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- Page 1 MITSUBISHI Industrial Sewing Machine TECHNICAL MANUAL MECHANICAL VERSION Single-Needle Lockstitch, Electronic Bar Tack Machine Model PLK-E03BT A180E515P01...
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Page 2: For Your Safety
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).
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Page 4: Table Of Contents
CONTENTS 1. STRUCTURE OF THE MACHINE ······································································ 2. SPECIFICATION ·································································································· 3. 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 operation panel ·································································· 3-6. - Page 5 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 hook ·············· 20 7-3. Adjustment of the clearance between the shuttle hook and the needle ··········· 21 7-4.
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Page 6: Structure Of The Machine
1. STRUCTURE OF THE SEWING MACHINE PLK-E03BT electronic bar tack machine is constructed with the following main parts. Thread Stand Machine head Halt switch Operation panel Table top (optional) Control Servo-motor Steel stand Start switch / Work holder switch －1－... -
Page 7: Specification
2. SPECIFICATION (1) Specification of mechanism Sewing area : X-Direction (left/right) Y-Direction (fore/backward) 30 mm 30 mm Maximum sewing speed : 2500 rpm Sewing speed : 10 steps variable from 200 to 2500 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... -
Page 8: Installation
Please do not operate the sewing machine with excessive modifications from the standard specification 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. -
Page 9: Installation Of The Power Switch
33-6 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. -
Page 10: Installation Of The Oil Pan
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 Caution For the safety, please make sure to carry the sewing machine head by more than two people. (1) Make sure to hold the machine table with the caster stopper. -
Page 11: Putting Across The V-Belt
3-10 Putting across the V-belt Caution For the safety, when tilt or raise the sewing machine head, please make sure to hold the sewing machine head with both hands by two people at least. (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. -
Page 12: Connection Of The Electric Cables
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.8) from sewing machine head (NO.3). -
Page 13: Installation Of The Belt Cover
< Back side view of the Control box > Connect with Main motor cable Power supply cable Stepping motor cable Solenoid output cable RS-232C (optional use) Operation panel cable Extension I/O cable Input signal cable 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. -
Page 14: 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.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). -
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 Please use high quality white machining oil. NOTE 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. -
Page 16: Proper Operation
Turn the power switch (NO.1) ON. Load system software with following the instructions [Method of PLK-E03BT system installing]. After loading the system software, keep the system floppy disks with in care. 5-1 Installation of the needle Caution Please make sure to turn the power switch OFF before installing or replacing the needle. -
Page 17: Threading The Upper Thread
5-3 Threading the upper thread Caution 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 Caution Please make sure to pull the upper thread out of the needle before winding the bobbin thread. - Page 18 (4) Press the Ｂ key, then operation mode changes winding mode show as above picture. (5) Pass through the thread from the thread stand (NO.3) as shown on the below figure then, wind the thread to the empty bobbin (NO.5) in the arrow mark “a” direction couple times and insert the bobbin (NO.5) into the bobbin winder (NO.6).
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Page 19: Setting The Bobbin
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. -
Page 20: Proper Sewing
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. Caution 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. -
Page 21: The Sewing Operation
-2. The sewing operation Caution 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 tabletop. - Page 22 (4) Read pre-installed bar tacking pattern data by following procedure. (5) Press Ｄ key, then operation mode changes to [pattern read mode] as shown below. LED1 LED2 LED3 LED4 LED5 Ａ Ａ Ａ Ａ Pattern read function Changeover to normal mode The pattern No.
- Page 23 ● Standard Patterns (16 Types) Description Stitch Pattern Description Stitch Pattern 16×2.5mm 6×2.5mm 41-stitch 20-stitch 16×2.5mm 6×2mm 35-stitch 28-stitch 16×2.5mm 6×2mm 29-stitch 21-stitch 16×2.5mm 6×2mm 67-stitch 14-stitch Left 8×2.5mm 18×0mm 28-stitch 24-stitch Right 8×2.5mm 18×0mm 21-stitch 12-stitch 6×2.5mm 14×0mm 37-stitch 26-stitch 6×2.5mm 14×0mm...
- Page 24 (6) Set sewing speed by pressing A key on the setting panel. Then LCD shows like below. LED1 LED2 LED3 LED4 LED5 Changeover to normal mode function The setting value displayed in LED 5 is validated, and the normal mode is returned to.
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Page 25: Adjustment Of The Thread Tension
6-3. Adjustment of the thread tension The thread tension between the upper and bottom thread should be balanced in the best condition. When the upper thread tension is well balanced with the bobbin thread tension, both threads are interlocked along the centerline of fabric layers as shown on the below figures. NOTE Normally weaker bobbin thread tension brings better sewing quality. -
Page 26: Standard Adjustment
7. STANDARD ADJUSTMENT Caution 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 finger guard etc.) back on the original location after the sewing machine adjustment. -
Page 27: Adjustment Of The Position Between The Needle And The Shuttle Hook
7-2. Adjustment of the position between the needle and the shuttle hook (1) Turn the power switch OFF. (2) Turn the sewing machine pulley by hand then, move up the needle bar (No.1) from the lowest position and stop it at the position (No.2) where the needle bar timing mark C is matched to the needle bar bushing bottom line. -
Page 28: Adjustment Of The Clearance Between The Shuttle Hook And The Needle
7-3. Adjustment of the clearance between the shuttle hook and the needle (1) Please take the same procedures as above paragraph 7-2. from (1) to (5). (2) Loosen the outer hook setscrew (No.3) and turn the eccentric pin (No.4) so that the clearance between the shuttle hook point and the needle becomes 0.05～0.1mm. -
Page 29: Adjustment Of The Thread Guide
7-5. Adjustment of the thread guide (1) Remove the E-shaped snap ring (No.3) which is engaging the movable knife (No.2) and the link (No.1) then, loosen the setscrews (No.4) and remove the sliding plate (S)(No.5). (2) Loosen the setscrews (No.10) and move the thread guide (No.6) to the position where the needle center line (No.8) divides the needle groove (No.7) evenly and the rear side line (No.9) of the needle is aligned with the shoulder (No.9) of the thread guide (No.6). -
Page 30: Adjustment Of The Wiper
7-6. Adjustment of the wiper (1) Loosen the wiper setscrew (NO.3) and adjust the wiper (NO.1) to be positioned where the wiper (NO.1) passes under the needle (NO.2) with about 2 mm clearances right after the sewing machine is stopped running at the needle upper position ( the thread take up lever is highest position). -
Page 31: Adjustment Of The Bobbin Winder
7-7. Adjustment of the bobbin winder (1) Adjustment of the winding volume Loosen the setscrew (No.2) of the adjusting lever (No.1) and adjust the position of the adjusting lever (No.1). If move the adjusting lever (No.1) to the arrow direction "a", the winding volume is reduced, and if move the adjusting lever (No.1) to the arrow direction "b", the winding volume is increased. -
Page 32: Adjustment Of The Trimmer Cam Follower
Caution When the clamp goes down, the clearance between the pressure plate (NO.1) and the roller (NO.2) should be adjusted more than 1 mm. (1) Turn the power switch off. And remove 2 springs (NO.3). (2) Loosen the 4 setscrews (NO.4). (3) Put the clamps (right / left) (NO.5) down. -
Page 33: Adjustment Of The Position For Movable Knife Point
7-10. Adjustment of the position for the movable knife point (1) Tilt the sewing machine head to the left to be able to see the bottom component parts. (2) Open the cylinder cover (3) Check with the point (No.1) of the movable knife whether it is located at the position apart 0.5mm from the front face of the hook retainer (No.2). -
Page 34: Adjustment Of The Fixed Knife Position
7-11. Adjustment of the fixed knife position (1) Open the cylinder cover (No.1). (2) Remove the E-shaped snap ring (No.4), which engages the movable knife (No.2) and the link (No.3). (3) Loosen the setscrews (No.5) then, remove the sliding plate (NO.6). (4) Turn the sliding plate (No.6) upside down and loosen two setscrews (No.9) then, adjust the fixed knife (No.10) position to be positioned for the blade edge (No.7) to have the clearance 0.5mm from the edge of the needle plate (No.8). -
Page 35: Adjustment Of The Thread Tail After The Trimming
7-14. Adjustment of the thread tail after the trimming Adjust the thread tail (No.3) from the needle after the trimming with turning the nut (No.2) of the pre-tension (No.1). If turn the nut (No.2) to the clockwise, the thread tail becomes shorter and if turn the nut (No.2) to the counter-clockwise, the tread tail becomes longer. -
Page 36: Adjustment Of The Synchronizer
(1) Loosen the setscrew (NO.3) of the upper thread tension regulator (NO.2) by a hexagonal wrench. (2) Adjust the position of the upper thread tension regulator (NO.2).. (3) Tighten the setscrew (NO.3). 7-17. Adjustment of the synchronizer [NOTE] (a) When the sewing is finished, the arm timing mark and the pulley timing mark are matched with each other then, the sewing machine is stopped... -
Page 37: Adjustment Of The Mechanical Home Position
7-18. 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. (1)Center of sewing area (2)Standard home position (3)Adjustable... -
Page 38: Shifting The Mechanical Home Position X Direction
7-18-1. Shifting the mechanical home position to the X direction (1) Remove the right cover on the machine bed casting. (2) Loosen 2 setscrews (NO.1) and adjust the X-detector (NO.2) position. If X-detector is moved to right direction, mechanical home position shifts left (arrow - A direction in below figure).If moves left, mechanical home position shifts right to (arrow - B direction in below figure). -
Page 39: Adjustment Of The X-Y Contact Pressure
7-19. Adjustment of the X-Y contact pressure [NOTE] When take the X-Y table apart or the X-Y table became weak in the joints, adjust the X-Y table contact pressure. The adjustment should be made the X-Y table movement as smooth as possible without having play. If the X-Y table contact pressure is too tight, the over pressure induces the out of control on the X-Y table movement. -
Page 40: Adjustment Of The Y Stepping Motor Position
7-20-2. Adjustment of Y stepping motor position (1) Remove the motor cover. (2) Loosen 4 setscrews of the Y-stepping motor adapter (NO.2). (3) Press the Y-motor adapter (NO.2) to arrow direction lightly. (4) Fasten setscrews (NO.4) securely, and put the motor cover to original position. [NOTE] After adjustment, please make sure that there is no gap in the gear mechanism. -
Page 41: Maintenance
8. MAINTENANCE Caution Please make sure to turn the power switch always OFF when clean up the sewing machine. Before or after the sewing operation, clean up the sewing machine and check the oil level in the oil tank. 8-1. Cleaning (1) Turn the power switch OFF. -
Page 42: Bad Sewing Condition & Its Cause And Remedy
9. 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 43 Ref. page Bad condition Cause Remedy & Item 7-14 Pre-tension is too loose Make pre-tension tighter Adjust trimmer cam position Trimmer timing is delayed Thread tail from 7-17 Adjust synchronizer position needle is too Upper thread tension release long after Control unit Delay tension release timing timing is too fast...
- Page 44 Ref. Page Bad condition Cause Remedy & Item Decrease sewing speed 6-2(5) Sewing material is too heavy Decrease feeding speed Control unit Work holder Select heave material setting Control unit does not work X or Y driving gear clearance is Adjust X or Y driving gear 7-20 not proper...
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Page 45: Appendix
Tabletop and stand drawings. Ref.1 ···············Table cut-out for PLK-E03BT machine Ref.2 ···············Table and stand Ref.3 ···············Stand components NOTE Tabletop and stand must be produced refer to below drawings. Recommendable measurements for original MITSUBISHI tabletop and stand are shown in the figures. －40－... -
Page 46: Ref.1. Table Cut Out Drawing
Ref.1 <Table cut-out for PLK-E03BT machine> Ref.2 <Table and stand> Fi g. N o D escri pti on Q ty. Tabl e Top S tand (A ) S tand (B ) S upport f ram e (A ) S upport f ram e (B ) -
Page 47: Ref.3. Stand Components Drawings
Ref.3 <Stand components> (472.3) Stand (A) Description H01: SPCC 2.3T Material H02: SPCC 2.3T 101: WELD NUT M8 Surface Treatment Paint(unti-corrosion) Caution String chamfer, except as noted (chamfer slightly) Trigonometry 2-φ6 9-φ11 9-Weld Nut M8 DIVISION OF DIM LIMIT to 100 ±0.4 over 100 to 300 ±0.5... - Page 48 2-M12 +0.3 60.5 (60.5) 36.5 Stand (B) Description H01: SPCC 2.3T Material H02: SPCC 2.3T H03: SPCC 2.3T H04: SPHC 4.5T 101: WELD NUT M8 Surface Treatment Paint(unti-corrosion) Caution String chamfer, except as noted (chamfer slightly) Trigonometry DIVISION OF DIM LIMIT to 100 ±0.4...
- Page 49 Description Bolt with SW-PW (large) Description Bolt with SW-PW (small) M8 X 20 M8 X 20 Material SS100 Material SS100 Surface Treatment Electroplated Coating Surface Treatment Electroplated Coating Trigonometry Trigonometry M8ネジ Description Screw plate (A) Description Wide-rimmed washter (large)8 Material SPHC 4.5T Material SPCC 2.6T...
- Page 50 Description Shaft housing Material SPHC 4.5T Surface Treatment Elactroplated Coating Caution String chamfer, except as noted (chamfer slightly) Trigonometry φ8.5 (4.5t) +0.3 φ8 DIVISION OF DIM LIMIT to 100 ±0.4 over 100 to 300 ±0.5 over 300 to 1000 ±0.7 over 1000 ±1.0 -0.3...
- Page 51 Description Caster Description Staple (L) Material RUBBER WHEEL Material SWM-N 2.3D 2003 Permitted load: 40Kg (per each) PVC coating Lock mechanism is requireda Trigonometry Trigonometry CASTER Description Washer 12 415EA-Rφ75(HAMMER) Material SWRH62~72 Surface Treatment Elactroplated Coating Trigonometry SWM-N 2.3D 2003 Description Wood screw 5.8X32 Material...
- Page 52 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 SEP.2001. Contents subject to change without notice...
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