Janome DC5100 User manual

SERVICE MANUAL
PARTS LIST
DC5100

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 ..................................................................................................................................... 12
BELT COVER.................................................................................................................................... 13
BASE PLATE .................................................................................................................................... 14
BED COVER ..................................................................................................................................... 14
FRONT COVER ................................................................................................................................ 15
REAR COVER .................................................................................................................................. 16
FREE ARM COVER.......................................................................................................................... 17
MECHANICAL ADJUSTMENT
NEEDLE DROP POSITION .............................................................................................................. 18
NEEDLE BAR HEIGHT .................................................................................................................... 19
NEEDLE TO HOOK TIMING ............................................................................................................. 20
CLEARANCE BETWEEN NEEDLE AND HOOK ............................................................................. 21
BACKLASH (BETWEEN LOWER SHAFT GEAR AND HOOK GEAR) .................................................... 22
FEED DOG HEIGHT ........................................................................................................................ 23
ZIGZAG SYNCHRONIZATION ......................................................................................................... 24
TENSION RELEASE MECHANISM ................................................................................................. 25
STRETCH STITCH FEED BALANCE ADJUSTMENT ..................................................................... 26
NEEDLE THREAD TENSION ........................................................................................................... 27
BUTTONHOLE LEVER..................................................................................................................... 28
PRESSER FOOT HEIGHT AND ALIGNMENT ................................................................................ 29
PART REMOVAL AND REPLACEMENT
NEEDLE THREAD TENSION UNIT ................................................................................................. 30
THREADER PLATE .......................................................................................................................... 31
REPLACING THE PRINTED CIRCUIT BOARD “A” .............................................................................................. 32
REPLACING THE PRINTED CIRCUIT BOARD “F” .............................................................................................. 33
REPLACING SLIDE VOLUME .............................................................................................................................. 34
REPLACING DC MOTOR AND ADJUSTING MOTOR BELT TENSION ............................................................... 35
REPLACING THE FUSES .................................................................................................................................... 36
REPLACING MACHINE SOCKET (UNIT) ............................................................................................................ 37
REPLACING TRANSFORMER ............................................................................................................................. 38
REPLACING THE ZIGZAG WIDTH MOTOR ........................................................................................................ 39
REPLACING THE FEED STITCH MOTOR ........................................................................................................... 40
ADJUSTING THE BOBBIN WINDER SWITCH .................................................................................................... 41
OILING .......................................................................................................................................................... 42
................................. 43-61
PARTS LIST ...................................................................................................................

SEWING MACHINE
1
MODEL DC5100
EXTENSION TABLE
(ACCESSORY BOX)
NEEDLE PLATE
NEEDLE THREADER
THREAD CUTTER
FACE COVER
THREAD TENSION DIAL
THREAD TAKE-UP LEVER
THREAD GUIDE
SPOOL PIN SPOOL HOLDER FLIP TOP STITCH CHART
SCREEN BRIGHTNESS
ADJUSTING DIAL
FUNCTION TOUCHPAD
SPEED CONTROL LEVER
UP/DOWN NEEDLE POSITION
BUTTON
AUTO-LOCK BUTTON
REVERSE STITCH BUTTON
FEED BALANCING
DIAL
HOOK COVER PLATE RELEASE
BUTTON
HOOK COVER PLATE
NEEDLE CLAMP SCREW
NEEDLE
PRESSER FOOT
THUMBSCREW
PRESSER
FOOT HOLDER
CARRYING HANDLE
BOBBIN WINDER SPINDLE
BOBBIN WINDER STOPPER
HANDWHEEL
POWER SWITCH
MACHINE SOCKETS NOMENCLATURE PLATE
FEED DOG DROP LEVER
FREE-ARM
BUTTONHOLE LEVER
PRESSER FOOT LIFTER
HOLE FOR ADDITIONAL
SPOOL PIN
LOCATE AND IDENTIFY THE PARTS

SEWING MACHINE
2
MODEL DC5100
(1)
(2)
(3)
(4)
(2)
(A)
(3)
(B)
10
1/8 3/8 5/8
(4)
(1)
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.
INSERTING THE BOBBIN
PLACE THE BOBBIN IN THE BOBBIN HOLDER WITH THE
THREAD RUNNING OFF IN THE COUNTERCLOCKWISE.
(1) END OF THREAD
GUIDE THE THREAD INTO THE NOTCH (A) ON THE FRONT
SIDE OF THE BOBBIN HOLDER.
DRAW THE THREAD TO THE LEFT, SLIDING IT BETWEEN THE
TENSION SPRING BLADES.
(2) NOTCH (A)
CONTINUE TO DRAW THE THREAD LIGHTLY UNTIL THE
THREAD SLIPS INTO NOTCH (B).
PULL OUT ABOUT 15 CM (6") OF THREAD.
(3) NOTCH (B)
ATTACH THE HOOK COVER PLATE.
CHECK THE THREADING BY REFERRING TO THE CHART
SHOWN ON THE HOOK COVER PLATE.
(4) THREADING CHART

SEWING MACHINE
3
MODEL DC5100
1
3
(1)
(3)
(4)
(5) (6)
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.
(2) DRAW THE THREAD AROUND THE CHECK SPRING HOLDER FROM RIGHT TO LEFT, THEN
PULL UP THE THREAD.
(3) FIRMLY DRAW THE THREAD FROM RIGHT TO LEFT AND PULL IT TOWARD YOU INTO THE
EYE OF THE THREAD TAKE-UP LEVER, THEN DOWN TO THE LOWER THREAD GUIDE.
(4) DRAW THE THREAD FROM RIGHT TO LEFT BEHIND THE LOWER THREAD GUIDE.
(5) SLIDE THE THREAD BEHIND THE NEEDLE BAR THREAD GUIDE FROM THE LEFT.
(6) THREAD THE NEEDLE FROM FRONT TO BACK USING THE NEEDLE THREADER.
(2)
(4)

4
SEWING MACHINE MODEL DC5100
CONNECTOR DIAGRAM
REFER TO THE DIAGRAM FOR LOCATING THE CONNECTOR POST ON THE CIRCUIT BOARD
A
B
C
D
E
F
G
HB
C
D
EF
G
H
A: BUTTONHOLE SENSOR
B: SEWING LIGHT
C: UPPER SHAFT SENSOR
D: FEED MOTOR
E: ZIGZAG WIDTH MOTOR
F: DC MOTOR
G: POWER TRANSFORMER (PRIMARY
CIRCUIT)
H: POWER TRANSFORMER (SECONDARY
CIRCUIT)
I : PRINTED CIRCUIT BOARD “F”
J: MACHINE PLUG (PRIMARY CIRCUIT)
K: SLIDE VOLUME
L: MACHINE PLUG (SECONDARY CIRCUIT)
M: BOBBIN WINDER SWITCH
N: TOUCH PANEL
A-BOARD
EACH CONNECTOR SHOULD BE CONNECTED AS FOLLOWS;
A
I
J
J
K
L
L
F-BOARD
M
M
N

5
SEWING MACHINE MODEL DC5100
GENERAL TROUBLE SHOOTING PROCEDURE
(MACHINE DOESN’T WORK WELL)
IS NEEDLE SET OK?
IS POWER SUPPLY OK?
IS THREADING OK?
N.G.
O.K.
O.K.
N.G.
ELECTRIC QUICK CHECK
END
CORRECT IT
START
BASIC CHECK
MECHANICAL ELECTRICAL CAN’T JUDGE
ELECTRIC QUICK CHECK
ADJUSTMENT
SEWING CHECK
REPLACE PARTS

6
SEWING MACHINE MODEL DC5100
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
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.
INSERTTHE NEEDLE PROPERLY.
CHANGE THE NEEDLE.
RETHREAD.
USE THE RECOMMENDED
SEWING NEEDLE AND THREAD.
USE A #11 BLUE TIP NEEDLE.
SEE MECHANICAL ADJUSTMENT
“NEEDLE BAR HEIGHT”.
SEE MECHANICAL ADJUSTMENT
“NEEDLE TO HOOK TIMING”.
SEE MECHANICAL ADJUSTMENT
“CLEARANCE BETWEEN NEEDLE
AND HOOK”.
P. 19
P. 20
P. 21
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 AREWORN.
SEE MECHANICAL
ADJUSTMENT “FEED DOG HEIGHT”.
RAISE THE FEED DOG.
MAKE SURE TO BRING BOTH
NEEDLE AND BOBBIN.
THREAD UNDER THE FOOTWHEN
STARTING SEWING.
CHANGE THE FEED DOG.
P. 23
WHAT TO DO WHEN

7
SEWING MACHINE MODEL DC5100
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. UPPER THREAD 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 NEEDLE THREAD TENSION
CORRECTLY.
USE APPROPRIATE NEEDLE FOR
FABRIC AND THREAD IN USE.
CHANGE THE NEEDLE.
REPAIR THE HOLE OR REPLACE
THE NEEDLE PLATE.
P. 27
4. BREAKING
BOBBIN
THREAD
1. INCORRECTLY THREADED
BOBBIN.
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.
THREAD BOBBIN CORRECTLY.
ADJUST THE POSITION OF 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.THE FABRIC MOVES WHILE
THE NEEDLE IS PIERCING
IT, OR THE NEEDLE ZIGZAGS
WHILE IN FABRIC.
5. FABRIC IS BEING PULLED TOO
STRONGLY WHILE SEWING.
SEE MECHANICAL
ADJUSTMENT “NEEDLE DROP
POSITION”.
CHANGE THE NEEDLE.
SEE MECHANICAL ADJUSTMENT
“CLEARANCE BETWEEN NEEDLE
AND HOOK”.
SEE MECHANICAL ADJUSTMENT
“ZIGZAG SYNCHRONIZATION”.
GUIDE THE FABRIC GENTLY
WHILE SEWING.
P. 18
P. 21
P. 24

8
SEWING MACHINE MODEL DC5100
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.
SEE MECHANICAL ADJUSTMENT
“BACKLASH (BETWEEN LOWER
SHAFT GEAR AND HOOK GEAR)”.
ELIMINATE THE LOOSENESS.
SEE REPLACING DC MOTOR AND
ADJUSTING MOTOR BELT TENSION
(DC MOTOR)”.
OIL ALL MOVING PARTS.
P. 22
P. 35
P. 42
7.DEFORMATION
PATTERN 1. INAPPROPRIATE FEED
BALANCE.
2. INAPPROPRIATE ZIGZAG
SYNCHRONIZATION.
3. UPPER THREAD TENSION
IS TOO STRONG.
SEE MECHANICAL ADJUSTMENT
“STRETCH STITCH FEED
BALANCE ADJUSTMENT”.
SEE MECHANICAL ADJUSTMENT
“ZIGZAG SYNCHRONIZATION”.
SEE MECHANICAL ADJUSTMENT
“NEEDLE THREAD TENSION”.
P. 26
P. 24
P. 27

9
SEWING MACHINE MODEL DC5100
Step1 LCD&LED
Next :
CLR
00
0908
07
06
05
04
03
02
01
SELF DIAGNOSTIC TESTS
SELF-DIAGNOSTIC TEST:
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.
•REMOVETHE PRESSER FOOT AND RAISETHE PRESSER FOOT LIFTER.
•TURN THE HANDWHEEL TOWARDYOU TO RAISE THE NEEDLE TO ITS HIGHEST POSITION.
•PLUG THE FOOT CONTROLTO THE MACHINE.
NOTE:
•BE CAREFUL:THE SEWING MACHINE MAY START RUNNING BY ITS OWN WHILE IN TEST MODE.
•TURN OFF THE POWER SWITCH BEFORE REPLACING ANY PARTS.
•REPEAT THE DIAGNOSTICTEST UNTIL THE PROBLEMS HAS BEEN RESOLVED.
TURN ON THE POWER SWITCH. IF ANY OF FOLLOWING PROBLEMS OCCUR, TAKE THE RECOM-
MENDED ACTIONS IN THE ORDER THEY ARE SHOWN.
•THE MACHINE DOES NOT RESPONDWHEN THE POWER SWITCH ISTURNED ON.
1. CHECK EACH CONNECTOR CONNECTION.
2. REPLACE THE MACHINE SOCKET.
3. REPLACE THE PRINTED CIRCUIT BOARD “A”.
4. REPLACE THE POWER SUPPLY CORD.
5. REPLACE THE POWER TRANSFORMER.
•THE SEWING MACHINE LIGHT DOES NOT LIGHT UP.
1. REPLACE THE LAMP.
2. REPLACE THE CIRCUIT BOARD “A”.
•THE LCD SCREEN DOES NOT DISPLAY.
1. REPLACE THE PRINTED CIRCUIT BOARD “A”.
TURN THE POWER SWITCH ON WHILE PRESSING
THE REVERSE BUTTON & AUTO-LOCK BUTTON.
THEN PRESS THE 01 BUTTON WITHIN 3 SECONDS
TO ENTER THE SELF-DIAGNOSTIC MODE.
THE STANDARD MODE SHOWS UP IFYOU DO NOT
PRESS THE 01 BUTTON WITHIN 3 SECONDS.TURN
THE POWER SWITCH OFF AND START OVER
AGAIN.
SELF-DIAGNOSTIC MODE

10
SEWING MACHINE MODEL DC5100
CORRECT RESULTS
•THE DISPLAY SHOWS “Self Check
Start”. LCD AND LED BLINKS.
•BEEPS WHEN ENTER THE LCD & LED
CHECK MODE.
PRESS CLR BUTTON TO PROCEED TO
THE NEXT STEP.
•THE DISPLAY SHOWS “Key” AND THE
MACHINE BEEPS.
•BEEPS WHEN ENTER THE KEY
CHECK MODE.
•BEEPS WHEN BUTTONS OR KEYS
ARE PRESSED.
•THE DISPLAY SHOWSTHE NAME OF
PRESSED BUTTON OR KEY.
PRESS CLR BUTTON TO PROCEED TO
THE NEXT STEP.
•THE DISPLAY SHOWS “Switch” AND
THE MACHINE BEEPS.
•THE DISPLAY SHOWS “ON” AND
BEEPS WHEN BOBBIN WINDER IS
MOVED TO THE RIGHT.
•THE DISPLAY SHOWS “OFF” AND
BEEPS WHEN BOBBIN WINDER IS
MOVED TO THE LEFT.
PRESS CLR BUTTON TO PROCEED TO
THE NEXT STEP.
•THE DISPLAY SHOWS “Sensor” AND
THE MACHINE BEEPS.
•WHEN THE BUTTONHOLE
LEVER IS PULLED, THE SCREEN
DISPLAYS "H".
WHEN THE BUTTONHOLE LEVER IS
POSITIONED IN CENTER, THE
SCREEN DISPLAYS "L".
WHEN THE BUTTONHOLE LEVER IS
PUSHED, THE SCREEN DISPLAYS "H".
WHEN NEEDLE IS IN THE HIGHEST
POSITION, THE SCREEN SHOWS:
[BS:H FS:L]
WHEN NEEDLE IS IN THE LOWEST
POSITION, THE SCREEN SHOWS:
[BS:L FS:H]
WHEN NEEDLE IS IN NEITHER THE
HIGHEST NOR THE LOWEST POSI-
TIONS.
[BS:L FS:L]
PRESS CLR BUTTON TO PROCEED TO
THE NEXT STEP.
TESTS
TURN THE POWER SWITCH ON
WHILE PRESSING THE
REVERSE BUTTON & AUTO-
LOCK BUTTON.THEN PRESS
THE 01 BUTTON WITHIN
3 SECONDS TO ENTER THE
SELF-DIAGNOSTIC MODE.
PRESS THE KEYS IN ORDER
AS DESCRIBED BELOW.
qREVERSE STITCH BUTTON
wAUTO-LOCK BUTTON
eUP/DOWN NEEDLE POSITION
BUTTON
rMODE KEY
tSTITCH WIDTH KEY “+”
ySTITCH WIDTH KEY”–”
uSTITCH LENGTH KEY “+”
iSTITCH LENGTH KEY “–”
PRESS THE REST OF KEYS IN
ORDER FROM LEFT TO RIGHT,
STARTING FROMTHE HIGHEST
COLUMN TO THE LOWEST
COLUMN.
MOVE THE BOBBIN WINDER TO
THE RIGHT.
MOVE THE BOBBIN WINDER TO
THE LEFT.
LOWER THE BUTTONHOLE
LEVER.
PULL, AND PUSH THE BUTTON-
HOLE LEVER, THEN CHECK THE
DISPLAY.
TURN THE HANDWHELL
TOWARD YOU TO MOVE THE
NEEDLE FROM HIGHESTTO
THE LOWEST POSITION.
CHECK THE SCREEN.
SELF DIAGNOSTICTESTS
1)
LCD & LED
2)
KEYS
3)
BOBBIN
WINDER
SPINDLE
4)
BUTTONHOLE
CENSOR
UPPER-SHAFT
CENSOR
DEFECTIVE RESULTS /
REPLACEMENT AND
ADJUSTMENT
DEFECTIVE RESULTS:
•DOES NOT ENTER THE SELF-
DIAGNOSTIC MODE.
REPLACE:
•REPLACE THE TOUCH PANEL.
•REPLACE THE BOARD A.
Step1 LCD&LED
Next :
CLR
Step2 Key
Step3 Switch
SP : OFF
Step4 Sensor
BH:L BS:L FS:L
DEFECTIVE RESULTS:
•DOES NOT DISPLAY THE NAME
OF BUTTON OR DOES NOT BEEP
WHEN BUTTONS ARE PRESSED.
REPLACE:
•REPLACE THE TOUCH PANEL.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
•DOES NOT DISPLAY THE NAME
OF BUTTON OR DOES NOT BEEP
WHEN BUTTONS ARE PRESSED.
REPLACE:
•REPLACE THE BOBBIN WINDER.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
• THE DISPLAY DOES NOT CHANGE
OR SHOWTHE CORRECT.
RESULTS WHEN THE
BUTTONHOLE LEVER IS PULLED
OR PUSHED.
REPLACE OR ADJUST:
•REPLACE THE BUTTONHOLE
LEVER SENSOR.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
• THE DISPLAY DOES NOT CHANGE
OR SHOWTHE CORRECT.
RESULTS WHEN THE NEEDLE IS
MOVED.
REPLACE OR ADJUST:
•REPLACETHE UPPER SHAFT
SENSOR.
•REPLACETHE BOARD A.

11
SEWING MACHINE MODEL DC5100
* PRESS THE CLR BUTTONTO RETURN TO ”STEP 1”. END THE SELF DIAGNOSTIC TESTS.
Step5 VeloSen
000
Step6 Volume
255
Step7 FootCont
210
Step8 Stm
BM Phase
MEM
Step8 Stm
FM Phase
MEM
Step9 SewMotor
CORRECT RESULTS
•THE DISPLAY SHOWS “VeloSen”.
•BEEP SOUND.
•THE VALUE SHOULD BE 365 TO 375
WHEN THE HANDWHEEL IS ROTATED
ONCE.
PRESS CLR BUTTON TO PROCEED TO
THE NEXT STEP.
•THE DISPLAY SHOWS “Volume” AND
THE MACHINE BEEPS.
•WHEN THE SPEED CONTROL LEVER
IS AT LEFT, THE SCREEN DISPLAYS
“000”TO “010”.
•WHEN THE SPEED CONTROL LEVER
IS AT RIGHT, THE SCREEN DISPLAYS
“255”TO “250”.
PRESS CLR BUTTON TO PROCEED
TO THE NEXT STEP.
•THE DISPLAY SHOWS “FootCont” AND
THE MACHINE BEEPS.
•WHEN THE FOOT CONTROL IS NOT
DEPRESSED,THE SCREEN SHOULD
DISPLAY “000”TO “016”.
WHEN THE FOOT CONTROL IS
DEPRESSED FULLY, THE SCREEN
SHOULD DISPLAY 210”TO “200”.
PRESS CLR BUTTON TO PROCEED
TO THE NEXT STEP.
• THE DISPLAY SHOWS “Stm” AND
THE MACHINE BEEPS.
•THE NEEDLE IS CENTERED.
• THE FEED MOTOR IS INITIALIZED.
(THE STITCH LENGTH IS “0”)
PRESS CLR BUTTON TO PROCEED
TO THE NEXT STEP.
• THE DISPLAY SHOWS “SewMotor”
AND THE MACHINE BEEPS.
TESTS
TURN THE HANDWHEEL
CLOCKWISE TO MOVE THE
NEEDLE FROM HIGHEST TO
THE LOWEST POSITION.
SET THE SPEED CONTROL TO
THE LEFTMOST POSITION.
THEN SLIDE THE SPEED
CONTROL LEVER FROM LEFT
TO RIGHT, THEN RETURN TO
LEFT.
DEPRESS THE FOOT CONTROL
FULLY, THEN RELEASE THE
FOOT CONTROL.
TURN THE HANDWHELL
TOWARD YOU TO MOVE THE
NEEDLE FROM HIGHESTTO
THE LOWEST POSITION.
CHECK THE SCREEN.
DEPRESS THE FOOT CONTROL
TO CHECK THE SEWING SPEED.
5)
VELOCITY
SENSOR
(DC MOTOR)
6)
SLIDEVOLUME
7)
FOOT CONTROL
8)
ZIGZAGWIDTH
MOTOR
FEED MOTOR
9)
DC MOTOR
DEFECTIVE RESULTS /
REPLACEMENT AND
ADJUSTMENT
DEFECTIVE RESULTS:
•THE VALUE DOES NOT CHANGE.
•THE VALUE DECREASES WHEN
THE FOOT CONTROL IS
DEPRESSED.
REPLACE:
•REPLACETHE DC MOTOR.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
•THE VALUE DOES NOT CHANGE.
•THE VALUE DOES NOT MATCH.
WITH THE CORRECT RESULTS.
REPLACE:
•REPLACETHE DC MOTOR.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
•THE VALUE DOES NOT CHANGE.
•THE VALUE DECREASES WHEN
THE FOOT CONTROL IS DE
PRESSED.
REPLACE:
•REPLACETHE FOOT CONTROL.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
•THE VALUE DOES NOT CHANGE.
• THE NEEDLE IS NOT CENTERED.
REPLACE:
•REPLACE THE ZIGZAG WIDTH
MOTOR.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
•THE VALUE DOES NOT CHANGE.
REPLACE:
•REPLACETHE FEED MOTOR.
•REPLACETHE BOARD A.
DEFECTIVE RESULTS:
•THE MOTOR DOES NOT START, OR
ROTATES UNSTABLY.
REPLACE:
•REPLACETHE DC MOTOR.
•REPLACETHE BOARD A.
SELF DIAGNOSTICTESTS

12
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. REMOVE THE 3 SCREWS (C) AND REMOVE THE TOP COVER (D).
TO ATTACH:
2. FOLLOW THE PROCEDURE ABOVE IN REVERSE.
FACE COVER (B)
SCREW (A)
SCREW (C)
SCREWS (C)
TOP COVER (D)

13
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
SCREW (A)
BELT COVER (B)
SCREW (A)
RIB (C)

14
SEWING MACHINE MODEL DC5100
SERVICE ACCESS (3)
BASE PLATE
BED COVER
TO REMOVE:
1. REMOVE THE 2 SCREWS (A) AND 4 SCREWS (B).
2. REMOVE THE BASE (C).
TO ATTACH:
3. REVERSE THIS PROCEDURE.
TO REMOVE:
1. REMOVE THE 2 SCREWS (D).
2. REMOVE THE BED COVER (E).
TO ATTACH:
3. MOVE THE DROP LEVER TO THE LEFT AND ATTACH THE BED COVER WITH
2 SCREWS (D).
SCREW (B)
BASE (C)
SCREW (B)
SCREW (A)
2 SCREWS (D)
DROP LEVER
BED COVER (E)

15
SEWING MACHINE MODEL DC5100
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.
TO ATTACH:
4. FOLLOW THE PROCEDURE ABOVE IN REVERSE.
SETSCREW (A)
SETSCREW (B)
SETSCREW (C)
SETSCREW (D)
SETSCREW (E)
SETSCREW (F)
SERVICE ACCESS (4)
HOOK

16
SEWING MACHINE MODEL DC5100
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.
TO ATTACH:
4. FOLLOW THE PROCEDURE ABOVE IN REVERSE.
SETSCREW (A)
SETSCREW (B)
SETSCREW (C)
SETSCREW (D)
SETSCREW (E)
PRESSER FOOT LIFTER
REAR COVER
TWIST AND REMOVE THE ARM COVER
PART FROM PRESSER FOOT LIFTER
SERVICE ACCESS (5)

17
SEWING MACHINE MODEL DC5100
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.
NEEDLE PLATE
SETSCREW (A)
SETSCREW (B) FREE ARM COVER
SERVICE ACCESS (6)

18
SEWING MACHINE MODEL DC5100
SETSCREW ECCENTRIC PIN
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 " ", THE DISTANCE BETWEEN BOTH ENDS
OF THE NEEDLE HOLE IN THE NEEDLE PLATE AND THE NEEDLE SHOULD BE 0.2 MM OR MORE. IF
NOT, ADJUST AS FOLLOWS.
ADJUSTMENT PROCEDURE:
1.TURN ON THE POWER SWITCH, SET THE STITCH PATTERN AT STRAIGHT " " AND THE ZIGZAG
WIDTH AT MAXIMUM " " THEN CHECK THE NEEDLE DROP POSITION.
2.IF THE NEEDLE DROP POSITION IS NOT IN THE CENTER OF THE NEEDLE PLATE HOLE WHEN THE
STRAIGHT STITCH IS SELECTED, OR IF THE CLEARANCE BETWEEN THE NEEDLE AND EDGE OF
THE NEEDLE PLATE HOLE ON BOTH SIDE IS LESS THAN 0.2 MM WHEN THE STITCH PATTERN IS SET
TO MAXIMUM ZIGZAG WIDTH, OPEN THE FACE COVER AND LOOSEN THE SETSCREW, THEN
ADJUST THE NEEDLE DROP POSITION BY TURNING THE ECCENTRIC PIN.
NOTE:
MAKE SURE THE ECCENTRIC PIN IS POSITIONED WITH ITS OFF-CENTER HEAD FACING
DOWNWARD.
3.WHEN YOU HAVE FINISHED ADJUSTING THE NEEDLE DROP POSITION, TIGHTEN THE SETSCREW
AND CLOSE THE FACE COVER.
ECCENTRIC PIN POSITION
(OFF CENTER HEAD)
ADJUST THE NEEDLE DROP POSITION BY TURNING THE
ECCENTRIC PIN AS SHOWN
NEEDLE PLATE HOLE
0.2 MM OR
MORE
A=B
0.2 MM OR
MORE