Mitsubishi Electric PLK-G2516R Technical Manual
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Mitsubishi Electric PLK-G2516R Technical Manual

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INDUSTRIAL SEWING MACHINE
MODEL
PLK-G2516R
TECHNICAL MANUAL
SEWING MACHINE HEAD
A180E612P02

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Summary of Contents for Mitsubishi Electric PLK-G2516R

  • Page 1 INDUSTRIAL SEWING MACHINE MODEL PLK-G2516R TECHNICAL MANUAL SEWING MACHINE HEAD A180E612P02...
  • Page 2 FOR SAFE USE Before the installation, operation, and inspection for this product, read the “FOR SAFE USE” and the technical manuals carefully. Also read the other technical manuals, “Control Unit” and “Operation Panel” describing some instructions, which are not in this manual, and use the sewing machine properly. SAFETY INDICATIONS Indicates that incorrect handling may cause hazardous conditions, resulting DANGER...
  • Page 3 SAFETY PRECAUTIONS DANGER To prevent from receiving an electric shock, always turn off a power switch and unplug power supply when opening a control box, and then open after ten minutes passes. CAUTION USAGE ENVIRONMENT Please do not operate the sewing machine under the following conditions. (1) In the ambient temperature of 35 degrees (95°F) or more than 35 degrees, or the ambient temperature of 5 degrees or less than 5 degrees (41°F).
  • Page 4 (9) Please make sure to fit the safety protective equipment (the motor cover or the others) and the accessory protective equipment (the eye guard) that removed temporarily for installation. (10) If the table and the steel stand are not MITSUBISHI original, the table and the steel stand have to be strong enough to withstand the weight and vibration of the sewing machine.

  • Page 5: Table Of Contents

    CONTENTS 1. STRUCTURE OF THE SEWING MACHINE···································· 2. SPECIFICATION······································································· 3. INSTALLATION········································································ 3-1. Preparation of the table·········································································· 3-2. Preparation of the steel stand·································································· 3-3. Installation of the control box··································································· 3-4. Installation of the operation panel····························································· 3-5. Installation of the power switch and foot switch············································ 3-6.
  • Page 6 7. STANDARD ADJUSTMENT························································ 7-1. Adjustment of the needle bar position······················································· 7-2. Adjustment of the position between the needle and the shuttle hook··············· 7-3. Adjustment of the hook positioner's position ·············································· 7-4. Adjustment of the lubrication for the rotating hook······································· 7-5. Adjustment of the presser foot timing························································ 7-6.

  • Page 7: Structure Of The Sewing Machine

    1. STRUCTURE OF THE SEWING MACHINE PLK-G2516R electronic pattern sewing machine consists of the following main parts. <10> <2> <1> <3> <5> <9> <8> <4> <11> <7> <6> <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...

  • Page 8: Specification

    2. SPECIFICATIONS Sewing area : X-direction (left/right) 250 mm, Y-direction (front / back) 160 mm Maximum sewing speed : 2,800 rpm Setting speed : 10 speed levels in 200 rpm to 2,800 rpm Stitch length : 0.1 to 20.0 mm Stitch type : Single needle lock stitch Maximum number of needles...

  • Page 9: Installation

    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.

  • Page 10: Preparation Of The Steel Stand

    (2) When fitting the caster to the steel stand, the steel stand has to be strong enough to withstand the weight and vibration of the sewing machine. (3) If the steel stand is MITSUBISHI PLK-G2516R original, assemble the steel stand with the assembling instructions enclosed in the packing.

  • Page 11: Installation Of The Oil Pan

    3-6. Installation of the oil pan (1) Remove the oil pan A (No.1) from the accessory box then, set the oil bottle (No.2) to the oil pan A (No.1). (2) Put the oil pan at the position shown on the figure then, fix the oil pan with staples (No.3). (3) Set the damper cushions (No.4) to the table.

  • Page 12: Installation Of The Tilting Detect Switch

    <1>: Hinge shaft (two shafts) <3> <2>: Set screw (two screws) <8> <3>: Hinge (two hinges) <9> <4>: Hinge rubber (two rubbers) <5>: Support plate (two plates) <6>: Socket bolt (four bolts) <7>: Flat washer (four washers) <8>: Head rest <4>...

  • Page 13: Installation Of The Gas Spring

    3-10. Installation of gas spring CAUTION (1) The sewing machine is heavy. For the safety, please make sure to install the sewing machine head by more than one person. (2) When tilting the sewing machine, please stand at the hinge side and hold the sewing machine with both hands.

  • Page 14: Connection Of The Electric Cables

    3-11. Connection of the electric cables CAUTION (1) Please make sure to ground the place where there is a mark. Failure to do so may cause electric shock and/or malfunction. (1) Connect the machine head and the control box with cables as shown on the figure. (2) Hold the dangling cables under the table with accessory tie holders (MB60A0420) and cord ties (MB60A0201).

  • Page 15: Installation Of The Thread Stand

    3-12. Installation of the thread stand (1) Assemble the parts (No.1 to No.11) of the thread stand as shown on the figure. (2) Fit the thread stand into the hole at the far right on the table stand with the nut (No.13) and the washers (No.12).

  • Page 16: Installation Of The Spindle Motor

    <1>: Air presser regulator unit <2>: wood screw (two screws) <3>: Air tube (sizeφ8) <4>: Manifold (with magnet valves) <5>: Manifold air fitting <3> <6>: Air outlet fitting <6> <7>: Intake air fitting <1> <4> <7> <5> <2> 3-14. Installation of the spindle motor (1) If the spindle motor (No.1) has been removed from the machine for the adjustment or the like, fix the spindle motor as the procedure described below.

  • Page 17: Lubrication

    4. LUBRICATION CAUTION (1) Please make sure to turn power switch off before lubricating. (2) Please pay attention that oil does not get on your skin or in your eyes as it may cause an inflammation. (3) Please make sure to keep oil out of the reach of children who may drink oil by mistake. [Notice] Please make sure to lubricate when operating for the first time after the installation.

  • Page 18: Installation Of The Needle

    5-2. Installation of the needle CAUTION (1) Please make sure to turn the power switch off before installing or replacing needles. (2) Please 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).

  • Page 19: Winding The Bobbin Thread

    5-4. Winding the bobbin thread CAUTION (1) Please do not touch the rotating part during winding thread. Doing so may cause injury and/or the machine failure. [Notice] Please make sure to pull the upper thread out of the needle before winding the bobbin thread. (1) Route the thread as shown in the below figure then, wind the thread to the bobbin (No.1) in the direction of “a”...

  • Page 20: Setting The Bobbin

    5-5. Setting 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 through the thread hole (No.5). 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 21: Sewing

    6. SEWING CAUTION (1) Before starting the sewing, please make sure the position and the function of the halt switch. (2) Please do not touch the operating parts during sewing operation. (3) It is very dangerous to operate the sewing machine without safety guards (eye guards, belt covers, link covers, finger guards or the others).

  • Page 22: Operation Of The Halt Switch

    6-2. Operation of the halt switch <1> (1) If accidents such as a thread breakage, needle breakage and others happened during the sewing, press the halt switch immediately. The sewing machine stops instantly. (2) To cancel the halt state, press the halt switch again. (3) When continuing sewing, step on the grey foot switch to restart at the halted position.

  • Page 23: Standard Adjustment

    7. STANDARD ADJUSTMENT CAUTION (1) Please make sure to turn the power switch off before adjusting the sewing machine. (2) When adjusting the sewing machine with the power switch on, please be careful not to step on the foot switch by mistake. (3) Please be careful not to be injured by a sharp part such as the needle and the shuttle hook point.

  • Page 24: Adjustment Of The Position Between The Needle And The Shuttle Hook

    7-2 Adjustment of the position between the needle and the rotating hook (1) Turn the power switch OFF. (2) Open the cylinder cover (No.1). (3) Remove the bobbin case (No.2). (4) Remove the sliding plate (No.3). (5) Loosen the hook set screws (No.4). (6) Turn the sewing machine pulley by hand then, 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.

  • Page 25: Adjustment Of The Hook Positioner's Position

    7-3 Adjustment of the hook positioner’s position (1) Remove the sliding plate. (2) Loosen the hook positioner set screw (No.4) and adjust the hook positioner (No.1) position to align the right side 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.

  • Page 26: Adjustment Of The Lubrication For The Rotating Hook

    7-4 Adjustment of the lubrication for the rotating hook (1) Open the cylinder cover (No.1). (2) Tighten the oil flow adjusting screw (No.2) lightly by fingers or a screw driver until it is stopped the turn. NOTE Do not tight the oil flow adjusting screw (No.2) too much. (3) Adjust the oil flow in the range of one reverse turn from the deadlock position of the oil flow adjusting screw (No.2).

  • Page 27: Adjustment Of The Presser Foot Timing

    7-5. Adjustment of the presser foot timing With changing the timing to sewing materials, the skip stitches can be prevented or the seam tightness can be improved. For example, the delay of the presser foot timing against the needle movement prevents the skip stitches especially to thin materials, and the advance of the presser foot timing can improve the seam tightness especially to thick materials.

  • Page 28: Adjustment Of The Presser Foot Lift

    7-6. Adjustment of the presser foot lift The presser foot lift can be returned factory default setting at 15mm as the procedure shown below. Also, if the presser foot does not move after changing the presser foot correction value and the stroke, carry out the procedure below.

  • Page 29: Adjustment Of The Presser Foot Height Position

    <9> <7> <8> <4> <3> 41mm <3>: Gauge <4>: Presser foot bar holder <7>: Detector plate set screw <8>: Detector plate <9>: Presser foot drive motor 7-7. Adjustment of the presser foot height position The height of presser foot can be returned factory default setting as the procedure shown below. (1) Turn the power switch on, and set the correction value at 0.

  • Page 30: Adjustment Of The Presser Foot Walk During The Sewing

    7-9. Adjustment of the presser foot walk during the sewing (1) The presser foot walk during the sewing can be adjusted with the walk at zero or the walk of 2 to 10mm. The walk at zero requires the exclusive parts (Option). Please feel free to contact the sewing machine stores.

  • Page 31: Adjustment Of The Wiper

    7-11. Adjustment of the wiper (1) Loosen the wiper 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 needle upper position.

  • Page 32: Changing The Work Holder

    <1>：Adjusting knob <1> <2>：Air regulator <2> 7-13 Changing the work holder (1) Remove the work 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 motise (No.3) with the pin (No.2) of the clamp adapter.

  • Page 33: Adjustment Of The Thread Trimmer

    7-14 Adjustment of the thread trimmer 7-14-1 Structure of the thread trimmer mechanism The thread trimmer mechanism of sewing machine is shown on the figure. <4> <1> <12> <3> <2> <11> <5> <8> <10> <9> <7> <6> <1>: Knife mounting unit <2>: Knife bracket <3>: Trimming cam <4>: Air cylinder <5>: Stopper <6>: Cam follower crank 2 <7>: Cam follower crank 1 <8>:Knife driving shaft <9>:Driving crank <10>: Movable knife <11>: Stationary knife <12>: Thread guide CAUTION...

  • Page 34: 7-14-2.2 Mutual Relation Among The Movable And Stationary Knife Edge

    (2) Knife mounting unit Under the condition that the rotating hook and the hook positioner are removed, attach the knife mounting unit (No.1) with the set screw (No.2). <1>: Knife mounting unit <2> <2>: Set screw <1> 7-14-2.2 Mutual relation among the movable and stationary knife edge (1) Rotate the movable knife (No.1) by hand when it is engaged with the stationary knife (No.2), there is 0.3mm space between the movable and stationary knife edges.

  • Page 35: 7-14-2.3 Connection Of The Knife Bracket And The Driving Crank

    7-14-2.3 Connection of the knife bracket and the driving crank (1) Connect the knife bracket (No.1) and the driving crank (No.2) with the link (No.3). (2) Loosen the driving crank set screw (No.4) and adjust the attaching position of the driving crank (No.2) in the right and left direction so that the link (No.3) can contact with the same flat surface of the knife bracket (No.1) and the driving crank (No.2) without any distortion.

  • Page 36: 7-14-2.5 Adjustment Of The Mounting Position Of The Air Cylinder

    7-14-2.5 Adjustment of the mounting position of the air cylinder (1) Attach the thread trimmer air cylinder (No.1) by fixing with the bolt (No.2). When the thread trimmer air cylinder (No.1) is released, there will be a clearance of apporox. 1mm at section A . To adjust this clearance, loosen the set screw (No.4) for the mounting plate (No.3), and move the entire mounting plate (No.3).
  • Page 37 (1) Loosen 2 set screws (No.9) of the thread trimmer cam (No.8).Remove the slide plate and place the 4mm thickness gauge (No.10) on the top of sewing machine bed. Slide the gauge (No.11) in between the needle bar and the 4mm thickness gauge (No.10). Use the 26.2mm part of T side. <11>...

  • Page 38: 7-14-2.7 Adjustment Of The Knife Engagement

    7-14-2.7 Adjustment of the knife engagement (1) The standard position for the movable and stationary knife <3> <2> The standard mutual position for the movable 5.5～ <1> 2.5mm (No.1) and stationary (No.2) knife is as shown on the figure. (2) Adjustment of the amount for the knife engagement Activate the thread trimmer air cylinder, and rotate the upper shaft.

  • Page 39: Adjustment Of The Thread Take Up Spring

    (4) Adjustment of the attaching position of the protector Attach the protector (No.6) underneath the movable <7> knife (No.1) and fix it with the same set screw (No.7) for the movable knife (No.1) at the position where the point of the protector (No.6) is off 0.5mm left from the <1>...

  • Page 40: Adjustment Of The Thread Tail After The Trimming

    7-16. Adjustment of the thread tail after the trimming (1) Adjust the thread tail with the pre-tension (No.1). (2) When turning the nut clockwise, the thread tail becomes shorter. <1> When turning the nut counterclockwise, the thread tail becomes longer. <1>: Pre-tension 7-17.

  • Page 41: Adjustment Of The X-Y Mechanical Home Position

    7-19. Adjustment of the X-Y mechanical home position The mechanical home position (No.1) is fixed at the center of the sewing area as the factory default setting. The machine can be moved within the area (No.2) covered with diagonal lines. <2>...

  • Page 42: Adjustment Of The Y Direction

    → → To use the sensor from the send returning, press [Home returning method since the second time returning] on the standard screen and set it ON. <2> <1>: Detector plate X <3> <2>: Detector <3>: Detector plate set screw <1>...

  • Page 43: Maintenance

    8. MAINTENANCE CAUTION (1) Please make sure to turn the power switch off before cleaning the sewing machine. (2) Please pay attention to that staining your skin or eyes with oil may cause an inflammation. 8-1. Cleaning (1) Remove the dust and the thread waste sticking the threading parts or the hooks area regularly.

  • Page 44: Troubleshooting

    9. TROUBLESHOOTING CAUTION (1) Please make sure to turn the power switch off before adjusting the sewing machine. (2) If the adjustment is required while the power switch on, do not step on the foot switch by mistake. Condition Cause Corrective action Reference Upper thread tension is too...
  • Page 45 Trimming is not Movable knife is at wrong Adjust position of movable 7-14-2.7 functioned. position. knife properly. Refer to the condition Skip stitching happens in “Frequent skip stitching trimming. happens”. Operation Trimming setting is off. Turn trimming setting on. panel section Upper thread tension is too Stitch forming is loose.

  • Page 46: Appendix

    APPENDIX MEMO If the steel stand is not MITSUBISHI original, produce the parts with reference to the following drawings. <2> <1> <3> <6> <5> <7> <4> - 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 Stand part <3>···thickness 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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