Janome 5030 User manual

SERVICE MANUAL
MODEL:5030
81030DC
5050
81050DC
5100
81100DC
N 2000
DC3100

INDEX
WHAT TO DO WHEN .......................................................................................................................... 1-3
CHANGING EXTERNAL PARTS
FACE COVER......................................................................................................................................... 4
FREE-ARM COVER .............................................................................................................................. 5
FRONT COVER...................................................................................................................................... 6
REAR COVER........................................................................................................................................ 7
MECHANICAL ADJUSTMENT
PRESSER BAR HEIGHT ....................................................................................................................... 8
NEEDLE DROP POSITION.................................................................................................................... 9
ADJUSTMENT OF HOOK TIMING ...................................................................................................... 10
ADJUSTMENT OF NEEDLE BAR HEIGHT ......................................................................................... 11
CLEARANCE BETWEEN NEEDLE AND TIP OF ROTARY HOOK...................................................... 12
FEED DOG HEIGHT ............................................................................................................................ 13
TOP TENSION ..................................................................................................................................... 14
STRETCH STITCH FEED BALANCE .................................................................................................. 15
REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE................................... 16
ADJUSTING BUTTONHOLE LEVER POSITION................................................................................. 17
SELF-DIAGNOSTIC TEST
SELF-DIAGNOSTIC TEST .............................................................................................................. 18-23
TO DISPLAY THE VERSION OF THE PROGRAM .............................................................................. 23
REPLACING THE ELECTRONIC COMPONENTS
PRINTED CIRCUIT BOARD A CONNECTION.................................................................................... 24
PRINTED CIRCUIT BOARD A ............................................................................................................. 25
PRINTED CIRCUIT BOARD F2 ........................................................................................................... 26
PRINTED CIRCUIT BOARD F1 ........................................................................................................... 27
PRINTED CIRCUIT BOARD L ............................................................................................................. 28
DRIVING MOTOR (DC MOTOR).......................................................................................................... 29
SWITCHING REGULATOR UNIT......................................................................................................... 30

1
Condition Cause How to fix Reference
1. Skipping
Stitches
1. Needle is not inserted properly.
2. Needle is bent or worn.
3. Incorrectly threaded.
4. Needle or thread are
inappropriate for the fabric
being sewn.
5. Sewing on stretch fabric.
6. Inappropriate needle bar height.
7. Inappropriate needle to hook
timing.
8. Inappropriate needle to hook
clearance.
Insert the needle properly.
Change the needle.
Rethread.
Use the recommended sewing needle
and thread.
Use a HA x #11 blue tip needle.
See mechanical adjustment “Needle bar
height”.
See mechanical adjustment “Adjustment
of hook timing”.
See mechanical adjustment “Clearance
between needle and tip of the rotary
hook”.
P. 1 1
P. 1 0
P. 1 2
2. Fabric not
moving
1. Incorrect feed dog height.
2. Feed dog is in down position.
3. Thread on bottom side of
fabric is jammed up.
4. Feed dog teeth are worn.
Adjust the presser bar level to make
the pressure stronger. See mechanical
adjustment “Feed dog height”.
Raise the feed dog.
Make sure to bring both needle and
bobbin threads under the foot when start
sewing.
Change the feed dog.
P. 1 3
WHAT TO DO WHEN

2
Condition Cause How to Fix Reference
3. Breaking
upper
thread.
1. Initial sewing speed is
too fast.
2. Thread path is incorrect.
3. Needle is bent or dull.
4. Top tension is too strong.
5. Needle size is inappropriate for
fabric.
6. Needle eye is worn.
7. Needle hole in needle plate is
worn or burred.
Start with medium speed.
Use the proper thread path.
Replace with a new needle.
Adjust top tension correctly.
Use appropriate needle for fabric and
thread in use.
Change the needle.
Repair the hole or replace the needle
plate.
4. Breaking
bobbin
thread.
1. Bobbin holder is incorrectly
threaded.
2. Too much thread is wound
on the bobbin.
3. Lint is stuck inside the bobbin
holder.
4. Thread quality is too low.
5. Thread is jamming around the
bobbin holder.
Set the bobbin thread correctly.
Adjust the position of bobbin winder
stopper.
Clean the bobbin holder.
Change to a high quality sewing thread.
Clear out the jamming thread.
5. Needle
breaks
1. Needle is hitting the needle plate.
2. Needle is bent or worn.
3. Needle is hitting the hook.
4. Fabric is being pulled too strongly
while sewing.
See mechanical adjustment “Needle drop
position”.
Change the needle.
See mechanical adjustment “Clearance
between needle and tip of the rotary
hook”.
Guide the fabric gently while sewing.
P. 9
P. 1 2

3
Condition Cause How to fix Reference
6. Noisy
operation
1. Backlash between hook gear
and lower shaft gear is too
great.
2. Lower shaft gear is loose.
3. Inappropriate belt tension.
4. Not enough oil.
5. Upper shaft gear is loose.
Eliminate the backlash.
Eliminate the looseness.
See part removal and replacement
“driving motor (DC motor)”.
Oil all moving parts.
Eliminate the looseness.
P. 2 9
7. Deformation
pattern
1. Inappropriate feed balance.
2. Top tension is too strong.
Adjust the feed balancing screw.
See mechanical adjustment
“Top tension”.
P. 1 5
P. 1 4

4
CHANGING EXTERNAL PARTS
FACE COVER
To remove:
1. Remove the cap and setscrew qand lift the face cover to disengage the rib on the inside.
Remove the face cover w.
To attach:
2. Follow the above procedures in reverse.
q
w

5
FREE-ARM COVER
To remove:
1. Remove the setscrew qand w.
Move the free-arm cover eto the left.
Remove the free-arm cover.
To attach:
Follow the above procedures in reverse.
CHANGING EXTERNAL PARTS
q
w
e

6
CHANGING EXTERNAL PARTS
FRONT COVER
To remove:
1. Remove the face cover and free-arm cover (See page 4 and 5).
2. Remove the setscrews q(2 pcs.).
3. Remove the setscrews w(4 pcs.), back cover e.
4. Remove the setscrews r(2 pcs.).
5. Loosen the setscrew t.
6. Disengage the front cover and rear cover hooks.
7. Remove the front cover.
8. Disconnect all the connectors from the circuit board A.
NOTE:
Do not disconnect the connectors by pulling on cord. To disconnect, grasp the connector, not the cord.
To attach:
7. Follow the above procedures in reverse. See "PRINTED CIRCUIT BOARD A CONNECTION". (Page 24)
q
ww
e
w
rr
t

7
CHANGING EXTERNAL PARTS
REAR COVER
To remove:
1. Remove the face cover and free-arm cover (See page 4 and 5).
2. Remove the setscrews q(2 pcs.) and the setscrews w(3 pcs.).
3. Remove the setscrews e(4 pcs.) and back cover r.
4. Remove the setscrews t(2 pcs.).
6. Disengage the front cover and rear cover hooks.
7. Remove the front cover.
To attach:
5. Follow the above procedures in reverse.
q
ee
r
e
tt
w

8
6.0 mm
MECHANICAL ADJUSTMENT
PRESSER BAR HEIGHT
The distance between the bottom of the presser foot in up position and the needle plate should be 6.0 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 the presser foot lifter w.
3. Loosen the setscrew q. Raise the presser foot lifter and tighten the setscrew qfirmly.
Attach the needle and face plate.
NOTE:
Make sure that the presser foot should be parallel to the feed dog slots in the needle plate.
q
Feed dog slots
Presser foot should be parallel
to the feed dog slots.
w

9
0.2 mm
or more
0.2 mm
or more
A = B
MECHANICAL ADJUSTMENT
NEEDLE DROP POSITION
Set the stitch pattern to “ ”. The standard needle drop position should be at center of the needle plate hole.
Select zigzag stitch “ ”, and set the stitch width at “7.0”. The clearance between the needle and the edge of the
needle hole should be at least 0.2 mm on either side. If not, adjust as follows:
1. Turn the power switch off. Remove the face cover. (See page 4.)
2. Loosen the hexagonal socket screw 3 x 4 q. Adjust the needle drop position by turning the eccentric pin.
The direction of eccentric pin should be as shown in Fig. 1.
3. Attach the face cover.
NOTE:
Check the hook timing after this adjustment.
needle plate hole
Fig. 1
w

10
The amount of ascending travel of the needle bar from its lowest position to the position ( ) where the tip of
the rotary hook exactly meets the right side of the needle should be 3.25 to 3.55 mm.
1. Remove the needle plate and bobbin holder.
2. Turn the power switch on.
3. Select the pattern (left position). Set the zigzag width at 0.
4. Remove the free-arm cover. (See page 5.)
Turn the handwheel toward you to lower the needle at its lowest position.
5. Loosen the hexagonal socket screw w(2 pcs.).
6. Move the needle bar 3.4 mm from the lowest position.
7. Turn the lower shaft gear until the tip of hook meets the right side of the needle while holding the handwheel.
8. Tighten the hexagonal socket screw w(2 pcs.).
9. Attach the free-arm cover, bobbin holder and needle plate.
MECHANICAL ADJUSTMENT
ADJUSTMENT OF HOOK TIMING
w
Needle plate
Bobbin holder
w
Lower shaft gear
Left position ( )
(#14)
Tip of hook meets the
right side of the needle
Lowest needle position
3.25 – 3.55 mm

11
Before proceeding with this adjustment, check the hook timing (refer to page 10). The distance between the
upper edge of the needle eye and the tip of the hook should be in the range of 1.6 to 2.0 mm when the tip of the
hook timing meets right side of the needle in the left needle position ( ) as the needle ascends from its lowest
position.
1. Remove the needle plate, bobbin holder and face plate.
2. Turn the power switch on.
3. Select the pattern (left position). Set the zigzag width at 0.
4. Turn the handwheel toward you until the tip of hook meets the right side of the needle.
5. Loosen the hexagonal socket screw q.
6. Move the needle bar to adjust the needle bar height, and tighten the hexagonal socket screw q.
Be careful not to turn the needle bar.
7. Attach the bobbin holder, needle plate and face cover.
MECHANICAL ADJUSTMENT
ADJUSTMENT OF NEEDLE BAR HEIGHT
1.6 – 2.0 mm
q
Needle setting
groove
Upper edge of needle hole
Hook race (unit)
Hook race
Tip of hook meets the right side of the needle
Left position ( )
(#14)
Needle plate
Bobbin holder

12
Adjustment procedure:
1. Remove the needle plate and bobbin holder. Attach the master needle. Turn the power switch on and set the
zigzag width at maximum.
2. Remove the face cover. (See page 4.)
3. Loosen the setscrews q(2 pcs.).
4. Turn the handwheel toward you. Adjust the clearance between the needle and the tip of the rotary hook, by
moving the hook base plate up or down, to within –0.1 to +0.05 mm at the left and right needle position.
5. Tighten the setscrews q(2 pcs.).
6. Attach the face cover. Remove the master needle. Attach the bobbin holder and needle pate.
7. Check the clearance between the needle and the edge of the needle hole in the needle plate (see page 9).
* The clearance between the needle and the point of hook should be –0.1 to +0.05 mm.
CLEARANCE BETWEEN NEEDLE AND TIP OF THE ROTARY HOOK
MECHANICAL ADJUSTMENT
–0.1 to +0.05 mm
Needle bar supporter
adjusting plate q
Needle plate
Bobbin holder
Tip of hook

13
The highest position of the feed dog should be between 0.80 and 0.90 mm from the surface of the needle
plate.
1. Lower the presser foot and turn the power switch on.
2. Turn the handwheel toward you to set the feed dog at the highest position.
3. Remove the free-arm cover. (See page 5.)
4. Loosen the setscrew qand nut w.
5. Adjust the feed dog height by turning the adjusting screw e.
The highest position of the feed dog should be between 0.80 and 0.90 from the surface of the needle plate.
6. Tighten the nut wand setscrew q.
7. Attach the free-arm cover.
FEED DOG HEIGHT
MECHANICAL ADJUSTMENT
A B
e
w
Presser foot
Feed dog
0.80 – 0.90 mm
Surface of the needle plate
q

14
MECHANICAL ADJUSTMENT
TOP TENSION
The top tension should be between 65 and 80 g when pulling the thread up in the direction of arrow.
* Use polyester sewing thread #50 (White).
* If it is not within the above limit, adjust as follows.
1. Set the tension dial “4”.
2. Remove the face cover and front cover. (See page 4 and 6.)
3. Lower the presser foot.
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4. Check the top tension and attach the cover.
White polyester thread size 50
Pull the thread at the speed of 110 mm/sec in the direction of arrow
Cover

15
MECHANICAL ADJUSTMENT
STRETCH STITCH FEED BALANCE
To check:
1. Enter the self-diagnostic mode (see below).
Attach the Satin stitch foot F. Place a fabric under the presser foot. Lower the presser foot.
2. Press the locking stitch button to start test sew, and check the results (the standard figure length of 5
pieces of figure 8 is 33-39 mm).
3. If stretch patterns are distorted, correct them with the feed balancing dial.
If stretch patterns are too deformed and cannot be corrected with the feed balancing dial, adjust as follows.
To adjust:
1. Remove the feed balancing dial cover. Turn the dial at standard position as illustrated.
Turn the power switch ON.
Select the straight stitch and set the stitch length at “0”. Place a fabric under the presser foot.
Lower the presser foot. (Do not set bobbin and needle threads)
2. Turn the hexagonal socket screw to the left to loosen it.
Move the gear up (A) or down (B) to adjust the feed.
* Do not move the gear right or left when adjusting.
Start the machine and check the movement of the fabric.
Adjust the hexagonal socket screw position (gear position) until the fabric will not be fed with the stitch
length setting at “0”.
3. Tighten the socket screw and attach the feed balancing dial cover.
Enter the self-diagnostic mode and test sew again. Check that the standard length of 5 pieces of figure 8 is
33-39 mm. If not, turn the feed balancing dial to correct it.
36–39mm
Correct IncorrectIncorrect
Feed balancing dial
(Standard position)
Hexagonal socket screw
Feed balancing dial cover
(A)
(B)
TO ENTER SELF-DIAGNOSTIC MODE:
Turn the power switch on while
simultaneously pressing auto-
lock button and needle up/down
button.
The LCD display will
indicate “01”.
Press the value set key
7 times to display the “08”.
Press the start/stop
button to display the
“88” and to enter
the stretch stitch test
mode.
Gear
The standard figure length of 5 pieces of figure
8 is 33-39 mm

16
X
Threader plate
supporter
Threader
positioning
plate
FIG. 3
Pin
Adjustment of left or right direction
Threader plate
Nut w
View from "X"
q
Vertical adjustment FIG. 2
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 down to remove it (see FIG 1).
2. To install the needle threader plate, line the groove up with the pin and push it up to snap fit.
TO ADJUST THE THREADER PLATE POSITION:
1. If the hook on the threader positioning plate touches the top or bottom side of the needle hole, loosen
setscrew qand adjust the hook position (FIG.2).
2. If the hook on the threader plate touches the left or right side of the needle hole, loosen setscrew wand
adjust the hook position (FIG 3).
Replacing the threader plate supporter
(with the threader plate attached) FIG. 1
MECHANICAL ADJUSTMENT

17
BH sensor
1.6 mm gap
TO ENTER ADJUSTING MODE
MECHANICAL ADJUSTMENT
ADJUSTING BUTTONHOLE LEVER POSITION
TO ADJUST THE BUTTONHOLE LEVER GUIDE:
1. Enter the diagnostic test of buttonhole sensor mode. (See pages 18 and 19. The LCD should display 03 and
BH symbol.)
2. Remove the face cover (see page 4) and loosen the setscrew q.
3. Move the buttonhole lever guide so the BH symbol disappear when the buttonhole lever is lowered.
Tighten the setscrew.
TO ADJUST THE BUTTONHOLE SENSOR POSITION:
4. Attach the buttonhole foot (R).
5. Lower the buttonhole lever to its lowest position and open a 1.6 mm gap between the slider and the
buttonhole foot.
6. Turn the adjusting screw wto the left until the LCD display BH symbol.
7. Next, turn the adjusting screw to the right until the BH symbol disappears.
8. Turn off the power switch.
9. Attach the face cover.
q
Buttonhole lever guide
Buttonhole foot (R)
Buttonhole lever
w
NOTE:
If there is any lint or dust in the buttonhole sensor slit, loosen the screw eand clean it out with a swab.
e

18
TO ENTER SELF-DIAGNOSTIC MODE:
Preparation:
1. Turn the power switch off.
2. Move the bobbin winder spindle to the left.
3. Raise the feed dog.
4. Set the speed control lever to the left.
5. Remove the presser foot and raise the presser foot lifter.
6. Turn the hand wheel toward you to raise the needle to its highest position.
NOTE:
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(Enter self-diagnostic mode, then select the step number of the diagnostic test you require by pressing the
start/stop button .)
To begin:
Turn on the switch. If any of the following problems occur, take the recommended actions in the order they
are shown.
1. The machine does not respond when the power switch is turned on:
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2. The sewing machine lamp does not light up:
 
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SELF-DIAGNOSTIC TEST
1. Turn the power switch on while
simultaneously pressing auto-lock
button and needle up/down button.
2. The LCD display
will indicate “01”.
3. Press the start/stop
button to enter the
self-diagnostic mode.