DC2010

1. DC2010 Service Seminar

3. Top Cover Removal 1. Remove the two screws behind the handle on the top cover. 2. Open the face plate and locate the black screw at the left end of the front panel and remove it. 3. Lift up on the top cover and remove it from the machine. 1

4. Belt Cover Removal 1. Locate the screw underneath the hand wheel and remove it. 2. Lay the machine on it’s back and remove the screw on the middle right edge of the base plate. 3. Stand the machine back up and gently start to remove the belt cover taking it from the rear to the front of the machine. 2

5. Bed Cover Removal 1. Remove the accessory tray from the machine. 2. Locate the two screws on the bed cover and remove them. 3

6. Front Cover Removal 1. Open the face plate and take a philip’s head screwdriver and insert it through a metal bracket and into the screw and just loosen the screw. 2. Lay the machine on it’s back and remove the screw on the edge of the base plate that holds the front panel to it. 3. Stand the machine back up and turn the machine around to see the right side. Inside the machine there is a screw that needs to be loosened. Also at the bottom edge of the right side loosen the screw that holds the front panel. 4

7. At the top of the machine loosen the screw on the right side of the machine by the hand wheel. • On the left side of the machine remove the screw completely. 3. Using a small flat head screw driver insert it underneath the rear panel where it meets the front panel by the needle bar area and push down gently to release the holding clip. Then once the clip has been released start to grab the front panel and start removing it from the left side of the machine to the right. 4. When removing the front panel never tear it away from the machine. Always check to see if there are any wires holding the panel to the machine. Start to unplug the 11 wire connections coming from the machine to the A-board which is attached to the front panel. Only unplug the wires that are holding the front panel to the machine. 5

8. A- Board Removal SPEED CONTROL F-BOARD 1. Inspect the inside of the front panel and identify the different electronics. A-BOARD 2. In order to remove the A-board lay the front panel down and remove the six screws that hold it to the front panel. 3. Unplug the f-board and speed control from the A-board, and lift the A-board out. 6

9. Speed Control F-Board Light Bulb Bobbin Winder BH Sensor Upper Shaft Sensor Foot Control Zig Zag Step Motor Transformer White Feed Step Motor Machine Socket DC Motor Transformer Black 7

10. 3.15 Thermal Fuse 3.15A thermo fuse, part # 000182904 Locate the white fuse on the back of the A-board. This is a 3.15amp, 250 volts thermal fuse. This is the fuse that must be replaced when you get both Error #1 and Error #2. The other 2 fuses are 2.5 amp, 250 volts and in very rare cases need to be replaced. The best way to check to see if this fuse needs to be replaced is to initialize the machine twice. When you turn on the machine and the needle bar is in the highest position the zz motor should initialize and set itself. If it does not you would get an “E1” message. Next turn off the machine and turn the needle to it’s lowest position. Now that the needle is in low position when the machine is turned on it will initialize the feed step motor first. If it turns on and gives you an “E2” message then we know that the white thermal fuse has to be replaced. This fuse controls the step motors of the machine and very rarely do both step motors have to be replaced. This is the same procedure for many of Janome models such as: 6500P,6600P,DC3050,DC3018,6260QC,HT2008,4900QC,DC2007LE 8

11. Installing the A-board 1. Reattach the speed and F-board plugs to the top of the A-board. 2. Line up the A-board and place in and tighten the six screws that hold the A-board to the front panel. 9.

12. Removing the Zig Zag Motor 1. I n order to remove the zz motor the front panel must be removed. Locate the zz motor and the two small philip’s head screws that attach it to the zz rod to the needle bar. Remove the two small screws. 2. Next come in with a screw driver from the right hand side of the machine and remove the screw holding the zz step motor to the casting of the machine. 3. Turn the machine around to look at the right hand side. There is a second screw that is holding the zz step motor unit to the casting of the machine. Remove this screw. 10.

13. 1. Remove the screw that holds the plastic wire guide for the upper shaft sensor. The upper shaft sensor is part of the zz motor unit. 2. As you take the zz motor out you will have to cut a plastic tie that holds the wire to the casting. Once the tie is cut you can take it out fully. 11

14. Installing the Zig Zag Motor 1. Before you install the new zz motor first be aware of the black shield plate that is on the upper shaft, The sensor comes attached to the zz motor unit and you want to be careful not to break anything by shoving the new motor in. 2. Line up the zz motor in the machine and with the black shield plate. Take the screw that holds the unit to the casting and replace it and tighten. 3. Take the other screw and place it back into it’s spot on the right hand side of the machine. 4. Reattach the screw that goes through the plastic holder fir the upper shaft sensor wires. 12

15. 5. Take a plastic zip tie and wrap it around the casting and the zz motor wire and pull so it holds it snug to the casting. Cut the excess tail length 6. Take the two small philip’s head screws and replace them into the zz connector to the zz rod. Make sure that these are tightened really well. If they come loose they will throw of you needle position later. 13

16. Removing the DC Motor 2. Remove the two screws that hold the motor unit to the casting of the machine. 1. Remove the motor belt from the hand wheel. 4. Inspect the motor and make sure it is clean. Check the sensor and the shield plate to make sure it not broken and that it is turning smoothly 3. Guide the motor wire through the machine and remove the dc motor unit. 14

17. Installing the DC Motor 1. Guide the motor unit wire through the casting towards the front of the machine and install and tighten the two screws temporarily. Correct 7mm deflection TOO LOOSE 2. Place the motor belt onto the hand wheel and around the motor idler. The motor is the adjustment for the correct tension on the motor belt. When the motor is screwed into a high position on the machine, the belt is loose. If the motor is pushed down and screwed in, the tension on the motor belt will be tighter. The correct tension should be about a 7mm deflection. 15

18. Front Panel Attachment 1. When attaching the front panel first start by plugging in the machine socket plug and then the transformer plug. The black plug spot will be marked by a black line on the board. 2. Continue to plug in the remaining 9 plugs. 3. Start to line up the front panel with the machine. Be careful to line up the tabs on the front panel with their respective screws left on the machine. 16

19. 4. Gently line up the front panel right bottom tab with the screw in the casting of the machine and tighten it. 5. Tighten the screw on the inside of the machine. Make sure that when attaching the front panel there is no wires in the way. 6. Tighten the screw on the right side of the machine and place in the screw on the left side and tighten. 7. Take the screwdriver and from the left side of the machine guide the screwdriver through the hole in the metal bracket and tighten the screw. 8. Lay the machine down and insert the screw on the bottom and tighten. 17

20. Adjusting Center Needle Position Front to Back 1. Install the needle plate. Turn on the machine to initialize the needle. Bring the needle down to the needle plate and check to see if it is the center. 3. If an adjustment is needed, locate the 2mm hex screw at the top of the needle bar unit. Loosen the 2mm hex screw and either push the needle bar in to kick the needle towards the front of the plate or pull it out to have the needle go towards the rear of the plate. Make sure to look at a side view to see if it is cenetered. 18

21. Adjusting Center Needle Position Left To Right 1. Turn on the sewing machine. With the needle plate installed turn the handwheel to bring the needle into the needle plate opening. The needle should be centered left-to-right in the needle plate opening. If it is not centered, locate the adjusting screw and the set screw. Center 2. To make the adjustment, loosen the set screw, using a 1.5 mm Allen key or hexagon screwdriver. The Allen key should be on the side of the needle threader unit. Turn the adjusting screw until the needle is centered. Then tighten the set screw. 19.

22. Adjusting Hook Timing 1. Remove the presser foot, needle plate and bobbin case. To check the hook timing, push the needle bar all the way to the left. Rotate the hand wheel towards you to bring the needle all the way down, then continue to rotate the hand wheel until the tip of the hook is at the right side of the needle. At this position the tip of the hook should be 1.6 to 2.0 mm above the top of the eye of the needle. 2. To make the adjustment, place the machine on its back. Loosen the two 2.5 mm screws on the lower shaft gear. While holding the hook race, rotate the hand wheel until the hook timing is correct. Then tighten the screws. 20

23. Adjusting Hook To Needle Clearance 3. The clearance between the hook and the needle should be as close to zero as possible, without the hook hitting the needle as it passes behind the needle in both left and right needle positions. You can use a small flat head screwdriver to push against the needle to see how far of a gap there is in left, center and right positions. 4. If the hook is hitting the needle, or if the hook-to-needle clearance is too large, place the machine on its back. Loosen the 3 screws on the hook base plate. Move the hook base plate until the clearance is correct. Then tighten the screws. After making this adjustment, the hook gear backlash also must be checked. 21

24. Adjusting the Hook Gear Backlash . 8mm or less 1. Rotate the hand wheel towards you until the hook point is below the legs of the feed dog. Hold the hook and rotate it left and right. At this position there should be .8mm or less rotary movement, backlash, in the hook. 2.5mm 2. If the backlash is not correct, place the machine on its back. Loosen the 2.5mm set screw. Place a small screwdriver in the slot of the lower shaft left bushing and rotate the bushing. If there is too much rotary play in the hook, move the slot DOWN. If there is too little rotary play in the hook, move the slot UP (make sure not to move the bushing left or right.) 22

25. Adjusting the Feed Dog Height 1. Install the needle plate and the presser foot. With the presser foot in the down position, turn the hand wheel to bring the feed dog to its highest position. The feed dog should be .8 to .9mm above the surface of the needle plate. . 8 to. 9mm above 2. Loosen the lock screw. Turn the adjusting screw clockwise to raise the feed dog and counterclockwise to lower the feed dog. Then tighten the set screw and the lock nut. Note: It is normal that the front of the feed dog are positioned slightly lower than the back of the feed dog. 23

26. Adjusting the Needle Threader Plate 1. To adjust the needle Threader plate pull down the threader. Locate the small Phillips head screw and remove the screw using a fine Philip’s head screwdriver. 2. If the threader is off left to right, move the plate so it lines up in the needle eye. Part # phldrvsp1 3. To adjust the height of the threader pin, insert a 1.5mm hexagon screwdriver into the hole of the threader setting block. If the threader pin is too high, lower the setting block. If the threader pin is too low, raise the setting block. Do not rotate the setting block left or right when you make this adjustment. Tighten the screw. 24

27. Adjusting the Buttonhole Lever 1. Locate the buttonhole lever and pull the lever down. Make sure that the buttonhole foot is off of the machine. Nothing should be hitting the lever. At this point the black shield plate on the lever should be in the middle of the sensor. Notice how the slit is lined up perfectly in the middle. 2. If an adjustment is needed locate the 1.5 hex screw that has the lock nut around it and take the 1.5 hex driver and place it into the 1.5 screw, and turn it to the left or right in order to center the shield plate within the sensor. This is a fine adjustment and cannot be made if anything is hitting against the buttonhole lever. 25

28. Reinstalling the Bed Cover 1. When getting ready to install the bed cover make sure that the feed dog drop switch is over the raised arrow on the inside of the bed cover. 2. Make sure that the needle is in the highest position. Slide the bed cover on and be careful of the feed cam. Install the two screws. 26

29. Reinstalling the Belt Cover 1. Take the belt cover and gently place it back onto the right side of the machine being careful of the clips. 2. Install the screw underneath the hand wheel and tighten. 3. Lay the machine on it’s back and insert the screw and tighten. 27

30. Reinstalling the Top Cover 1. Gently lay the top cover on the machine being sure not to break any of the clips. 28

31. TOO CLOSED TOO OPEN GOOD 4. Put a piece of fabric under the presser foot and thread the machine. Choose a decorative stitch that you are familiar with and sew a sample. Access plate 7. If an adjustment is needed, place the machine on its back. Locate the access plate on the bottom of the machine. Take off the plate and turn the adjusting screw counterclockwise if the stitch is too open or clockwise if the stitch is overlapping. 29