Mitsubishi Electric PLK-J2516R-YU User manual

INDUSTRIAL SEWING MACHINE
MODEL
PLK-J2516R-YU
TECHNICAL MANUAL
SEWING MACHINE HEAD
A180E803P02

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
DANGER
Indicates that incorrect handling may cause hazardous conditions, resulting
in death or severe injury.
CAUTION
Indicates that incorrect handling may cause hazardous conditions, resulting
in medium or slight personal injury or physical damage. Note that CAUTION
level may lead 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 machine without
protective equipment such as a needle guard, an eye guard,
a belt cover or the others.
Please turn off the power switch when threading, changing
a needle and a bobbin, cleaning, and lubricating.
2
Caution for fingers injury:
Indicates a possibility of fingers (hands) injury in a certain
condition.
3
Caution for squeezing fingers:
Indicates a possibility of squeezing fingers in a certain condition.

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).
(2) In the ambient temperature of 55 degrees (131°F) or more than 55 degrees, or the ambient
temperature of -10 degrees or less than -10 degrees (18°F) during transportation.
(3) In the relative humidity exceeding 85% or less than 45%.
(4) In the open-air place or the location that receives direct sunlight.
(5) In the place near heat sources such as heating devices.
(6) In the atmosphere filled with dust, explosive gas, or 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 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.
(5) The sewing machine is heavy. For the safety, please make sure to install the sewing machine head
by more than one person.
(6) 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.

SEWING
(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.
(3) Please make sure to turn power switch off before lubricating.
(4) Please pay attention that oil does not get on your skin or in your eyes as it may cause an
inflammation.
(5) Please make sure to keep oil out of the reach of children who may drink 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 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 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.
(3) Please be careful not to be injured by a sharp part such as the needle and the shuttle hook point.
(4) Please make sure to put the safety guards (eye guards, belt guards, link covers, and finger guards
or the others) back on the initial position after the sewing machine adjustment.

CONTENTS
1. STRUCTURE OF THE SEWING MACHINE····································
1
2. SPECIFICATIONS·····································································
2
3. INSTALLATION········································································
3
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. Installation of the oil pan·········································································
3-7. Installation of the machine head·······························································
3-8. Installation of gas spring·········································································
3-9. Installation of the tilting detect switch·························································
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 air piping·····································
3-11-2. Piping of the oil drainage tube··························································
3-12. Installation of the thread stand·······························································
3-13. Installation of the eye guard···································································
3
4
4
4
4
5
5
6
7
8
9
9
10
11
12
13
13
14
14
15
17
17
4. LUBRICATION·········································································
18
4-1. Filling the oil tank··················································································
18

5. PROPER OPERATION······························································
19
5-1. Setting of the main servo motor upper positon·············································
5-2. Installation of the needle·········································································
5-3. Threading the needle thread···································································
5-4. Winding the bobbin thread······································································
5-5. Setting the bobbin·················································································
5-6. Setting the bobbin case··········································································
5-7. Operation of the halt switch·····································································
5-8. Adjustment of the thread tension······························································
5-9. Adjustment of upper thread tension··························································
19
21
22
23
24
24
25
25
26
6. STANDARD ADJUSTMENT························································
27
6-1. Adjustment of the needle bar position·······················································
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 up spring·····························
6-8-2. Adjusting intensity of the thread take up spring······································
6-9. Adjustment of the thread tail after the trimming··········································
6-10. Adjustment of the air pressure·······························································
6-11 Changing the work holder·····································································
27
28
30
31
32
33
33
34
34
34
35
35
36

7. VARIOS ADJUSTMENT·····························································
37
7-1. How to exchanging the tension spring of the needle thread tensioner unit········
7-2. Adjustment of the detector position of the presser foot unit····························
7-3. How to replace with a special pressor foot·················································
7-4. Adjustment of the pressor foot holder position············································
7-5. Adjustment of the thread trimmer·····························································
7-5-1. Structure of the thread trimmer mechanism···········································
7-5-2. Assembling and readjustment of the thread trimmer mechanism···············
7-5-2.1 Attaching the knife bracket and the knife mounting unit··························
7-5-2.2 Mutual relation among the movable and stationary knife 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 home position···································
7-6-2. Adjustment of the X direction·····························································
7-6-3. Adjustment of the Y direction·····························································
7-6-4. The X-Y drive timing belt tension························································
37
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46
46
46
46
47
48
48
49
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51
53
53
54
55
55
8. MAINTENANCE·······································································
56
8-1. Cleaning····························································································
8-2. Greasing····························································································
8-3. Disposing of oil waste···········································································
56
56
57
9. TROUBLESHOOTING·······························································
58
10. APPENDIX
10-1. Air piping drawing
10-2. Steel stand drawings

- 1 -
1. STRUCTURE OF THE SEWING MACHINE
PLK-J2516R-YU electronic 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>

- 2 -
2. SPECIFICATIONS
Model
PLK-J2516R-YU
Stitch type
Single needle lock stitch
Hook
Double size rotating hook
Class of needle
DPX17#18
Sewing area
X-direction (left/right) 300 mm
Y-direction (front / back) 200 mm
Maximum sewing speed *1
2,300rpm (Continuous feeding) 2,300rpm (M3 feeding)
Setting speed
10 speed levels in 200 rpm to 2,300 rpm (M3 feeding)
Stitch length
0.1 to 20.0 mm (min. resolution 0.1 mm)
Maximum number of needles
20,000 per pattern
Storable sewing data item
9,000 patterns *2
Data memory
USB memory
Type of motor
Mitsubishi Electric 750W direct servo motor
Work holder lift
30 mm
Needle bar stroke
40.0 mm
Thread take up lever stroke
73.0 mm
Presser foot drive
Direct drive by stepping motor
Presser foot 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 port
External device I/F
USB port, Terminal I/O: 16 input, 16 output
Thread trimmer system
Arc engagement with fixed knife and movable knife
Machine dimensions
(W)x(L)x(H)
1,200mm x 1,144mm x1,230mm
Weight
187kg
Power
In 200V to 240V single-phrase or three-phrase
The power in 110V to 120V or in 380V to 415V is compatible with
power unit (option)
*1: Sewing speed may be limited by the operation or sewing condition.
*2: The max. patterns may be limited depending on the number of stitches of each pattern in the memory.

- 3 -
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.

- 4 -
3-2. Preparation of the steel stand
(1) If the steel stand is not MITSUBISHI original, please refer
to the dimensions shown on the figure at the right.
(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-J2516R-YU original,
assemble the steel stand with the assembling instructions
enclosed in the packing.
3-3. Installation of the control box
Install the control box with the instructions in the paragraph “[3] Installation”in the CONTROL UNIT
technical manual.
3-4. Installation of the operation panel
Connect the operation panel PLK-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 prevent the cables from hanging down.
(5) Hook up the connector (No.8) of the foot switch (No.7) to the control box CON L.
(6) As for the control box connector, refer to the instructions in the paragraph “3-10.Connection of the
electric cables” in this manual.
[Notice] Power plug (No.5) is not included in accessory box.
<1>: Power switch
<2>: Wood screw
<3>: Power switch connector
<4>: Electrical cable
<5>: Power plug
<6>: Staple (six staples)
<7>: Foot switch
<8>: Foot switch connector
<1>
<2>
<3>
<6>
<8>
<5>
<7>
<4>

- 5 -
3-6. Installation of the oil pan
(1) Remove the oil pan (No.1) from the accessory box then, set the oil bottle (No.2) to the oil pan (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.
3-7. Installation of the machine head
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.Also, please lock the caster on the steel stand.
(3) When tilting the sewing machine, the work clamp 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 hinges to the hinge shafts.
(4) Fit the screw holes of the hinges (No.3) to the bolt setting holes then, fix the machine with the socket
bolts (No.6) and the flat washers (No.7).
<1>: Oil pan
<2>: Oil bottle
<3>: Staple (four staples)
<4>: Damper cushion
(six cushions)
<1>
<2>
<3>
<4>
<5>
<6>
<7>
<1>: Hinge shaft (two shafts)
<2>: Set screw (two screws)
<3>: Hinge (two hinges)
<4>: Hinge rubber (two rubbers)
<5>: Support plate (two plates)
<6>: Socket bolt (four bolts)
<7>: Flat washer (four washers)
<3>
<4>
>
<1>
上側
<4>
<2>

- 6 -
3-8. Installation of gas spring
DANGER
(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.Also, please lock the caster on the steel stand.
(3) When tilting the sewing machine, the work clamp 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) Before tilting the sewing machine, insert the accessory stopper (No.1) into the hole of work clamp 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 spring unit (No.2) when the machine head returned to the initial position.
Fix the gas spring unit not to be inclined when the machine head is in initial position.
(6)After install the gas spring unit, remove the stopper (No.1).
<1>: Stopper <2>: Gas spring unit <3>: Socket bolt (two bolts) <4>: Flat washer (two washers)
<5>: Flat washer (large) (two washers) <6>: Nut (two nuts) <7>: Bracket <8>: Shaft
<9>: Flat washer <10>: Snap pin
<2>
<3>
<4>
<5>
<6>
<7>
<8>
<10>
<9>
<2>
<1>

- 7 -
(7) Attach the cover (No.11) to the gas spring unit with the screws (No.12).
3-9. Installation of the tilting detect switch
(1) Install the switch units (No.1) with the Screws (No.2).
(2) Adjust the switch units (No.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 screws)

- 8 -
3-10. 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.
Connect the machine head and the control box with cables as following below instruction.
Connect each connector fully to ensure sufficient contact.
CON F Power supply
(Connect to power switch box)
CON G Operation panel
CON ＭMain 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 motor
(Connect to sewing machine head
stepping motor)
CON E PF axis stepping motor
(Connect to sewing machine head
PF axis stepping motor)

- 9 -
3-10-1. How to remove the motor cover
(1)Remove the five of screws (No.2) and remove the motor cover (No.1).
3-10-2. Connection of the PF axis cables
(1) Prepare the PF axis motor cable (No.1) and PF axis encoder cable (No.2) which 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 axis encoder cable
<2>
<1>

- 10 -
3-10-3. Connection of the XY axis cables
(1) Install the XY motor cable (No.1) to the sewing machine with nylon clip FG (No.3) and screw (No.4)
which are enclosed in accessory box.
(2) Install the XY encoder cable (No.2) to the sewing machine with nylon clip (No.5) and screw (No.6)
which are enclosed in accessory box.
(3) Connect each of the XY axis motor cable (No.1) and XY axis 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 of connector position.
<1>: XY axis motor cable <2>: XY axis encoder cable
<3>: Nylon clip FG <4>: Screw <5>: Nylon clip <6>: Screw
<1>
X
X
Y
Y
X
X
Y
Y
<3>
<4>
<5>
<6>
<2>
Motor side
Motor side

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3-10-4. Connection of the main servo cables
(1) Wiring the main servo motor cable (No.1) and main servo encoder cable (No.2) to the back side of 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>

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3-10-5. Connection of the I/F board cables
(1) Connect the I/F board signal cable (No.1) to the I/F board connector which enclosed in accessory box.
(2) Connect the I/F board power cable (No.2) to the I/F board connector which enclosed in accessory
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 signal cable <2>: I/F board power cable
<1>
<2>

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3-10-6. Connection of the optional output connector
(1) Connect the optional output connector (No.1) to the I/F board connector.
Note If not connected this connector, the oil discharging function does not work.
3-10-7. Fixing of the cables
(1) Attach the two of tie 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 output connector
<1>
<3>
<2>
<1>: Tie holder <2>: Wood screw <3>: Cord tie