work holder pedal, remove lhe motor coveÍ and Hook
install the furnished chain to the pedal as shown in Fig.
5.12, using care not to allow its contact with the leads. Chain
Small hook
Chain

Caulion
When the machine head is tilted, the chain muí be
loosêned by unhooking. lÍ the head is titted withoú Pedal

unhooking, the chein may break Írom the tension.

Motoí cover
Fig. 5.12

6. Checkpoints Íor Operation

The maximum stitching speed will difÍer according to the stitching pitch. The maximum speed limit
âúomatically operates according to the stitching pitch as shown in the Íollowing tables. Set the
appropriate speed according to the Íabric.

Nole
The stitching speed is dêteÍmined by the speed dial and the stitch length oÍ thê stitching pattem.
The speed dial value determines the maximum stitching speed, and the stitch length limits the
stitching speed.

-7 -
 < Dial value and maximum stitching speed > < Stitch length and speed limit>
Dial value Max. stitching speed Stilch length Speed limit
9 2000 s/min 0.1 - 4.0 2000 s/min
8 1820 s/min 4.1 - 4.5 18í I s/min
7 1670 s/min 4.6 - 5.0 1666 s/min
6 1zl30 s/min 5.1 - 6.0 1428 s/min
5 1250 s/min 6.1 - 7.5 í250 s/min
.1000
4 s/min 7.6 - 10.0 1000 s/min
80o s/min 10.1 - 1?.7 800 s/min
2 600 s/min 606 s/min
1 400 s/min 400 s/min
0 200 s/min 20o s/min

7. Handling the Sewing Machine Head

Namê oÍ Maior Parts o, Machine Head
PLK-A1 006/40804F

Pretensioner Bobbin winder adjusteÍ

Bobbin windeí
PÍesser loot Thumb nú ten§on Needle Synchíonizer
adjusting scíerY Íegulatoí thrêad

Fac€ platê

I B€lt cover

Swilch coveí

I-IALT ${itch

Oil gauge

Eye guaíd

Presser íool
Cênleí slidê
plate Needle plate
X-Y coveÍ, Íight

Cylinder covêr
X cgver, Íight
Slide plate \MpeÍ Woú holder Fêêd plate

Fig. 7.1

-8-
 PLK-A05PF

Presser Íoot
Thumb nut
Neêdle thread
adjusting screw

Face plate

Switch cover

HALT switch

Eye guard

Píesser Íool
Cênter slide
plale Needle plate

Fig. 7.2

7.1 Lubrication
(1) Supplying lhê lubricant
Some oil must be applied to A to F as indicated by arrows in Fig. 7.3 to 7.5 beÍore starting
operation. (PLK-Ao5PF does not have D and E points.)

PLK-A1006/A0804F PLK-AOsPF Common

c A
BA H
J

Fig. 7.3 Fig. 7.4 Fig. 7.5

BeÍore starting the initial operation after the installation oÍ the sewing machine, pour a suitable
amount oÍ lubricant through holes A, B, C, D, E, F, G, H, J and K (during regular operation,
lubricant is given aúomaticalty and thereÍore not necessary to add).
* Apply lubricant to the reverse surÍace oÍ the presser plate.

(2) Filling the oil tank with lubricant (on aÍm side and bed side)
Fill the oil tank with lubricant until lubricant level reaches the center mark oÍ oil gauge through holes
H and K. Note that too much oil may cause a spill when the head is tilted.
Note
For lubricant, use white spindle oil #2.

o
 Presser plate

K
Oil gauge

Relâiner
Fig. 7.6 Fig. 7.7

(3) Supplying thê lubricant to the X-Y table

Remove the X covers (left and right) and Íeed plate, shoi/n inFig.7.7, and apply sêveral drops of
oil to the retainer once a month.

({) Ol disposâl
Oil is discharged ÍÍom the drain pipe and collected in the oil bonb. Oil must be dbposêd of
periodically before the pot is filled tully. (See Fig. 5.3, s.4)

7.2 lnsiallâtion oí needle (see Fig. 7.8)

(1) BeÍore installing and removing the needle, tum ofÍ the power Íor saÍety.
(2) lnsert the needle into the needle socket unit it stops et the bottom of neêdle socket.
(3) With the neêdle prime groove tumed to the front, tighten the needle set screlv to secure the needle.
(4) For better stitching, though it depends on stitching conditions, it is recommended to set the needle
tumed about 1e in the affow direction.
FLrlly insôrt tho needle, turn the Neêdle not íully PÍimê gíoove Íacing in
p.ime groovo io the íront and inseíted. wíong direction.
tighten the sêt screw.

Gap 7E

LJ X X
V

Fig. 7.8

7.3 Threading the Needle Thread

The needle thread should be threaded, as shown in Fig. 7.1 ,

7.2 and 7.9 and o,tend about 4 cm from the needle.

Needle thíead
@ Thr€ad guide
@ Takê-up spdng

O Tension discs

@ Threád gutdc

Fig. 7.9

- 10 -
7.4 Winding the Bobbin Thread
(1) Pass the thread coming Írom the spool holder Bobbin winder
reducê To incíease adjusleí
base as shown by Fig. 7.10 and wrap the end
oÍ threed around the bobbin several times in the
To

ThÍead guidê
c)
|
direction of arrow a. o Spool holdeí
(2) Push the adiust lever in the direction of arrow b.
(3) Lower the work holder using the work holder t
b
switch.
(4) Setting thê bobbin winder switch on the control
panel to the ON posnion (LED lights) loweÍs the
presser Íoot and allows the sewing machine to
i-- Adjust lever

enter the bobbin winder mode. Fig.7.1o

(5) Step on the start switch.
While the staít switch is pressed down, the sewing machine will opeÍáe et a speed oÍ
approximately 600 s/min.
(6) Upon completion of the tread winding, press the bobbin winder key again. Cl-his tums the LED ofÍ.)
(7) When polyester and nylon threads are wound, reduce especially the thread tension by adiusting
thê pressure applied on the bobbin winder adiuster plate.
(8) lf the thread is wound on one side, turn the windíng amount oÍ the thread guide on the top cover
to the minimum side.
(9) To wind the bobbin thread during stitching, the bobbin will be aúomatically wound with steps (1)
and (2), and will stop aúomatically when completed.
Notê
When the thread is wound on the bobbin, the needle thread must be separated Írom the needle.

7.5 lnstalling the Bobbin

(1) Put the bobbin @ into the bobbin case c
Threed ouidê
(2) Pú the thread @ into the slit @ and lead it groove (9 and or bobb;n câsê
hole
B
D
7.6 lnsialling the Bobbin Case E
(1) Set the needle bar to its highest position and open the Fig. 7.1í
bonom cover. (See Fig.7.12.)
(2) Open the bobbin case latch @ tutty anO Íit it securely inlo
the inner hook. F
Note
The thread ênd should be extended aboú 2.5 cm Írom the
square hole in the bobbin case.
Fig. 7.12
7.7 Removing lhe lnner Hook
The inner hook can be removed by moving the hook clamp in the
direction of arrow to horizontal position, as shown in Fig. 7.13.

Hook damp

CylindeÍ cover
Fig.7.13

- 1í -
7.8 ThÍead Tension
When the needle thread tension is well balanced with the bobbin thrêad tension, the needle thread is
intêrlocked with lhe bobbin thread atong the center line of fabric layers as shown in Fi9,7,14.

@@@
Íonsion adiusüng

o X X
Ío incÍeâso

Balanc€d needle lhÍead Tight needle thread Loosê needle thÍead To íeduce
tension and bobbin tension, oÍ loose tension, oí tight
lhread tension bobbin thíead tênsion bobbin th.ead tension Bobbin çâsê

Fig. 7.14 Fig.7.15

(í) Bobbin threâd tension
The bobbin thread tension can be adiustêd by tuming the Tension adjusting
thread tension adiusting screw. The tension is increased by thumb nut
turning the scÍe\{, clockwise and reduced by tuming it
counterclockwise. (Fig. 7.í5) To incÍeasê
To reduce
(2) Neêdle threâd tension
The needle thread tension is adiusted in reference to the
bobbin thread tension. To adjust, turn the tension regulating Fig.7.Í6
thumb nú in Fig.7.16.
Notê
Excessive tension may resutt in puckering or a broken Needle thíead
thread.
Thread guide
with Íett aíoa
Fig. 7.17
7.9 Lubrication with Silicone Oil Unk
Bell crank

When applying silicone oil to the needle thread, mount the thread Steppêd scÍew
B
guidê with the Íelt area onto the bottom paÍt oÍ the face plate, es A
shown in Fig.7.17, and supply the oil to the felt area.

7.10 Adiustiqg lhe PresseÍ Foot

(1) Check that the needle passes through the center oÍ the n íod

presser Íoot hole.

(2) Adiusting lhê veÍtical strokê oÍ the presseÍ Íoot
I
1) ln the PLK-A10O6/40804F, fix the upper feed lifting crank Prgsser Íod tG-
shown in Fig. 8. í 1 so that the veÍtical stroke of the bell sêl scíêw tE
crank (reÍer to Fig. 7.18) is parallel with the presser rod PaessêÍ Íoot
when the sewing machine is manually set et the Up sel screw
position (maximum balance position). (Ihe eccentric Íing
must be set properly at this time.) Fig.7.í8 PLK-A1006/40804F
2) Fix the presser rod set screw or presser foot set screw so
that if rhe sewing cloth is inserted and thê pulley is
Presseí foot set scres.
manually rotated the clearance between the bottom of
the pÍessêr foot and the top oÍ thê sewing cloth is 0 to
0.5 mm whên the prêsseÍ foot is at the lowest point. Prêsser íoot
(ReÍer to Fig. 7.19) Adiust the direction oÍ the presser
rod so that the needle passes through the center of the
presser foot hole. (Refer to Fig. 7.18) S€wing cloth 0.-O.5mm
Fig.7.19

-12-
 3) The standard height oÍ the presser Íoot is where there is
a clearance oÍ 0 to 0.5 mm between the bottom and the
top oÍ the sewing cloth as noted above. A smaller
clearance (lower presser Íoot) will help to avoid stitch
skipping. A slight sound may be heard if the presser Íoot
PÍêsser adjusting
is pressêd against the sewing cloth. The needle thread Sub-adjusiing
sçÍew
tension will decrease or the cloth may calch on the
presser Íoot causing miíakes in the pattern iÍ sewing is Approx. 3oÍnm .
Appío(. 2omm
caÍried cú Íor long with a small clearance. When
lowering the presser Íoot, make sure it is the minimum Bolt
Thumb screw
required distance. when using the presser foot withoú o
pressing down on the sewing cloth, iÍ the presser rod is
set higher and the presser Íoot is adjusted only with the
position where it is installed on the presser rod when the
cloth thickness changes, operations will be easier.
(3) The vertical movement amount oÍ the presser íoot is set at 4 Fig. 7.20 PLK.Aí 006/A0804F
mm at the Íactory. To increase the vertical movement
Píesser adjustrnent
amount in the PLK-41006/40804F models, loosen the bolt
shown in Fig.7.2O, lift it up and then Íix. There will be a Appíox. 28m
veÍtical movement amount o, approximately í0 mm at the
highest position. FoÍ the PLK-Ao5PF, the presser foot Thumb nut
veÍtical movêment emount is set at 4 mm. To increase the
vertical movement amount, replâce the optional leveÍ (part o
code: MA05A0950), to allow a vertical movement amount oÍ
7 mm. (Use oÍ the wiper will not be possible.) To replace
the optional lever, rêmove the slepped screw. Remove the Fig. 7.21 PLK-AO5PF
lever and presser foot when the presser Íoot is not to be
used. (ReÍer to Fig. 7.22)
(4) To adjust the presser foot pressing pressurê, loosên the Stepped scíew
thumb nut shown in Figs. 7.2O and 7.21. Turning the
presser adjustment screw clockwise will incÍease the
pressurê, and counterclockwise will decrease the pressure.
The standard position is shown on the right. The sub- Leveí Presseí Íod
edjusítment screw does not usually require âdiustment. set sêíew
Presser rod II
Nole o
The height oÍ the presser Íoot must be adiusted when
the thickness oÍ the sewing cloth changes. Fig. 7.22 PLK.AO5PF

WoÍk holdêÍ
7.1í Replacemênt oÍ the WoÍt HoldeÍ
ins{allaüon scÍew
Food plate
(1) When replecing the work holder, Íemovê the work Posiüoning plats installaüon scÍew
holder instellation screw shown in Fig. 7.23.
(2) Do nol loosen the positioning plate. Use the
positioning plate as a reference when replacing the
Feed plate Positionlng plate
work holder to install it to its original position.

Fig' 7'a
7.12 Replâcemênt oÍ the Fêêd Plate
(1) When replacing the Íeed plate, remove the feêd plate set scrêw shourn in Fig. 7.23 and then
replacê.
@ Do not loosen the positioning plAe. Use thê positioning plate as a reference when Íeplecing the
Íeed plate to install it to its original position.

- 13 -
7.13 Position oí lhe WoÍk HoldêÍ and Dimensions
The relation oÍ the work holder and home position is shown in Fig. 7.24 and Table 7.1

Table 7.1
Positioning Woík holdeÍ
Work holdeí plate installaüon screw PLK-A1006 PLK-AO8O4F PLK-AO5PF
'100 80 50
!áH B 118 100 70
138 120 90
(,
D 60 40 40
E 72 GJ 63
F 12.5 16.7 16.7
94.5 89.7 89.7

Fig. 7.24
Shaft
P Bobbin
8. Adjustment and Maintenance ó
b
8.1 Adiusting the Bobbin Winder
eo @
a
(Í) Adjusring the winding volume
To reduce the winding volume, first loosen screw @ and @
move the adiust lever toward the bobbin; conversely, to usl leveí
increase the volume, move it in the opposite diÍection.
The adiust lever is set so that it will return in the direction oÍ Fig.8.í
arrow 'a' with the thÍead wound up to 80% oÍ its Íull volume
on the bobbin.
(2) Adiusling thê turn ing oÍ ihe bobbin
Loosen screws and @ of the bobbin winder completely, mount a bobbin on which thread has
been appropriately wound onto the shaÍt, and push the adiust lever in the direction of anow 'b'.
Nelt, move the bobbin w'nder com pletely in the direction oÍ arrow 'D'. Once resistance is Íelt,
tighten up screws @ and D to Íinalize the positioníng operation.

8.2 Adiusting the Needle Position

(1) Lower the presser foot.
(2) Tum the pulley to position the needle bar to
its lowest position.
(3) Remove the rubber plug Íro m the Íace
plate e) and loosen the set scÍew of nêedle
Face plale
bâr clamp.
(4) Move the needle bar up and down to sá the
timing mark @ on tne bar against the bottom
end oÍ metal and lock the bar at this position
using the needle bar connecti ng stud set screw. tleêdls bar
(Set the mark against the bottom oÍ metal connocting stud
when DP x 5 type is used.) s€t scígw Ne€dlê baÍ mêtal
* There are 4 timing marks which are selected Éô For DPx5 ]]mlng mark on
depending on the type oÍ needle. @
DPxÍ7 flêgdlc bar

Fig.8.2 Fig. 8.3

-14-
8.3 Adjusfing the Timing between Driver Molion end lnneÍ Hook Motion l-bad oÍ
(1) Loosen the driver set screw with an Allen wrench. inner hook Needle centeí
(A hole to insert the wrench ls provided under the cylinder.)
(2) Adiust the driver so rhat the head of inner hook is matched with the
needle_ cenler when the pulley is tumed and thê timing
maÍk @ t @ I i" poirúed againsi the boüom end oÍ needte bar
metal. (See Fig. 8.3)
(3) ln this condition, ad.iust the longitudinal
position oÍ driver so as to create a gap oÍ Fig.8.4
0 mm between the driver and the needle
and Íinally lock the driver set screw.
. Lateral adiustment of driver position 0.05 to 0.1mm
The timing can bê adiusted also, as
the approximating method, by
ô/li
creeting a gap oÍ aboú 3.2 mm
between the hook's head and the
right side of needle when the Íormer,
hook's hêad, retreated to the leÍt limit
as shown by Fig. 8.8.
Rotaüng hook's
sgt acÍêw frn

Fig.8.5
Bed
Xàett tension
adjust scÍêw B
Fig. 8.6
(4) After the head oÍ inner hook was adjusted
as above, move the position oÍ rotating Hed oí imêí hook 3.2@
hook so that the gap of 0.05 to 0.1 mm is 0a
produced between the hêad of inner
hook and the needle. (See Fig. 8.4) The
rotating hook can be moved by turning
the eccentric pin with a minus (-) dÍiver Itook clamp
afteÍ the Íotating hook's set screw was
líole Íoí
loosened. The rotating hook has e play Driver set scÍew
driv€Í sotting
oÍ approximately 0.5mm in the rotating
direction so turn the set screw to the right Fig. 8.7 Fig. 8.8
end tighten.

8.4 Adjusting thê Thread Guide (ebove Hook) (see Fig. 8.9) Thíead guide Shoulder Thrêad guide
(1) Adiust the thread guide above the hook so that its left sel screw sêt scí6w
and right shoulders are aligned with the needle side
surÍace.
lÍ this adiuslment is improper, threâd trimming may not be
done properly.
(2) Adiust the thread guide so that a gap (standard gap: 0.8 0
Needle
Hook retainer
mm) that permits needle thread to smoothly pass through Threád guide
is made.
Note that a gap too large may cause thread trimming Fig.8.9
Íailure and a gap too small may cause unbalanced thread
tension, uneven length oÍ trimmed nêedle thread and Lever Link
jamming oÍ thread in the hook.
(3) Since the condition oÍ the thread guide surÍaces with
which thread comes into contact lergêly âÍÍects the stitch Woík holder
quality and thread trimmer perÍormance, careÍully check
that the surface condition is smooth enough.
Note: Adiust the position of the thread guide afteÍ adjusting Feed plate Spacer Adjusüng Pl8le
the gap between the inner hook and hook's head. aí work hôldêr
(ractorv-adjusêd: 1&nn)
s.sHeight AdiusrmeÍt oÍ woÍk HoldeÍ
Height-oÍ woíx holder can be adiusted as Íollows. Fig' 8'í0
(1) Prepare a spacer having e thickness oÍ desired height oÍ work holder plus í mm (You can use
anything adequate to the purpose which is found in the shop.).
lnseÍt the spacer between the work holder and the Íeêd plate.
(Example: lÍ you wish to adiust the height to 13 mm, prepere a spacer 14 mm thick.)
(2) Loosen the set screws, move the adjust plate till it contacts the link and retighten the set screws.
There are 2 set screws at both sides.
Please note that the height oÍ work holder (see Fig. 8.7) is adiusted at í8 mm when the machine
is shipped Írom the Íactory.

- 15 -
 (3) When a cloth has the thickness exceeding 8
mm where n is held down with the work nolder,
the adjustmênt at the shipmênt (18 mm) cannot
provide a sufficient holding Íorce. Follow steps
(1) and (2) above to adiust the height et 20 to
2.mm. @ô
(4) Position adiustment of presser solenoid
Loosen the sêt screw oí presser solenoid in Fig. a
8.11, 8.12, 8.13 and adiust the position oÍ
solenoid so that, when the solenoid is o
magnetDed (the plunger is contacting the
solenoid), the presser plate is positioned 0.5 Solenoid set scÍew
mm above the lower limit. Lock the solenoid at
this position.
Fig.8.11 PLK-AO5PF
Upp6í íeed liÍting crank (íight)
Solenoid sel screw (x4) Solenoid set scÍew
PlungoÍ
Solenoid

tE-
Eccêntric Íing
ftessêÍ plate Arm

SciscÍw [llto shdt

Fig.8.t2 PLK-41006/40804F Fig. 8.13

8.6 Adiuíing the Timing oÍthe Presser Foot Motion (Except PLK-Ao5PR
To adjust the veÍtical motion of the presseÍ Íoot, remove the
cover on thê left of the arm, and make the ad,ustment through Upper veͧcal cÍank
the window. (See Fig. 8.14) @

(1) Loosen thê eccentric ring set screw I

(2) Tum the pulley and stop it when the needle bar reaches its
lowest position. The eccentric ring set screw @ will be
positioned at the front (standard position).
E
(3) Loosen the eccentric ring set screw
@. D

\., (4) Secure the eccentric ring @, and tum the pulley slowly to
position ring @. @
(5) The timing is increased when the pulley is tumêd ín the @
CÍank Íod
foíward direction (of arrow D ); conversêly, it is reduced
Fig.8.14
when it is turned in the other direction.
(6) AÍter the adjustment, press down on the eccentric ring @ in the direction oÍ the arrow while
tightening up set screws @ and in that order-
(7) Position and secure the upper veÍtical feed crank using its clemping screw so that the vertical
centêr line oÍ the bell crank is made perellel to the presser Íoot bar when the tekê-up lever is at itrs
highest position.

8.7 Adiusting the Verticâl Stroke o, the Presser Foot (Except PLK-A 05PD
(1) Thê stroke oÍ the pressêr Íoot can be adjusted to zero and within a range from 2 to 10 mm. When
connecting the link and arm using the step screw shown in Fig. 7.18, the stroke range is 4 to 10
mm; when connecting at screw hole A, it is 2 to 5 mm; and when connecting at screw hole B, it is
zero. The stroke is factory-set to 4 mm at the position in Fig. 7.18. To adiust the stroke in each
range, loosen tfie top end bottom adjusting bolE. fÍ cúnnêcting hole A or B is used, the lift
distancê of the inside presser Íoot in the halt status will increase by between 1 and 2 mm. Since
the height of the inside presser Íoot also changes, loosen the presser bar set screw to readiust the
height oÍ the presser bar.

-16-
 (2) Since the amount oÍ noise and vibration incíease in direct proportion to the extent of the veÍtical
sÍoke, it is recommended that the stroke be adiusted to âs low as possible.

8.8 Adiusting thê Lr'n oÍ Prcasêr Foot at Stitching Stop

(í) FoÍ rhê PLK-A10OC/AO804F (See Fig. 8.15)
1) Make sure the adlustmênt oÍ timing, veÍtical stroke and height of presser Íoot duÍing stitching
are standard.
2) Turn up the machine head and loosen the set screw in Fig. 8.1s.
Set scÍew

Set screw

\,
DÍiving aÍm
Botary solenoid

Fig.8.í5 PLK-41 006/40804F Fig. 8.í6 PLK-AO5PF

3) The position oÍ inner presser to which it is lifted when the rotary solenoid is tumed Íully to its
limn, is the highe§ position which the inner presser is lifted when the machine stopped. Ad.iust
the mounting angle oÍ driving arm end lock with the set screw.
(2) For the PLK-Ao5PF (See Fig. 8.í6)
1) Make sure the adjustment oÍ timing, vertical stroke and height oÍ presser Íoot during stitching
are standard.
2) Having the motor cover removed, loosen set screws (4 pcs.) securing the mounting plate of
presser Íoot driving solenoid and turn the solenoid in the aÍrow direction. lf the solênoid is
locked in that position, the height oÍ presser Íoot is raised and, iÍ it is turned and locked in
reverse, the presser foot is lowerêd.

8.9 Adiusting lhe Wip€r

(1) When not using the wiper, turn OFF thê wipêr
switch shown in Fig.8.17.
(2) The wiper drive crank should be Íixed to the lvipeí
switch
rotary solenoid shaft so that it can swing evenly
to the left and the right, as shown in Fig. 8.17. Wipeí drivê
(3) Make sure the drive crank can rotate thÍough its cÍank
entire movable range when the rotery solenoid
Cfivên
is turned by hand with the dÍive crank cÍank
depressêd backwerd. PÍessêÍ íool
(4) Locate and fix the driven crank so that the wiper
point is found at position shown in Fig. 8.18 PLK-A1oO6/40804F
when the wiper is retumed to the start position.
(5) Loosen the wiper set screw end ediust the
wiper height so that the wiper passes about I
mm over the position where the presser foot
stopped.
lMpei dÍive
ae cíank

Wpeí switch Driven cíank

Wipoí sêtting Wpeí Presser Íoot

App,ox. 5 mm Appíox. 1 mm
AppÍox. 5 mm Fig.8.17 PLK.A05PF
Fig. 8.18
-17 -
8.í0 AdiGtlng the Home Position
(Í) The home position is set to the center oÍ the sewing area at the time oÍ shipping,
It can be adiusted within the range shown below.
o PLK.AÍ 006 @ PLK.AOSO4F @ PLK-A05PF
lnlüdly r.t hruâ[y rêt
(Bâd(
(B.d(
!td.) (Bâêr(

Flg. 8.r9 Fig. 8.20 Frg. 8.2í

@ area: Can be adjusted nith the standard Y-home positbn detector disc.
@area: Can be adlusted wilh the etteched Y-home position detec{or disc.
§larea: Can be adlusted with the optional Y-home position detector disc,
(2) PrepaÍation Íor Home PGition AdiuímeÍ
1) Set the switch 2 (SW3) in the control box to'ON'position.
When this switch is not set to 'ON', the efÍective sewing eÍea is reduced by the distarrce of
shifted home position.
Ex.: When the innially set homê position is moved by 20 mm in the X direction, and by 10 mm
in the Y diÍection, the area sheded in Fig. 8.22 to 8.24 is reduced Írom the oÍiginal efÍêctive
sewing area.
o PLK-A1006 @ PLK.AOSO4F o PLK-A05PF

Flg. a.22 Fig. 8.23 Ftg. 8.24

2) Trace the initially set home position and the X and Y lines which cross ãt the desired home
position on a paper. PeÍÍorm home retum opeÍation and place the paper so that the initially set
home position traced.on the paper comes ,ust undeÍ the needle and careÍully s€cure the paper
in that position using adhesive tape.
After that, peÍÍorm the setting oÍ the home position as instructed in the ne{t paragÍaph.

(3) PLK-A1006/40804F Setting oí home position in X direction (See Fig. 8.25, 8.26)
1) Remove the left and right x-Y covers and the X-
cover plate.
2) Afler loosening two detecting plate set screws, the
home position can be shifted either 10 the right or
to the left by the respective travelling oÍ the plate.
3) After the setting, move the X-Y table by hand to
make sure the X home position detecting plate
does not come into contact with the synchronizer,
bed and the like.
Dêtêc,ting plate
4) PerÍorm home position return operation to check
damping screw
that the x-Y table stops at the nêwly set home
Oetesting
position. plato
Y-axis fixed
(4) PLK-AO5PF Setting oÍ home position in X diÍection td@ Synchronizer
(See Fig. a.27, A.2al X-axis fixsd
Íacê
1) Remove the motor cover.
2) After loosening plate set screws, homê position
can be shifted to the fore by turning the detecting Fig. 8.2s PLK-A1006/A0804F
plate clockwise as viewed Írom the leÍt side oÍ the
sewing machine head.

- 18 -
 3) PeÍÍorm resevhome position Íetum operation
GESEr/HOME) to check that the X-Y table stops X dêtecloí
et the newly set home position. 0arge)

X-home posiüon
(5) Setting oÍ home position in Y direction detecling plats
(See Fig. 8.27, 8.28)
1) Remove the motor cover. Fig.8.26 PLK-A1006/40804F
2) AÍteÍ loosening plate set screws, homê position can be shifted to the Íore by turning the
detecting plate clockwisê as viewed from the left side oÍ the sewing machine head.

VY+ome position
deteqting disc

Deteqling plate
sêt acrew

X detesloÍ (large) DêGcting plata

Y dêtector (sÍnall) s€t scÍew
Fig. 8.27 Fig. 8.28

The PLK-Ao5PF uses a disk type also Íor the Y detecting plate
Note
lnstall the detecting plate so that it does not contact the detector

8.1í Adiusting lhe X-Y table

(1) Adiusting thê position oí X-Y table
1) Tum off the power and Íemove the needle X-Y covers (left and righD and X covers (leÍt and
rigfrt). Then adiust the table so that the movable race end and retainer end strike the stopper
almost at the same time vvhen thê movable race is moved leÍtward and rightward.
(See Fig. 8.29)
2) lÍ the rêtainer stríkes thê stoppêr earlier than thê movable racê, let hit the rêtainer against thê
stopper several times to adiust.
3) Adjust the table in the Y direction in the sâme manner as instructed abovê.
4) When the movable race is moved, the travel oÍ the retaineÍ is equal to the halÍ that oÍ the
movable race. (See Fig. 8.30)
Fletainer

I I

Movable racê
I
I Í I
Â

il
1 @ Stopper
Whên movâbtg racê is locatBd
at thê íight sxtromity

Fig. 8.29 Fig. 8.30

5) When the stitching area is expanded aÍter stÍtching has been done in a relatively small aÍea foÍ
a long time, the movable race may not move smoothly. ln this case, wipe the race with a rag
dampened with oil and move the movablê race by hand to make the movement smooth.

- 19 -
 (2) Adjusting the X-Y lable contect presaure
1) To ad,ust contact pressure oÍ the X-Y teble,
Y-axis fixed Íacq (B)
Y-axis §xed race
e
remove the X-Y covers (lêft and right) shown in damping sc{ew
Fig. 8.31 and the X covers end loosen Íixed Y-axis fixêd râca (Â}
race set screws (X) (2 screws) to such en
ttut
extent that the fixed race (x) may be moved.
2) X-axis contact pressure increases when two
corúect pressurê adiusting screws (X) eÍe Adiu§ing scÍew 0g
tightened. X€xis Íixed Íacê (B)
X-axis fixed race
3) Y-axis contact pressure can be adiusted in the clamging scíe{í
same manner es Íor the x-axis. Adjusting scÍew 00
X-axis fixed
4) Contact pressure should be as light as race (À
possible, and not ceuse arry play.
Fig. 8.31
(3) Adiuíing thê bêA lensiom (X-Y table)
í) To edjust tension of the X-exis belt, remove the
right X-Y cover (sêe Fi$.7.1,7.2), loosen the
nú shown in Fig. 8.32, loosen the four bracket Bíâcket
set screws to such a degree that the bracket Nut
can be moved and then tighten the belt tension
Eblt lension
adjusting screw (X).
adiusting scíew 0q
2) The recommended belt tension is that no slack tl I

occurs when belt is lightly depressed by Íinger. J

After adjusting the timing belt and pulley
engegement, tighten the Íour bracket set
screws. Bíâckêt sêt scíêw

(4) Adiusting the Y-belt lension (X-Y table) Fig. 8.32

1) To adiust tension of lhe Y-axis belt remove the
belt cover and motor cover, loosen the bracket
set screw shown in Fig. 8.33 and tighten the Y bêlt tension
adjusting scíew
belt tension adiusting screw (Y).
2) The recommended belt tension is that no slack
occurs when belt is lightly depressed by Íinger.
B.ad(€i sgt
8.12 Adiustlng thê SynchronlzeÍ sêíew

(Í) Adjuíiíig thê neêdle bar stop (UP) pGition

(See Fig. 8.34)
'l
) Whên stitching is completed, the sewing
machine should stop, the timing maÍk (A) on
the arm being aligned with the timing mark (8) Fig.8.33
on the pulley.
2) lf the timing merks ere miseligned oveÍ 3 mm,
loosen the synchronizer shaft coupling set Sêt sêrew
scÍew and turn the coupling to adiust the
needle bar stop (UP) position. I I

Stopping timing is slow when the coupling is t

tumed clockwise, and advances when turned FI
counterclockwise.
3) lf the nêêdle bar stop is too early, the needle Timing maÍk (A)
threed may leave the needle eye at start oÍ
Iming maÍk (B)
stitching. SynchÍonizer covêÍ
lf the needle stop is slow, the needle stops at a
Fig. 8.34
lower position and the wiper might be caught
by the needle, or the movable kniÍe does not
move since the cam Íollower roller of thread
trimmer cannot enter the cam groove.

20-
 (2) Adiusting lhe position detecling discs Detêcting discs
Atthough the three position dêtecting discs usually
do not require adiustmênt, it is recommended to
meke the tollowing checks.
'l)
Draw oú the synchronizer cover toward the
cable. (See Fig. 8.35)
2) There are three position detecting discs in the
synchronizer. The ÍÍont one (red) is used for
delection oÍ DOWN position, middle one (black)
Cable
Íor detection oÍ UP position, and rear onê (blue)
is for thread release timing. (See Fig. 8.36)
3) Each position dêtecting dlsc nas a matching hote. Fig' 8'35
When any one oÍ position detecting discs is adjusted, make sure that all matching holes ere
exactly alignêd with each other. A scale is provided on the second (black) po§ition detecting
disc. Adiust  mark of Íirst disc (red) at 115' on the scale and A mark oÍ third disc (blue) at 34ry
on the scale.
Red disc disc
Black Blue disc
(Down position) (UPpoGition) Ohrêad release timing)
Mârk
Mark

Graduate
Fi9. 8.36

8.13 Adjusring the Thread TrimmeÍ

(1) Adjust the cam Íollower so that the roller is Íound on Nut
the cam shoulder aboú 1 mm Írom the thread trimmer
cam, as shown in Fig. 8.37. Cam ,otlower
cÍank
(2) DepÍess the cam ÍolloweÍ crank in the direction of Slopper screw
arrow shown in Fig. 8.37 by hând when the needle íed Stoppêí
is lowered to make sure the roller can be engaged Cam gí@ve
and disengaged with the cam groove smoothly. Approx. I mm
(3) The roller engaging and disengaging area should be
within the range where the cam groove is concentric Rolleí
with the arm shaft.
lÍ the roller cânnot be engeged and disengaged
smoothly, check that the Íoller is on the shoulder, Cam groow Díiüng shaft
loosen the nú shown in Fig. 8.37, tighten the stopper ThÍêad lrimmeÍ
screw until it comes into contact with the cam Íollower catn Shouldeí
crank stopper, loosen the stoppeÍ screw by aboú 1/3
turn and thên tighten the nut. Fig' 8'37
(4) To remove the knife assembly, loosen E-type stop ring (ckclip) shown in Fig. 8.38, Íeed plate shown
in Fig. 7.1, 7.2 and Íout slide plete set screws.
The movable and Íixed knives and slide plate can be removed at the same time.
(5) To adiust the movable knúe, loosen the movable kniÍe position adjusting screw on the back oÍ bed
and adiust the kniÍe drive cÍank so that the movable kniÍe point stops 0 to 0.5 mm epaÍt from the
hook retainer when the stnching is stopped, es shown in Fig. 8.38. (See Fig. 8.39),
lÍ the movable kniÍe is located too Íar Írom the needle hole, the thread may not be trimmed
satisÍactorily, or the E-type stop ring strikes the thread guide set screw shown in Fig. 8.9. However,
the movable knife lpceted too close to the needle hole, trimmed needle thread tail might be caught
between the Íüeci*níe and the movable knife.

-21 -
 E-type snap ring
Hook retaineí

t'l
í{§
oÉ
Movable knire

lftirê drive
crank
Nêedle hole

Fixed kniÍê O
0-0.5mm Movable kniÍe position
adjusling screw

Fig. 8.38 Fig. 8.39

8. t4 Adjusting the Trimmed Thread Tail Length

(1) Length oÍ thread tail left on the bobbin after trimming is not adjustable. lf trimmed thread does not
extend longer than aboL,t 22 mm Írom the bobbin case horn (see Fig. 7.11), stitch may skip. lnthis
case, the Íollowing checking and adiustment should be performed.
(2) Since trimmed thread contracts when bobbin thread tension is too large, or when elastic thread is
used, decrease bobbln thread tension and needle thread tension as well. For the same reason,
it is Íecommended to wind thread with smaller tension.
(3) When the clêarance in Fig. 8.40 is more than 0.2 mm, thin thread may be cLú before the movable
knife is actuated.
To prevent this, install the Íixed kniÍe being distant Írom the needle plate hole or remove the spacer
below the needle plate to provide cleaÍance of 0.2 mm or smaller between thê fixed kniÍe and the
needle plate, as shown in Fig. 8.40. care should be taken when the needle plate is installed again
so that it is not lnstalled in wrong direction.
The notch on the reverse of needle plate should be on the same side as the Íixed knife.
(4) Trimmed needle thrêad tail length can be adjusted by tuÍning the pretensioner thumb nú shown
in Fig. 8.41. Thread tail lengrth becomes short when the thumb nú is turned clockwise.

Paêlensionêí

Notch on the íeverse

of needle plate Needle plalê Spacêr

Adjus{ing nut

Max. 0.2 mm
Fixed knire Slidê olâte

Fig. 8.40 Fig.8.41

8.15 Adjusting the Thread Release (fension Disc PressuÍe)

(1) thread release is not properly adjusted, trimmed thread tail length
lÍ
shortens and stitch may skip or needlê thread may leave the
needle at start oÍ sewing.
(2) lÍ the tension discs do not close when the presser foot is lowered,
needle thread tension becomes faint and thread tensions are
unbalanced.
(3) When the thread release is properly adjusted, gap ranging Írom 0.8
mm to 1.0 mm is created when the tension discs open, as shown 0.8 mm to í.0 mm
in Fig. 8.42. X
Fig. 8.42
 (4) The tension discs open when the presser foot
rises (the work holder is at the home position
while the powêr is on, or FEED withoú
stitching), or when threads are trimmed.
(5) Adjusting the tension disc release (opening
degree oÍ tension disc when threads are
tíimmed)
Vúre clamping
Nut A Nut B

Fully turn the Íotary solenoid (small) crank in the

direction indicated by anow in Fig. 8.z13 and +
adiust lhe posilion oÍ the crenk after relêesing
the crank set screw, so that the tension discs cQ
open 0.8 mm to 1.0 mm.
lÍ tension disc opening is not adjustable within
the movable range oÍ the drive crank, loosen
the wire clamping scrêw and adiust the position Fig.8.43
oÍ the wire.

8.16 Adjusting the Stroke oí TakÊup Spring

(1) Loosen the needle thíead tension stud set
screw
(2) Turn the tension regulating thumb
@
nú O cbckwise or counterclockwise to adlust
I to 10 mÍn
the stroke of take-up springr.
The stroke increases when the thumb nú is o
turned clockwise, and decreases when turned @
counterclockwise.

Note r
The stendeÍd stroke oÍ takê-up spring (gap Fig. 8.44
between take-up spring @ and thread guide
I
@) ranges trom mm to 10 mm.

4.17 Adiusting the LlMI-STOP Z MotoÍ Ben Tension

(1) Removê the belt cover.
(2) Loosen two nuts shown below. V+ell
(3) Adjust motor position by the upper nú so that
appropriate tension is given to the bett by the
gravity o, the motor.
After the adiustment, tighten the lower nú.
(See Fig. 8.45) Nut
L|M|-STOP Z motoÍ

Fig. 8.45

8.18 Sewing Machine Drive Motor

Reler to the lnstruction Menual contÍol unit section (4180E206)

23-
Troubleshooting (Sewing Machine mechanism)

Trouble Causê Femedy ReÍerence pege

The thread is not KniÍe blade is damaged, or Replace damaged knife. 8.13(4Xs) P.21
trimmed. worn
Needle stops too early Adjust needle stop 8.12(1) P.20
position.
Fixed kniÍe is not Adjust posnion oÍ Íixed 8.13(5) P.21
positioned properly. kniÍe.
The thread trimming Tum the dip s,witch in the ReÍer to the
prohibition switch is ON. control panel oFF. lnstÍuction
manual (control
unit).
Thê thrêâd comes Tension discs do not open Adiust the needle thread 8.r 5(s) P.23
oú oÍ the needle when thread is Íimmed. release.
before the Íirst
Needle is too thick Íor Replace the needle 7.2 P.10
stitch. thread used.
Ohe tength of
remaining needle Timing of thread tension Adiust the synchronizer. 8.14(4) P.22
thread is shoÍt.) release is too late.
Thê thread take-up spring Decrease the thread take- 8.16 P.23
tension is too high. up spring tension.
Stitch€ are not Bobbin thread tension is Adiust bobbin thread 7.8(1) P.12
interlocked at staÍt too high. tension.
oÍ sewing. Length oÍ trimmed end 1. Adiust pretension discs. 8.14(4) P.2.
thread (needle thread) is 2. Check threading 7.3 P.l0
too shoÍt after thread 3. Check the synchronizer 8.12(2) P.20
trimming. timing oÍ threed lension
release.
4. Adiust the thread take- 8.16 P.23
up spring tension
The needle thread The pÍetension is too weak. Adiust the pretension. 8.14(4) P.22
is too long after
trimming.
The stitching The X-Y table is loose. Adjust the x-Y table. 8.11 P.'Í I
pattern is deviated. Move the X-Y table 8.11(1)
The retainer is in contact P.1e
with the stopper. completely to the lefvright,
Íronvback areas manually.
The presser weight is too The serrúing speed is Rêfer to the
large. decreased. lnslruction
(One kilo more than the manual (control
standard unit is loaded.) unit).
The Íabric is not pressed Modify thê pÍesser. Contact
properly. Mitsubishi Íor
special pressers.
Part of the Íabric contacts ModiÍication oÍ the fabric Contact
the sewing machine. pressing method Mitsubishi Íor
(Especially stifÍ Íebric.) Consider tuming the special pressêrs.
stitching direction 9e or
18e, etc.
CIhê stitching data inpú
mu§ be changed)

-24-
MEMO

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DtNrc ALOG MAÂUNOUCrll TOI(YO 1@ÍEIEX: J24532 CAot! MILCO ÍOXYO
\ivORI§ .T/T , YÁOA.I'II{AIII 5 . TIIGASHI.I(U , AÁGOYA , JÁPÀN

(9304)MEE Printed in Japan SpeciÍications subject to change without notice.