Tuesday, February 07, 2017

Janome sewing machine - Janome 2160DC - DXL603 – Troubleshooting – Mechanical adjustment – Self diagnosis

TROUBLESHOOTING
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.
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.
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
6. Noisy operation
1. Backlash 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.
# Oil all moving parts.
# Eliminate the looseness.
7. Deformation pattern
1. Inappropriate feed balance.
2. Top tension is too strong.
Adjust the feed balancing screw.
MECHANICAL ADJUSTMENTS 
Presser bar height Adjustment
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 (2).
3. Loosen the setscrew (1). Raise the presser foot lifter and tighten the setscrew (1) 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.
Adjustment of hook timing
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 (2) (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 (2) (2 pcs.).
9. Attach the free-arm cover, bobbin holder and needle plate.
Adjustment of needle bar height
Before proceeding with this adjustment, check the hook timing . 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 (1).
6. Move the needle bar to adjust the needle bar height, and tighten the hexagonal socket screw (1). Be careful not to turn the needle bar.
7. Attach the bobbin holder, needle plate and face cover.
Top tension
The top tension should be between 65 and 80g when pulling the thread up in the direction of C.
3 Use polyester sewing thread #50 (White).
# If it is not within the above 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 tight, turn the lead screw in the direction (B).
4. Check the top tension and attach the cover.
Self-diagnostic Test
Preparation:
1. Turn the power switch off.
2. Move the bobbin winder spindle to the left.
3. Raise the feed dog.
4. Set the speed control lever to the left.
5. Remove the presser foot and raise the presser foot lifter.
6. Turn the hand wheel toward you to raise the needle to its highest position.
Notes:
# Be careful: the sewing machine may start running in its own while in test mode.
# Turn off the power switch before replacing any parts.
# Repeat the diagnostic test until the problem has been resolved.
# You can skip steps in the diagnostic procedure and go directly 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 the following problems occur, take the recommended actions in the order they are shown.
1. The machine does not respond when the power switch is turned on:
# Check each connector connection
# Replace the machine socket
# Replace the Switching regulator.
# Replace the A-board
2. The sewing machine lamp does not light up:
# Replace the light bulb
# Replace the A-board
To enter self-diagnostic mode:
1.Turn the power switch on while simultaneously pressing needle up/down button and the locking stitch button.
2. The LCD display will indicate “01”.
3. Press the start/stop button to enter the self-diagnostic mode.