Janome Air Thread 2000D Professional, Service Bulletin

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Page 2: ...ed Tools and Gauges Phillips Head Screwdriver Large Phillips Head Screwdriver Medium Phillips Head Screwdriver Fine Tip Flat Head Screwdriver Large Flat Head Screwdriver Medium Needle Clamp Screwdrive...

Page 3: ...3 Required Tools and Gauges Needle Plate Screwdriver Small 1 5mm Allen Key 2 0mm Allen Key 2 5mm Allen Key 3 0mm Allen Key 1 5mmHexagon Driver 2 0mm Hexagon Driver 2 5mm Hexagon Driver...

Page 4: ...4 Required Tools and Gauges 3 0mm Hexagon Driver 7 0mm Nut driver 7 0mm Wrench Tweezers Scissors...

Page 5: ...5 Required Tools and Gauges Step Gauge Lower Looper Timing Gauge...

Page 6: ...6 Required Tools and Gauges Needle Bar Gauge Set Upper Looper Timing Gauge...

Page 7: ...7 Top Cover Removal Loosen the 2 screws that hold the top cover Gently start lifting up the top cover...

Page 8: ...8 Top Cover Removal Release the 6 locking hooks then remove the top cover...

Page 9: ...9 Face Plate Removal Using the tip of the needle gently remove the cap Use a phillips screwdriver to loosen and remove the screw...

Page 10: ...10 Face Plate Removal Slightly lower the needle threader lever about 4 5mm then pull the face plate from the back to release it then remove it...

Page 11: ...11 Presser Foot and Looper Cover Guide Removal Loosen the screw then remove the presser foot unit Push the looper cover door to the right to open...

Page 12: ...12 Presser Foot and Looper Cover Guide Removal Loosen and remove the 2 screws Remove the looper cover guide door...

Page 13: ...13 Belt Cover Removal Using the tip of the needle gently remove the cap Loosen and remove the screw...

Page 14: ...14 Belt Cover Removal Loosen and remove the screw that holds the belt cover to the bottom of the machine Gently start releasing the hooks...

Page 15: ...15 Belt Cover Removal Once you release the 4 hooks then remove the belt cover Hook Hook Hook Hook...

Page 16: ...Lift the base cover to clear the rubber cushion then remove the cover Remove the 3 hinge screws together with the black rubber cushions Remove the setscrew circled DO NOT remove the bottom left rubber...

Page 17: ...Disconnect the hook from the cover remove the cover Important Before you remove the looper cover note that the detecting arm hook is positioned between the 2 C clips When you install back the cover p...

Page 18: ...18 Side Cover Removal Remove the side cover door Remove the 2 screws...

Page 19: ...19 Front Cover Removal Turn the handwheel to bring the upper looper shaft to its lowest point Remove the screw and the needle plate...

Page 20: ...20 Front Cover Removal Loosen the screw do not remove it Loosen the screw do not remove it...

Page 21: ...21 Front Cover Removal Loosen the screw do not remove it Loosen the screw do not remove it...

Page 22: ...22 Front Cover Removal Loosen the screw do not remove it Loosen the screw do not remove it...

Page 23: ...23 Front Cover Removal Lift the looper threader lever half way Remove the screw...

Page 24: ...t Cover Removal Push the looper threader lever all way up then remove the front panel Push the front cover slightly up until it clears the detecting arm hook then slowly pull the cover away from the m...

Page 25: ...25 Rear Cover Removal Remove the screw Remove the 2 screws...

Page 26: ...26 Rear Cover Removal Remove the rear cover Loosen the screw...

Page 27: ...27 Upper Knife and Front Guard Removal Remove the 2 screws Remove the hexagon bolt then remove the upper knife...

Page 28: ...28 Upper Knife and Front Guard Removal Remove the front guard Lift the front feed dogs slightly then start pulling the front guard away from the machine...

Page 29: ...29 Adjusting Needle Bar Height Install the needle plate Remove the left needle...

Page 30: ...0 Adjusting Needle Bar Height The distance between the tip of the right needle HA x 1SP 14 and the surface of the needle plate should be between 11 6mm 12 2mm when the needle is at the highest positio...

Page 31: ...adjustment is needed first locate the hole on the needle threader shaft Raise the needle bar to the highest point Take the AT2000D step gauge and place it under the needle The tip of the needle shoul...

Page 32: ...or down to the proper position DO NOT rotate the needle bar or the alignment with the presser foot and needle plate will be off Using a 2mm hexagon driver insert the tip of the driver into the needle...

Page 33: ...33 Adjusting Presser Bar Height The distance between the bottom of the of the presser foot and the surface of the needle plate should be between 5 2mm 5 8mm when the presser foot is up...

Page 34: ...Adjusting Presser Bar Height Raise the presser foot insert the step gauge just under the presser foot pin then lower the presser foot Install the presser foot push it all way up then tighten the scre...

Page 35: ...ting Presser Bar Height Loosen the 2 5mm hexagon screw and move the presser bar up or down to the proper position DO NOT rotate the presser bar or the alignment with the needle plate and feed dogs wil...

Page 36: ...djusting Main and Sub Feed Dogs The highest position of main and sub feed dog should be between 0 9mm 1 1mm from the surface of the needle plate Press and hold the release lever to remove the presser...

Page 37: ...or lower the feed dog as needed Tighten the 3 0mm hexagon screw If an adjustment is needed loosen the 2 0mm screw then using a 2 0mm hexagon wrench turn the 2 0mm adjusting screw clockwise to raise t...

Page 38: ...38 Replacing Lower Looper Using a pair of tweezers gently start pushing down the clear rubber tube until the lower looper pipe and the connecting pipe are disconnected Remove the needle plate...

Page 39: ...Gently connect the 2 metal pipes Using the tweezers gently start pushing the clear rubber tube up until the rubber tube is the middle of the 2 metal pipes Turn the handwheel toward you to bring the l...

Page 40: ...the Philips head screw move the looper up or down to the 65 7mm position When done tighten the screw Please DO NOT overtighten the screw Place the lower looper gave U groove onto the lower looper shaf...

Page 41: ...g Insert the clamp then insert the spacer push them up until the spacer is resting against the needle bar bushing Tighten the wing head thumb screw Turn the handwheel to bring the needle bar to its lo...

Page 42: ...t this point the tip of the lower looper should be entering the right needle exactly as shown above Remove the black spacer Very slowly turn the handwheel toward you until the clamp is resting against...

Page 43: ...bolt at the bottom of the lower looper arm To adjust loosen the 7mm hexagon bolt slightly at the bottom of the lower looper arm and move the lower looper arm into position Then tighten the screw Be s...

Page 44: ...the bottom of the lower looper arm To adjust loosen the 7mm hexagon bolt slightly at the bottom of the lower looper arm and move the lower looper arm into position Then tighten the screw Be sure to c...

Page 45: ...ween the needles and rear guard should between 0 05 0 25mm Turn the handwheel to bring the needle bar to it s lowest point Loosen the two 2 5mm hexagon screws Move the needle guard closer or away to o...

Page 46: ...ween the needles and rear guard should between 0 05 0 25mm Turn the handwheel to bring the needle bar to it s lowest point Loosen the two 2 5mm hexagon screws Move the needle guard closer or away to o...

Page 47: ...should between 0 0 05mm Install the front needle guard move it closer or away from the needles to obtain the correct clearance Hold the front needle guard in position and tighten the 2 screws Be sure...

Page 48: ...Using a pair of tweezers gently start pushing down the clear rubber tube until the upper looper pipe and the connecting pipe are disconnected Using a 2 0mm hexagon wrench loosen the screw on the uppe...

Page 49: ...49 Removing and Installing Upper Looper Gently pull the upper looper to the left Remove the looper Install the upper looper do not tighten the 2 0mm screw yet...

Page 50: ...the 2 0mm hexagon screw temporarily be sure the upper looper does not hit the lower looper Gently connect the 2 metal pipes Using the tweezers gently start pushing the clear rubber tube up until the...

Page 51: ...ntil the bulge of the gauge touches the upper looper pin Rotate the upper looper until the tip of the looper is aligned with the guide line Tighten the 2 0mm temporarily Remove the Gauge Turn the hand...

Page 52: ...ntil the bulge of the gauge touches the upper looper pin Rotate the upper looper until the tip of the looper is aligned with the guide line Tighten the 2 0mm temporarily Remove the Gauge Turn the hand...

Page 53: ...e the upper shaft up or down to obtain the 1 2mm clearance Tighten the screws Turn the handwheel towards you to bring the upper looper shaft to its lowest point The clearance between the upper looper...

Page 54: ...54 Upper Looper Timing When the upper looper is at the leftmost position the distance between the center of the right needle and the tip of the upper looper should be between 7 8mm 8 2mm...

Page 55: ...oper should be between 0 0 01mm To make an adjustment loosen the 2 0mm screw on the upper shaft obtain the correct clearance then tighten the screw If an adjustment is needed loosen the 2 0mm hexagon...

Page 56: ...Timing The Fig 1 shows the correct distance between the 2 loopers when the lower looper is moving from left to right and the upper looper is moving upward Fig 2 and 3 show incorrect timing Incorrect t...

Page 57: ...Looper Timing If an adjustment is needed loosen the two 2 0mm hexagon screws If you need to advance the upper looper move the cam away from you to delay the upper looper move the cam towards you Tigh...

Page 58: ...justing Chaining Finger Position Set the chaining finger lever to S position If an adjustment is needed loosen the two 1 5mm hexagon screws Move the chaining finger set plate as needed Tighten the 2 s...

Page 59: ...59 Lower Knife Removal Installation If it becomes necessary to replace the lower knife use a Phillips screwdriver to remove the 2 screws Install a new knife then tighten the screws...

Page 60: ...Adjusting the Upper Knife Height Timing When the upper knife is at the lowest position the front lower corner of the upper knife should be between 1 0mm 2 0mm below the cutting edge of the lower knif...

Page 61: ...Knife Height To adjust the upper knife height turn the handwheel towards you to bring the knife to its lowest position Loosen the hexagon bolt move the knife both directions to the correct positions...

Page 62: ...Knife Timing When the needle bar is at the highest position the upper knife should be also at the highest position If an adjustment is needed loosen the two 2 0mm screws rotate the cam to correct it t...

Page 63: ...t is needed use a small screwdriver to raise the adjusting plate then turn the dial as shown above Set the tension dials at 3 If you have a tension gauge use a 50 weight thread The following list are...

Page 64: ...lower looper threads meet at the edge of the fabric and both needle threads are tight in the fabric When the left needle tension is loose you will notice these loops on the bottom of the fabric To co...

Page 65: ...edle tension turn the right needle tension to a higher number When either upper looper tension is too loose or the lower looper tension is too tight or both the upper looper thread is pulled to the bo...

Page 66: ...66 Removing and Adjusting the Needle Threader Pull the needle threader unit towards the back to remove Remove the 2 screws...

Page 67: ...67 Removing and Adjusting the Needle Threader Release the threader shaft by rotating the holding plate then swing it upward Using a Phillips screwdriver remove the small screw...

Page 68: ...der While holding the plate onto the shaft insert the left side of the plate into the threader plate then push the needle threader upwards 3 Insert the holding plate 1 onto to the black shaft then pus...

Page 69: ...69 Removing and Adjusting the Needle Threader Install the needle threader unit Tighten the screw...

Page 70: ...eader Lower the needle threader shaft Check both needles if an adjustment is needed loosen the screw move the threader plate up down or left right then tighten the screw Bring the needle threader shaf...

Page 71: ...71 Removing and Installing the Looper Threader Air Remove the 5 screws...

Page 72: ...stalling the Looper Threader Air Grab the looper threader air unit pull it up then remove it Reinstall the looper threader air make sure to place the looper thread air base plate behind the cover dete...

Page 73: ...73 Removing and Installing the Looper Threader Air Insert and tighten the screw Insert and tighten the 4 screws...

Page 74: ...bleshooting and Adjusting the Looper Threader Air When threading the upper or lower looper using looper threader air and a 60 thread a thread of 30mm 1 5 or longer should come out from the eye of the...

Page 75: ...75 Troubleshooting and Adjusting the Looper Threader Air Never drop oil or grease into the upper and lower looper air threading holes because it will clog the pipes...

Page 76: ...nd Adjusting the Looper Threader Air If the length of the thread from one of both looper is coming out short or fails to come out it is possible that there is lint or thread stuck in the pipes or the...

Page 77: ...e Looper Threader Air The AT2000D comes with 2 looper threading wires Open the kit using one wire insert the tip of the wire into the looper threading hole DO NOT insert the closed end of the wire Ins...

Page 78: ...Slowly continue to feed the wire through the pipe until the wire comes out from the eye of the looper about 3 inches DO NOT use thread heavier that 60 Knot the thread into wire hook then pull the wir...

Page 79: ...79 Troubleshooting and Adjusting the Looper Threader Air While holding the thread from both ends pull and release the thread several times until lint has been removed...

Page 80: ...er Air Very Important Whenever you adjust upper or lower looper shaft or remove reinstall the air thread system you must always check the air pipes to make they are aligned precisely otherwise the air...

Page 81: ...81 Troubleshooting and Adjusting the Looper Threader Air If an adjustment is needed please loosen the appropriate screws align the pipes then tighten the screws...

Page 82: ...82 Removing Motor and Machine Socket Unit Loosen the 2 screws Remove the motor belt...

Page 83: ...83 Removing Motor and Machine Socket Unit Remove the 2 screws Remove the 2 large screws...

Page 84: ...84 Removing Motor Machine Socket Unit and C Board Remove the 2 screws Using a 5 0mm hexagon nut driver loosen and remove the nuts Disconnect the motor terminals remove the motor...

Page 85: ...85 Removing Motor Machine Socket Unit and C Board Remove the 2 screws Remove the C board cover...

Page 86: ...86 Removing Motor Machine Socket Unit and C Board Remove the screw Pull the circuit board C away from the top cover Disconnect the white harness by pulling it up...

Page 87: ...rd If it becomes necessary to replace the C board using a hexagon nut driver remove the 2 nuts from the machine socket unit Disconnect the C board terminals then remove the C board Reconnect the white...

Page 88: ...88 Reinstalling Motor Machine Socket Unit and C Board Be careful not to pinch the wires Reinstall the cover Tighten the screws Reinstall and tighten the screw...

Page 89: ...89 Reinstalling Motor Machine Socket Unit and C Board Reconnect the motor terminals tighten the nuts Tighten the 2 screws...

Page 90: ...90 Reinstalling Motor Machine Socket Unit and C Board Reinstall the motor tighten the 2 large screws temporarily Reinstall the machine socket unit Tighten the 2 screws...

Page 91: ...or Machine Socket Unit and C Board Reinstall the motor belt Loosen the 2 large screws Adjust the motor belt timing to deflect between 5 6mm when you push it with your finger see above Tighten the 2 la...

Page 92: ...oot lifter is in the UP position the machine should not run If an adjustment is needed loosen the screw slightly move the micro switch set plate to the left then tighten the screw Micro switch contact...

Page 93: ...afety Switch When the front and side looper cover doors are closed the machine should not run If an adjustment is needed loosen the screw slightly move the micro switch set plate to the left then tigh...

Page 94: ...94 Removing and Reinstalling the LED Push the locking tab outward to open the LED holder Open the holder remove the LED from the holder...

Page 95: ...ng a pair of scissors or a cable tie cutter cut and discard the 2 cable ties Remove the LED cord from the rear cable guide Disconnect the LED connector from the machine socket unit Reverse the above s...

Page 96: ...96 Rear Cover Replacement Gently push the rear cover towards the machine Tighten the screw...

Page 97: ...97 Rear Cover Replacement Tighten the screw Reinstall and tighten the 2 screws...

Page 98: ...Replacement Put the take up lever in the middle position Grab the front cover stat to reinstall from the top Bring the rest of the front cover towards the front of the machine until it clears the dete...

Page 99: ...99 Front Cover Replacement Reinstall and tighten the screw Reinstall and tighten the screw...

Page 100: ...100 Front Cover Replacement Tighten the screw Tighten the screw...

Page 101: ...101 Front Cover Replacement Tighten the screw...

Page 102: ...102 Looper Cover Replacement Install and tighten the 2 screws Important Before you put back the looper cover make that the detecting arm hook is positioned between the 2 C clips...

Page 103: ...103 Side Cover Replacement Place the side cover on the machine Install and tighten the 2 screws Check to make sure the side cover is perfectly aligned with the needle plate and rear cover...

Page 104: ...104 Base Cover Replacement Place the base on the machine Reinstall the 3 hinge screws together with the black rubber cushions Reinstall the setscrew...

Page 105: ...105 Belt Cover Replacement Reattach the belt cover Be careful not to break the locking hooks Hook Hook Hook Hook...

Page 106: ...106 Belt Cover Replacement Push the belt cover until there is no gap between the belt cover and rear cover Install and tighten the screw...

Page 107: ...107 Belt Cover Replacement Reattach the cap Lay the machine on its back Reattach and tighten the screw...

Page 108: ...108 Presser Foot and Looper Cover Guide Replacement Reinstall and tighten the 2 screws Reattach the looper cover guide door...

Page 109: ...109 Face Plate Replacement Slightly lower the needle threader lever about 4 5mm then attach the face plate to the machine...

Page 110: ...110 Face Plate Installation Reattach the cap Reinstall and tighten the screw...

Page 111: ...111 Top Cover Replacement Place the top cover hooks on top of the front panel...

Page 112: ...112 Top Cover Replacement Tighten the 2 screws Gently lower the top cover...