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Mitsubishi PLK-E1008H Technical Manual

Electronic pattern sewing machine
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MITSUBISHI
Industrial Sewing Machine
TECHNICAL MANUAL
MECHANICAL VERSION
Electronic Pattern Sewing Machine
Model PLK-E1008H
A180E534P01

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Summary of Contents for Mitsubishi PLK-E1008H

  • Page 1 MITSUBISHI Industrial Sewing Machine TECHNICAL MANUAL MECHANICAL VERSION Electronic Pattern Sewing Machine Model PLK-E1008H A180E534P01...
  • Page 2 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.
  • Page 3 ENVIRONMENT STANDARD Caution For avoiding the sewing machine from the troubles, please do not operate the sewing machine under the following conditions. 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).

  • Page 4: Table Of Contents

    CONTENTS STRUCTURE OF THE MACHINE ····································································· SPECIFICATION ·································································································· INSTALLATION ··································································································· 3-1. Preparation of the table ····················································································· 3-2. Preparation for the steel stand ········································································· 3-3. Installation of the motor ····················································································· 3-4. Installation of the control box ··········································································· 3-5. Connection of the teaching panel ····································································· 3-6.
  • Page 5 ··············································································· 22 STANDARD ADJUSTMENT 7-1. Adjustment of the shuttle ·················································································· 7-2 Adjustment of the position between the needle and the shuttle ························ 7-3 Adjustment of the needle bar height ······························································· 7-4 Adjustment of the needle-to shuttle clearance ················································· 7-5 Adjustment of the needle-to-driver clearance ··················································· 7-6 Test mode operation ························································································...

  • Page 6: Structure Of The Machine

    1. STRUCTURE OF THE SEWING MACHINE PLK-E1008H electronic pattern sewing machine is constructed with the following main parts. (1)Sewing machine head (2)Thread stand (3)Teaching panel (4)Control Unit (5)Power switch (6)Work holder foot switch (7)Start foot switch (8)Table (9)Air regulation gauge (10)Limi-servo motor (11)Wooden table (12)Emergency stop switch...

  • Page 7: Specification

    2. SPECIFICATION (1) Specification of mechanism Sewing area : X-Direction(left/right) Y-Direction(fore/backward) 100mm 80mm Maximum sewing speed : 700spm Sewing speed : 10 steps variable from 200 to 700 stitch/min 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 Class of needle...

  • Page 8: 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 5 drawing.

  • Page 9: Installation Of The Power Switch

    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. ) with the wood screw (NO. ) underneath the table as shown on the figure.

  • Page 10: Connection Of The Foot Switch

    3-7 Connection of the foot switch Connect the foot switch (NO. ) to the control box (NO. ) The foot switch is enclosed in the accessory box. 3-8 Installation of the oil pan (1) Assemble the oil pan (2) (NO. ) and oil bottle (NO. ), which enclosed accessory box.

  • Page 11: Putting Across The V-Belt

    3-10 Putting across the V-belt (1) Put the V-belt (NO. ) across the sewing machine pulley (NO. ) and the motor pulley (NO. ) with passing it through the slit on the table top. (2) The V-belt (NO. ) is enclosed in the ac-cessory box.

  • Page 12: Installation Of The Belt Cover

    CON A Main motor ON B 押しボタンスイッチ CON C Stepping motor CON E RS-232C(option) CON F Teaching panel CON G I/O signal CON D Output of solenoid CON H Input signal CON I Foot switch 3-12 Installation of the belt cover (1) Attach the belt cover mounting plate (NO.

  • Page 13: Installation Of The Thread Stand

    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. ) in the thread stand hole on the table top. (3) Fix the thread stand (NO. ) firmly from the rear side of the table with tightening the nut (NO.

  • Page 14: Connection Of The Air Tube

    3-14 Connection of the air tube (1) Remove the stepping motor cover. (2) Attach the air pressure regulator assembly (NO. ) underneath the table with the wood screws (NO. ). These are enclosed in the accessory box. (3) The prepared holes are provided for the wood screws on the rear surface of the table. (4) Cut the part of size ø8 air tube (NO.

  • Page 15: Lubrication

    4. LUBRICATION Caution 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. Please use high quality white machining oil.

  • Page 16: Proper Operation

    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.

  • Page 17: Threading The Upper Thread

    5-3 Threading the upper thread Please make sure to turn the power switch OFF before threading the upper thread. Please thread the upper thread with referring to the below figures. 5-4 Winding the bobbin thread Please make sure to pull the upper thread out of the needle before winding the bobbin thread.
  • Page 18 (b) Press the [wind mode key](NO. ). ② (c) Then wind mode window will be appeared. ⑥ Pass through the thread from thread stand as shown on the figure then, wind the thread to the empty bobbin(NO. ) in the arrow mark “A” direction couple times, and insert the bobbin winder.

  • Page 20: Setting The Bobbin

    5-5 Setting the bobbin 5-5-1 Taking out the bobbin As shown below, press the bobbin removal lever (NO. ) found at the right side of the hook to the right. The bobbin case (NO. ) will open, and the bobbin (NO. ) can be removed from the case.

  • Page 21: Proper Sewing

    6. PROPER SEWING 6-1. Operation of the emergency stop switch If an emergency such as a thread breakage, needle breakage and any other emergency is happened during the sewing operation, please hit immediately the emergency stop switch. The sewing machine running is stopped instantly. Before start the sewing operation, please make sure the location of the emergency stop switch and keep it in mind the function and how to use it.

  • Page 22: The Teaching Operation

    6-2. The teaching operation Detail descriptions for pattern input are mentioned in TECHNICAL MANUAL <Operation Panel Section>. As for the input method of PLK-B1008H, it is necessary to operate the peculiarity compared with other PLK machines. Peculiar point is STOP code [USTP] just after TRIM code is required for thermal trimming sequence. There are two ways to put codes in the pattern data (Using Code Data Input method in the Input Mode or Modifying code data method in the Modification mode).

  • Page 23: The Thermal Cutting Operation

    6-4. The thermal trimming operation There are 3 operation switches for thermal trimming operation. Switch changes between Automatic (normal mode) and Manual (test mode). changes the validity of the thread trimmer. Switch changes the validity of the needle thread device to valid (needle/bobbin thread) Switch or invalid (only bobbin thread).

  • Page 24: The Sewing Operation

    6-5. The sewing operation (Refer to the figure on the following page) It is very dangerous to operate the sewing machine without the safety guards(Eye guard, Belt cover, Link cover, Finger guard etc.). Please make sure to always operate the sewing machine with the safety guards. Please do not put unnecessary articles except for the sewing operation on the table top.

  • Page 26: Adjustment Of The Thread Tension

    6-6. Adjustment of the thread tension The thread tension between the upper and bobbin thread should be balanced in the best condition. When the upper thread tension is well balanced with the bobbin thread tension, the both threads are interlocked along the center line of fabric layers as shown on the below figures. Normally weaker bobbin thread tension bring better sewing quality.

  • Page 27: Standard Adjustment

    7. STANDARD ADJUSTMENT Please make sure to turn the power switch OFF before adjust the sewing machine. If the adjustment is required under the power switch is ON, keep the start foot switch away from the foot. Be careful not to be wounded by the needle or the inner hook point. Please make sure to put the safety guards (Eye guard, Belt guard, Link cover and adjustment.

  • Page 28: Adjustment Of The Needle Bar Height

    (3) Remove the cover of the arm top. (4) Loosen screw (NO. ) (5) Loosen screw (NO. ), and adjust so that marker dot (NO. ) engraved on the eccentric cam of the vertical rod is aligned with marker line (NO. ) engraved on the main shaft. (6) Then, tighten screw (NO.

  • Page 29: Adjustment Of The Needle-To Shuttle Clearance

    (NO. ) is 0.25 ~ 0.35 mm. To adjust the needle-to-shuttle clearance, (1) Loosen screw (NO. ). (2) Adjust the clearance by moving shuttle driving shaft bushing (NO. ) to the left and right. (3) After adjustment has been completed, tighten screw (NO. ) firmly. 7-5 Adjustment of the needle-to-driver clearance Correct clearance between the needle (NO.
  • Page 30 The standard for adjusting the clearance between the needle and the blade point of the shuttle Use a standard Schmetz 794-Nm230 needle. (1) Adjust the clearance (NO. ) between the convex section of needle (NO. ) and driver (NO. ) to 0. (2) Align the needle center with the blade point of shuttle (NO.

  • Page 31: Test Mode Operation

    7-6 Test mode operation 7-6-1. Entrance for the test mode operation test mode operation used adjustment of mechanical position (height or stroke) thermal thread trimmer equipment and also for check the position of the sensors of the cylinders. For entrance this mode, (1) Turn the power switch ON.
  • Page 32 7-6-2. Key function in the test mode In the test mode, each key on the teaching panel works to operate the thermal thread trimmer equipment (cylinders or relay) independently. Relationship between the key and the equipment is as below. In the Test mode, Start switch is disabled.
  • Page 33 The heater will heat while pressed. The needle cooler will (Max. 2.5 seconds) output while pressed. Not used Not used Hold down for more than a second, and set the thread trimming mode setting Not used changeover. (The setting is set when a beep is heard.) The heater buzzer is turned ON or OFF.

  • Page 34: Adjustment Of The Presser Foot

    7-7 Adjustment of the presser foot 7-7-1 Adjustment of the driving shaft arm(front) and the presser foot (1) Turn the power switch OFF (2) Remove the side cover and the face cover. (3) Turn the sewing machine pulley by hand and stop the driving shaft arm-rear(NO. ) at its maximum swing position in arrow direction.

  • Page 35: Adjustment Of The Tension Release

    At normal position, the sensor ID(NO. ) is ON and the sensor IE(NO. ) is OFF. At activate position, these sensor will be reversed. Check the sensors by using E-MODE (test mode) 7-8 Adjustment of the tension release When tension close (the tension release plate (NO. ) leaves from the tension disc(NO. ) ), the sensor IC(NO.

  • Page 36: Upper Thread Heat Cut Device

    7-9 Upper thread heat cut device For a secure sewing at the seam beginning, a certain quantity of drawn-forward needle thread is required. The drawn-forward occurs after completion of seam with the clamps still lowered. Function sequence of Upper thread heat-cut procedure The sewing pattern is finished.

  • Page 37: Setting Of The Thickness Detector

    7-9-2 Setting of the thickness detector Place material maximum allowable thickness(10mm) or spacer between the upper and lower clamp (NO. ). Pull down the air cylinder(NO. ). Loosen the setting screw(NO. ). Pull the thickness detector (NO. ) downward until it touches the lower clamp (NO.
  • Page 38 7-9-4 Adjustment of the upper thread heater The upper heater must be an angle of approx. 90°to the thread positioned by the thread wiper. The fully extended heater must have a clearance of approx. 1 mm to the clamped material. The fully extended heater must touch on the thread positioned by the thread wiper with a slight pressure.

  • Page 39: Adjustment Of Lower Thread Cut Heater

    7-10 Adjustment of lower thread cut heater The lower heater is in it’s initial position, when the thread puller(NO. ) is outside the area of needle hole (NO. ). (1) Distance between thread puller(NO. ) and lower heater(NO. ) should be about 6mm. For correction of the lower heater(NO.

  • Page 40: Adjustment Of The Bobbin Winder

    7-11. Adjustment of the bobbin winder The amount of thread has already been adjusted so that thread can be wound round approximately nine-tenths of the bobbin. If the amount is excessive or insufficient, adjust by following method. (1) Loosen the adjusting screw (NO. ) and nut (NO. ). (2) Turn the adjusting screw (NO.

  • Page 41: Adjustment Of The Thread Take Up Spring Tension

    7-13. Adjustment of the Thread take up spring tension The standard stroke of thread take-up spring (NO. ) is 8 to 15 mm. To adjust operating range, (1) Loosen screw (NO. ) (2) Adjust the operating range by moving thread the take-up spring adjusting plate (NO.
  • Page 42 The relation of the hook (bobbin case) position and upper stop plate (balance's uppermost position) is shown below. The upper stop position (balance's uppermost position) is the position where the bobbin case holding spring knob (1) and holding spring release pin (2) are aligned as shown in the figure. (If the bobbin removal lever (3) is pressed to the right in this state, the bobbin case will open.)

  • Page 43: Adjustment Of The Mechanical Home Position

    7-15. Adjustment of the mechanical home position [NOTE] The mechanical home position is fixed at the center of the sewing area when the sewing machine is shipped from the factory. However, it can be moved within the area covered with diagonal lines. Original home position Adjustable area After...

  • Page 44: Shifting The Mechanical Home Position To The X Direction

    [NOTE] If do not cancel the sewing area limit, shifting the mechanical home position make the effective sewing area narrower than the original. (Example) If shift the mechanical home position to the X direction 30mm, the Y direction 20mm without canceling the sewing area limit, the area covered with diagonal lines becomes invalid and the effective sewing area becomes narrower as a bold rectangle shown on the figure.

  • Page 45: Shifting The Mechanical Home Position To The Y Direction

    [NOTE] (a) In the case described above, available amount of adjustment of the home position is 0 to 25mm. For further adjustment, Loosen set screw(NO. ) and move position of the detector adapter(NO. ). (b) If move the detector adapter(NO. ) to the right, the mechanical home position is shifted to the left.

  • Page 46: Adjustment Of The X-Y Detector Clearance

    7-16. Adjustment of the X-Y detector clearance [NOTE] The work holder stop position which is the mechanical home position is detected by the X-Y detectors. If the clearance between the detector and the detector plate is changed, the mechanical home position is also changed. If such aberration is happened, make the following adjustment.

  • Page 47: Adjustment Of The X-Y Timing Belt Tension

    7-17 Adjustment of the X-Y timing belt tension [NOTE] The proper condition of the X-Y timing belt tension is standing that they will not be got any yield even it is slightly pushed by hand. 7-17-1 Adjustment of the X timing belt tension (1) Remove the X-bellow (left) and X-Y cover.

  • Page 48: Adjustment Of The Y Timing Belt Tension

    7-17-2. Adjustment of the Y timing belt tension (1) Loosen set screws(NO. ) of the brackets. (It’s located machine arm tail)Also loosen set screw(NO. ) of the bracket. (2) If tighten the tension adjust screw (NO. ), the Y timing belt tension will be increased. (3) After the adjustment, tighten the set screws(NO.

  • Page 49: Bad Sewing Condition & Its Cause And Remedy

    8. BAD SEWING CONDITION & ITS CAUSE AND REMEDY [NOTE] Please fix the troubles during the sewing machine operation with referring to the following instructions. Beside, if the trouble conditions are not coming under these classification, please contact the sewing machine dealers nearby. Ref.
  • Page 50 Needle and shuttle hook djust needle and shuttle hook clearance is too big clearance properly Needle and shuttle hook Adjust needle and shuttle hook timing is not correct timing properly Skip stitching Needle is bent Change it new needle ---- often happens Adjust needle and diver clearanc Needle is bent by driver...
  • Page 51 Ref. Page Bad condition Cause Remedy & Item Slow down sewing speed Sewing material weight is Select sewing material weight level Control heavy at feeding unit Control Slow down feeding speed Sewing pattern unit X-Y timing belts are loose is distorted Adjust X-Y timing belt tension 7-17 properly...

  • Page 53: Appendix

    APPENDIX 1. CHART OF CONNECTING WIRES...

  • Page 54: Wiring Between The Power Switch To Relay

    2 WIRING BETWEEN THE POWER SWITCH TO RELAY The cables from 101 to 104 are enclosed in accessory box.
  • Page 55 WIRING PHASE COUNTRY DIAGRAM VOLTAGE POWER SWITCH M 97345099 1 φ 110V POWER UNIT 3 φ 380V OFF ON EXCEPT POWER SWITCH M 97345099 1 φ ,3 φ 200~240V POWER SWITCH NOISE FILTER UNIT 1 φ 220V M 97349099 POWER SWITCH POWER φ...
  • Page 56 3 PLK-E1008H I/O TABLE INPUT OUTPUT TERMINAL SIGNAL TERMINAL SIGNAL CUSTOMIZE FUNCTION SOL No. FUNCTION CON I-2 START COND-1 LOWER TRIMMER CON I-3 CLAMP COND-9 WIPER CON H-3 STOP COND-2 TENSION RELEASE TE1-A2 THICKNESS DETECTOR UP COND-10 CLAMP LEFT TE1-A4...

  • Page 57: Trimming Time Chart

    4 . TRIMMING TIME CHART trim (feed) Start sw. [DSW] [SRC] [UP] [SRT] [FN4] Presser foot DOWN OPEN Tension release CLOSE 400ms PULL Thread puller BACK 350ms Wiper sweep BACK Heater Pre heating Thickness detector DOWN Lower trimmer BACK 1000ms Upper trimmer BACK...
  • Page 58 5 PLK-E1008H TABLE ASSEMBLY 5-1 Table cut-out 5-2 Table and stand Description Table top Stand (A) Stand (B) Support frame (A) Support frame (B) Bolt with SW-PW(L) M8X20 Bolt with SW-PW(S) M8X20 Bolt with SW-PW(M) M8X20 Wide-rimmed washer (L) 8...

  • Page 59: Anaerobic Adhesive Used Location

    6 ANAEROBIC ADHESIVE USED LOCATION Below parts are fixed by anaerobic adhesive. If these parts are disassembled, make sure to clean their bonding part with thinner. And please put anaerobic adhesive before reassembling.
  • Page 60 MITSUBISHI ELECTRIC CORPORATION FACTORY AUTOMATION SYSTEM OFFICE TOWER “Z” 14F 8-12 1chome, Harumi CHUO-KU, TOKYO 104-6212, JAPAN Phone : +81-3-6221-6060 Fax : +81-3-6221-6076 New publication, effective JUN.2002. Specifications subject to change without notice.

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