Janome 1600P PROFESSIONAL - User manual

Servicing Manual
1600P, 1600-DB &1600-DBX

Replacing the External Parts
Face plate .................................................................................................... 1
Top Cover .....................................................................................................1
Belt Cover .................................................................................................... 1
Motor Cover ................................................................................................. 1
Base ............................................................................................................. 1
Mechanical Adjustment
Needle Bar Height ........................................................................................ 2
Presser Bar Height ....................................................................................... 2
Feed Dog Height ..........................................................................................3
Feed Dog Alignment ....................................................................................3
Feed Cam Timing .........................................................................................4
Feed Lifting Cam Timing ..............................................................................5
Needle to Hook Timing ................................................................................. 6
Clearance between Needle and Hook Point ................................................6
Hook Stopper Position ................................................................................. 7
Bobbin Winder Stopper ................................................................................8
Check Spring Stroke ....................................................................................9
Pretension Dial ............................................................................................. 9
Knee Lifter Lever ........................................................................................ 10
Needle Stop Position ..................................................................................11
Needle Threader (1600P only) ................................................................... 12
Replacing the Electronic Components
Location of the Electronic Components .....................................................13
Location of the Connectors ........................................................................ 14
Internal Wiring ............................................................................................ 15
Circuit Board-A ........................................................................................... 16
Circuit Board-F and Slide Volume .............................................................. 16
Driving Motor ........................................................................................ 17-18
Power Transformer ..................................................................................... 19
Machine Socket .......................................................................................... 19
Light Bulb ................................................................................................... 20
Adjustment of the Thread Cutter Mechanism
(1600P and 1600-DBX only)
Static Cutter Blade ..................................................................................... 21
Thread Cutter Blade................................................................................... 22
Thread Guide Plate .................................................................................... 23
Needle to Cutter Cam Timing..................................................................... 24
Thread Drawing Lever ................................................................................ 25
Auto Tension Release ................................................................................ 26
Thread Cutter Troubleshooting ................................................................... 27
Table of Contents

1
Replacing the External Parts
1. Face Plate
2. Top Cover
3. Belt Cover
4. Motor Cover
5. Base
Remove the setscrew (1) and washer (2). Re-
move the face plate (3).
Remove the 2 setscrews (4).
Lift the top cover (5) and pull out the motor
connector (6). Remove the top cover.
Remove the 3 setscrews (7) and remove the belt
cover (8).
NOTE:
When attaching the belt cover, engage the hooks
with the motor cover.
Remove the 3 setscrews (9) and remove the
motor cover (10).
Remove the 4 hinge screws (11), washers (12),
rubber feet (13) and base washers (14). Remove
the base (15).
(1)
(2)
(3)
(4) (4)
(5)
(6)
(7)
(7)
(8) (10)
(9)
(9)
(11)
(15)
(11)
(11)
(11)
(12)
(13)
Follow the above procedures in reverse.
To attach:
To remove:
(14)

2
Mechanical Adjustment
1. Needle Bar Height
2. Presser Bar Height
[1] Remove the face plate.
[2] Turn the handwheel to bring the needle bar (1) to the
lowest position.
[3] Loosen the setscrew (2). Move the needle bar (1) up
or down and match the upper hairline (3) with the
bottom edge of the needle bar bushing (4).
NOTE:
Be sure not to rotate the needle bar when adjusting the
needle bar height. The needle clamp screw should be
parallel to the upper shaft.
[4] Tighten the setscrew and attach the face plate.
(1)
(3)
(4)
(2)
The distance between the bottom of the presser foot in
up position and the needle plate should be 5.7 - 6.3 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
thepresser foot lifter.
(Use the 4th step from the left of the Gauge 767G-
001).
[3] Loosen the setscrew (1). Raise the presser foot lifter
while holding presser bar. 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 (2) in the needle plate and that the needle
does not touch the presser foot.
6 mm
(1)
(2)
Presser foot should be parallel
to the feed dog slots.
6mm

3
3. Feed Dog Height
When the feed dog is fully raised the height should be
0.8 - 1.0 mm above the needle plate.
[1] Set the stitch length dial at 6 (Maximum). Turn the
hand wheel to bring the feed dog to the highest
position.
[2] Loosen the setscrew (1).
[3] Turn the eccentric pin (2) to adjust the feed dog height
to 0.9 mm.
- If the feed dog is too low, turn the pin to the right (3).
- If the feed dog is too high, turn the pin to the left (4).
[4] Tighten the setscrew (1).
0.8 - 1.0
mm
(1) (3)
(4)
(2)
4. Feed Dog Alignment
The lateral gaps between both sides of feed dogs and
needle plate slots should be even.
The clearance between the front end of the center feed
dog and center slot should be 4.2 - 4.8 mm when the
stitch length dial is set at 0.
[1] Remove the base and lay the machine on its back.
[2] Set the stitch length dial at 0.
[3] Loosen the setscrews (1). Move the feed base (2) up
or down to adjust the clearance (3) between the front
end of the center feed dog and center slot to 4.5 mm.
(Use the marking on the Gauge 767G-001). Adjust the
lateral position of the feed dogs by moving the feed
rock shaft (4) to the right or left if necessary.
[4] Tighten the setscrews (1). Set the stitch length dial
at 6 and turn the handwheel to check if the feed dogs
do not touch the needle plate.
[5] Attach the base.
(1)
(3)
(4)
(2)
Lateral gaps should be even.
4.2 - 4.8
mm
4.5 mm

4
5. Feed Cam Timing
To Check:
[1] Lower the needle bar by turning the handwheel until
the point of the needle is 17.9 mm (for 1600P-DB/
DBX) or 17.5 mm (for 1600P) above the upper
surface of the needle plate (1).
[2] The feed dogs should not move when moving the
reverse stitch lever up and down.
If the feed dogs move, adjust the feed cam timing as
follows.
To Adjust:
[1] Remove the base and lay the machine on its back.
[2] Lower the needle bar until the needle point is 17.9
mm (for 1600P-DB/DBX) or 17.5 mm (for 1600P)
above the needle plate (1).
(Use the third step from the right for 17.9 mm or the
marking for 17.5 mm on the Gauge 767G-001).
[3] Loosen the setscrews (2).
While moving the reverse stitch lever, turn the feed
cam (3) in the direction either Aor Buntil the feed
dogs stop moving.
[4] Tighten the setscrews (2) and attach the base.
(1)
(3)
(2) A
B
17.9 mm (1600P-DB/DBX)
17.5 mm (1600P)
17.9 mm
17.5 mm

5
6. Feed Lifting Cam Timing
To check:
[1] Lower the needle bar until the point of needle is level
with the upper surface of the needle plate (1) (1600P-
DB/DBX) or 0.4 mm below the needle plate (1600P).
[2] The top of the feed dogs (2) should be 0 - 0.1 mm
above the needle plate.
To adjust:
[1] Remove the base and lay the machine on its back.
* You may set the stitch length dial at any position.
[2] Loosen the setscrew (3).
Lower the needle bar until the needle point is level
with the needle plate (1)(1600P-DB/DBX) or 0.4 mm
below the needle plate (1600P).
[3] Loosen the setscrew (4).
[4] If the feed dogs are higher, turn the feed lifting cam
(5) in the direction A.
If the feed dogs are lower, turn the feed lifting cam (5)
in the direction B.
[5] Tighten the setscrew (3) and attach the base.
(1)
(4)
(2)
(1)
(1)
(5)
A
B
0.4 mm
0 - 0.1 mm
1600P-DB/DBX 1600P
(3)
(4)

6
7. Needle to Hook Timing
8. Clearance between Needle
and Hook Point
[1] Remove the needle plate.
[2] Loosen the 3 setscrews (1). Pull out the hook race
very slightly (less than 0.5 mm).
[3] Raise the needle bar from the lowest position until the
lower hairline (2) of the needle bar matches the edge
of the needle bar bushing (3).
NOTE:
The needle bar rises 2 mm from the lowest position.
[4] Rotate the hook to match the hook point (4) with the
right side of the needle.
[5] Tighten the setscrews (1) slightly and proceed with
the adjustment of the clearance between the needle
and hook point.
(4)
(1)
(2)
(3)
Lowest position
2 mm
2 mm
The clearance between the needle and hook point
should be 0 - 0.1 mm.
[1] Turn the handwheel to bring the hook point (1) behind
the needle (2).
[2] Knock on the hook race rim lightly to make a slight
clearance between the needle and hook point.
NOTE:
Do not knock on the hook body.
[3] Tighten the setscrews firmly and check the needle to
hook timing and the thread path (3) (0.4 - 0.8 mm). If
not, replace the hook race stopper with new one.
(There is no way to adjust.)
[4] Attach the needle plate.
(1)
(2)
(1)
0 - 0.1
mm
0 - 0.1
mm 0.4 - 0.8 mm
(3)

7
9. Hook Stopper Position
[1] Remove the base, needle plate and feed dog.
[2] Loosen the setscrew (1) and move the hook stopper
(2) so that the center of the needle (3) is located
between the center of the hook stopper (4) and outer
side of the hook stopper spring (5).
[3] Tighten the setscrew (1) and attach the feed dog,
needle plate and base.
(1)
(2)
(3)
(5)
(4)
(2)

8
10. Bobbin Winder Stopper
The amount of thread wound on the bobbin should be
16.5 - 19.5 mm in diameter.
[1] Loosen the setscrew (1). Turn the bobbin winder
stopper (2) to adjust the thread amount.
- If the amount is too much, turn the stopper in the
direction A.
- If the amount is not enough, turn the stopper in the
direction B.
[2] Tighten the setscrew (1) firmly.
(1)
(2)
A
B
16.5 -19.5 mm

9
11. Check Spring Stroke
The amount of the needle thread supplied by the check
spring should be 11 - 15 mm.
[1] Thread the machine up to the thread guide (1) and
lower the presser foot.
Lower the needle bar to the lowest position.
[2] Hold the thread end and mark the point (2) on the
thread beside the thread guide.
NOTE:
There should be no slack in the thread.
[3] Pull the thread gently to the left until it stops {the
check spring (3) travels full stroke}.
[4] Measure the length of thread drawn out.
(Use the markings on the Gauge 767G-001 for 11 mm
and 15 mm).
[5] Loosen the setscrew (4) and move the tension dial
guide (5) to adjust the stroke.
- If the length is too long, turn the guide in the direc-
tion A.
- If the length is too short, turn the guide in the direc-
tion B.
[6] Tighten the setscrew (4).
(1)
(2)
(3)
(5)
(4)
(1)
(4)
A
B
11 - 15 mm
12. Pre-tension Dial
The standard position of the pretension dial is as follows:
1600P and 1600P-DBX:
The screw head (1) sinks 4 mm below the dial face.
(Use the marking on the Gauge 767G-001 for 4 mm).
1600P-DB:
The screw head (1) is level with the dial face.
(1)
(2)
4 mm
Level
1600P and 1600P-DBX
1600P-DB
11 mm15 mm
4 mm

10
13. Knee Lifter Lever
The presser foot rises 7.5 mm when it is fully raised with
the knee lifter.
[1] Remove the base and lay the machine on its back.
[2] Loosen the nut (1) on the knee lifter lever (2) slightly
and turn the adjusting screw (3) to adjust the height.
- If it is lower than 7.5 mm, turn the adjusting screw
(3) clockwise.
- If it is higher than 7.5 mm, turn the adjusting screw
(3) counterclockwise.
(Use the 5th step from the left of the Gauge 767G-001
for 7.5 mm).
[3] Tighten the nut (1) firmly and attach the base.
NOTE:
Lower the needle bar to the lowest position and check if
the needle clamp does not hit against the presser foot
when it is fully raised.
7.5 mm
(1) (2)
(3)
7.5 mm

11
14. Needle Stop Position
[1] Turn the power switch (1) on while pressing the Up/
Down needle position button (2) and bobbin winding
button (3) at the same time.
[2] Remove the top cover.
[3] Lower the needle bar by turning the hand wheel until
the needle point is 19.1 mm (for 1600P-DB/DBX) or
18.7 mm (for DP-1600P) above the upper surface of
the needle plate (4).
(Use the first step from the right for 19.1 mm or the
second step from the right for 18.7 mm).
[4] Loosen the setscrew (5). Rotate the upper shaft
shielding plate (6) toward you until the green LED (7)
turns on.
[5] Tighten the setscrew (5) and turn the power switch
off.
[6] Attach the top cover.
(1)
(2) (3)
(5)
(4)
(6)
(7)
19.1 mm (1600P-DB/DBX)
18.7 mm (1600P)
19.1 mm
18.7 mm

12
15. Needle Threader (1600P only)
To remove:
[1] Remove the face plate.
[2] Pull the threader (1) out from the threader shaft (2).
To attach:
[3] Align the groove (3) of the theader with the pin (4) on
the threader shaft. Push the threader up until it snaps
in place.
To adjust:
[1] If the threader hook (1) thrusts or hits against either
left or right edge of the needle eye (2):
Loosen the setscrew (3). Move the threader plate (4)
to adjust the lateral position of the threader hook (1).
[2] If the threader hook (1) thrusts or hits against either
top or bottom edge of the needle eye (2), or misses
the needle eye (2):
Loosen the setscrew (5). Move the threader position
setting plate (6) up or down to adjust the vertical
position of the threader hook (1).
(1) (2)
(3)
(5)
(4)
(6)
(1)
(2)
(1)
(2)
(3)
(4)

13
Replacing the Electronic Components
1a. Location of the Electronic Components (1600P-DB)
Lamp
Circuit board-F
Slide volume
Circuit board-A
Bobbin winder motor
Bobbin winder switch
Upper shaft sensor
Driving motor
Machine socket
Power transformer
Circuit board-MS
Arm lamp
Lamp
Circuit board-F
Slide volume
Circuit board-A
Bobbin winder motor Bobbin winder switch
Upper shaft sensor
Driving motor
Machine socket
Power transformer
Circuit board-MS
Arm lamp
Thread cutter switch
Capacitor
Push-pull solenoid
1b. Location of the Electronic Components (1600P and 1600P-DBX)

14
Motor sensor
Circuit borad-F
Thread cutter switch*
Machine socket (primary)
Power transformer
(primary)
Driving motor
Machine socket (secondary)
Slide volume
Arm lamp
Power transformer
(secondary)
Bobbin winder
switch
Push-
pull
solenoid*
Capacitor*
Upper shaft sensor
Lamp
Motor sensor Circuit board-F
Machine socket (primary)
Power transformer
(primary)
Driving motor
Machine socket (secondary)
Slide volume
Arm lamp
Power transformer
(secondary)
Bobbin winder
switch
Upper shaft sensor
Lamp
2b. Location of the Connectors (1600P and 1600P-DBX)
2a. Location of the Connectors (1600P-DB)
NOTE:
* only for 1600P and 1600-DBX

15
3. Internal Wiring
Motor cord
Motor sensor cord
Machine socket cord (primary)
Machine socket cord (secondary)
Push-pull solenoid cord*
Capacitor cord*
Cord binder
Cord guide (1)
Thread cutter cord* Cord guide (2)
Motor cord
Motor sensor cord
Cord guide (1)
Setscrews for cord guide (1)
To prevent the internal wirings from contacting the moving parts or being caught in the joint
of the external parts, the internal wirings should properly be routed and secured as illus-
trated.
Cord binder
NOTE:
The item marked with * is applicable to 1600P and
1600-DBX only.

16
4. Circuit Board-A
To remove:
[1] Remove the top cover.
[2] Pull out connectors from the circuit board-A.
Remove the cords from the cord clips (1).
[3] Remove the setscrews (2) and the board-A
case lid (3).
[4] Pull out the connectors under the case lid.
Remove setscrews (4) and circuit board-A.
To attach:
[5] Install the circuit board-A and secure it with
the setscrews (4).
[6] Insert the following connectors:
(5) Machine socket (primary)
(6) Power transformer (primary)
(7) Driving motor
[7] Attach the board-A case lid (3) and secure it
with the setscrews (2).
Insert the remaining connectors and secure
the cords with the cord clips (1) on the case
lid.
Attach the top cover.
NOTE:
Do not disconnect the connectors by pulling on cord.
To disconnect, grasp the connector, not the cord.
5. Circuit Board-F and Slide Volume
[1] Remove the top cover.
[2] Loosen the 4 setscrews (1) and remove the
ornamental panel (2).
[3] Pull out the circuit board-F connector from the
circuit board-A. Remove the 3 setscrews (3)
and circuit board-F (4).
[4] Pull out the slide volume connector from the
circuit board-A. Remove the CS rings (5) and
slide volume (6).
[5] To attach: follow the above procedure in
reverse.
NOTE:
Do not disconnect the connectors by pulling on cord.
To disconnect, grasp the connector, not the cord.
(1) (2)
(3)
(4)
(4)
(5)
(6)
(7)
(1) (2)
(3) (5)
(4)
(1) (1)
(2)
(6)

17
6. Driving Motor
To remove:
[1] Remove the belt cover and motor cover.
[2] Pull out the motor sensor connector (1).
[3] Pull out the motor connector (2), while pushing the
connector lock (3).
[4] Remove the nuts (4) and driving motor (5).
NOTE:
Do not disconnect the connectors by pulling on cord.
To disconnect, grasp the connector, not the cord.
(to be continued on next page.)
(1)
(4)
(5)
(3)
(2)
(2)

18
6. Driving Motor (continued)
To attach:
[1] Install the driving motor (1) to the motor bracket (2)
and attach the motor belt (3). Tighten the nuts (4)
firmly.
[2] Loosen the setscrews (5) slightly and move the motor
up or down to adjust the motor belt tension.
The belt should deflect 4 - 5 mm when applying 300
grams of load to the middle of the belt.
Tighten the setscrews (5) firmly.
[3] Insert the motor connector (6) and motor sensor
connector (7).
[4] Attach the motor cover and belt cover.
(1)
(2)
(3)
(5)
(4)
(6)
Motor belt tension
4 - 5 mm
(7)