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Janome Memory Craft 500E Service Manual
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Janome Memory Craft 500E Service Manual

Janome Memory Craft 500E Service Manual

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Summary of Contents for Janome Memory Craft 500E

  • Page 3 TABLE OF CONTENTS Tools & Gauges……………………………………………………………………………………….…………………………..5 Face Plate Removal……………………………………………………………………………………………………………..7 Base Plate & Bed Cover………………………………………………………………………………………………………8-9 Front Panel Removal………………………………………………………………………………………………………...10-13 Printed Circuit Board “A” Removal…………………………………………………………………………………….14-16 Printed Circuit Board “A” Connection Diagram……………………………………………………………………17 Printed Circuit Board “F” Removal & Installation……………………………………………………………...…18 Printed Circuit Board “A” Installation………………………………………………………………………………..19-20 Rear Cover &...
  • Page 5 REQUIRED TOOLS & GAUGES Small, Flathead Screwdriver Phillip’s Head Screwdriver #PREDVR (150mm) #SD150 Phillip’s Head Screwdriver 1.5mm Hexagon Key (Fine Tip) #TLHW15 #PHLDRVSP1 2.0mm Hexagon Key Large, Flathead Head #TLHW20 Screwdriver #DRIVER2 2.5mm Hexagon Key 1.5mm Hexagon #TLHW25 Screwdriver #TLHS15 #TLHS15 2.0mm Hexagon Screwdriver...
  • Page 7 FACE PLATE REMOVAL 1. Locate and remove the set screw from the back of the face plate. 2. Grab under the front of the face plate, and pull towards you to release the clips and pull towards you to release the clips from the front and rear panels.
  • Page 8 BASE PLATE & BED COVER REMOVAL 1. Remove the 2 screws that hold the needle plate down, and remove needle plate. 2. Place machine on it’s back gently. Remove 6 screws for the base plate. Remove base plate. 3. Put the machine back up so your looking at the front.
  • Page 9 4. Locate and remove white cap on the 5. Remove set screw from the side of the thread cutter cover. thread cutter cover. 6. Gently lay machine on it’s back, and loosen washer screw inside the small access hole. Then slide cover off from the left side.
  • Page 10 FRONT PANEL REMOVAL 1. Place machine in the up right position. Slide carriage arm to the left towards the needle bar. 2. Look in through the left side of the machine by the needle bar, and locate and loosen the washer screw right above the thread guide.
  • Page 11 4. Look on the right side of the machine by the hand wheel, and remove the white cap, and remove set screw. 5. With a small flat head screwdriver release the clips for the belt cover. Once clips are released, remove belt cover. 6.
  • Page 12 8. Push down gently and pull to release clips by 7. With a small flat head release the clip holding LCD unit. the front panel and the rear panel together by the needle bar. 9. Use both hands to pull front panel away 10.
  • Page 13 12. To remove grab 1 set of wires at a time, 11. Looking in though the right side by the and pull straight out. Start from the top, and hand wheel, you will be able to access the work your way down. harnesses for the A-Board.
  • Page 14 PRINTED CIRCUIT BOARD “A” REMOVAL 1. Disconnect 3 harnesses in the top right corner of the a board. 2. Remove 3 set screws on the right side of the a board case. 3. Once removed pick up case from the right side and slide of from the left.
  • Page 15 4. With the a board away from the machine. Locate the 2 flexible cables on the top of the a board. 5. With your finger go underneath the smaller of the 2 flexible cables, and pull straight back. TRY NOT TO ANGLE OR BEND THE CABLE 6.
  • Page 16 8. Remove 4 self tapping set screws at each corner of the a board. 9. Grab the bottom corner of the a board, and remove from case.
  • Page 17 PRINTED CIRCUIT BOARD “A” CONNECTION DIAGRAM LCD MODULE FLEXIBLE PCB TOUCH PANEL NOT USED CIRCUIT BOARD L1 CIRCUIT BOARD L2 BOBBIN THREAD WINDING CIRCUIT BOARD L3 NOT USED CIRCUIT BOARD F PRESSER FOOT LIFTER PHASE SENSOR SENSOR THREAD DETECTION SENSOR X-MOTOR SWITCHING POWER SUPPLY...
  • Page 18 PRINTED CIRCUIT BOARD “F” REMOVAL & INSTALLATION 2. Lift up on the F board, and unravel harness 1. Remove the 2 self tapping set screws on to the A board. the right and left side of the F board. 3. When installing F board, you have to line up the buttons on the front of the board to the buttons on the front panel.
  • Page 19 PRINTED CIRCUIT BOARD “A” INSTALLATION 1. Going in from the left side first, lay the A board in the protective case. 2. Replace the 4 set screws on each end of the A board. board. 3. With the large flexible cable clip open. Slide the flexible cable into position, then push down GENTLY...
  • Page 20 4. Slide the board in from the left. Guide the 3 clips into position on the left side. Lay board flat in front panel, lining up the 3 holes for the set screws. 5. Replace 3 set screws to hold case in position on front panel.
  • Page 21 REAR COVER & Y ARM REMOVAL 1. Turn machine around. Locate and remove 3 set screws on the top side of the rear cover. 2. Towards the bottom of the rear panel remove 2 set screws by the carriage arm. carriage arm.
  • Page 22 4. Gently slide the carriage arm towards the needle bar. 5. Locate and remove the small set screw underneath the carriage arm. That hold a small plastic clip on the rear cover. 6. Once clip is removed from carriage arm. You can grab the rear cover by the needle bar and thread cutter, and slide it out from the machine.
  • Page 23 7. Remove set screw on back side of carriage arm. 8. Turn machine around. Remove set screw on the end of the carriage arm. screw on the end of the carriage arm. 9. Lift up from front of machine, and remove carriage arm cover.
  • Page 24 THREAD TENSION UNIT REMOVAL 1. Locate and remove the Phillip’s head set screw directly behind the large white gear on the tension unit 2. Remove Phillip’s head set screw located 3. Remove Phillip’s head set screw that holds underneath the check spring. wire clamp on the front of the casting.
  • Page 25 THREAD TENSION UNIT ADJUSTING TENSION 1. Locate the small flat head screw on the left side of the tension unit. With a small flat head screwdriver turn the screw counter clockwise until you can’t turn anymore. (DO NOT TURN MORE THEN NEEDED).
  • Page 26 THREAD TENSION UNIT THREAD SENSOR & SHIELD PLATE 3. The thread check sensor shield plate should be within the center of the sensor as possible. Keep the sensor and the shield plate clean as possible . A drop of oil or piece of thread can cause the sensor to read incorrectly, and will give you a “rethread”...
  • Page 27 6.Turn the white gear so the metal bracket is riding on the top of the white bump of the gear. This opens the tension discs and lets the machine know when to cut the thread. 7. Notice the set plate going through the second sensor. This set plate should not touch the sides or back of the sensor.
  • Page 28 DC MOTOR REMOVAL & INSTALLATION 1. To remove the DC motor, first slide the 2. Locate and remove the 2 large washer screws motor belt off the belt wheel. on the motor bracket, to remove the motor completely. 3. When replacing the motor, keep the 2 4.
  • Page 29 SWITCHING POWER SUPPLY REMOVAL 1. Locate and remove 3 set screws that hold the switching power supply box on the machine. 2. Loosen washer screw that holds the cord guide plate in position. Once loosened pull the cord guide plate out a little and remove the harness for the power supply.
  • Page 30 WHERE TO LUBRICATE 1. Put a small drop of oil on each of the 2. On the top of the rear cover, underneath the following. The presser bar, both sides of the handle there is a square cap. Remove the cap needle bar, and the take-up lever.
  • Page 31 WHERE TO LUBRICATE 5. Put one drop of oil on both sides of the Y- arm rail where the carriage slides on. 6. Put one drop of oil on the silver washer where the belt wraps around and a small amount of white lithium grease on the gears.
  • Page 32 AUTOMATIC THREAD CUTTER REMOVAL 1. Looking at the thread cutter from the front of the machine you will see 4 Phillip’s set screws. Remove the 2 set screws closest to the hook. 2. To separate the thread cutter plate from the thread cutter stepping motor from the thread cutter stepping motor remove the other set of Phillip’s set screws.
  • Page 33 AUTOMATIC THREAD CUTTER SERVICING & ADJUSTMENTS 1. Remove any lint or debris from both the top and underside of the cutter. Put one small drop of oil on the underside of the long extended blade. 2. When turning the machine on, and you get a buzzing noise coming from the thread cutter you will have to the thread cutter you will have to...
  • Page 34 REAR COVER & Y-ARM COVER INSTALLATION 1. To replace rear cover, start by hooking it 2. Lift the top of the rear cover upwards to into the socket unit, then swing it inwards join the clip which holds the back cover to the towards the needle bar.
  • Page 35 5. Replace the 3 Phillip’s set screws towards 6. Starting from the rear of the machine place the the top of the rear cover. Y-arm cover on the Y-arm. 7. Replace Phillips set screw on the backside of the Y-arm cover. 8.
  • Page 36 FRONT PANEL INSTALLATION PART 1 1. In order to calibrate the carriage unit, you 2. Raise the presser foot and replace the need to have the wires plugged into the needle plate. “A” board but have the front cover away from the machine.
  • Page 37 X AND Y - CARRIAGE ARM SENSORS CALIBRATION 2. Attach hoop with template. 1. Select built in stitch #1. the carriage arm will go to center position. 3. Turn the hand wheel towards you to bring 4. If the hole of the template is too far to the the needle so it enter the hole of the front or the rear, loosen the Phillip’s set screw template.
  • Page 38 5. If the hole of the template is too far to the 6. Turn the hand wheel to bring the needle all left or right, loosen the Phillip’s screw that the way back up. holds the X-arm sensor in position. If the hole is too far to the left of the needle, move the sensor towards the left of the machine.
  • Page 39 FRONT PANEL INSTALLATION PART 2 1. Pivot the front cover on to the front of the 2. On the top of the machine behind the machine. Make sure the clips lock into place. horizontal spool pin. Replace 2 Phillip’s SELF-TAPPING screws.
  • Page 40 PRESSER FOOT HEIGHT ADJUSTMENT 1. When both the presser foot and needle bar are down, the gap between the foot and the top of the needle plate should be between 1.0 – 1.3mm. Use the presser foot height gauge. The gauge is 1.0-1.3mm 1.2mm thick.
  • Page 41 NEEDLE BAR POSITION ADJUSTMENT 1. Remove the presser foot then turn the hand 2. Locate and loosen the 2 Phillip’s set screws on wheel towards you to bring the needle down. Stop the top of the presser bar plate. when the needle is just entering the needle plate. 3.
  • Page 42 NEEDLE BAR HEIGHT ADJUSTMENT 1. Remove needle plate and needle. 2. Turn the hand wheel to bring the tip of the hook race to 6 o’clock, then insert gauge. Make sure the flat edge insert gauge. Make sure the flat edge of the gauge is touching the tip of the hook.
  • Page 43 4. Turn the hand wheel towards you. When the needle is in the lowest position, the needle bar height gauge should be barely scoring the radial gauge. 5. If an adjustment needs to be made, loosen the 2mm hex screw on the needle bar height block.
  • Page 44 NEEDLE-TO-HOOK TIMING ADJUSTMENT 1. Remove both gauges. Put needle back into 2. When you are in timing mode, one of the two machine. Then turn hand wheel to bring the 2.5mm hex screws will be showing. You do not needle to it’s lowest position. Keep turning want to loosen this one first.
  • Page 45 NEEDLE-TO-HOOK CLEARANCE ADJUSTMENT 1. Turn the hand wheel towards you to bring the needle to the lowest position. Keep turning hand wheel until the tip of the hook is touch the right side of the needle. The distance between the back of the needle and the tip of the hook should be 0.0 –...
  • Page 46 HOOK BACKLASH ADJUSTMENT 1. The hook race should have .60 - .80mm of backlash. Rotate the hand wheel to turn the hook race 1/3 of a rotation each time to check if the backlash is properly adjusted. 2. On the left side of the lower shaft is a 2.
  • Page 47 NEEDLE STOP POSITION ADJUSTMENT 1. While the machine is running, press the start/stop button. 2. The needle bar will go all the way up, continue it’s sewing rotation, and drop down 1mm from the highest position. If down 1mm from the highest position. If the needle does not drop down or stays up.
  • Page 48 NEEDLE THREADER ADJUSTMENTS 1.To replace the threader or a single piece on the threader. Pull down the needle threader down. Remove the small Phillip's set screw that hold the threader on the vertical black shaft. Once removed all the components of the threader will come off.
  • Page 49 POSITIONS OF BOBBIN STOPPERS ADJUSTMENTS 1. With the bobbin case in the machine, turn the hand wheel backwards. The bobbin case will turn slightly to show a gap between itself and the right bobbin stopper. The gap should be .8mm. The stoppers must also be aligned properly.
  • Page 50 BED COVER INSTALLATION 1. With the machine turned off, slowly push 2. Replace bed cover. the Y-arm towards the right of the machine. 3. Gently place machine on its back, then line 4. Once bottom is aligned, bring machine back up the 2 pieces of the bed cover to the holes upright.
  • Page 51 BASE PLATE & THREAD CUTTER COVER INSTALLATION 1. Gently place the machine on its back. Replace the 6 Phillip's set screws. 2 in the middle of the cover, and 4 on the outside by the rubber feet. 2. Replace thread cutter cover. 3.
  • Page 52 FACE PLATE INSTALLATION 1. Place the face plate into position from the rear cover. Aligning the clips from the rear cover to the face plate. 2. Swing the face plate towards the front of 2. Swing the face plate towards the front of the machine.
  • Page 53 ERROR CODES - This error is a universal error. The Y-step - This error is a universal error. The Y-step - Thread check sensor may not be plugged in. - Thread check sensor may not be plugged in. motor, X-step motor, Y-step motor sensor, - Thread check sensor may be dirty.
  • Page 54 TOUCH SCREEN CALIBRATION 1. Turn the machine off. While holding down the start/stop button, turn the machine on 2. Release the button once you get to the main menu in service mode. 3. Press and release the start/stop button once. Once you get into the new menu, press the thread cutter button to start touch screen calibration.
  • Page 55 1. Using the touch panel stylus, press the plus marks on the screen. 2. Now press the center of the page selector selector 3. When the calibration is over it will say “OK” on the screen. If calibration is not successful it will read “NG”...
  • Page 56 BOBBIN SENSOR CALIBRATION 2. Insert the empty bobbin into the bobbin case. 1. Press ‘Bobbin’ to enter the bobbin thread sensor menu. 3. Press ‘Key’ to get the value then 4. Insert the half-empty bobbin gauge into the press ‘Empty’ to save it into the bobbin case.
  • Page 57 6. Now insert the full bobbin gauge 5.Press ‘Key’ to get the value then press ‘Half”. 8. Press ‘OK’ to permanently save into the 7. Press ‘Key’ to get the value then press machines memory, and to exit out of the menu ‘Full’...
  • Page 58 SELF CHECK MODE 1. Press the ‘Foot Sensor’ to go into foot 2. Looking at ‘Foot U/D’ it says H sensor menu. 3. Move the presser bar lever up and 4. When the presser bar lever is down the down to test the sensor. screen will read ‘L’...
  • Page 59 SELF CHECK MODE 1. Looking at the ‘TTM sen’ it should read ‘H’ this sensor is to read the opening and closing of the tension discs when cutting the thread. 2. Press thread cutter button to test.