Janome DC5100 Service Manual
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Janome DC5100 Service Manual

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SERVICE MANUAL
PARTS LIST
DC5100

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Summary of Contents for Janome DC5100

  • Page 1 SERVICE MANUAL PARTS LIST DC5100...

  • Page 2: Table Of Contents

    CONTENTS LOCATE AND IDENTIFY THE PARTS ....................... 1 WINDING THE BOBBIN ............................ 2 THREADING THE MACHINE ..........................3 CONNECTOR DIAGRAM ..........................4 GENERAL TROUBLE SHOOTING PROCEDURE .................... 5 WHAT TO DO WHEN ............................6-8 SELF-DIAGNOSTIC TESTS .........................9-11 SERVICE ACCESS FACE COVER ........................... 12 TOP COVER .............................

  • Page 3: Locate And Identify The Parts

    MODEL DC5100 SEWING MACHINE LOCATE AND IDENTIFY THE PARTS SPOOL PIN SPOOL HOLDER FLIP TOP STITCH CHART THREAD GUIDE SCREEN BRIGHTNESS THREAD TAKE-UP LEVER ADJUSTING DIAL THREAD TENSION DIAL FACE COVER FUNCTION TOUCHPAD THREAD CUTTER NEEDLE THREADER SPEED CONTROL LEVER...

  • Page 4: Winding The Bobbin

    SEWING MACHINE MODEL DC5100 WINDING THE BOBBIN (1) PASS THE THREAD AROUND THREAD GUIDE. (2) THEN THROUGH THE HOLE IN THE BOBBIN. (3) PUT THE BOBBIN ON THE BOBBIN WINDER SPINDLE, AND PUSH THE BOBBIN TO THE RIGHT. (4) WHEN THE BOBBIN IS FULLY WOUND, IT WILL STOP AUTOMATICALLY. RETURN THE BOBBIN WINDER TO ITS ORIGINAL POSITION BY MOVING THE SPINDLE TO THE LEFT, AND CUT THE THREAD AS SHOWN.

  • Page 5: Threading The Machine

    MODEL DC5100 SEWING MACHINE THREADING THE MACHINE RAISE THE PRESSER FOOT LIFTER, AND PASS THE THREAD THROUGH POINTS (1) TO (6). (1) HOLD THE UPPER THREAD AND PASS THE THREAD UNDER THE THREAD GUIDE. PULL THE THREAD DOWN ALONG THE RIGHT CHANNEL.

  • Page 6: Connector Diagram

    SEWING MACHINE MODEL DC5100 CONNECTOR DIAGRAM REFER TO THE DIAGRAM FOR LOCATING THE CONNECTOR POST ON THE CIRCUIT BOARD EACH CONNECTOR SHOULD BE CONNECTED AS FOLLOWS; A : BUTTONHOLE SENSOR H : POWER TRANSFORMER (SECONDARY B : SEWING LIGHT CIRCUIT) C : UPPER SHAFT SENSOR I : PRINTED CIRCUIT BOARD “F”...

  • Page 7: General Trouble Shooting Procedure

    SEWING MACHINE MODEL DC5100 GENERAL TROUBLE SHOOTING PROCEDURE (MACHINE DOESN’T WORK WELL) START IS NEEDLE SET OK? IS POWER SUPPLY OK? BASIC CHECK IS THREADING OK? N.G. O.K. CORRECT IT CAN’T JUDGE MECHANICAL ELECTRICAL O.K. ELECTRIC QUICK CHECK N.G. ADJUSTMENT...

  • Page 8: What To Do When

    SEWING MACHINE MODEL DC5100 WHAT TO DO WHEN CONDITION CAUSE HOW TO FIX REFERENCE 1. SKIPPING 1. NEEDLE IS NOT INSERTED INSERT THE NEEDLE PROPERLY. STITCHES PROPERLY. 2. NEEDLE IS BENT OR WORN. CHANGE THE NEEDLE. 3. INCORRECTLY THREADED. RETHREAD.
  • Page 9 SEWING MACHINE MODEL DC5100 CONDITION CAUSE HOW TO FIX REFERENCE 3. BREAKING 1. INITIAL SEWING SPEED IS START WITH MEDIUM SPEED. UPPER TOO FAST. THREAD 2. THREAD PATH IS INCORRECT. USE THE PROPER THREAD PATH. 3. NEEDLE IS BENT OR DULL.
  • Page 10 SEWING MACHINE MODEL DC5100 CONDITION CAUSE HOW TO FIX REFERENCE 6. NOISY 1. BACKLASH BETWEEN HOOK SEE MECHANICAL ADJUSTMENT P. 22 OPERATION GEAR AND LOWER SHAFT “BACKLASH (BETWEEN LOWER GEAR IS TOO GREAT. SHAFT GEAR AND HOOK GEAR)”. 2. LOWER SHAFT GEAR IS ELIMINATE THE LOOSENESS.

  • Page 11: Self-Diagnostic Tests

    SEWING MACHINE MODEL DC5100 SELF DIAGNOSTIC TESTS PREPARATION: • TURN OFF THE POWER SWITCH. • SHIFT THE BOBBIN WINDER SPINDLE TO THE LEFT. • RAISE THE FEED DOG. • SHIFT THE SLIDE VOLUME TO THE LEFT. • REMOVE THE PRESSER FOOT AND RAISE THE PRESSER FOOT LIFTER.

  • Page 12: Self Diagnostic Tests

    SEWING MACHINE MODEL DC5100 SELF DIAGNOSTIC TESTS DEFECTIVE RESULTS / TESTS REPLACEMENT AND CORRECT RESULTS ADJUSTMENT • THE DISPLAY SHOWS “Self Check TURN THE POWER SWITCH ON DEFECTIVE RESULTS: Start”. LCD AND LED BLINKS. • DOES NOT ENTER THE SELF- WHILE PRESSING THE LCD &...
  • Page 13 SEWING MACHINE MODEL DC5100 SELF DIAGNOSTIC TESTS DEFECTIVE RESULTS / REPLACEMENT AND TESTS CORRECT RESULTS ADJUSTMENT • THE DISPLAY SHOWS “VeloSen”. TURN THE HANDWHEEL DEFECTIVE RESULTS: • BEEP SOUND. CLOCKWISE TO MOVE THE • THE VALUE DOES NOT CHANGE. VELOCITY NEEDLE FROM HIGHEST TO •...

  • Page 14: Service Access

    SEWING MACHINE MODEL DC5100 SERVICE ACCESS (1) FACE COVER TO REMOVE: 1. OPEN THE FACE COVER. REMOVE THE 2 SCREWS (A) AND REMOVE THE FACE COVER (B). TO ATTACH: 2. FOLLOW THE PROCEDURE ABOVE IN REVERSE. TOP COVER TO REMOVE: 1.

  • Page 15: Belt Cover

    SEWING MACHINE MODEL DC5100 SERVICE ACCESS (2) BELT COVER TO REMOVE: 1. REMOVE THE 2 SCREWS (A), THEN UNHOOK THE RIB (C) AND REMOVE THE BELT COVER (B). TO ATTACH: 2. FOLLOW THE PROCEDURE ABOVE IN REVERSE RIB (C) BELT COVER (B)

  • Page 16: Base Plate

    SEWING MACHINE MODEL DC5100 SERVICE ACCESS (3) BASE PLATE TO REMOVE: 1. REMOVE THE 2 SCREWS (A) AND 4 SCREWS (B). 2. REMOVE THE BASE (C). TO ATTACH: 3. REVERSE THIS PROCEDURE. BED COVER TO REMOVE: 1. REMOVE THE 2 SCREWS (D).

  • Page 17: Front Cover

    SEWING MACHINE MODEL DC5100 SERVICE ACCESS (4) FRONT COVER TO REMOVE: 1. REMOVE THE TOP COVER, BELT COVER AND BED COVER. 2. LOOSEN THE SETSCREWS (A), (D), (E) AND REMOVE THE SETCREWS (B), (C) AND (F). 3. REMOVE THE FRONT COVER.

  • Page 18: Rear Cover

    SEWING MACHINE MODEL DC5100 SERVICE ACCESS (5) REAR COVER TO REMOVE: 1. REMOVE THE BELT COVER. 2. REMOVE THE SETSCREWS (A), (B), (C), (D) AND (E). 3. TO REMOVE THE COVER, DETACH THE PRESSER FOOT LIFTER SECTION FIRST, WITH THE PRESSER FOOT LIFTER IN THE DOWN POSITION.

  • Page 19: Free Arm Cover

    SEWING MACHINE MODEL DC5100 SERVICE ACCESS (6) FREE ARM COVER TO REMOVE: 1. REMOVE SETSCREW (A) AND THE NEEDLE PLATE. 2. REMOVE THE BED COVER (SEE PAGE 14). 3. REMOVE SETSCREW (B) AND THE FREE-ARM COVER. TO ATTACH: 4. FOLLOW THE PROCEDURE ABOVE IN REVERSE.

  • Page 20: Mechanical Adjustment

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (1) NEEDLE DROP POSITION SET THE STITCH PATTERN AT " "; THE STANDARD NEEDLE DROP POSITION SHOULD BE AT THE CENTER OF THE NEEDLE PLATE HOLE. WHEN THE NEEDLE SWINGS IN MAXIMUM ZIGZAG WIDTH "...

  • Page 21: Needle Bar Height

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (2) NEEDLE BAR HEIGHT THE DISTANCE BETWEEN THE UPPER EDGE OF NEEDLE EYE AND THE TIP OF THE HOOK SHOULD BE IN THE RANGE OF 1.6-2.0 MM WHEN THE TIP OF HOOK MEETS THE RIGHT SIDE OF THE NEEDLE IN ASCENDING TRAVEL OF NEEDLE FROM ITS LEFT AND LOWEST POOSITION.

  • Page 22: Needle To Hook Timing

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (3) NEEDLE TO HOOK TIMING WHEN THE MACHINE IS SET THE STRAIGHT STITCH PATTERN NO.2 ( LEFT NEEDLE POSITION), THE AMOUNT OF ASCENDING TRAVEL OF THE NEEDLE BAR FROM ITS LOWEST POSITION TO THE POSITION WHERE THE TIP OF THE HOOK MEETS THE RIGHT SIDE OF THE NEEDLE SHOULD BE 3.25 - 3.55 MM.

  • Page 23: Clearance Between Needle And Hook

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (4) CLEARANCE BETWEEN NEEDLE AND HOOK THE CLEARANCE BETWEEN THE TEST PIN AND THE TIP OF THE HOOK SHOULD BE BETWEEN –0.10 AND +0.05 MM. PREPARATION: 1. TURN ON THE POWER SWITCH AND SET THE STITCH PATTERN TO MAXIMUM ZIGZAG WIDTH "...

  • Page 24: Backlash (Between Lower Shaft Gear And Hook Gear)

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (5) BACKLASH (BETWEEN LOWER SHAFT GEAR AND HOOK GEAR) JOG THE HOOK RACE BACK AND FORTH TO CHECK ROTARY PLAY. THE STANDARD PLAY SHOULD BE 0.8 MM (0.03˝) OR LESS WHEN THE HOOK POINT IS WITHIN THE FEED DOG WIDTH.

  • Page 25: Feed Dog Height

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (6) FEED DOG HEIGHT THE HIGHEST POSITION OF THE FEED DOG SHOULD BE BETWEEN 0.8 TO 0.9 MM FROM THE SURFACE OF THE NEEDLE PLATE WHEN THE THE PRESSER FOOT IS RAISED. 1. LOWER THE PRESSER FOOT.

  • Page 26: Zigzag Synchronization

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (7) ZIGZAG SYNCHRONIZATION 1. PATTERN: (ZIGZAG STITCH) THE NEEDLE SHOULD START SWING BETWEEN 6.3 TO 7.5 MM ABOVE THE SURFACE OF THE NEEDLE PLATE WHEN THE MACHINE IS SET FOR ZIGZAG STITCHING. 1. REMOVE THE FRONT COVER (REFER TO PAGE 15).

  • Page 27: Tension Release Mechanism

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (8) TENSION RELEASE MECHANISM CORRECT SETTING: WHEN THE PRESSER FOOT LIFTER IS RAISED, THE TENSION DISK SUPPORTER SHOULD MOVE APPROXIMATELY 1 MM. TO ADJUST: 1. REMOVE THE TOP COVER, BELT COVER AND FRONT COVER (SEE PAGES 12, 13 AND 15).

  • Page 28: Stretch Stitch Feed Balance Adjustment

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (9) STRETCH STITCH FEED BALANCE ADJUSTMENT 1. WHEN A STRECH PATTERN IS SEWN WITH THE FEED BALANCING DIAL (C) SET AT THE STANDARD SETTING MARK '' '' , THE PATTERN SHOULD BE AS INDICATED WITH THE '' MARK IN THE FOLLOWING FIGURE.

  • Page 29: Needle Thread Tension

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (10) NEEDLE THREAD TENSION TO CHECK: 1. THE STANDARD TENSION SHOULD BE 75 TO 90 GRAMS WHEN THE TENSION DIAL IS SET AT "4", MESURED BY A #50 WHITE POLYESTER THREAD BEING PULLED AT APPROXIMATELY 110 MM/SEC.

  • Page 30: Buttonhole Lever

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (11) BUTTONHOLE LEVER TO ADJUST THE BUTTONHOLE LEVER GUIDE: 1. ENTER ADJUSTING MODE, TURN THE POWER SWITCH ON WHILE PRESSING THE "REVERSE" AND "AUTO-LOCK" BUTTONS. PRESS THE #4 KEY WITHIN 3 SECONDS. THE LCD SCREEN SHOWS "BH SENSOR [H] OR [L]".

  • Page 31: Presser Foot Height And Alignment

    SEWING MACHINE MODEL DC5100 MECHANICAL ADJUSTMENT (12) PRESSER FOOT HEIGHT AND ALIGNMENT WHEN THE PRESSER FOOT IS RAISED, THE CLEARANCE BETWEEN THE PRESSER FOOT AND THE NEEDLE PLATE SHOULD BE 5.7 TO 6.3 MM. WHEN THE PRESSER FOOT IS LOWERED, THE EDGE OF THE FOOT AND THE FEED DOG WINDOW ON THE NEEDLE PLATE SHOULD BE PARALLEL.

  • Page 32: Part Removal And Replacement

    SEWING MACHINE MODEL DC5100 PART REMOVAL AND REPLACEMENT (1) NEEDLE THREAD TENSION UNIT TO REMOVE: 1. REMOVE THE FRONT COVER (SEE PAGE 15). 2. REMOVE SCREWS (A) AND (B) AND THE NEEDLE THREAD TENSION UNIT (C). TO ATTACH: 1. REVERSE THIS PROCEDURE.

  • Page 33: Threader Plate

    SEWING MACHINE MODEL DC5100 PART REMOVAL AND REPLACEMENT (2) THREADER PLATE WHEN THE HOOK OF THE THREADER PLATE IS DAMAGED, CHANGE OR ADJUST THE PART AS FOLLOWS. TO CHANGE THE THREADER PLATE: 1. RAISE THE NEEDLE TO ITS HIGHEST POSITION AND LOWER THE THREADER KNOB TO ITS LOWEST POSITION.

  • Page 34: Replacing The Printed Circuit Board "A

    SEWING MACHINE MODEL DC5100 REPLACING THE PRINTED CIRCUIT BOARD "A" TO REMOVE: 1. REMOVE THE FRONT COVER (SEE PAGE 15). 2. UNPLUG THE CONNECTORS FROM THE BOARD "A". 3. REMOVE THE 6 SCREWS AND REMOVE BOARD "A". NOTE: TO DISCONNECT THE CONNECTORS: 1.

  • Page 35: Replacing The Printed Circuit Board "F

    SEWING MACHINE MODEL DC5100 REPLACING THE PRINTED CIRCUIT BOARD "F" TO REMOVE: 1. REMOVE THE FRONT COVER UNIT 2. UNPLUG THE CONNECTOR OF THE PRINTED CIRCUIT BOARD "F". 3. REMOVE THE 2 SETSCREWS AND PRINTED CIRCUIT BOARD "F". TO ATTACH: 4.

  • Page 36: Replacing Slide Volume

    SEWING MACHINE MODEL DC5100 REPLACING SLIDE VOLUME REPLACING SLIDE VOLUME TO REMOVE: 1 REMOVE THE FRONT COVER. 2 DISCONNECT THE SLIDE VOLUME CONNECTOR. 3 REMOVE THE PRINTED CIRCUIT BOARD "A". 4 REMOVE THE CS RINGS (2). 5 REMOVE THE SLIDE VOLUME.

  • Page 37: Replacing Dc Motor And Adjusting Motor Belt Tension

    SEWING MACHINE MODEL DC5100 REPLACING DC MOTOR AND ADJUSTING MOTOR BELT TENSION TO REMOVE: 1. REMOVE THE FRONT AND REAR COVERS (SEE PAGE 8). 2. DISCONNECT THE MOTOR CONNECTOR. REMOVE THE TWO SETSCREWS, THEN REMOVE THE DC MOTOR AND BELT.

  • Page 38: Replacing The Fuses

    SEWING MACHINE MODEL DC5100 REPLACING THE FUSES REPLACING THE FUSES TO REMOVE: 1. REMOVE THE FRONT COVERS (SEE PAGE 15). 2. REMOVE THE PRINTED CIRCUIT BOARD "A". REMOVE THE FOUR SETSCREWS AND REMOVE THE COVER FROM THE PRINTED CIRCUIT BOARD "A".

  • Page 39: Replacing Machine Socket (Unit)

    SEWING MACHINE MODEL DC5100 REPLACING MACHINE SOCKET (UNIT) TO REMOVE: 1. REMOVE THE FRONT AND REAR COVER (SEE PAGE 16). 2. REMOVE THE TWO SETSCREWS AND REMOVE THE MACHINE SOCKET. TO INSTALL: 3. TO INSTALL THE MACHINE SOCKET, FOLLOW THE ABOVE PROCEDURE IN REVERSE.

  • Page 40: Replacing Transformer

    SEWING MACHINE MODEL DC5100 REPLACING TRANSFORMER TO REMOVE: 1. REMOVE THE FRONT COVER 2. REMOVE THE TWO SETSCREWS AND REMOVE THE TRANSFORMER. TO INSTALL: 3. TO INSTALL THE TRANSFORMER, FOLLOW THE ABOVE PROCEDURE IN REVERSE NOTE: PLACE THE REAR END OF THE TRANSFORMER ON THE TRANSFORMER SUPPORT.

  • Page 41: Replacing The Zigzag Width Motor

    SEWING MACHINE MODEL DC5100 REPLACING THE ZIGZAG WIDTH MOTOR TO REMOVE: 1. REMOVE THE FRONT AND REAR COVER. 2. REMOVE THE TWO SETSCREWS (A) AND REMOVE THE ZIGZAG WIDTH MOTOR PROTECTOR PLATE. CUT THE BINDER. 3. REMOVE THE TWO ZIGZAG ROD SETSCREWS (B).

  • Page 42: Replacing The Feed Stitch Motor

    SEWING MACHINE MODEL DC5100 REPLACING THE FEED STITCH MOTOR TO REMOVE: 1. REMOVE THE FRONT COVER AND REAR COVERS (SEE PAGE 15 AND 16) 2. REMOVE THE SNAP RING (E-3) 3. REMOVE THE TWO SETSCREWS AND REMOVE THE FEED MOTOR.

  • Page 43: Adjusting The Bobbin Winder Switch

    SEWING MACHINE MODEL DC5100 ADJUSTING THE BOBBIN WINDER SWITCH ADJUST THE BOBBIN WINDING SWITCH 1. REMOVE THE FRONT COVER. 2. SET THE BOBBIN WINDER ARM IN THE SEWING POSITION AND LOOSEN THE SETSCREW. ADJUST THE CLEARANCE BETWEEN THE BOBBIN WINDER ARM AND THE SWITCH FIXING PLATE TO 0.7 TO 1.3 MM.

  • Page 44: Oiling

    SEWING MACHINE MODEL DC5100 OILING FACTORY LUBRICATED PARTS WILL PROVIDE YEARS OF HOUSEHOLD SEWING WITHOUT ROUTINE OILING, BUT YOU SHOULD STILL CHECK FOR POSSIBLE LUBRICATION NEEDS WHENEVER SERVICING MACHINES. OIL: USE GOOD QUALITY SEWING MACHINE OIL AT THE POINTS (A, B, C, D, E, F,G,H,I,J & K) INDICATED BY THE BLACK ARROWS.

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