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Janome
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2160QDC
Service Manual
45 pgs2.21 Mb0

Janome 2160DC, DXL603, 3160QDC, 2160QDC Service Manual

SERVICE MANUAL
2160DC, DXL603
INDEX
What to do when .............................................................................................................................. 1 - 3
Changing External Parts
Face Cover ............................................................................................................................................. 4
Free-arm Cover...................................................................................................................................... 5
RearF Cover...........................................................................................................................................8
Mechanical Adjustment
Presser Bar Height................................................................................................................................. 9
Needle Drop Position ........................................................................................................................... 10
Adjustment of Hook Timing .................................................................................................................. 11
Adjustment of Needle Bar Height......................................................................................................... 12
Clearance between Needle and Tip of Hook Rotary............................................................................ 13
Feed Dog Height .................................................................................................................................. 14
Feed Dog Adjustment (Only for model 3160QDC)............................................................................... 15
Top T ension .......................................................................................................................................... 16
Replacing the Electronic Components
Circuit Board-A connection .................................................................................................................. 17
Self-diagnostic T est ......................................................................................................................... 18-22
Circuit Board-A................................................................................................................................23-24
Driving Motor........................................................................................................................................ 25
Switching regulator Unit ....................................................................................................................... 26
Adjusting Buttonhole Lever Position..................................................................................................... 27
Parts List........................................................................................................................................ 29-43
1
Condition Cause How to fix Reference
1. Skipping Stitches
1. Needle is not inserted properly.
2. Needle is bent or worn.
3. Incorrectly threaded.
4.Needle or thread are inappropriate for the fabric being sewn.
5. Sewing on stretch fabric.
6. Inappropriate needle bar height.
7. Inappropriate needle to hook timing.
8. Inappropriate needle to hook clearance.
Insert the needle properly.
Change the needle.
Rethread.
Use the recommended sewing needle and thread.
Use a HA x #11 blue tip needle.
See mechanical adjustment “Needle bar height”.
See mechanical adjustment “Adjustment of hook timing”.
See mechanical adjustment “Clearance between needle and tip of the rotary hook”.
P. 12
P. 11
P. 13
2. Fabric not moving
1. Incorrect feed dog height.
2. Feed dog is in down position.
3.Thread on bottom side of fabric is jammed up.
4. Feed dog teeth are worn.
Adjust the presser bar level to make the pressure stronger. See mechanical adjustment “Feed dog height”.
Raise the feed dog.
Make sure to bring both needle and bobbin threads under the foot when start sewing.
Change the feed dog.
P. 14
What to do when
2
Condition Cause How to Fix Reference
3. Breaking upper thread.
1. Initial sewing speed is too fast.
2. Thread path is incorrect.
3. Needle is bent or dull.
4. Top tension is too strong.
5. Needle size is inappropriate for fabric.
6. Needle eye is worn.
7. Needle hole in needle plate is worn or burred.
Start with medium speed.
Use the proper thread path.
Replace with a new needle.
Adjust top tension correctly.
Use appropriate needle for fabric and thread in use.
Change the needle.
Repair the hole or replace the needle plate.
4. Breaking bobbin thread.
1. Bobbin holder is incorrectly threaded.
2. Too much thread is wound on the bobbin.
3. Lint is stuck inside the bobbin
holder.
4. Thread quality is too low.
5. Thread is jamming around the bobbin holder.
Set the bobbin thread correctly.
Adjust the position of bobbin winder stopper.
Clean the bobbin holder.
Change to a high quality sewing thread.
Clear out the jamming thread.
5. Needle breakes
1. Needle is hitting the needle plate.
2. Needle is bent or worn.
3. Needle is hitting the hook.
4. Fabric is being pulled too strongly while sewing.
See mechanical adjustment “Needle drop position”.
Change the needle.
See mechanical adjustment “Clearance between needle and tiip of the rotary hook”.
Guide the fabric gently while sewing.
P. 10
P. 13
3
Condition Cause How to fix Reference
6. Noisy operation
1. Bac klash between hook gear and lower shaft gear is too great.
2. Lower shaft gear is loose.
3. Inappropriatte belt tension.
4. Not enough oil.
5. Upper shaft gear is loose.
Eliminate the backlash.
Eliminate the looseness.
See part removal and replacement “driving motor (DC motor)”.
Oil all moving parts.
Eliminate the looseness.
P. 25
7. Deformation pattern
1. Inappropriate feed balance.
2. Top tension is too strong.
Adjust the feed balancing screw.
See mechanical adjustment “Top tension”.
P. 16
4
Changing External Parts
Face cover
To remove:
1. Loosen the setscrew q and lift the face cover to disengage the rib on the inside. Remove the face cover w.
To attach:
2. Follow the above procedures in reverse.
q
w
5
Free-arm cover
To remove:
1. Loosen the setscrew q and w. Move the free-arm cover to the left. Remove the free-arm cover.
To attach:
Follow the above procedures in reverse.
Changing External Parts
q
w
e
6
Changing External Parts
Front cover (1)
To remove:
1. Remove the face cover and free-arm cover (See page 4 and 5).
2. Remove the setscrews (A) q (2 pcs.).
3. Remove the setscrews (B) w (5 pcs.), back cover e.
4. Remove the setscrews (C) r (2 pcs.).
5. Disconnect all the connectors from the circuit board A.
NOTE:
Do not disconnect the connectors by pulling on cord. To disconnect, grasp the connector, not the cord.
To attach:
6. Follow the above procedures in reverse.
q
w
w
w
r
r
e
7
Changing External Parts
Front cover (2)
4. Disengage the front cover and rear cover hooks.
5. Remove the front cover.
To attach:
Follow the above procedures in reverse.
8
Changing External Parts
Rear cover
To remove:
1. Remove the face cover and free-arm cover (See page 4 and 5).
2. Remove the setscrews (A) q (4 pcs.).
3. Remove the setscrews (B) w (5 pcs.) and back cover.
4. Remove the setscrews (C) e (2 pcs.). Remove the rear cover.
To attach:
5. Follow the above procedures in reverse.
q
q
w
w
e
Back cover
Rear cover
9
６.０mm
Mechanical Adjustment
Presser bar height
The distance between the bottom of the presser foot in up position and the needle plate should be 6.0 mm.
1. Remove the face plate and needle.
2. Lower the feed dog below the needle plate. Place a block 6 mm thick under the presser foot and lower the presser foot lifter w.
3. Loosen the setscrew q. Raise the presser foot lifter and tighten the setscrew q firmly. Attach the needle and face plate.
NOTE:
Make sure that the presser foot should be parallel to the feed dog slots e in the needle plate.
q
e
Presser foot should be parallel to the feed dog slots.
w
10
0.2 mm or more
0.2 mm or more
Ａ=Ｂ
Mechanical Adjustment
Needle drop position
Set the stitch pattern to “ ”. The standard needle drop position should be at center of the needle plate hole q. Select zigzag stitch “ ”, and set the stitch width at “5.0”. The clearance between the needle and the edge of the needle hole in the needle plate should be at least 0.2 mm on either side. If not, adjust as follows:
1. Turn the power switch off. Remove the face cover. (See page 4.)
2. Loosen the hexagonal socket screw 3 x 4 w. Adjust the needle drop position by turning the eccentric pin e. The direction of eccentric pin should be as shown in Fig. 1.
3. Attach the face cover.
NOTE:
Check the hook timing after this adjustment.
q
Fig. 1
11
The amount of ascending travel of the needle bar from its lowest position to the position ( ) where the tip of the rotary hook exactly meets the right side of the needle should be 3.25 to 3.55 mm.
1. Remove the needle plate and bobbin holder.
2. Turn the power switch on.
3. Select the pattern (left position). Set the zigzag width at 0.
4. Remove the free-arm cover.
Turn the handwheel toward you to lower the needle at its lowest position.
5. Loosen the hexagonal socket screw w (2 pcs.).
6. Move the needle bar 3.4 mm from the lowest position.
7. Turn the lower shaft gear until the tip of hook meets the right side of the needle while holding the handwheel.
8. Tighten the hexagonal socket screw w (2 pcs.).
9. Attach the free-arm cover, bobbin holder and needle plate.
Mechanical Adjustment
Adjustment of hook timing
w
Needle plate
Bobbin holder
w
Lower shaft gear
Left position ( ) (#14)
Tip of hook meets the right side of the needle
Lowest needle position
3.25 – 3.55mm
12
Before proceeding with this adjustment, check the hook timing (refer to page 11). The distance between the upper edge of the needle eye and the tip of the hook should be in the range of 1.6 to 2.0 mm when the tip of the hook timing meets right side of the needle in the left needle position ( ) as the needle ascends from its lowest position.
1. Remove the needle plate, bobbin holder and face plate.
2. Turn the power switch on.
3. Select the pattern (left position). Set the zigzag width at 0.
4. Turn the handwheel toward you until the tip of hook meets the right side of the needle.
5. Loosen the hexagonal socket screw q.
6. Move the needle bar to adjust the needle bar height, and tighten the hexagonal socket screw q.
Be careful not to turn the needle bar.
7. Attach the bobbin holder, needle plate and face cover.
Mechanical Adjustment
Adjustment of needle bar height
1.6 – 2.0 mm
Needle plate
Bobbin holder
Hexagonal socket screw
Needle setting groove
Upper edge of needle hole
Hook race (unit)
Hook race
Tip of hook meets the right side of the needle
Left position ( ) (#14)
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