Janome 2160DC, Service Manual

Page 1: ...SERVICE MANUAL 2160DC DXL603...

Page 2: ...k 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 Tension 16 Replacing the Electron...

Page 3: ...le 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 o...

Page 4: ...in 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 ho...

Page 5: ...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 loos...

Page 6: ...anging 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...

Page 7: ...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...

Page 8: ...etscrews 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 pull...

Page 9: ...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...

Page 10: ...e 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 t...

Page 11: ...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 fi...

Page 12: ...ce 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...

Page 13: ...heel 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 o...

Page 14: ...lect 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 needl...

Page 15: ...within 0 1 to 0 05 mm at the left and right needle position 5 Tighten the setscrew A 2 pcs 6 Attach the face cover Remove the master needle Attach the bobbin holder and needle pate 7 Check the clearan...

Page 16: ...highest position 3 Remove the free arm cover 4 Loosen the setscrew A q and nut w 5 Adjust the feed dog height by turning the adjusting screw e The highest position of the feed dog should be between 0...

Page 17: ...he feed dog should be parallel to the surface of the needle plate 4 Tighten the setscrew C left screw 5 Loosen the hexagonal socket screw and remove it The highest position of the feed dog should be p...

Page 18: ...ove limit adjust as follows 1 Set the tension dial Auto 2 Remove the cover 3 Lower the presser foot If the top tension is too loose turn the lead screw in the direction A If the top tension is too tig...

Page 19: ...d F Printed circuit board L q Printed circuit board P Black w Feed motor White e Thread cutter motor 3160QDC exclusive White r Bobbin winding switch Blue t Power switch White y Zigzag width motor Gree...

Page 20: ...rectly to the test you want to perform Enter self diagnostic mode then select the step number of the diagnostic test you require by pressing the start stop button To begin Turn on the switch if any of...

Page 21: ...pulled buzzer sounds and LCD displays BH symbol When the buttonhole lever is pushed buzzer sounds and LCD displays BH symbol LCD displays SC 04 When the bobbin winder spindle is moved to the left buz...

Page 22: ...xt step Bobbin symbol Buzzer does not sound Stitch width or length symbol does not appear REMEDY Replace the circuit board A Replace the circuit board P Zigzag motor does not get default position REME...

Page 23: ...right or left position LCD displays SC 10 Machine runs slow then fast and the needle bar stops at its highest position LCD displays SC 11 Press the needle up down position button to display on or of o...

Page 24: ...o page 19 21 and fix the defective part The defective part number See page 19 21 Steps and items section Turnthe power switch off when the self diagnostic test is finiished To display the version of t...

Page 25: ...he screws 6pcs and the circuit board A To attach 1 Follow the above procedures in reverse NOTE Do not disconnect the connectors by pulling on cord To disconnect grasp the connector not the cord Replac...

Page 26: ...tch button q within 2 5 seconds The LCD displays F A or d 3 Press the locking stitch button to select the appropriate setting of the circuit board A Model 3160QDC Press locking stitch button to select...

Page 27: ...r belt Tighten them with setscrews 2pcs lightly 2 Move the motor up or down to adjust the motor belt tension The belt should deflect 5 mm when applying 200 grams of load to the middle of the belt Tigh...

Page 28: ...the rear cover 2 Remove the setscrews A 3 pcs and the switching regulator 3 Remove the setscrews B 4 pcs To attach 4 Follow the above procedures in reverse Replacing the Electronic Components Switchin...

Page 29: ...sition 4 Attach the buttohole foot R e 5 Lower the buttonhole lever r to its lowest position and open a 1 6 mm gap between the slider and the buttonhole foot 6 Turn the adjusting screw t to the left u...

Page 30: ......

Page 31: ...29 PARTS LIST KEY PARTS NO NO DESCRIPTION 2160DC DXL603 PARTS LIST MODEL 2160DC DXL603...

Page 32: ...30 PARTS LIST 2160DC DXL603 1 2 3 4 4 5 5 6 7 8 8 9 10 10 11 12 13 14 15 16 16 18 19 20 17 21 22 16 16 25 23 24 2 25...

Page 33: ...56000 508634101 000103509 000072302 808021005 808037004 808511007 808005003 000036005 Upper shaft unit Hexagonal socket screw 4x4 Hexagonal socket screw 4x6 Washer FT80 Shaft fixing metal Lower shaft...

Page 34: ...0DC DXL603 1 2 3 4 5 6 7 8 9 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 15 33 34 35 36 37 38 39 40 41 42 44 44 45 46 48 47 49 50 43 51 52 53 54 54 56 55 57 9 10 58 9 44 11 59 61 61 62...

Page 35: ...sion release lever Thread tension release spring Presser foot lifter Snap ring E 5 Presser bar spring adjusting plate Washer 4 Snap ring E 3 Presser bar Presser bar spring Presser bar supporter Hexago...

Page 36: ...34 PARTS LIST 2160DC DXL603 1 2 3 23 24 26 27 28 28 25 36 29 30 31 32 33 34 35 37 14 14 38 40 41 39 43 44 45 14 46 42 47 48 28 25 49 50 4 5 16 19 10 15 11 7 7 6 10 8 19 17 21 12 14 9 13 18 22 20...

Page 37: ...10406 627569106 102261000 Hook race whole unit Hook race unit Lower shaft unit Lower shaft Upper shaft gear Spring pin 3x18 Washer Shaft fixing metal Lower shaft ring Hexagonal socket screw 4x4 Feed f...

Page 38: ...36 PARTS LIST 2160DC DXL603 6 6 6 7 2 3 5 4 7 1 20 24 21 22 23 25 26 28 29 30 31 32 33 34 27 7 35 37 38 39 36 7 42 41 43 7 44 7 40 40 8 11 9 10 12 13 14 15 16 17 18 19...

Page 39: ...essure adjustment unit Presser foot pressure adjusting set plate Presser foot pressure dial Adjusting arm 1 Adjusting arm 2 Snap ring E 3 Setscrew 4x8 Needle plate unit Needle plate Support needle pla...

Page 40: ...38 PARTS LIST 2160DC DXL603 1 5 2 3 4 6 7 8 9 10 11 13 12 12 18 12 12 19 14 15 16 17 10 10 12 12...

Page 41: ...03 502009000 000081005 822020503 808622105 808060202 840602006 000104108 808061007 808508001 Rear cover unit Rear cover Top cover thread guide unit Setscrew 2 6x5 Thread guide unit Snap ring CS 8 Spoo...

Page 42: ...40 PARTS LIST 2160DC DXL603 31 28 32 28 29 30 30 30 1 2 4 5 7 8 9 10 11 6 11 11 12 13 14 15 16 17 22 23 24 21 18 20 19 25 25 26 27 28 3...

Page 43: ...unit UK Front cover U S A Continental Europe Front cover UK Front cover lid Panel U S A Cntinental Europe Panel UK Button 1 Button 2 Slide volume Slide volume set plate Setscrew 2 6x6 B Printed circu...

Page 44: ...42 PARTS LIST 2160DC DXL603 1 2 3 4 5 6 7 8 9 10 11 12 17 18 19 13 14 15 16...

Page 45: ...830377008 C 1036 808800109 808800121 808800109 741811000 484701022 Attachment unit Satin foot Zipper foot Blind hem foot Overedge foot Bobbin Assorted needle set Screw key Lint brush Seam ripper Butto...