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MACHINE DIAGNOSIS CLASS

MACHINE DIAGNOSIS CLASS. INTRODUCTION.

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MACHINE DIAGNOSIS CLASS

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  1. MACHINE DIAGNOSIS CLASS

  2. INTRODUCTION In the following chapters of this book we will learn how to diagnose many different models of Janome Sewing Machines. We will start from mid-range computerized following up to the high end embroidery machines. Even though there are many different models, it is important to remember that we can use the same thought process for many of them. You will see that many of the machines come up with different error codes, such as messages or numbers. In many instances this will lead us to where we have to work on, or maybe tell us what we have to replace. Even though maybe one message means one thing on one machine it may be represented by a different code on another. It is important to learn how to diagnose the machines by not only looking at error codes but in listening to our machines. Some machines when turned on will start to initialize, and then, make a bad noise. The only way in diagnosing these machines is by listening, putting your ear to the machine and pin pointing the area that the noise is coming from. Another way of diagnosing the machine is to watch the machine and to follow the pattern of the machine initializing. Every computerized machine must go through a certain number of steps before it can be ready to sew. When we have a machine that has a problem and has the same message that comes on for everything, and does not make any noise it is important for us to watch and to track the machines progress in booting up. If we see a certain step not occur when the machine is turned on, then that will lead us to a starting point in diagnosing our machine. This class was designed to go beyond the regular self diagnostic checks that most computerized machines have built in to them. In using the three different steps listed above: reading, listening, or watching our machines we can better diagnose and fix our machines at a better pace for our customers. The overall outcome is to make you the technician more at ease in dealing with computerized machines. 1.

  3. DIAGNOSING YOUR MID-RANGE COMPUTERIZED MACHINES Chapter 1

  4. IDENTIFYING THE PARTS ON YOUR COMPUTERIZED SEWING MACHINE A computerized machine is made up by some basic components that you will find in all computerized sewing machines. The basics are A-board which is the brain. The Zig Zag Step Motor which is the needle bar movement. The Feed Step Motor which is the feed dogs. The Photo Sensor which can appear either on the upper shaft or lower. This part with it’s circular or propeller shaped shield plate is the nerve center of the machine. There are other step motors on other machines as well as other boards, but all mid- range computerized machines have these four items. Feed step motor & sensor from 4900qc Zig zag step motor & sensor from DC3050 Shield plate & photo sensor from 4900QC A-board w/ built in screen from 6260qc A-board from 4900qc 2.

  5. ZIG ZAG STEP MOTORS AND FEED STEP MOTORS FOR 6500P,6600P,DC3050,DC3018,4900QC,6260QC, DC2007LE,HT2008,7061NX,HF3022,HF8048,2040 When a mid-range computerized machine gives you an error message of an E1 or BM that means something is happening to the zig zag motor. Besides seeing the error code pop up you might also hear a vibrating noise coming from the needle bar area. Before we give up and say that we need to replace the zz motor there are a few things that must be done first. When a sewing machine is turned on the needle bar should go to center needle position. If you get an error message, vibrating noise, or if it just sits out of position then we will focus on the needle bar and zz motor. It is important always to turn the machine off and to grab the needle bar and move it from left to right. In doing this you can feel if something is blocking the needle bar from moving freely. If so that is why the error code and noise came on. If you feel that the motor feels sluggish and has a slight bind to it, then most likely the motor is bad. It is important to go into the machine and to locate the zz motor. Most step motors have a sensor that need to be cleaned by blowing some air through them. Also it is important to see if the sensor is aligned correctly and that its designated shield plate is going through smoothly without rubbing or hitting the sensor. Also always check to see if the motor is plugged in correctly. 3.

  6. When a mid-range computerized machine gives you an E2 or FM error message that means something is happening to the feed step motor. Besides the error message that might come up, when the needle bar is lowered you might hear a grunting noise from underneath which means the feed motor cannot initialize. First locate the motor and see if there is anything loose underneath or if something is obstructing the feed system. As always check the plug and the sensor on the motor to make sure everything is cleaned and in the proper position. The most important thing to remember about these machines is that there is a special fuse on the A-board that gives power to the step motors. This fuse is a 3.15 thermal fuse. If a machine was jammed badly or for any other reason you get one of the error messages it is important to check to see how many error messages you can get. For example, if I had a 6500p that came in with a BM error message I would first check my fuse. The easiest way to do this without taking anything apart is by testing the other step motor in the machine which would be the feed step motor. If the machine gives you a BM or E1 (zig zag error), turn the machine off. Once the machine gives you an error it will not change its mind and start changing error codes. The easiest way to find out other error codes is to trick the machine. Once we turn the machine off we would turn the hand wheel to bring the needle down. By turning the hand wheel we are resetting the position for the shield plate that goes through the photo sensor. In return the photo sensor tells the A-board that the needle is now down and that the feed step motor should be the first motor to be initialized. Now the machine can be turned on and the first motor to be initialized will be the feed step. If it comes up as FM or E2 (feed step error), then we know that there is a 98% chance that the 3.15 thermal fuse is bad. It is always better to check all the step motors in a machine first then to rip it apart and go inside of the machine. Most of the time you will be able to diagnose this error message over the phone and have a fuse waiting for your customer. Please remember that if you get one message it is important to check and see if the other error messages come on first before deciding that it is only a fuse that you need. If only the one message comes on then please go into the particular area and see if anything can be adjusted and if not, then replaced. 4.

  7. 4900QC E5 Error 1. Besides the Error 1 or Error 2 message that could occur there is another message that sometimes pops up on a 4900QC. 2. Error 5 usually comes on the machine when it has jammed. Most of the time this occurs when the customer misses the take up lever. On the 4900QC the take up lever is behind a metal bracket and a face cover that cannot be opened. If the light on the front panel is not lit, then the hand wheel should be turned in order to thread the machine properly. If the light is not lit, the take up lever is in the down position. The machine should not be threaded now. Causes jamming 3. If you consistently get the E5 Error then the motor should be changed out. 5.

  8. 4900QC K-Board 1. If you turn on the 4900QC and the screen is half black or lines through it then the K-Board will need to be replaced. 2. If the screen is not lighting up then it is important to check the wire connections. 3. Always check the flexible cable to make sure it is inserted correctly on the K-Board as well as the A-Board. Be very careful of the black locking tabs. 4. Also check the contrast dial to make sure that someone did not turn it down. 6.

  9. Diagnostic System Preparation & Test for 4900QC 1. Turn off the power switch. Slide the bobbin winder knob to the left. 2. Slide the drop feed lever to the left. (this view is shown from the back side) 3. Push the slide volume to the left. 7.

  10. 4. Raise the presser bar lifter. 5. Remove the presser foot. 6. Place the needle bar at its highest position. 8.

  11. Diagnostic System 1.Turn the machine on. While holding in the Needle Up-Down and Lock Stitch buttons, turn on the power switch and release the two keys. Then push the number 1 button within 3 seconds. 2. The Step 1 Buzzer, LCD and Led. When working properly, the machine will beep the LCD and Led lights will blink in 1 sec intervals. Lamp also will be lit . If any of this does not occur first check the flexible flat cable, if still no response replace the A, or F board. Press the Clear button to proceed to step 2. 3. Step 2: Checking button function. Press all the buttons on the front cover except C button. When a button is pressed, the name of the button will appear on the LCD screen. If it does not work correctly, replace the A, K or F board. Press the Clear button to proceed to step 3. 9.

  12. 4.Step 3: Checking 3 switches. • SP is for bobbin winder • FL is for foot lifter • TD is for tension dial Move the bobbin winder knob to the left and right. With the knob in the left position, OFF will be shown on the screen. With the knob in the right position, the screen will show ON. Lower and raise the presser bar lifter lever. With the lever in the up position, the screen will show UP and the screen will show DOWN with the lever down. 10.

  13. When the tension dial is on AUTO mode the LCD shows ON. When the tension unit is set other than AUTO, the screen shows OFF. If these functions do not work, adjust or replace the sensors for the bobbin winder, foot lifter, or tension dial. If these suggestions did not work then replace the A board. Press the Clear button to proceed to step 4. 11.

  14. 5.Step 4: Checking BH and upper shaft photo sensor. Fsen Bsen Gently pull down the buttonhole lever as far as it will go, but do not force it. When the BH lever is down and free the screen should show L. When the lever is pushed to either the front or back, the screen will show H. If the sensor does not work correctly, adjust the position of the shield plate, adjust the position of the photo sensor or replace the sensor or the A board. 1 H H 2 L H 3 L L 4 H L 5 L L 6 L H To check the upper shaft sensor, first make sure the needle bar is at its highest point and then start to turn the handwheel toward you slowly. You will see that the bsen and fsen display on your lcd screen will change in increments of 6 and each time it changes, it will beep. See diagram. 1 2 6 3 5 Fsen represents the shield plate for reading the feed motor. Bsen represents the shield plate for reading the ZZ motor. Press the Clear button to proceed to step 5. 4 12.

  15. 6.Step 5: Checking the speed sensor. Make sure the bobbin winder spindle is pushed to the left.Turn the handwheel toward you slowly. The number on the screen should increase until it reaches between 370 to 376, then start at 000 again. If this does not operate correctly, clean the photo sensor on the DC motor, adjust the position of the photo sensor in the DC motor or replace the motor or the A board. Press the Clear button to proceed to step 6. 7.Step 6: Checking the slide volume. When the slide volume lever is at its left position, the number on the screen should be 000 to 002. When the lever is at the right, the number should be 253 to 255. If the display does not change or if it indicates a wrong number, replace the speed control lever or replace the A board or K board. Press the Clear button to proceed to step 7. 13.

  16. 8.Step 7: Foot controller check. The display shows 000 to 016 when the foot control is not depressed. The display shows 208 to 250 when the foot control is fully depressed. The display shows 251 to 255 when the foot control is disconnected. If the display does not change or if it indicates the incorrect value, replace the foot control or the machine socket or the A board. Press the Clear button to proceed to step 8. 14.

  17. 9.Step 8: Checking stepping motors. To check the zig zag stepping motor, place the needle bar in its highest position. The display should show Stepping Motor, BM Phase. When the Memory button is pushed, you should hear the zig zag stepping motor initialize and the needle bar should vibrate. To check the feed stepping motor, place the needle bar in its lowest position. The display should show Stepping Motor, FM Phase. When the Memory button is pushed, you should hear the feed stepping motor initialize and the feed dog should vibrate. If the display shows “E1 error” or “E2 error” replace the thermo fuse first, part number 000182194. If the error message still comes up replace the A board or the stepping motors. Press the Clear button to proceed to step 9. 15.

  18. JP760 & JP720 1. The JP760 & JP720 are slightly different then the other computerized machines. They do not have sensors attached to the individual step motors. This machine only gives out three basic error messages. 2. If you get a “Lo”message when you try to run the machine then something could be wrong with the main motor. It is always important to check the machine thoroughly. You would want to check to see if something is tight in turning the hand wheel. The motor belt could have slipped off as well. After checking all basic options and if you still get the message then change the main DC motor. 3. If there is a problem with one of the step motors it will flash “co” on the screen. The best way to check to see what is going on , is to go into the machine and check all the plugs. EXAMPLE- If the zig zag is working and the feed step motor is not, then the feed step motor might have to be changed or the balance screw might need to be serviced. EXAMPLE- If the needle changes position everytime it is turned on then there could be a problem with the zig zag motor, and it might need to be changed. 4. If the machine comes up with an E9 message then check the shield plate on the upper shaft. It could be possible that it is rubbing against the photo sensor or the photo sensor could be unplugged. If the machine gives you this message and you feel it binding, do not try to turn it. It could be hitting the sensor and if forced to turn it could break it. 16.

  19. 6600P & 6500P 1. Besides the BM / E1 error messages or the FM / E2 error messages that come on the 6000 series, there is another message that could appear. 2. The “Stop for safety purposes” message comes on if the machine is jammed, the motor is bad, the clutch is tight and stuck, if the belt is off, or if something is unplugged. Check the machine thoroughly to see if anything is jammed especially the cutter. 3. On this machine it is very important to check the photo sensor on the lower shaft. Since it is on the bottom it is very important to clean this sensor and to check to see if the shield plate is going through the sensor. If the sensor is dirty or if the shield plate is hitting the sensor then the error message above could come on. 17.

  20. Diagnostic System Preparation • In preparation for using the diagnostic system, do the following: • Lay the machine on its back. • Remove the 4 screws with the cushions. • Remove the center screw. • Remove the base. 6. Remove the 3 belt cover screws. 7. Push in on the back of the belt cover as you remove it. 18.

  21. 8. Slide the bobbin winder knob to the right. 9. Slide the drop feed lever to the left. 10. Slide the speed adjusting lever to the left. 19.

  22. 11. Raise the presser bar lifter. 12. Place the needle bar at its highest position. 13. Remove the thumb screw and the presser foot. 20.

  23. Diagnostic System 1.Turn the machine off. While holding in the Needle Up-Down and Lock Stitch buttons, turn on the power switch and release the two keys. Then push the number 1 button within 3 seconds. 2. The Step 1 screen will appear. When working properly, the machine will beep, the thread cutter, up-down and edit LEDs will blink, the LCD screen will blink and the sewing light will turn on. If it does not work correctly, you may to change the F, K or A board. Press the Clear button to proceed to step 2. 3. Step 2: Checking button function. Press all the buttons on the front cover (Press Clear, C, last). When a button is pressed, the name of the button will appear on the LCD screen. If it does not work correctly, replace the F, K or A board. Press the Clear button to proceed to step 3. 21.

  24. 4.Step 3: Checking 4 switches. Move the bobbin winder knob to the left and right. With the knob in the left position, ON will be shown on the screen. With the knob in the right position, the screen will show OFF. Lower and raise the presser bar lifter lever. With the lever in the up position, the screen will show UP and the screen will show DOWN with the lever down. 22.

  25. Turn the handwheel to bring the needle all the way down, then continue to turn the handwheel until the needle is halfway up. Move the activating arm for the auto thread cutter to the left and right. With the arm in the left position the screen will show OFF. With the arm in the right position, the screen will show ON. Move the drop feed lever to the right and left. With the drop feed lever in the right position, the screen will show DOWN. With the lever in the left position, the screen will show UP. If one of the switches does not operate properly, first try to adjust the switch position, then replace the switch and then replace the A board. Press the Clear button to proceed to step 4. 23.

  26. 5.Step 4: Checking photo sensors. Pull down the buttonhole lever. The screen should show L. When the lever is pushed to either the front or back, the screen will show H. If the sensor does not work correctly, adjust the position of the shield plate, adjust the position of the photo sensor or replace the sensor or A board. Rotate the handwheel toward you. Each sensor indicator should change from H to L as the lower shaft turns. If one of the sensors does not work correctly, adjust the position of the shield plate, adjust the position of the photo sensor or replace the sensor or A board. Csen represents the auto thread cutter sensor. Fsen represents the feed sensor. Bsen represents the zig zag sensor. Press the Clear button to proceed to step 5. 24.

  27. 6.Step 5: Checking the speed sensor. Turn the handwheel toward you slowly. The number on the screen should increase until it reaches between 414 and 420, then start at 0 again. If this does not operate correctly, clean the photo sensor on the DC motor, adjust the position of the photo sensor in the DC motor or replace the motor or A board. Press the Clear button to proceed to step 6. 7.Step 6: Checking the speed control lever. When the speed control lever is at its left position, the number on the screen should be 000 to 002. When the lever is at the right, the number should be 253 to 255. If the display does not change or if it indicates the wrong number, replace the speed control lever or replace the K board or A board. Press the Clear button to proceed to step 7. 25.

  28. 8.Step 7: Foot controller check. The display shows 000 to 016 when the foot control is not depressed. The display shows 208 to 250 when the foot control is fully depressed. The display shows 251 to 255 when the foot control is disconnected. If the display does not change or if it indicates the incorrect value, replace the foot control or the machine socket or the A board. Press the Clear button to proceed to step 8. 9.Step 8: Checking the 3 solenoids. SOL1 represents the auto thread cutter solenoid. SOL2 represents the bobbin winding prevention lever solenoid. SOL3 represents the upper shaft clutch solenoid. In order to check each solenoid, the corresponding number button is pressed. 26.

  29. To check the auto thread cutter solenoid, solenoid 1, first turn the handwheel to bring the needle all the way down, then continue to turn the handwheel until the needle is halfway up. As you push button number 1 once, the display will change from OFF to ON and the solenoid arm will move to the right. By pushing button number 1 again the display will show OFF and the solenoid arm will move to the left. To check the bobbin idling prevention lever solenoid, solenoid 2, push button number 2 once. The solenoid arm will move down and the bobbin case lever will move to the left. The display will show ON. By pushing button number 2 again, the display will show OFF, the solenoid arm will move up and the bobbin case lever will move to the right. 27.

  30. To check the upper shaft clutch solenoid, solenoid 3, first turn the handwheel to bring the needle all the way up. As you push button number 3 once, the display will change from OFF to ON and the solenoid arm will move down. By pushing button number 3 again the display will show OFF and the solenoid arm will move up. If any of the solenoids do not operate correctly, first be certain that the parts that are connected to the solenoid move freely. Then replace the solenoid or the A board. Press the Clear button to proceed to step 9. 28.

  31. 10.Step 9: Checking stepping motors. To check the zig zag stepping motor, place the needle bar in its highest position. The display should show Stepping Motor, BM Phase. When the Memory button is pushed, you should hear the zig zag stepping motor initialize and the needle bar should vibrate. To check the tension stepping motor, bring the needle bar halfway down. The display should show Stepping Motor, with a dashed line. When the Memory button is pushed, you should hear the tension stepping motor initialize. 29.

  32. To check the feed stepping motor, place the needle bar in its lowest position. The display should show Stepping Motor, FM Phase. When the Memory button is pushed, you should hear the feed stepping motor initialize and the feed dog should vibrate. If the display shows “BM init error,” “TD init error” or “FM init error,” replace the thermo fuse first, part number 000182194. If the error message still comes up replace the A board or the stepping motors. Press the Clear button to proceed to step 10. 11. Step 10: Checking the sewing and bobbin winding motors. To check the DC sewing motor, lower the presser bar and push the foot control. If the motor does not operate, check the motor belt tension, then replace the motor or the A board. To check the bobbin winding motor press the bobbin winding button once to start the motor and a second time to stop the motor. If the bobbin winding motor does not operate, replace the motor or the A board. To exit the Diagnostic System, turn off the power switch. 30.

  33. DIAGNOSING YOUR MC9000 Chapter 2

  34. The MC 9000 is very similar to many of the top of the line sewing & embroidery machines. It is a very straight forward machine in diagnosing. Even though the MC9000 does give us error messages, it does not give us number codes . When the MC9000 is turned on the machine will go through a series of initialization steps. This is the perfect way to follow the machine and to see if anything is wrong with it. When turned on the base unit arm will move, the needle bar will center itself and the tension unit will set itself. When the needle is lowered you will hear the feed step motor set itself as well. The only motor that does not have to set itself in the beginning is the main DC motor. This motor will only start to work with its sensor when the start button or foot control is depressed. That is one easy way to follow the steps and to come up with a quick diagnosis. In the following pages we will go over the most common problems that you might encounter. The two most common messages on the MC9000 31.

  35. TENSION UNIT FOR 9000 TRACK NORMAL SETTING GEAR TURNED OFF TRACK Top tension adjustment screw. Counterclockwise will close the horizontal gear and clockwise will open the gear. 1. If you turn on the machine and do not hear the tension unit initialize you will get an error message. You will need to take off the top cover. The tension unit has a horizontal gear that the customer can move from the outside of the tension unit by opening the face plate. Sometimes the customers get carried away and open the gear all the way causing the gear to come off of it’s track. If this happens, the track needs to be held back and the gear turned counterclockwise so it can go back on the track. 2. If that is not the problem it is important to check the plug to the A-board. Make sure everything is plugged in nicely. 32.

  36. If the tension unit sets itself correctly but when you press start you hear a whirling sound coming from it, then it is possible that something is holding back the check spring pin. Sometimes if you are making the machine sew by itself without thread you would put a piece of paper in between the tension unit and front panel. The piece of paper can only be stuck in after the machine starts to run. • Another reason why the machine could be making a whirling sound is that there is a piece of black foam that outlines the check spring path. Sometimes after cleaning the machine and blowing it out this piece could become dislodged and prevent the pin from coming forward in the beginning start up process. • If none of these steps help the tension unit, then either the tension unit or the A-board need to be replaced. Black foam lining came dislodged, will cause whirling sound 33.

  37. BASE UNIT FOR 9000 1. If you turn on the machine and the base arm does not set itself and you get an error message the first thing to do is to check the plugs. To do this you will need to take off the belt cover to expose the plugs. Always double check plugs to make sure they are in properly. A lot of times this is the problem Lint in gear 2. If you turn on the machine and the base starts to vibrate and makes a bad noise you need to take the base off and check for lint in the gears. While you are servicing the base check the sensors as well to make sure they are clean and that the shield plates are going in correctly. If this does not help the problem then either a base or step motor might need to be replaced. Clean sensors 34.

  38. WHEN THE MC9000 HAS NO POWER 1. If you turn on the machine and there is no power at all first try a different cord and make sure the outlet is good. If the machine still has no power then check the fuse that is in the c-board first. Take off the base unit and locate the black box at the bottom of the machine. Remove the three screws that hold the C-board to the casting of the machine. 2. Start to turn the C-board down to unplug the three wires that go into the box. If you have fuse pullers you can go right through one of the plug holes and grab out the fuse to check. 3. Check the fuse and make sure there are no bubbles on it or black spots are if the coil is broken. If it needs to be replaced, please use Janome slow blow fuse # 000182177. If the new fuse does not work it could be the C-board that is bad. If you have tried a different fuse and need to try a C-board to see if that is the problem, then you can use the same board from the 5000 ,5700 and the 8000. Even though the 8000 C-board will not fit properly it will still be able to give power to the machine to see if it was in fact the C-board that is causing it to have no power. 35.

  39. 5. If the C-board did not work then you will need to replace the A-board. To change the A-board you need to remove the front panel. Remove the thread guide behind the light bulb. Loosen the screw to the left of the customers stitch balance adjustment. 6.Loosen the screw on the inside of the machine and at the top by the hand wheel. 7. Gently start to remove the front panel and disconnect the wires that hold the front panel to the machine. 36.

  40. 8. Remove the six screws that hold the A-board into the machine. 9. Remove the 2 flexible cables by lifting up gently on the locking clip. Unplug the F-board wire and remove the A-board. 10. When replacing the A-board it is necessary to transfer the black cap for the contrast and the micro switch cover for the bobbin winder to the new A- board unit. When finished reconnect all the wires and put the front panel back to the machine. MAKE SURE ALL WIRES ARE PLUGGED IN CORRECTLY. 37.

  41. SCREEN CALIBRATION FOR MC9000 1. Hold down the s/s button, the reverse button and the stitch lock button. Make sure to hold all three down at once and then turn on the machine. Once you see a blue screen that says press + mark, you can let go of the buttons. 2. Press into the middle of each plus mark with something soft. 3. Follow the marks until it is done. Repeat this step 3 times to make sure it is locked in. When you have finished each time turn off the machine and wait 5 seconds. 38.

  42. LCD UNIT FOR 9000 1. If the screen is not working, has lines through it, or does not calibrate, then it might need to be replaced. First you want to check all the connections that go from the LCD unit to the A-board. If the connections are good, then you would need to remove the front panel and the A-board in order to get to the LCD unit. 2. Locate the triangle bracket. Remove one of the screws and loosen the other in order to tilt it to the side. 3. Remove the 4 screws and lift the LCD unit out. 4. Replace the 4 screws and the triangle bracket and put the machine back together. 39.

  43. WHAT TO DO WHEN YOU GET THIS MESSAGE!!! 1. If you get this message then something might be binding the machine. First thing to do is to check the photo sensor at the top of the machine. Check the clutch area by the hand wheel and the clutch spring. If everything is turning nice and you checked your hand wheel area then most likely the main DC motor will need to be replaced. SEE CHAPTER 3 (10000/01) PG. 53-55 2. Always inspect the upper shaft. If you see black residue coming from the shaft it is very important to change the shaft and bushing. Just oiling it will cause the machine to keep coming back to you. Small area to see the bushing 40.

  44. ZIG ZAG & FEED STEP MOTOR ZIG ZAG STEP MOTOR 1. If you turn the machine on and hear a vibration coming from the needle bar area that means that something is stuck in the zig zag step motor area or the motor could be bad. Turn off the machine and grab the needle bar and move it left to right to see if something is binding it. If not go up to the zz motor through the top shaft and clean out it’s sensor and inspect it to see if it looks okay. Last but not least, check the plug wire on the side of the A-board. If this does not work then the zz motor will need to be replaced or the A-board. 2. If you turn on the machine and hear a noise coming from below, check the feed step motor to see if anything is loose or binding. Clean the sensor and blow it out with air. If you still have problems with the feed step motor then it will need to be replaced or the A-board will need to be replaced. FEED STEP MOTOR 41.

  45. STITCH BALANCE ADJUSTMENT 3 2 1 1. If your decorative stitches do not look right first check the stitch balance dial on the outside of the machine. Make sure it is even. If still not correct you can go into a test mode on the screen to sew an 8 test. Press the s/s button and the reverse button at the same time. Turn on the machine and let go, within 3 seconds press the reverse button, let go and then press the needle up down button to go into the Sew 8 test. Must be even 2. Sew eight of the number eight. Measure the distance between 5 of the 8’s. The measurement should be between 32 and 38 mm. The middle row is correct in the picture. They should look even and like the # 8. 3. If not turn, off the machine and lay the machine on it’s back. Remove the plate on the bottom of the base and inside there is an adjustment screw. Turn the adjusting screw counterclockwise if the measurement is more than 38 mm. Turn the machine on the same way as before to go into the sew 8 test and sew another row to see if any more adjustments are needed. 42.

  46. FOOT SENSOR ADJUSTMENT • When you are doing embroidery the machine should not work with the P- foot in the up position. This is a safety precaution. If the machine does do embroidery with the foot in the up position then an adjustment needs to be made. If you like you can go into a test mode built into the machine. • Hold down the s/s button and reverse button at the same time. Let go when the test screen comes on. Within 3 seconds press the stitch lock button once, let go and press it a second time to go into the foot sensor test. 2 3 1 P-foot is down P-foot is up 2. When the P-foot is up the screen should read closed, when it is down it should read open. If it reads open when the foot is up, locate the black shield plate on the left side of the machine. There is an off white piece about the same shape as the black piece behind it. To start, loosen the screw, line the two pieces up and then raise only the black piece a bit and tighten the screw. Look at the screen and raise and lower the foot. If the message reads correctly then you are done, if not repeat the same step. 43.

  47. DIAGNOSING YOUR MC10000 / MC10001 Chapter 3

  48. When you turn on your 10000/10001 the machine goes through an initialization process. The needle bar centers itself, the threader moves and activates, the base moves and the tension unit sets itself. When the needle is lowered the feed step motor initializes and the machine has set itself for sewing. The only motor that does not have to set itself in the beginning is the main motor. If you turn on the machine and you get an error message with a number code, the number code can lead us to where we have to look. If the machine comes on and gives and error message but no number code, then we would watch the machine as it set itself up. If we notice that one of the step motors did not set itself, then we would look in that area. The following pages will show you the number codes as well as what to look for if they do come up. 44.

  49. ZIG ZAG STEP MOTOR 1. If the machine comes up with a #02 error code then that means that there is something wrong with the zig zag motor, or something preventing it from moving. 2. Turn off the machine.Locate the zig zag step motor in the machine. The needle bar is connected and runs off of the zig zag step motor. Grab the needle bar and move it left to right to see if something is blocking the needle bar from moving which in return would jam the step motor. Check to make sure that the zig zag motor plug is in the A-board properly. Check the sensor attached to the zig zag step motor and blow it out with air. If you did all this and still get the message then the step motor would need to be replaced. 45.

  50. FEED STEP MOTOR 1. If the machine is turned on and it comes up with a #04 error code then that means something is going on with the feed step motor. The feed step motor controls the feed system and makes sure that the feed dogs are moving properly. 2. Turn off the machine. Locate the feed step motor and clean out the sensor attached to it. Check the surrounding feed system area to make sure that nothing is loose or too tight. Check to make sure that the step motor is plugged into the A-board. If you did all this and still have a problem then the motor will need to be replaced. 46.

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