Mitsubishi Electric PLK-J2516R-YU Technical Manual Download Page 10

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3. INSTALLATION

CAUTION

(1) Please have some specialists, who have enough experience for the sewing machine installations,

install the sewing machine.

(2) Please have a Qualified Electrician perform necessary electric wiring.

(3) Please do not operate until the sewing machine is repaired when any damage or fault is found on the

sewing machine at the installation.

(4) Please do not refurbish the sewing machine.

3-1. Preparation of the table

(1) If the table is not MITSUBISHI original, the thickness of the table is required to have 40mm and that is

strong enough to withstand the weight and Vibration of the sewing machine.

(2) Manufacture the table as shown on the figure below.

Summary of Contents for PLK-J2516R-YU

Page 1: ...INDUSTRIAL SEWING MACHINE MODEL PLK J2516R YU TECHNICAL MANUAL SEWING MACHINE HEAD A180E803P02 ...

Page 2: ...to a serious consequence according to the circumstances Always follow the instructions of both levels because they are important to personal safety CAUTION INDICATIONS No Caution indication Description 1 Precaution for sewing machine operation Indicates that removing the safety and operating the sewing machine for some other purposes with power on are prohibited Please do not operate the sewing ma...

Page 3: ... corrosive gas 7 In the place where the fluctuation in the power voltage of 10 or more than 10 or the power voltage of 10 or less than 10 of the fixed power voltage 8 In the place where the power source cannot supply enough voltage to keep the motor running 9 In the place filled with strong electric noises such as high frequency welders INSTALLATION 1 Please have some specialists who have enough e...

Page 4: ...ouch the operating parts during sewing operation 9 It is very dangerous to operate the sewing machine without safety guards eye guards belt covers link covers finger guards or the others Please make sure to operate the sewing machine with safety guards 10 Please make sure to turn the power switch off when stopping the sewing machine temporarily ADJUSTMENT 1 Please make sure to turn the power switc...

Page 5: ...3 10 Connection of the electric cables 3 10 1 How to remove the motor cover 3 10 2 Connection of the PF axis cables 3 10 3 Connection of the XY axis cables 3 10 4 Connection of the main servo cables 3 10 5 Connection of the I F board cables 3 10 6 Connection of the optional output connector 3 10 7 Fixing of the cables 3 11 Connection of the air tube 3 11 1 Installation of the filter regulator and ...

Page 6: ...2 Adjustment of the position between the needle and the rotating hook 6 3 Adjustment of the hook positioner s position 6 4 Adjustment of the oil lubrication for the rotating hook 6 5 Adjustment of the oil lubrication for the machine head 6 6 Setting of the presser foot movement 6 7 Adjustment of the wiper 6 8 Adjustment of the thread take up spring 6 8 1 Adjusting movable range of the thread take ...

Page 7: ... edge 7 5 2 3 Connection of the knife bracket and the driving crank 7 5 2 4 Adjustment of the component parts of the knife driving mechanism 7 5 2 5 Adjustment of the mounting position of the air cylinder 7 5 2 6 Adjustment of the mounting position of the thread trimmer cam 7 5 2 7 Adjustment of the knife engagement 7 6 Adjustment of the X Y table detector 7 6 1 Adjustment of the X Y mechanical ho...

Page 8: ...ectronic pattern sewing machine consists of the following main parts 1 Sewing machine head 2 Main shaft motor 3 Halt switch 4 Control box 5 Operation panel 6 Work holder switch 7 Start switch 8 Gas spring 9 Steel stand 10 Thread stand 1 4 2 10 5 6 7 8 9 3 ...

Page 9: ...ot lift 18 0 mm max 24 0 mm Variable in 0 1 mm step Presser foot stroke Digital adjustment stroke 0 1 to 10 0 mm Upper thread tensioner Manual Automatic Setting on pattern switchover Wiper system Back to front wiping system Oil lubrication Replenishment with the oil braids from the oil tanks Spray method Inside of the sewing machine head only Operation panel 6 5 inch color LCD touch panel with USB...

Page 10: ... not operate until the sewing machine is repaired when any damage or fault is found on the sewing machine at the installation 4 Please do not refurbish the sewing machine 3 1 Preparation of the table 1 If the table is not MITSUBISHI original the thickness of the table is required to have 40mm and that is strong enough to withstand the weight and Vibration of the sewing machine 2 Manufacture the ta...

Page 11: ...LK G PAL with the CON G on the rear of the control box 3 5 Installation of the power switch and foot switch 1 Mount the power switch No 1 with the wood screw No 2 at the position as shown on the figure 2 Hook up the connector No 3 of the power switch to the control box CON F 3 Attach the power plug No 5 to the incoming electrical cable No 4 4 Fix the electric cables with the staples No 6 to preven...

Page 12: ...p slides toward the hinges Remember to move the work clamps fully to the right side of the table and attach the stopper before tilting the sewing head 1 Put the machine head carefully on the damper cushion 2 Insert the hinge shafts No 1 into the hole on the machine and fix with set screws No 2 3 Fit the hinge rubbers No 4 and the support plates No 5 into the holes of the hinges No 3 then set the h...

Page 13: ...amp to prevent the sliding of work clamp 2 Set up the gas spring unit No 2 on the sewing table and temporarily fix it with the socket bolts No 3 the flat washers No 4 5 and the nuts No 6 so that it can be still movable 3 Fit the holes of the gas spring head side to the bracket No 7 hole then insert the shaft No 8 4 Attach the snap pin No 10 and the flat washer No 9 5 Adjust the position of the gas...

Page 14: ...1 position so that the machine table push the switch when the machine head in initial position and turns on the switch NOTE The switch unit No 1 is temporarily fixed at the back side of the sewing machine bed Fix it to the proper place as shown on the below figure Notice if the switch is not turned on error M 038 will occur 11 Cover 12 Screw six screws 11 12 Snap 1 2 1 Switch units 2 Screw two scr...

Page 15: ...upply Connect to power switch box CON G Operation panel CON Ｍ Main servo encoder CON J I F board signal Connect to I F board MIF CON P XY axis encoder CON Q PF axis encoder CON L Foot switch CON A I F board power Connect to I F board MIF CON H general purpose port Connect to PC CON B Main servo motor Connect to spindle servo motor CON K universal serial communication port CON D XY axis stepping mo...

Page 16: ...h housed in the motor cover and wiring that to the back side of the table by passing through the square hole 2 Connect each of the PF axis motor cable No 1 and PF axis encoder cable No 2 to CON E and CON Q connector which has control box Please refer to previous paragraph 3 10 Connection of the electric cables for detail of connector position 1 Motor cover 2 Screw 1 2 1 PF axis motor cable 2 PF ax...

Page 17: ...s encoder cable No 2 to the each cable of machine motor Notice The cable connector has X Y difference When connecting the cable match the connectors identify mark shown in each connector 4 Connect each of the XY axis motor cable No 1 and XY axis encoder cable No 2 to CON D and CON P connector which has control box Please refer to previous paragraph 3 10 Connection of the electric cables for detail...

Page 18: ...f the table by passing through the long hole 2 Connect each of the main servo motor cable No 1 and main servo encoder cable No 2 to CON B and CON M connector which has control box Please refer to previous paragraph 3 10 Connection of the electric cables for detail of connector position 1 Main servo motor cable 2 Main servo encoder cable 1 2 ...

Page 19: ...essory box 3 Wiring the I F board signal cable No 1 and I F board power cable No 2 to the back side of the table by passing through the long hole 4 Connect each of the I F board signal cable No 1 and I F board power cable No 2 to CON J and CON A connector which has control box Please refer to previous paragraph 3 10 Connection of the electric cables for detail of connector position 1 I F board sig...

Page 20: ... holders No 1 with wood screws No 2 which enclosed in accessory box There are wood screw prepared holes for the tie holders No 1 on the rear surface of the table 2 Insert the cord tie No 3 to the tie holder No 1 and fix the cables as shown in the below figure At this time please make any allowance for the machine side cables so as not to pull the cables when tilting the sewing machine 1 1 Optional...

Page 21: ...ve assembly No 7 is located at the left side surface of the sewing machine head Beside pass the other end of the air tube No 3 through the cut out hole of the table top then insert it into the air outlet fitting No 5 of the air presser regulator No 1 3 Insert the one end of the resting air tube into the intake air fitting No 4 of the air coupling to be adopted with the air supply source provided i...

Page 22: ... capable of reducing the excess of lubrication oil 1 Prepare the oil drainage tube No 3 which connected with air ejector No 2 which is also connected with magnet valve assembly No 1 The oil drainage tube No 3 is housed in the motor cover in bundled state 1 Magnet valve assembly 2 Air ejector 3 Oil drainage tube 1 2 3 ...

Page 23: ...o 7 4 Insert the end of the oil drainage tube No 3 into the hole of the oil pan No 5 about 50 mm If the oil drainage tube No 3 has bended near the oil pan No 5 cut off the excessive length of the oil drainage tube No 3 Notice When the oil bottle No 6 filled with waste oil the outflow pressure from drainage tube will scatter the waste oil to the outside of the oil pan No 5 Please dispose the waste ...

Page 24: ...th the nut No 13 and the washer No 12 3 13 Installation of the eye guard 1 Mount the eye guard No 1 with screw No 2 to sewing machine head 1 Upper column pipe 2 Lower column pipe 3 Spool stand base 4 Spool mat 5 Spool holder 6 Spool shaft 7 Spring washer 8 Nut 9 Thread hunger 10 Spool holder 11 Column joint 12 Washer 13 Nut 1 Eye guard unit 2 Screw 1 2 1 12 3 4 6 7 8 9 2 10 11 5 13 ...

Page 25: ...d presser bar The above is the same when the machine has not been used for a long time 1 The oil tanks are set at three places of the machine Pour oil through the oil holes of No 1 to No 3 to the oil tanks 2 The oil tank No 1 and No 2 have level marks at the center of the tank Running out the oil may cause the machine to make abnormal noise and seize up When the amount of oil decreases to one thir...

Page 26: ...o motor upper position 1 Remove the all of any parts tools and screws on the sliding table After make sure the work environment safety Turn the power switch on At this time do not press the home position return icon 2 Press the icon from the function mode 3 Input the pass word and press the icon NOTE If press the home position return icon the icon is displayed with shading and cannot display the n...

Page 27: ... 20 5 Following the screen indication set up the main motor up position After the completion of setting press the icon and then press the icon 6 After adjustment turn the power switch off ...

Page 28: ...e pay attention for the fingers not to be injured by the needle point 1 Loosen the set screw No 1 then insert a new needle No 2 until the needle head is reached the end of the hole of the needle bar No 3 2 Tighten the set screw No 1 with facing the needle groove No 4 to the front 3 1 2 4 1 Set screw 2 Needle 3 Needle bar 4 Needle groove ...

Page 29: ... 22 5 3 Threading the needle thread CAUTION 1 Please turn the power switch off when threading a needle Thread the needle thread as shown on the figure ...

Page 30: ...pped on 3 When the bobbin finishes winding a certain amount 80 to 90 of the outside diameter of bobbin of thread the bobbin presser arm is returned to the initial position Adjust the amount of the winding thread with the subsidiary arm No 4 4 To wind the bobbin thread during the sewing operation carry out the procedure 1 above then the bobbin winding is performed automatically For the bobbin windi...

Page 31: ...ot set the bobbin No 2 into the bobbin case No 1 over again to get the proper rotation 5 6 Setting the bobbin case 1 Pull the bobbin thread about 50mm out of the thread hole of the bobbin case No 4 2 Open the cylinder cover No 1 3 Open the bobbin case latch No 2 and hold it then fit it securely in the shuttle hook No 3 4 ｂ 2 3 5 1 1 Bobbin case 2 Bobbin 3 Thread 4 Bobbin case slit 5 Bobbin case th...

Page 32: ...he halted position Press the jogging in forward reverse direction icon so that the sewing start position will move 4 To cancel sewing press the home position return icon 5 8 Adjustment of the thread tension 1 Adjust the bobbin thread tension with the thread tension adjusting screw No 2 on the bobbin case No 1 The thread tension become loose if turn the thread tension adjusting screw No 2 to the co...

Page 33: ...ghtening the thread tension adjusting nut No 1 clockwise and the upper thread tension becomes loose when loosening the thread tension adjusting nut counterclockwise NOTE It is possible to adjust the upper thread tension automatically Please refer to the instructions OPERATION PANEL technical manual concerning about Digital tension 1 Thread tension adjusting nut 1 ...

Page 34: ...power switch off then stop the needle bar No 1 at the lowest position 2 Move the needle bar to the position where the needle bar timing mark A is matched to the needle bar bushing No 2 bottom line For the needle class DPx17 3 If the position of the needle bar timing mark A is not matched to the needle bar bushing bottom line remove the rubber plug No 3 from the face cover then loosen the needle ba...

Page 35: ...n move up the needle bar No 5 from the lowest position and stop it at the position No 6 where the needle bar timing mark C is matched to the needle bar bushing bottom line NOTE If the needle class is DPX5 match the needle bar timing mark D to the needle bar bushing bottom line 1 2 3 4 1 Cylinder cover 2 Bobbin case 3 Sliding plate 4 Hook set screw C D C 5 6 5 Needle bar 6 Needle bar bushing bottom...

Page 36: ...rely 10 After the adjustment put the sliding plate and bobbin case back to the original locations and close the cylinder cover 11 When put the sliding plate back on the sewing machine in order for the needle No 8 to come into the right center of the needle hole of the needle plate No 9 make sure that the needle plate hole center matches with the needle point then tighten the set screws securely 8 ...

Page 37: ...ter the adjustment securely tighten the hook positioner set screw No 4 and put the sliding plate back on the sewing machine NOTE When put the sliding plate back on the sewing machine in order for the needle to come into the right center of the needle hole of the needle plate make sure that the needle plate hole center matches with the needle point Refer to the previous paragraph 6 2 11 1 Hook posi...

Page 38: ...justing screw No 2 4 It can be checked the oil flow with the situation that the oil splashes on the paper covered over the running rotating hook 5 After the adjustment close the cylinder cover No 1 Notice The oil flow is adjusted for the sewing speed at 2 300rpm as the factory default setting When using other speeds adjust the oil flow each time 1 Cylinder cover 2 Adjusting screw A The deadlock po...

Page 39: ...very ten thousand stitches NOTE1 Please adjust the oiling amount for each sewing condition For example increase the OL1C value or shorten the oil injection time OL1T when much oil is consumed However it is necessary to note the machine seizing when limit the oiling amount NOTE2 When shorten the oil injection time OL1T set the value to 3 5 as a guide 2 It is also possible to lubricate once at the s...

Page 40: ...per set screw No 3 and adjust the wiper No 1 to be positioned where the wiper No 1 passes under the needle No 2 point with a clearance of about 2mm right after the sewing machine stops at the take up lever upper position 2 When setting the presser foot No 4 to upper position during the sewing of thick material the setting may not leave the clearance of passing wiper The wiper cannot be used in thi...

Page 41: ...ame height of the center line A of the thread take up spring unit No 4 6 8 2 Adjusting intensity of the thread take up spring 1 Loosen the lock nut No 1 and turn the adjusting shaft No 2 with screw driver When the adjusting shaft No 2 won t screw well loosen the set screw No 3 slightly When tightening the screw driver clockwise the thread take up spring tension becomes loose and when loosening the...

Page 42: ...high trouble such as operation faults may occur Always set the pressure to within 0 4Mpa 1 Air pressure is provided from an air source Lift and turn the air regulator s adjustment knob No 1 located under the table to adjust the air pressure 2 If turn the adjusting knob No 1 to the clockwise the air pressure is increased 3 If turn the adjusting knob No 1 to counter clockwise the air pressure is dec...

Page 43: ...holder No 1 by pressing it down from the engaged area with the pin No 2 of the clamp adapter 2 Prepare another work holder and securely engaged its U shaped mortise No 3 with the pin No 2 of the clamp adapter 1 Work holder 2 Pin 3 U shaped mortise 1 3 2 ...

Page 44: ...he others back on the initial position after the sewing machine adjustment 7 1 How to exchanging the tension spring of the needle thread tensioner unit According to following procedures exchange the tension spring No 1 It is same way to exchanging the optional stronger tension spring NOTICE It is required to use the factory original tension spring 1 Turn the thumb screw No 2 and decrease the tensi...

Page 45: ...rder NOTE 1 Bearing No 6 is consist of three parts Please taking care not to make misassembling by referring following figure NOTE 2 Locate the groove of the tension disc No 9 to the thread release pin No 12 when removed tension disc No 9 No 10 and tension disc holder No 11 9 10 11 12 1 Tension spring 2 Thumb screw 3 Set screw 4 Set screw 5 Tensioner shaft 6 Bearing 7 bearing holder 8 Washer 9 Ten...

Page 46: ...f the sliding plate NOTICE The presser foot movement is based on the origin detection position To prevent the sewing trouble and parts breaking adjust the detector position exactly 1 Remove the eye guard No 1 by referencing the previous paragraph 3 13 Installation of the eye guard 2 Remove the three of fixing screws No 2 and remove the face cover No 3 3 Remove the needle No 4 1 Eye guard 2 Fixing ...

Page 47: ...8 0 mm If different please change to the initial set value 18 0 mm c Press the Presser foot ZNPP Distance from PF sensor edge to the top surface of slide plate Check if the value is 240 24 0 mm If different please change to the initial set value 240 d For prevent the detection error please use the factory default presser foot e For prevent the detection error and miss positioning of presser foot h...

Page 48: ...oosen the fixing screw No 6 and move downward the detector bracket No 7 and tighten the screw again and press the origin return icon NOTICE Please be careful not to step on the foot switch by mistake 8 Continue the above adjustment up to be a correct distance 18 mm NOTICE From the second home position returning it does not use the home position return sensor Make sure to turn the power switch off ...

Page 49: ...he standard presser foot only at needed it is necessary to change the ZNPP Distance from PF sensor edge to the top surface of needle plate from default value For example to using a special presser foot which length is 2 mm longer change the value to 220 22 0 mm from default value 240 24 0 mm as showing in the following figure According to the following procedures change the ZNPP value 1 Press the ...

Page 50: ...andard one 4 Press the icon and down the presser foot to the top of the needle plate In this time set the gap between bottom of presser foot and top of needle plate to be 0 to 0 2 mm The screen indicates ZNPP default value Upper and current value Lower NOTE The ZNPP value can be set every 0 1 mm ...

Page 51: ... 44 5 After the completion of setting press the memory icon and then press the icon NOTE The ZNPP value is flickering until press the icon 6 Following the screen indication put the power switch off ...

Page 52: ...sser foot holder lower No 4 position 4 After adjustment make sure if the presser foot No 7 is remaining on the sliding plate On the other hand adjust the presser foot hole position to the needle No 8 with turning the presser bar 5 Then tighten the each of set screws No 5 securely while holding the block No 9 by both presser foot holders No 3 No 4 and make sure if there are no gap between both pres...

Page 53: ...hich the needle moves from its lower to upper position 7 5 2 Assembling and readjustment of the thread trimmer mechanism If take the trimmer mechanism apart and assemble it again please refer to the following instructions for the readjustment 7 5 2 1 Attaching the knife bracket and the knife mounting unit 1 Knife bracket Under the condition that the rotating hook and the hook positioner are remove...

Page 54: ...tween the movable and stationary knife edges This is standard condition 2 If this space is too wide it causes a thread tail from the needle to be pulled out after the automatic thread trimming If it is too narrow it causes the failure of the trimming For avoiding these incidents adjust this space precisely 3 For this adjustment suitably move the knife bracket or the knife mounting unit mentioned a...

Page 55: ... driving mechanism and adjust the locations as shown on the figure 2 When assembling the parts always firstly insert the knife driving shaft No 6 into the driving crank No 1 3 Fix the cam follower crank 1 No 3 on the knife driving shaft No 6 at the right end position 77mm away from the front surface of the sewing machine bed as shown on the figure 4 Fix the stopper No 5 on the knife driving shaft ...

Page 56: ...er No 1 After adjusting securely tighten the nut No 7 for the air cylinder No 1 7 5 2 6 Adjustment of the mounting position of the thread trimmer cam Before the trimmer mechanism is activated the cam follower crank 2 No 1 is located under the condition that a point of tangency of the cam follower No 4 is over the tangential line of the knife driving shaft No 2 and the lower shaft No 3 at 1 5mm dis...

Page 57: ...thread trimmer cam No 8 with the two set screws No 9 at the point where the thread trimmer cam No 8 contacts with the cam follower No 13 3 Make sure that the clearance between the thread trimmer cam No 8 right end and the cam follower No 13 left end is 0 5mm to 1 0mm when the cam follower crank 2 No 1 is returned to the C arrow direction after the air cylinder is set back to the original condition...

Page 58: ...o 1 will rotate with the thread trimmer cam When the edge of movable knife No 1 is reached at most left position the amount if the engagement with the stationary knife No 2 becomes 1 5mm to 2 0mm This is the standard condition For this adjustment loosen the set screw No 4 of the driving crank No 5 then move the driving crank No 5 to have the proper engagement After the adjustment tighten the set s...

Page 59: ... engaging presser after removing the slide plate and loosening the lock nut No 4 use the adjusting screw No 5 If tighten the adjusting screw No 5 the knife engaging presser becomes tight and if loosen the adjusting screw No 5 it becomes loose After the adjustment tighten the lock nut No 4 securely 4 Adjustment of the attaching position of the protector Attach the protector No 6 underneath the mova...

Page 60: ...the mechanical home position 2 Press the on the standard screen to open the MENU mode 3 Press the Cancellation of sewing area limit in order 4 Select the on the Cancellation of sewing area limit screen and press the 5 When turning the power off then the setting of the sewing area limit is cancelled NOTE When modify the home positon somewhere other than the center of sewing area please refer to the...

Page 61: ...the power switch on Press the home position return icon and check the mechanical home position 6 If the mechanical home position is not the desired position carry out the same procedure 4 and 5 again In that case turn the power switch off each time Notice The machine has a function that the motor memorizes the home position at the first home position returning operation after the switch is turned ...

Page 62: ...t the same procedure 3 and 4 again In that case turn the power switch off each time Notice The machine has a function that the motor memorizes the home position at the first home position returning operation after the switch is turned on Therefore from the second home position returning it does not use the home position return sensor Make sure to turn the power switch off to change the mechanical ...

Page 63: ...ly lowers the slide guide running life Remove the dust and the thread waste sticking regularly and greasing every six months For the guide rail grease to the both side of guide groove After greased apply the grease uniformly by moving the XY table by hand Recommended grease Lithium grease 2 2 Grease every six months to the following units which consisted by gear mechanism NOTE Remove the face cove...

Page 64: ... 57 8 3 Disposing of oil waste If the oil bottle No 1 is full filled with waste oil remove the oil bottle and dispose it regularly 1 1 Oil bottle ...

Page 65: ...ge the needle size to suitable size 5 2 Thread melts with heat Slow down the sewing speed Operation panel section Use needle cooler Bobbin thread is broken Bobbin thread tension is too tight Adjust thread tension 5 8 Parts on needle plate and presser foot touching thread are damaged Buff parts or change parts Bobbin case size is smaller than the thread size Change the thread size to suitable size ...

Page 66: ...e and fixed knife position is not proper Adjust movable and fixed knife position 7 5 2 7 Knife engaging presser is not proper Adjust the knife engaging presser 7 5 2 7 Skip stitching happens in trimming Refer to the condition Frequent skip stitching happens Setting of trimming timing is not proper Adjust the trimming timing Operation panel section Trimming setting is off Turn trimming setting on O...

Page 67: ...its needle or presser foot Adjust wiper position 6 7 Wiper setting is turned off Turn wiper setting on 6 7 Sewing pattern is changed Sewing material is not pressed properly Adjust work holder pressure 6 10 Sewing material in work holder slips Put slip stopper on presser plate Sewing material is too heavy Slow down sewing speed Operation panel section X Y timing belt tension is loose Adjust timing ...

Page 68: ......

Page 69: ...10 2 Steel stand drawings MEMO If the steel stand is not MITSUBISHI original produce the parts with reference to the following drawings 1 2 3 4 5 6 7 ...

Page 70: ...Stand part 1 Thickness 2mm Stand part 2 Thickness 2mm ...

Page 71: ...Stand part 3 Thickness 2mm Stand part 4 Thickness 2mm Stand part 5 Thickness 5mm Stand part 6 Rubber thickness 2 5mm Stand part 7 Permissible load more than 60kg Per wheel ...

Page 72: ...Printed in Japan ...

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