SERVICE MANUAL
Contents
1. DXL603 PARTS LIST KEY PARTS NO NO DESCRIPTION 1 808618005 Presser foot pressure adjustment unit 2 808077006 Presser foot pressure adjusting set plate 3 808078100 Presser foot pressure dial 4 808079008 Adjusting arm 1 5 808080002 Adjusting arm 2 6 000002105 Snap ring E 3 7 000081005 Setscrew 4x8 8 808626006 Needle plate unit 9 808067003 Needle plate 10 808068004 Support needle plate 11 000163703 Setscrew 2x3 5 12 502015009 Spring 13 000015503 Snap ring SC 2 4 14 502016000 Hook cover plate release button 15 502202005 Supporter plate 16 000130206 Setscrew 1 7x2 5 B 17 508116009 Nut 18 820390109 Setscrew 19 846271103 Hook cover plate 20 808614001 Idler unit 21 808038005 Idler set plate 22 625217100 Idler 23 000002806 Snap ring E 6 24 000115607 Setscrew TP 4x8 25 808615002 Bobbin winder unit 26 808039006 Bobbin winder set plate 27 508507001 Bobbin winder arm unit 28 000001609 Snap ring E 5 29 508111004 Clutch lever 30 000120203 Setscrew 3x8 B 31 856512100 Reef switch unit 32 000081706 Setscrew 2 5x5 33 808040000 Spring 34 000013903 Snap ring CS 5 35 808617004 DC motor unit 36 808502005 DC motor unit 37 000115700 Setscrew TP 4x10 38 808639301 Switching regulator unit U S A 808639208 Switching regulator unit Continental Europe UK 39 808525303 Switching regulator unit U S A 808525200 Switching regulator unit Continental Europe UK 40 000103509 Setscrew 4x10 41 808504007 Printed circuit board2. lt 0 2 mm or more or more 10 Mechanical Adjustment Adjustment of hook timing The amount of ascending travel of the needle bar from its lowest position to the position gt where the tip of the rotary hook exactly meets the right side of the needle should be 3 25 to 3 55 mm Remove the needle plate and bobbin holder Turn the power switch on Select the pattern E left position Set the zigzag width at 0 Remove the free arm cover Turn the handwheel toward you to lower the needle at its lowest position Loosen the hexagonal socket screw 2 2 pcs Move the needle bar 3 4 mm from the lowest position Turn the lower shaft gear until the tip of hook meets the right side of the needle while holding the handwheel Tighten the hexagonal socket screw 2 2 pcs Attach the free arm cover bobbin holder and needle plate wo MN oO oO Y O 0 Needle plate Bobbin holder Lower shaft gear Tip of hook meets the right side of the needle 1 Left position 3 25 3 55mm Lowest needle position 11 Mechanical Adjustment Adjustment of needle bar height 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 n
3. P unit 42 808093008 Cord guide 43 000188209 Nylon clip ACC 1 5 44 000188405 Nylon clip ACC 2 37 2160DC DXL603 PARTS LIST 2160DC DXL603 PARTS LIST KEY PARTS NO NO DESCRIPTION 1 808619006 Rear cover unit 2 808050106 Rear cover 3 827503108 Top cover thread guide unit 4 000162001 Setscrew 2 6x5 5 650503403 Thread guide unit 6 000014409 Snap ring CS 8 7 502007008 Spool pin 8 502008009 Spool pin support plate 9 000120203 Setscrew 3x8 B 10 739064003 Bed rubber cushion 11 502009000 Carrying handle 12 000081005 Setscrew 4x8 13 822020503 Spool holder 14 808622105 Face plate unit 15 808060202 Face plate 16 840602006 Thread cutter unit 17 000104108 Setscrew 4x20 18 808061007 Free arm cover 19 808508001 Extension table unit 39 2160DC DXL603 PARTS LIST 40 2160DC DXL603 PARTS LIST KEY PARTS NO NO DESCRIPTION 1 808630106 Front cover unit U S A Continental Europe 808630405 Front cover unit UK 2 808051200 Front cover U S A Continental Europe 808051705 Front cover Uk 3 808103002 Front cover lid 4 808072104 Panel U S A Cntinental Europe 808072403 Panel UK 5 808071103 Button 1 6 808054100 Button 2 7 808055008 Slide volume 8 808056102 Slide volume set plate 9 000160700 Setscrew 2 6x6 B 10 808505008 Printed circuit board A unit 11 000120203 Setscrew 3x8 B 12 808058104 Start stop button 13 808070102 Button 4 14 80850700
4. Presser foot lifter switch Green 43 DC motor White Controller Black Printed circuit board A Printed circuit board F 4 Y i Printed circuit board L 17 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 e 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 e Check each connector connection e Replace the machine socket e Replace the Switching regulator e Replace the A board 2 The sewing machine lamp does not light up e Replace the light bulb Replace the A board To enter self diagnostic mode mi LI Il or off 7 Tu
5. needle up down the 03 program button and the locking stitch button Replacing the Electronic Components Circuit board A 1 To remove 1 Remove the front cover See pages 6 7 2 Pull out connectors from the circuit board A 3 Remove the 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 Cirucit board A Setscrews Setscrews Setscrews Cirucit board F connector Cirucit board L connector 23 Replacing the Electronic Components Circuit board A 2 Setting the Circuit board A After install the circuit board A select the appropriate setting of the circuit boad A 1 Turn the power switch on while simultaneously pressing left cursor button E and the right cursor button After the buzzer sounds press the Icoking stitch button 1 within 2 5 seconds The LCD displays F A or d Press the locking stitch button to select the appropriate setting of the circuit board A e Model 3160QDC Press locking stitch button to select F e Model 2030DC XL601 Press locking stitch button to select A G e Model 2160QDC 2160DC DXL603 Press locking stitch button to select d Press the start stop button to determine the setting A long buzzer sounds when the setting correctly finished Turn th
6. 0 Printed circuit board F unit 15 000014306 Snap ring CS 3 16 808506009 Printed circuit board L unit 17 808057000 Lamp holder 18 735016307 Bobbin winder stopper 19 000101828 Setscrew 4x16 20 000071013 Washer 21 000061205 Nut 4 3 7 22 639005003 Rubber foot 23 000201405 Setscrew TP 4x16 24 000160102 Adjustable lock nut 4 25 739064003 Bed rubber cushion 26 000115205 Setscrew TP 4x6 27 000160401 Setscrew 4x16 B 28 000081005 Setscrew 4x8 29 808059105 Bed cover 30 000149312 Setscrew 3x8 31 639080002 Front cover set plate 32 808016007 Arm thread guide 41 2160DC DXL603 PARTS LIST 2 3 4 5 I gt SQ 6 7 8 A ES E ES 9 10 41 SES ESE D 12 13 14 Cs B 2 16 17 ZZ 2160DC DXL603 PARTS LIST KEY PARTS NO NO DESCRIPTION 1 808870007 Attachment unit 2 822804118 Satin foot 3 829801002 Zipper foot 4 825817009 Blind hem foot 5 822801001 Overedge foot 6 102261000 Bobbin 7 639804000 Assorted needle set 8 653802002 Screw key 9 802424004 Lint brush 10 647808009 Seam ripper Buttonhole opener 11 822019509 Spool holder 12 829803004 Spool stand 13 625031500 Spool pin 14 102403109 Felt 15 753801004 BH foot 16 856519004 Power supply cord U S A 830335004 Power supply cord Continental Europe 830377008 Power supply cord UK 17 C 1036 Foot control 18 808800109 Instruction book U S A 808800121 Instruction book Con
7. SERVICE MANUAL 2160DC DXL603 WV Eo COs WG g EEEE ae ee ta ends a E cha een seele 1 3 Changing External Parts FACE COVER OR E E E TE 4 Freesarim A ieee A ea 5 OM COVER ee ee uate avenraesamwcataseatyuahecsencneset 6 7 Rear IR sitive sehr teeta eae el ne alles oa acs ty See es ha ghey ta bt a tec ee eat co 8 Mechanical Adjustment Presser e 9 Needle Drop Position et ER ol EE 10 Adjustment of Hook Timing iarere E ae RR RE 11 Adjustment of Needle Bar Height ooooonoccccnnnnnocicinnnncoccccnnnnoncccnnn nn rc cn nano nc ccn nn rr 12 Clearance between Needle and Tip of Hook Rotary 13 A O SEE 14 Feed Dog Adjustment Only for model 3160QDC dococccconncccnonoccnononanononcconnanano conc nc nn non nn nn canarias 15 TOP TENSION A ES 16 Replacing the Electronic Components Circuit Board A connection os i en a Rad Ras 17 Self diagn stie Test OO 18 22 CircuitiBoard A ann ae Als tte AS 23 24 Driving MO SE reo RN 25 Switching regulator Unit tira ea 26 Adjusting Buttonhole Lever Position ooooccocnnnnnnccnnnnnocccccnnnnoncccnan nro rc cnn nar n cc nn rc 27 PartsiEist as ae lo tad io to lo aaa td lo e lo do dt cala tate da 29 43 What to do when Condition Cause How to fix Reference 1 Skipping 1 Needle is not inserted properly Insert the needle properly Stitches 2 Needle is bent or worn Change the needle 3 Incorrectly threaded Rethre
8. ad 4 Needle or thread are Use the recommended sewing needle inappropriate for the fabric being and thread sewn 5 Sewing on stretch fabric Use a HA x 11 blue tip needle 6 Inappropriate needle bar height See mechanical adjustment Needle bar P 12 height 7 Inappropriate needle to hook See mechanical adjustment Adjustment P 11 timing of hook timing 8 Inappropriate needle to hook See mechanical adjustment Clearance P 13 clearance between needle and tip of the rotary hook 2 Fabric not 1 Incorrect feed dog height Adjust the presser bar level to make the P 14 moving pressure stronger See mechanical 2 Feed dog is in down position 3 Thread on bottom side of fabric is jammed up 4 Feed dog teeth are worn 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 Condition Cause How to Fix Reference 3 Breaking 1 Initial sewing speed is too fast Start with medium speed upper thread 2 Thread path is incorrect Use the proper thread path 3 Needle is bent or dull Replace with a new needle 4 Top tension is too strong Adjust top tension correctly 5 Needle size is inappropriate for Use appropriate needle for fabric and fabric thread in use Needle eye is worn Change the needle Needle hole in needle plate is Repair the hole or replace the needle worn or burre
9. andwheel toward you LCD displays SC 07 Zigzag motor does not get default position REMEDY Replace the zigzag motor Replace the circuit board A Feed motor does not get default position REMEDY Replace the feed motor Replace the circuit board A 20 Self diagnostic Test Step and da e items to check Procedure Correct Condition Defective Condition 08 Attach the foot control to the sewing LCD displays SC 08 The foot control symbol does Foot control machine Depress the foot control as far as it goes then release it If the result is correct condition press the start stop button to proceed the next step If the result is defective condition press the reverse stitch button to proceed the next step LF e a The foot control symbol appears when the foot control is attached ur x non L u g uu Buzzer sounds when the foot control is deeply depressed Buzzer sounds when the foot control is relased not appear Buzzer does not sound REMEDY Replace the foot control Replace the machine socket Replace the circuit board A 09 Shift the slide volume from left to right LCD displays SC 09 Buzzer does not sound Slide volume then return to the left cr REMEDY If the result is correct condition press 34 0900 Replace the circuit board A the start stop button to proceed the gt next step Buzzer sounds at right or lef
10. aster needle Attach the bobbin holder and needle pate 7 Check the clearance between the needle and the edge of the needle hole in the needle plate see page 10 Needle plate Needle bar supporter adjusting plate Bobbin holder Tip of hook 0 1 to 0 05 mm 13 Mechanical Adjustment Feed dog height The highest position of the feed dog should be between 0 80 and 0 90 mm from the surface of the needle plate Lower the presser foot and turn the power switch on Turn the handwheel toward you to set the feed dog at the highest position Remove the free arm cover Loosen the setscrew A and nut Adjust the feed dog height by turning the adjusting screw 3 The highest position of the feed dog should be between 0 80 and 0 90 from the surface of the needle plate 6 Tighten the nut and setscrew A 7 Attach the free arm cover ar 0 MN Presser foot 0 80 0 90mm Sr eo Y Le ra MA Fre E _ Feed dog Surface of the needle plate 14 Mechanical Adjustment Feed dog adjustment Only for model 3160QDC The highest position of the feed dog should be parallel to the surface of the needle plate If not adjust as follows 1 Use a hexagonal socket screw 4 x 6 Insert the screw to the hole B Tighten the hexagonal socket screw as far as it goes 2 Loosen the setscrew C left screw 3 Turn hexagonal socket scre
11. d plate 4 Breaking Bobbin holder is incorrectly Set the bobbin thread correctly bobbin thread threaded Too much thread is wound on Adjust the position of bobbin winder the bobbin stopper Lint is stuck inside the bobbin Clean the bobbin holder holder Thread quality is too low Change to a high quality sewing thread Thread is jamming around the Clear out the jamming thread bobbin holder 5 Needle Needle is hitting the needle plate See mechanical adjustment Needle P 10 breakes drop position Needle is bent or worn Change the needle Needle is hitting the hook See mechanical adjustment Clearance P 13 Fabric is being pulled too strongly while sewing between needle and tiip of the rotary hook Guide the fabric gently while sewing Condition Cause How to fix Reference 6 Noisy 1 Backlash between hook gear and Eliminate the backlash operation lower shaft gear is too great 2 Lower shaft gear is loose Eliminate the looseness 3 Inappropriatte belt tension See part removal and replacement P 25 driving motor DC motor 4 Not enough oil Oil all moving parts 5 Upper shaft gear is loose Eliminate the looseness 7 Deformation 1 Inappropriate feed balance Adjust the feed balancing screw pattern 2 Top tension is too strong See mechanical adjustment P 16 Top tension Changing External Parts Face cover To remove 1 Loosen t
12. djust the buttonhole sensor position 4 Attach the buttohole foot R 5 Lower the buttonhole lever to its lowest position and open a 1 6 mm gap between the slider and the buttonhole foot 6 Turn the adjusting screw to the left until the LCD display BH symbol 7 Next turn the adjusting screw to the right until the BH symbol disappears 8 Turn off the power switch 9 Attach the face cover Note If there is any lint or dust in the buttonhole sensor slit loosen the 2 screws B and clean it out with a swab To enter adjusting mode Turn the power swith ON while press Press the start stop button to ing the needle up down button and h locking stitch button simultaneously Acc HIS BIO BU 0S BH sensor 27 PARTS LIST MODEL 2160DC DXL603 2160DC DXL603 PARTS LIST 2160DC DXL603 PARTS LIST KEY PARTS NO NO DESCRIPTION 1 808601005 Upper shaft unit 2 000111201 Hexagonal socket screw 4x4 3 000112800 Hexagonal socket screw 4x6 4 000036201 Washer FT80 5 508054008 Shaft fixing metal 6 820166001 Lower shaft ring 7 808003001 Upper shaft shielding plate 8 000004200 Spring pin 3x18 9 508021006 Upper shaft gear 10 000024206 Spring pin 3x30 11 502064003 Clutch ring 12 661024007 Clutch spring 13 508055009 Belt wheel 14 000002806 Snap ring E 6 15 731312005 Felt 16 000081005 Setscrew 4x8 17 508056000 Handw
13. dth rod 33 827088009 Zigzag width rod spring 34 820373003 Setscrew 2x3 35 678084007 Eccentric pin 36 808074003 Washer 37 000111902 Hexagonal socket screw 3x4 38 808009007 Supporter adjusting plate 39 000036500 Washer FT60 40 673022002 Spring washer 41 000070609 Washer 6 42 000013903 Snap ring CS 5 43 000072003 Washer 5 44 000101404 Setscrew 4x6 45 808010001 Supporter guide plate 46 508607105 Needle bar unit 47 808011002 Threader position set plate 48 000177205 Hexagonal socket screw 4x4 49 508509003 Needle bar connecting stud unit 50 844038018 Needle bar supporter spring 51 808606000 Buttonhole sensor unit 52 845002005 Sensor set plate 53 843502602 Printed circuit board E1 unit 54 000101105 Setscrew 3x4 55 830057021 Buttonhole lever guide 56 000103808 Setscrew 3x5 57 843625004 Buttonhole lever unit 58 808605009 Zigzag width motor unit 59 000053008 Cord binder 60 625102008 Washer 61 000081005 Setscrew 4x8 62 102408089 Needle HA1 14 63 660509008 Presser foot unit 64 832523007 Zigzag foot 65 660806008 Presser foot holder 66 660106001 Setscrew 33 2160DC DXL603 PARTS LIST 34 2160DC DXL603 PARTS LIST KEY PARTS NO NO DESCRIPTION 1 808632005 Hook race whole unit 2 808629009 Hook race unit 3 808634007 Lower shaft unit 4 808027001 Lower shaft 5 508021006 Upper shaft gear 6 000004200 Spring pin 3x18 7 000038502 Washer 8 508054008 Shaft fixing
14. e power switch off Model 3160QDC Model 2030DC Model 2160DC 24 Replacing the Electronic Components Driving motor To remove 1 Remove the front cover 2 Remove the setscrews 2pcs and the driving motor and the belt To attach 1 Install the driving motor and the motor 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 Tighten the setscrews 2pcs firmly 3 Attach the rear cover and the front cover Setscrew Setscrew DC motor unit 25 Replacing the Electronic Components Switching regulator unit To remove 1 Remove the front cover and 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 Switching regulator Setscrew A Setscrew A ped Setscrew B Setscrew A 26 Mechanical Adjustment Adjusting buttonhole lever position To adjust the buttonhole lever guide 1 Enter the buttonhole sensor adjusting mode See below The LCD should display BH symol 2 Remove the face cover see page 4 and loosen the setscrew A 3 Move the buttonhole lever guide so the BH symbol disappear when the buttonhole lever is lowered Tighten the setscrew To a
15. eedle ascends from its lowest position Remove the needle plate bobbin holder and face plate Turn the power switch on Select the pattern L left position Set the zigzag width at 0 Turn the handwheel toward you until the tip of hook meets the right side of the needle Loosen the hexagonal socket screw 1 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 oak oO IO Needle plate Hexagonal socket screw Bobbin holder Tip of hook meets the right side of the needle xe Hook race Left position 14 N Y 1 6 2 0 mm f le hol Hook race unit Upper edge of needle hole 12 Mechanical Adjustment Clearance between needle and tip of the rotary hook The clearance between the needle and the point of hook should be 0 1 to 0 05 mm Adjustment procedure 1 Remove the needle plate and bobbin holder Attach the master needle Turn the power switch on and set the zigzag width at maximum 2 Remove the face cover 3 Loosen the setscrew A 2 pcs 4 Turn the handwheel toward you Adjust the clearance between the needle and the tip of the rotarty hook by moving the hook base plate up or down to 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 m
16. he setscrew 1 and lift the face cover to disengage the rib on the inside Remove the face cover To attach 2 Follow the above procedures in reverse Changing External Parts Free arm cover To remove 1 Loosen the setscrew 1 and Move the free arm cover to the left Remove the free arm cover To attach Follow the above procedures in reverse ri 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 2 pcs 3 Remove the setscrews B 5 pcs back cover 4 Remove the setscrews C 4 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 JANOME 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 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 4 pcs 3 Remove the setscrews B 5 pcs and back cover 4 Remove the setscrews C 3 2 pcs Remove the rear cover To attach 5 Follow the above procedures in reverse Back cover TAN 00 Rear cover Mechanical Adjust
17. heel 18 508634101 Thread take up lever unit 19 000103509 Setscrew 4x10 20 000072302 Washer 4 21 808021005 Timing belt 22 808037004 Syncro belt 23 808511007 Thread tension unit 24 808005003 Needle bar crank rod 25 000036005 Washer FT60 31 2160DC DXL603 PARTS LIST 32 2160DC DXL603 PARTS LIST KEY PARTS NO NO DESCRIPTION 1 808640006 Presser bar base plate unit 2 808006200 Presser bar base plate 3 808007005 Thread tension release lever 4 503041007 Thread tension release spring 5 502024001 Presser foot lifter 6 000001609 Snap ring E 5 7 808076005 Presser bar spring adjusting plate 8 000072508 Washer 4 9 000002105 Snap ring E 3 10 508002104 Presser bar 11 808081003 Presser bar spring 12 508039007 Presser bar supporter 13 000111500 Hexagonal socket screw 4x8 14 808603007 Needle bar supporter unit 15 808008006 Needle bar supporter 16 842637006 Threader shaft unit 17 842638007 Threader plate unit 18 755064106 Threader guard plate 19 842088006 Thread retention plate 20 844095002 Threader plate 21 755096004 Setscrew 22 755095003 Nut 23 840036025 Threader shaft 24 000003508 Spring pin 2x8 25 000125105 Guide pin E 2x16 CH 26 842090001 Threader shaft spring 27 842096007 Threader lever spring 28 842091002 Threader guide plate 29 844036027 Threader lever plate 30 842092003 Threader lever 31 000078319 Setscrew 3x6 32 808015006 Zigzag wi
18. ment 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 3 Loosen the setscrew Raise the presser foot lifter and tighten the setscrew 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 IR dq SHE IKE A IB EA II 1 7 E q R So Presser foot should be parallel to the feed dog slots rie Sane Mechanical Adjustment Needle drop position Set the stitch pattern to af The standard needle drop position should be at center of the needle plate hole 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 2 Adjust the needle drop position by turning the eccentric pin 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 0 2 mm
19. metal 9 820166001 Lower shaft ring 10 000111201 Hexagonal socket screw 4x4 11 808028002 Feed fork 12 751150005 Actuator plate 13 808026000 Feed fork spring 14 000101105 Setscrew 3x4 15 808029003 Feed cam 16 000115009 Setscrew TP 3x8 17 508023008 Lower gear 18 508020005 Ring 19 000111108 Hexagonal socket screw 4x6 20 753183025 Feed lifting cam 21 820161006 Feed lifting pin 22 686035008 Feed lifting cam spring 23 000002507 Snap ring E 4 24 732034003 Lower shaft bushing 25 000081005 Setscrew 4x8 26 808098003 Lower shaft bushing set plate 27 000115607 Setscrew TP 4x8 28 000101703 Setscrew 4x12 29 808613000 Feed motor unit 30 808030007 Feed motor set plate 31 808031008 Feed regulator shaft supporter 32 000071013 Washer 4 33 000116103 Spring washer 4 34 823038002 Setscrew 35 808033000 Feed regulator shaft 36 000014409 Snap ring CS 8 37 808096001 Feed regulator shaft spring 38 808034001 Feed regulator shaft 39 808035002 Feed regulator 40 000004004 Spring pin 2 5x10 41 625508204 Feed regulator unit 42 000004107 Spring pin 3x14 43 808094009 Feed regulator spring 44 000001609 Snap ring E 5 45 000013501 Snap ring CS 12 46 808509105 Stepping motor unit 47 808013004 Gear 48 000110406 Hexagonal socket screw 3x4 WP 49 627569106 Bobbin holder unit 50 102261000 Bobbin 35 2160DC DXL603 PARTS LIST qt y US 5 IM Li Y va Dos FR f 2160DC
20. ndition press Buzzer sounds when presser foot lifter is The presser foot symbol lifter switch the start stop button to proceed the raised or lowered does not appear when the next step presser foot is lowered or 7 The presser foot symbol appears when goes not disappear when If the result is defective condition the foot lifter is lowered the presser foot is raised press the reverse stitch button to proceed the next step REMEDY VW m 5 a Replace the circuit board A uU Replace the presser foot lifter switch Adjust the presser foot lifter Presser foot en 5 PN switch position symbol gt 06 Turn the handwheel toward you LCD displays SC 06 Buzzer does not sound Upper shaft Lower the needle bar from its highest Stitch width or length symbol positioning to its lowest position does not appear sensor Raise the needle bar from its lowest Li AE position to its highest position JL REMEDY Replace the circuit board A ER Turn the handwheel eee If the result is correct condition press op displays stitch width symbol when Replace the circuit board P the start stop button to proceed the the needle bar is at zigzag phase next step If the result is defective condition press the reverse stitch button to Stitch width proceed the next step symbol LCD displays stitch length symbol when the needle bar is at feed phase Stitch length JL DE symbol 07 Turn the h
21. rn the power switch on while simultaneously indicate 01 pressing needle up down button and the locking stitch button The LCD display will Press the start stop button to enter the self diagnostic mode 18 Self diagnostic Test Step and items aa ie to check Procedure Correct Condition Defective Condition 01 Turn on the power switch while Sewing lamp and LCD backlight lits Sewing lamp does not lit Function of simultaneously pressing the start stop LCD displays 01 LCD backlight does not lit LCD buzzer button and locking stitch button LCD does not display 01 and lamp Press the start stop button 1 1 Buzzer does not sound lfth Iti diti li l LCD does not turned on the result is correct condition press LCD does not display any the start stop button to proceed the Buzzer sounds symbols or not in order next step LCD displays symbols and numbers in order If the result is defective condition LCD repeats displaying after all symbols and REMEDY press the reverse stitch button to numbers are shown Replace the circuit board A proceed the next step aceon SW am 77 7 6000 02 Press buttons 1 7 LCD displays SC 02 Buzzer does not sound Button 4 1 Buzzer sounds when button is pressed LCD does not display the Button number is displayed when
22. s moved to Bobbin symbol is not switch Return it to the left the left buzzer sounds displayed en is a ee nn When the bobbin winder spindle is moved to _REMEDY e start stop button to proceed the 1 poet p p ite right buzzer soun and LCD displays Replace the circuit board A A the bobbin symbol Replace the circuit board F If the result is defective condition press the reverse stitch button to proceed the next step _ 8 Bobbin symbol L nu IL 19 Self diagnostic Test Zigzag motor Step motor Feed motor Lower the needle bar from its highest to its lowest position Raise the needle bar from its lowest position to its highest position If the result is correct condition press the start stop button to proceed the next step If the result is defective condition press the reverse stitch button to proceed the next step Lt AL Wie LCD displays stitch width symbol when the needle bar is at middle position Zigzag motor get default position Stitch width symbol LCD displays stitch length symbol when feed motor gets default position Stitch length symbol Jt irs Bobbin symbol Step and ads i items to check Procedure Correct Condition Defective Condition 05 Raise or lower the preser foot lifter LCD displays SC 05 Buzzer does not sound Presser foot If the result is correct co
23. t is correct condition press the start stop button to proceed the next step If the result is defective condition press the reverse stitch button to proceed the next step LCD display 12 Thread cutter motor wii be initialized Press the thread cutter button The thread cutter icon will appear and blink as long as the thread cutter button is pressed The thread cutter motor does not work Thread cutter symbol does not appear when the thread cutter button is pressed Thread cutter symbol appears when the thread cutter button is not pressed REMEDY Replace the thread cutter motor Replace the thread cutter switch Replace the circuit board A 21 Self diagnostic Test Buzzer sounds after few seconds when the self diagnostic test has been finished The test result has been determined Correct Ll da Buzzer sounds and LCD displays 00 IL FOO Defective LI Caution buzzer sounds and LCD displays the defective part ai number Refer to 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 the program Turn the power switch on The LCD display will Press the cursor button Press the start stop button to while simultaneously indicate 01 i 4 twice to display display the version of the pressing
24. t position If the result is defective condition press the reverse stitch button to proceed the next step 10 Press the needle up down button LCD displays SC 10 The machine motor does not DC motor start If the result is correct condition press The motor stops immedi the start stop button to proceed the a ately next step i in The motor runs unstable If the result is defective condition u press the reverse stitch button to Machine runs slow then fast and the REMEDY proceed the next step needle bar stops at its highest position Replace the DC motor Replace the circuit board A 11 Lower the presser foot LCD displays SC 11 The thread tension disc does Solenoid Press the needle up down button Press the needle up down position not open Applicable for i mi button to display on or of off only model If the result is correct condition press Thread tension disc opens while the REMEDY 3160QDC the start stop button to proceed the LCD displays on Replace the solenoid next step If the result is defective condition press the reverse stitch button to proceed the next step LI u Je lor LE Replace the circuit board A 12 Thread cutter motor Thread cutter button Applicable for only model 3160QDC Turn the handwheel toward you to raise the needle bar at its highest position Press the needle up down button If the resul
25. the number correctly il 5 button is pressed bes REMEDY num Replace the circuit board A QQ ID 2 p a LI As Replace the circuit board F lof ars 5 If the result is correct condition press L na the start stop button to proceed the a LIC at LCD displays S3 when button 1 d F e isplays S3 when button 1 is pressed lf the faa 5 a a LCD displays S4 when button 2 is pressed press o A CULO LCD displays S5 when button 3 is pressed POO EE LCD displays S6 when button 4 is pressed LCD displays S7 when button 5 is pressed LCD displays S8 when button 6 is pressed LCD displays S9 when button 7 is pressed 03 Lower the buttonhole lever LCD displays SC 03 Buzzer does not sound Buttonhole Move the buttonhole lever back and When the buttonhole lever is pulled buzzer BH symbol does not appear Sensor forth sounds and LCD displays BH symbol If the result is correct condition press When the buttonhole lever is pushed a ircuit board A the start stop button to proceed the epiace the cIrCUIt DO aro A os p p buzzer sounds and LCD displays BH Replace the circuit board F symbol If the result is defective condition press the reverse stitch button to proceed the next step BH symbol 04 Move the bobbin winder spindle to the LCD displays SC 04 Buzzer does not sound Bobbin winder right When the bobbin winder spindle i
26. tinental Europe 808800109 Instruction book UK 19 741811000 Cover U S A Continental Europe 484701022 Cover UK 43
27. w to adjust the 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 A Hexagonal socket scrw 4 x 6 Setscrew C Hole B left screw Setscrew C 15 Mechanical Adjustment Top tension The top tension should be between 65 and 80g when pulling the thread up in the direction of C 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 e If the top tension is too tight turn the lead screw in the direction B 4 Check the top tension and attach the cover Pull the thread at the speed of 110 mm sec in the direction of arrow A White polyester thread size 50 16 Replacing the Electronic Components Circuit board A Connection NOTE Do not disconnect the connectors by pulling on cord To disconnect grasp the connector not the cord Printed circuit board P Black 2 Feed motor White 3 Thread cutter motor 3160QDC exclusive White 4 Bobbin winding switch Blue Power switch White Zigzag width motor Green Solenoid 3160QDC exclusive Black Printed circuit board F White 9 Printed circuit board L White Program Red Buttonhole sensor program Red 42
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