Mitsubishi Electric PLK-G2516R Technical Manual Download

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INDUSTRIAL SEWING MACHINE

MODEL

PLK-G2516R

TECHNICAL MANUAL

SEWING MACHINE HEAD

A180E612P02

Summary of Contents for PLK-G2516R

Page 1: ...INDUSTRIAL SEWING MACHINE MODEL PLK G2516R TECHNICAL MANUAL SEWING MACHINE HEAD A180E612P02 ...

Page 2: ...ecause 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 machine without protective equipment such as a needle guard an eye guard a belt cover or the others Pleas...

Page 3: ...e 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 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 th...

Page 4: ...k oil by mistake 6 Please make sure to turn the power switch off before threading a needle 7 Before starting the sewing please make sure the position and the function of the halt switch 8 Please do not touch 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 mak...

Page 5: ...stallation of the gas spring 3 11 Connection of the electric cables 3 12 Installation of the thread stand 3 13 Connection of the air tube 3 14 Installation of the spindle motor 3 4 4 4 4 5 5 6 6 7 8 9 9 10 4 LUBRICATION 11 5 PROPER OPERATION 11 5 1 Initial setting of the control box 5 2 Installation of the needle 5 3 Threading the upper thread 5 4 Winding the bobbin thread 5 5 Setting the bobbin 5...

Page 6: ...utual relation among the movable and stationary knife edge 7 14 2 3 Connection of the knife bracket and the driving crank 7 14 2 4 Adjustment of the component parts of the knife driving mechanism 7 14 2 5 Adjustment of the mounting position of the air cylinder 7 14 2 6 Adjustment of the mounting position of the thread trimmer cam 7 14 2 7 Adjustment of the knife engagement 7 15 Adjustment of the t...

Page 7: ...in parts 1 Sewing machine head 2 Main shaft motor 3 Halt switch 4 Control box 5 Operation panel 6 Work holder foot switch 7 Start foot switch 8 Gas spring 9 Steel stand 10 Thread stand 11 Work holder pedal Option 1 2 4 5 7 9 8 10 6 11 3 1 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 8: ...ng Bobbin Large size steel bobbin Thread trimmer system Arc engagement with fixed knife and movable knife Lubrication system Replenishment with the oil braids from the oil tanks Lubrication oil Pulley SF oil X Y drive system Stepping motor feedback control Timing belt drive system Machine dimensions 1 200 mm W 1 068 mm L 1 230 mm H Weight Total 168 5 Kg Type of motor XL K756 20 Type of controller ...

Page 9: ... original the table and the steel stand have to be strong enough to withstand the weight and vibration of the sewing machine 6 When fitting the caster to the steel stand that are not MITSUBISHI original the caster with locking function has to be strong enough to withstand the weight and vibration of the sewing machine 3 1 Preparation of the table 1 If the table is not MITSUBISHI original the thick...

Page 10: ... A on the rear of the control box See page 7 for the location 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 B 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...

Page 11: ...hine the work clamp slides toward the hinges Remember to move the work clamps fully to the right side of the casting before placing the sewing head in the sewing position 1 Put the machine head carefully on the damper cushion 2 Insert the hinge shafts No 1 into the hole on the machine then fix it to the machine with set screws No 2 3 Fit the hinge rubbers No 4 and the support plates No 5 into the ...

Page 12: ... Loosen the SW MW screws No 2 on the eye guard unit No 1 then mount the SW PW screws No 3 to the flat place of the sewing machine with the open guard 2 Return the open guard to the initial position then tighten the SW MW screws No 2 3 5 7 6 1 2 8 9 4 1 2 3 1 Eye guard unit 2 SW MW screw 3 SW PW screw two screws Snap 1 2 1 Switch unit 2 SW MW screw two screws 1 Hinge shaft two shafts 2 Set screw tw...

Page 13: ...the socket bolts No 2 the flat washers No 3 4 and the nuts No 5 so that it can be still movable 2 Fit the holes of the gas spring head side to the bracket No 6 hole then insert the shaft No 7 3 Attach the snap pin No 8 and the flat washer No 9 4 Adjust the position of the gas spring unit No 1 with the machine head returned to the initial position Fix the gas spring unit not to be inclined when the...

Page 14: ...re wood screw prepared holes for the tie holders MB60A0420 on the rear surface of the table 1 Solenoid cable 2 Solenoid power cable 3 Spindle encoder cable 4 Spindle motor cable 5 X Y spindle encoder cable 6 X Y spindle motor cable 7 P F spindle motor cable 7 1 3 6 5 4 2 X Y CON A CON E CON F CON G CON H CON J CON B CON C CON D CON K CON A Operation panel CON B Power supply CON C Various solenoid ...

Page 15: ...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 6 of the cut out hole of the table top then insert it into the air outlet fitting No 6 of the air presser regulator No 1 4 Insert the one end of the resting air tube No 3 into the intake air fitting No 7 o...

Page 16: ...rom 2 0 to 3 2mm 4 Turn the pulley No 8 in the direction of the arrow then slip the gauge No 5 in between the needle bar and the needle plate Use the part of R side 52 6mm on the gauge 5 Be careful not to make the motor turn and fit the coupling to the upper shaft and then tighten the bolt A No 6 first and the bolt B No 7 second 1 Spindle motor 2 Motor mark 3 Pin 4 Coupling 5 Gauge 6 Bolt A 7 Bolt...

Page 17: ...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 third or less than one third make sure to fill the tank with oil Also do not pour oil more than the level marks When tilting the machine head it may cause oil leak 3 The oil tank No 3 shows the oil amount by the tip of the indicator The appropriate oil amount is between...

Page 18: ... 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 5 3 Threading the upper thread CAUTION 1 Please turn the power switch off when threading a needle Thread the upper thread as shown on the figure 3 1 2 4 1 Set screw 2 Needle 3 Needle bar 4 Needle groove 12 From the library of Supe...

Page 19: ...hread continues winding to the bobbin while the start switch is stepped 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...

Page 20: ...bin 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 2 3 5 1 2 1 50mm 3 4 1 Bobbin case 2 Bobbin 3 Thread 4 Bobbin case slit 5 Bobbin case thread hole 1 Cylinder cov...

Page 21: ...set to the reading from internal memory mode The mode display at the left top on the screen is Press the when switching the reading from the internal memory to the reading from USB memory mode Pressing the also can switch the target Press the to switch the page with full of data 5 Select a data then set the data Press the target data number then press the 6 Set the sewing speed Set the appropriate...

Page 22: ...just 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 counterclockwise and the thread tension becomes tight if turn it to the clockwise 2 Adjustment of upper thread tension Adjust the upper thread tension corresponding to the bobbin Thread tension The upper thread te...

Page 23: ...p 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 DP 17 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 bar holder set screw No 4 4...

Page 24: ...le No 8 8 Move the hook by hand and adjust the clearance between the hook point and the needle to be about 0 05 mm 9 Hold the hook and tighten the hook set screws No 10 securely 10 After the adjustment put the sliding plate No 3 and bobbin case No 2 back to the original locations and close the cylinder cover No 1 NOTE When put the sliding plate No 3 back on the sewing machine in order for the need...

Page 25: ...of the projection No 3 with the right side of the needle No 2 as shown on the figure 3 After the adjustment securely tighten the hook positioner set screw No 4 and put the sliding plate back on the sewing machine 3 2 1 0 5 0 8mm 4 1 Hook positioner 2 Needle 3 Right side of hook positioner 4 Hook positioner set screw 19 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 26: ...he 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 position of the oil flow adjusting screw N...

Page 27: ... 1 and loosen the set screw A No 3 and B No 4 of the eccentric cam No 2 2 Keep the thread take up lever at the highest position then adjust the eccentric cam angle so that set screw B No 4 is positioned half size upper from the center line of the upper shaft shown on the lower right figure Retighten the set screws No 3 No 4 3 Turn the pulley by hand to check the timing then put the cover No 1 back...

Page 28: ...t lifting lever 6 PF motor cover 5 Turn the power switch on then press the home position return icon 6 Check the clearance between the presser bar holder No 4 and the arm with the 41mm part on the gauge No 3 Refer to the next figure 7 If the clearance is less than 41mm loosen the detector plate set screw No 7 on the presser foot drive motor No 6 and adjust the notch part of detector plate No 8 If ...

Page 29: ...essage M 096 OVER LIMIT OF PRESSER FOOT STROKE may show up This happens when the presser foot stroke is already set to the sewing data and by changing the correction value the stroke in sewing data becomes 0mm or less In that case make new sewing data without the presser foot stroke or read out a sewing data that the stroke does not become 0mm or less 7 8 Adjustment of the presser foot position Th...

Page 30: ...thod 2 described above 4 To adjust the walk in 4 to 10mm connect the link No 2 shown on the figure and adjust the method 2 described above 7 10 Adjustment of the presser foot spring pressure The presser foot spring pressure can be changed with the following two methods 1 To increase the spring pressure remove the face cover and loosen the bolt No 1 then adjust the spring A No 3 pressure with the a...

Page 31: ...FF screen and press the 7 12 Adjustment of the work holder pressure CAUTION If the secondary side air pressure is set too high trouble such as operation faults may occur Always set the pressure to within 0 4Mpa 1 The work holder 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 k...

Page 32: ...th the pin No 2 of the clamp adapter 2 Prepare another work holder and securely engaged its U shaped motise No 3 with the pin No 2 of the clamp adapter 1 Adjusting knob 2 Air regulator 1 2 1 2 3 1 Work holder 2 Pin 3 U shaped mortise 26 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 33: ...s lower to upper position 7 14 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 14 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 removed put the knife bracket No ...

Page 34: ... 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 at above 7 14 2 1 1 Movable knife 2 Sta...

Page 35: ...tions 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 No 6 by tightening the set screw No 7 ...

Page 36: ...cylinder No 1 and rotating the shaft section No 8 of the air cylinder No 1 After adjusting securely tighten the nut No 7 for the air cylinder No 1 7 14 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 o...

Page 37: ... hand Fix the 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 orig...

Page 38: ...engaging presser for the knives a The engaging presser for the movable No 1 and stationary knife No 2 can be controlled with adjusting the height of the stationary knife No 2 When the movable knife No 1 is rotated the contact of the both knives starts from the position where the distance between the edge of the stationary knife No 2 and the cut out line of the movable knife No 1 is 3mm This is the...

Page 39: ...e up spring No 1 stroke to be in 9 to 10mm which is standard stroke 2 Insert the screw driver into the slit of the thread tension regulator and adjust the thread take up spring tension When tightening the screw driver clockwise the thread take up spring tension becomes tight and when loosening the screw driver counterclockwise the thread take up spring tension becomes loose For the adjustment of t...

Page 40: ... moving the upper thread tension release to the direction A the width between the discs becomes bigger 7 18 Adjustment of the opening time of the upper thread tension release disks When the presser foot rises the thread tension disks are open for a given length of time and close The default setting is set at one minute intervals To change the set value carry out the procedure shown below 1 Turn th...

Page 41: ... X No 1 4 For the adjustment of the X direction mechanical home position loosen the detector plate set screws No 3 at the left and right side then move the detector plate X in the arrow direction as shown on the figure Set the clearance between the detector plate X and the detector within the range of 1 0 to 1 5mm 5 Turn the power switch on Press the home position return icon and check the mechani...

Page 42: ...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 43: ...gularly 2 The dust or the like sticking the X Y slide guide absorbs lubrication oil on the rails and significantly lowers the slide guide running life Clean the slide guide regularly and also pour some grease Recommended grease Multemp PS2 Produced by Kyodo Yushi Co Ltd Lithium grease 2 8 2 Disposing of oil waste If the waste oil pan is full filled in the oil bottle No 1 remove the oil bottle then...

Page 44: ...obbin thread is broken Bobbin thread tension is too tight Adjust thread tension 6 3 Parts on needle plate and presser foot touching thread are damaged Buff parts or change parts Upper thread is pulled from needle hole when starting sewing Thread tail is short Adjust thread tail with pre tension 7 16 Thread take up spring tension is too much Adjust thread take up spring tension 7 15 Frequent skip s...

Page 45: ...ck tilting detect switch 3 8 Work holder does not fall Foot switch is broken Change foot switch Work holder presser is not strong enough Increase work holder presser 7 12 Work holder switch is out of order Change it new work holder switch Wiper system does not work Wiper hits needle or presser foot Adjust wiper position 7 11 Wiper setting is turned off Turn wiper setting on 7 11 Sewing pattern is ...

Page 46: ...PENDIX MEMO If the steel stand is not MITSUBISHI original produce the parts with reference to the following drawings 2 1 3 5 6 4 7 40 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 47: ...Stand part 1 thickness 2mm Stand part 2 thickness 2mm 41 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 48: ...s 2mm Stand part 4 thickness 2mm Stand part 5 thickness 2mm Stand part 6 rubber thickness 2 5m Stand part 7 permissible load more than 60kg per wheel 42 From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 49: ...MEMO From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 50: ...MEMO From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 51: ...MEMO From the library of Superior Sewing Machine Supply LLC www supsew com ...

Page 52: ...Printed in Japan From the library of Superior Sewing Machine Supply LLC www supsew com ...

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