Janome DC4030P Service Manual
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Janome DC4030P Service Manual

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SERVICE MANUAL
MODEL : DC4030P

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Summary of Contents for Janome DC4030P

  • Page 1 SERVICE MANUAL MODEL : DC4030P...

  • Page 2: Table Of Contents

    DC4030P CONTENTS SERVICE ACCESS (1) FACE COVER ................2 SERVICE ACCESS (2) BED COVER ................3 SERVICE ACCESS (3) FRONT COVER ................4 SERVICE ACCESS (4) REAR COVER ................5 PRESSER BAR HEIGHT AND ALIGNMENT ..............6 NEEDLE DROP POSITION ....................7 NEEDLE TO HOOK TIMING ....................8 NEEDLE BAR HEIGHT ....................9...

  • Page 3: Service Access (1) Face Cover

    DC4030P SERVICE ACCESS (1) FACE COVER TO REMOVE: 1. Remove the 2 setscrews and remove the face cover. TO INSTALL: 2. Follow the above procedure in reverse. Setscrew Face cover...

  • Page 4: Service Access (2) Bed Cover

    DC4030P SERVICE ACCESS (2) BED COVER TO REMOVE: 1. Set the drop lever to the left and remove the 3 setscrews, remove the bed cover. TO INSTALL: 2. Set the drop lever to the left and install the bed cover.

  • Page 5: Front Cover

    DC4030P SERVICE ACCESS (3) FRONT COVER TO REMOVE: 1. Remove the bed cover and needle plate (see page 3). 2. Loosen the setscrew (A), remove the setscrew (B), (C), (D), (E), (F), (G), and (H). (Remove setscrew (I) and lamp set plate (2) when the setscrew (A) is hard to access.) 3.

  • Page 6: Service Access (4) Rear Cover

    DC4030P SERVICE ACCESS (4) REAR COVER TO REMOVE: 1. Remove the front cover (see page 4). 2. Remove the setscrews (A), (B), and (C), then remove the rear cover. * To remove the cover, detach the presser foot lifter section first, with the presser foot lifter in the down position.

  • Page 7: Presser Bar Height And Alignment

    DC4030P MECHANICAL ADJUSTMENT PRESSER BAR HEIGHT AND ALIGNMENT When the presser foot is raised, the clearance between the presser foot and the needle plate should be 5.7-6.3 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 8: Needle Drop Position

    DC4030P MECHANICAL ADJUSTMENT 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 " ", the distance between both ends of the needle hole in the needle plate and the needle should be 0.2 mm or more.

  • Page 9: Needle To Hook Timing

    DC4030P MECHANICAL ADJUSTMENT NEEDLE TO HOOK TIMING When the machine is set the straight stitch pattern " " (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 10: Needle Bar Height

    DC4030P MECHANICAL ADJUSTMENT 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 position.

  • Page 11: Needle Clearance To Shuttle

    DC4030P MECHANICAL ADJUSTMENT NEEDLE CLEARANCE TO SHUTTLE The clearance between the needle and the tip of hook should be -0.1 to +0.05 mm. PREPARATION: 1. Remove the needle plate, bobbin holder, and bed cover (see page 3), and replace the needle with the test pin.

  • Page 12: Backlash (Between Lower Shaft Gear And Hook Drive Gear)

    DC4030P MECHANICAL ADJUSTMENT BACKLASH (BETWEEN LOWER SHAFT GEAR AND HOOK DRIVE 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. If play exceeds 0.8 mm, adjust as follows.

  • Page 13: Feed Dog Height

    DC4030P MECHANICAL ADJUSTMENT 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 pressure foot pressure adjusting lever is set at "3" and the presser foot is lowered.

  • Page 14: Zigzag Synchronization

    DC4030P MECHANICAL ADJUSTMENT ZIGZAG SYNCHRONIZATION The needle should start swing 8.2 mm above the surface of the needle plate when the machine is set for zigzag stitching. 1. Remove the front cover (see to page 4). 2. Turn on the power switch, select the pattern no. 5 and set the machine at the maximum zigzag width.

  • Page 15: Needle Thread Tension

    DC4030P MECHANICAL ADJUSTMENT NEEDLE THREAD TENSION The standard tension should be 75 to 90 grams when the tension dial is set at "A" (auto), measured with a #50 white polyester thread being pulled at approximately 110 mm/sec. If the tension is outside the standard range, adjust as follows: ADJUSTMENT: 1.

  • Page 16: Stretch Stitch Feed Balance

    DC4030P MECHANICAL ADJUSTMENT STRETCH STITCH FEED BALANCE When a stretch stitch pattern is sewn with the feed balancing dial position set at the standard setting mark " ", the stitch pattern should look like the one marked with a "...

  • Page 17: Replacement And Adjustment Of The Needle Threader Plate

    DC4030P MECHANICAL ADJUSTMENT REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE If the hook of the threader plate is damaged, change and adjust the part as follows: TO CHANGE THE THREADER PLATE: 1. Push down the needle threader knob and pull the threader plate supporter (A) down to remove it (see FIG 1).

  • Page 18: Adjusting Buttonhole Lever Position

    DC4030P ADJUSTING BUTTONHOLE LEVER POSITION TO ADJUST THE BUTTONHOLE LEVER GUIDE: 1. Enter adjusting mode, by turning the power switch on while pressing the "Start/Stop" and "Auto-lock" buttons. Press the #4 key within 3 seconds. The LCD screen shows "BH sensor [H] or [L]".

  • Page 19: Connector Diagram

    DC4030P CONNECTOR DIAGRAM REFER TO THE DIAGRAM FOR LOCATING THE CONNECTOR POST ON THE CIRCUIT BOARD H : Power transformer (secondary circuit) (RED) A : Buttonhole sensor (BLK) I : Printed circuit board “F” (BLK) B : Sewing light (WHT)

  • Page 20: Self Diagnostic Tests

    DC4030P 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 21 DC4030P SELF DIAGNOSTIC TESTS DEFECTIVE RESULTS STEP AND CORRECT RESULTS PROCEDURE ITEMS TO CHECK * No beep sound. * Beep sounds when the buttons are Turn on the power switch while * Does not enter self-diag- pressed. simultanously pressing the needle up/ 7 - s e g m e n t nostic mode.
  • Page 22 DC4030P SELF DIAGNOSTIC TESTS OPERATION CORRECT CONDITION DEFECTIVE CONDITION STEP Press needle up/down button, LED * LED indicates "L" or "H". LED display is different from displays "06" for one second. that shown to the left. Buttonhole sensor 1. Lower the buttonhole lever.
  • Page 23 DC4030P SELF DIAGNOSTIC TESTS STEP OPERATION CORECT CONDITION DEFECTIVE CONDITION * LED indicates "00". * LED display is different from Press needle up/down button, that shown to the left. the LED displays "10" for one Foot second. controller 1. Replace foot control.

  • Page 24: Replacing Printed Circuit Board A

    DC4030P REPLACING PRINTED CIRCUIT BOARD A TO REMOVE: 1. Remove the front cover (see page 4). 2. Unplug the connectors from the board "A". 3. Remove the 8 screws and remove board "A". NOTE: TO DISCONNECT THE CONNECTORS: 1. Grasp the connector directly with your fingers and pull.

  • Page 25: Replacing Printed Circuit Board F And Slide Volume

    DC4030P REPLACING PRINTED CIRCUIT BOARD F AND SLIDE VOLUME REPLACING THE SLIDE VOLUME TO REMOVE: 1. Remove the front cover unit (see page 4). 2. Unplug the slide volume connector. 3. Remove the 2 CS rings (A), CS ring (B), 2 CS rings (C), and remove the side volume.

  • Page 26: Replacing Dc Motor And Adjusting Motor Belt Tension

    DC4030P REPLACING DC MOTOR AND ADJUSTING MOTOR BELT TENSION TO REMOVE: 1. Remove the front cover and rear cover (see pages 4 and 5). 2. Unplug the DC motor connector. 3. Remove the 2 setscrews, then remove the DC motor and belt.

  • Page 27: Replacing The Fuses

    DC4030P REPLACING THE FUSES REPLACING THE FUSES TO REMOVE: 1. Remove the front cover (see page 4). 2. Remove the four setscrews and remove the cover on printed circuit board "A". 3. Remove the fuse (pry it out with a screwdriver).

  • Page 28: Replacing Machine Socket (Unit)

    DC4030P REPLACING MACHINE SOCKET (UNIT) REPLACING THE MACHINE SOCKET TO REMOVE: 1. Remove the front cover and rear cover (see pages 4 and 5). 2. Remove the 2 setscrews and remove the machine socket. TO INSTALL: 3. To install the machine socket, follow the above procedure in reverse.

  • Page 29: Replacing The Transformer

    DC4030P REPLACING THE TRANSFORMER REPLACING THE TRANSFORMER TO REMOVE: 1. Remove the front cover (see page 4). 2. Remove the 2 setscrews and remove the transformer. TO INSTALL: 3. To install the transformer, follow the above procedure in reverse. NOTE Slide the two transformer wire tubes to the side of transformer and secure them to the zigzag stepping motor wire so they will not come in contact with any moving parts.

  • Page 30: Replacing The Zigzag Width Motor

    DC4030P REPLACING THE ZIGZAG WIDTH MOTOR REPLACING THE ZIGZAG WIDTH MOTOR TO REMOVE: Remove the front cover and rear cover (see pages 4 and 5). 2. Remove the two zigzag rod setscrews (A). Disconnect the connector from the board "A".

  • Page 31: Replacing The Feed Stitch Motor

    DC4030P REPLACING THE FEED STITCH MOTOR REPLACING THE FEED MOTOR TO REMOVE: 1. Remove the front cover and rear cover (see pages 4 and 5). 2. Remove the snap ring (E-3). Disconnect the connector from the board "A". 3. Remove the two setscrews (A), (B) and remove the feed motor.

  • Page 32: Adjusting The Bobbin Winder Switch

    DC4030P ADJUSTING THE BOBBIN WINDER SWITCH TO ADJUST THE BOBBIN WINDING SWITCH 1. Remove the front cover (see page 4). 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.

This manual is also suitable for:

Magnolia 7360

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