DC 5100

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
PARTS LIST .................................................................................................................................................... 43-61
SEWING MACHINE MODEL DC5100
LOCATE AND IDENTIFY THE PARTS

SPOOL PIN SPOOL HOLDER
THREAD GUIDE FLIP TOP STITCH CHART
THREAD TAKE-UP LEVER SCREEN BRIGHTNESS

ADJUSTING DIAL
THREAD TENSION DIAL
FACE COVER
FUNCTION TOUCHPAD
THREAD CUTTER
NEEDLE THREADER
SPEED CONTROL LEVER
NEEDLE PLATE
UP/DOWN NEEDLE POSITION

BUTTON
EXTENSION TABLE
FEED BALANCING AUTO-LOCK BUTTON
(ACCESSORY BOX)
DIAL
HOOK COVER PLATE REVERSE STITCH BUTTON
HOOK COVER PLATE RELEASE

BUTTON
PRESSER
FOOT HOLDER
NEEDLE CLAMP SCREW
NEEDLE
PRESSER FOOT
THUMBSCREW
CARRYING HANDLE
BOBBIN WINDER SPINDLE

BOBBIN WINDER STOPPER HOLE FOR ADDITIONAL
SPOOL PIN
HANDWHEEL PRESSER FOOT LIFTER
BUTTONHOLE LEVER
FREE-ARM
POWER SWITCH
FEED DOG DROP LEVER
MACHINE SOCKETS NOMENCLATURE PLATE
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.
(3)
(1)
(2)
(4)
INSERTING THE BOBBIN
PLACE THE BOBBIN IN THE BOBBIN HOLDER WITH THE

(1) 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.
(A) DRAW THE THREAD TO THE LEFT, SLIDING IT BETWEEN THE
TENSION SPRING BLADES.
(2) (2) NOTCH (A)
CONTINUE TO DRAW THE THREAD LIGHTLY UNTIL THE

THREAD SLIPS INTO NOTCH (B).
(B) PULL OUT ABOUT 15 CM (6") OF THREAD.
(3) NOTCH (B)
(3)
(4)
1/8 3/8 5/8
ATTACH THE HOOK COVER PLATE.
10
CHECK THE THREADING BY REFERRING TO THE CHART

SHOWN ON THE HOOK COVER PLATE.
(4) THREADING CHART
2
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.
3
(3)
1
(1)
(2)
(4)
(4)
(5)
(6)
3
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
D: FEED MOTOR J : MACHINE PLUG (PRIMARY CIRCUIT)
E: ZIGZAG WIDTH MOTOR K : SLIDE VOLUME
F: DC MOTOR L : MACHINE PLUG (SECONDARY CIRCUIT)
G: POWER TRANSFORMER (PRIMARY M: BOBBIN WINDER SWITCH
CIRCUIT) N: TOUCH PANEL
A
C
G
A-BOARD
B F
F-BOARD E
D
J
H
I B L
M
N
A
C
L
K
H
E
F
D
G
J
4
GENERAL TROUBLE SHOOTING PROCEDURE
(MACHINE DOESNT WORK WELL)
START
IS NEEDLE SET OK?

BASIC CHECK IS POWER SUPPLY OK?
IS THREADING OK?
N.G.
O.K.
CORRECT IT
MECHANICAL ELECTRICAL CANT JUDGE
O.K.
ELECTRIC QUICK CHECK
N.G.
ADJUSTMENT
REPLACE PARTS
SEWING CHECK
ELECTRIC QUICK CHECK
END
5
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.
4. NEEDLE OR THREAD ARE USE THE RECOMMENDED

INAPPROPRIATE FOR SEWING NEEDLE AND THREAD.
FABRIC BEING SEWN.
5. SEWING ON STRETCH USE A #11 BLUE TIP NEEDLE.

FABRIC.
6. INAPPROPRIATE NEEDLE SEE MECHANICAL ADJUSTMENT P. 19

BAR HEIGHT. NEEDLE BAR HEIGHT.

TO HOOK TIMING. NEEDLE TO HOOK TIMING.

TO HOOK CLEARANCE. CLEARANCE BETWEEN NEEDLE
AND HOOK.
2. FABRIC NOT 1. INCORRECT FEED DOG HEIGHT. SEE MECHANICAL

MOVING ADJUSTMENT FEED DOG HEIGHT. P. 23
2. FEED DOG IS IN DOWN RAISE THE FEED DOG.

POSITION.
3. THREAD ON BOTTOM SIDE OF MAKE SURE TO BRING BOTH

FABRIC IS JAMMED UP. NEEDLE AND BOBBIN.
THREAD UNDER THE FOOT WHEN
STARTING SEWING.
4. FEED DOG TEETH ARE WORN. CHANGE THE FEED DOG.
6
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. REPLACE WITH A NEW NEEDLE.
4. UPPER THREAD TENSION IS ADJUST NEEDLE THREAD TENSION P. 27

TOO STRONG. CORRECTLY.
5. NEEDLE SIZE IS USE APPROPRIATE NEEDLE FOR

INAPPROPRIATE FOR FABRIC. FABRIC AND THREAD IN USE.
6. NEEDLE EYE IS WORN. CHANGE THE NEEDLE.
7. NEEDLE HOLE IN NEEDLE REPAIR THE HOLE OR REPLACE

PLATE IS WORN OR BURRED. THE NEEDLE PLATE.
4. BREAKING 1. INCORRECTLY THREADED THREAD BOBBIN CORRECTLY.

BOBBIN BOBBIN.
THREAD
2. TOO MUCH THREAD IS ADJUST THE POSITION OF STOPPER.
WOUND ON THE BOBBIN.
3. LINT IS STUCK INSIDE THE CLEAN THE BOBBIN HOLDER.

BOBBIN HOLDER.
4. THREAD QUALITY IS CHANGE TO A HIGH QUALITY

TOO LOW. SEWING THREAD.
5. THREAD IS JAMMING CLEAR OUT THE JAMMING THREAD.

AROUND THE BOBBIN.
5. NEEDLE 1. NEEDLE IS HITTING THE SEE MECHANICAL P. 18

BREAKS NEEDLE PLATE. ADJUSTMENT NEEDLE DROP
POSITION.
2. NEEDLE IS BENT OR WORN. CHANGE THE NEEDLE.
3. NEEDLE IS HITTING THE HOOK. SEE MECHANICAL ADJUSTMENT P. 21

CLEARANCE BETWEEN NEEDLE
AND HOOK.
4. THE FABRIC MOVES WHILE SEE MECHANICAL ADJUSTMENT P. 24

THE NEEDLE IS PIERCING ZIGZAG SYNCHRONIZATION.
IT, OR THE NEEDLE ZIGZAGS
WHILE IN FABRIC.
5. FABRIC IS BEING PULLED TOO GUIDE THE FABRIC GENTLY

STRONGLY WHILE SEWING. WHILE SEWING.
7
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.

LOOSE.
3. INAPPROPRIATE BELT SEE REPLACING DC MOTOR AND P. 35

TENSION. ADJUSTING MOTOR BELT TENSION
(DC MOTOR).
4. NOT ENOUGH OIL. OIL ALL MOVING PARTS. P. 42
7. DEFORMATION 1. INAPPROPRIATE FEED SEE MECHANICAL ADJUSTMENT P. 26

PATTERN BALANCE. STRETCH STITCH FEED
BALANCE ADJUSTMENT.
2. INAPPROPRIATE ZIGZAG SEE MECHANICAL ADJUSTMENT P. 24
SYNCHRONIZATION. ZIGZAG SYNCHRONIZATION.
3. UPPER THREAD TENSION SEE MECHANICAL ADJUSTMENT P. 27

IS TOO STRONG. NEEDLE THREAD TENSION.
8
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.
TURN THE HANDWHEEL TOWARD YOU TO RAISE THE NEEDLE TO ITS HIGHEST POSITION.
PLUG THE FOOT CONTROL TO 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 DIAGNOSTIC TEST 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 RESPOND WHEN THE POWER SWITCH IS TURNED 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.
SELF-DIAGNOSTIC TEST:
TURN THE POWER SWITCH ON WHILE PRESSING
THE REVERSE BUTTON & AUTO-LOCK BUTTON.
01 02 03
THEN PRESS THE 01 BUTTON WITHIN 3 SECONDS

04 05 06
TO ENTER THE SELF-DIAGNOSTIC MODE.

07 08 09
THE STANDARD MODE SHOWS UP IF YOU DO NOT
00
PRESS THE 01 BUTTON WITHIN 3 SECONDS. TURN
THE POWER SWITCH OFF AND START OVER
SELF-DIAGNOSTIC MODE AGAIN.
Step1 LCD&LED
Next : CLR
9
DEFECTIVE RESULTS /
TESTS CORRECT RESULTS REPLACEMENT AND
ADJUSTMENT
TURN THE POWER SWITCH ON THE DISPLAY SHOWS Self Check DEFECTIVE RESULTS:
1) WHILE PRESSING THE Start. LCD AND LED BLINKS. DOES NOT ENTER THE SELF-
LCD & LED REVERSE BUTTON & AUTO- BEEPS WHEN ENTER THE LCD & LED DIAGNOSTIC MODE.
LOCK BUTTON. THEN PRESS CHECK MODE.
THE 01 BUTTON WITHIN REPLACE:
3 SECONDS TO ENTER THE Step1 LCD&LED
REPLACE THE TOUCH PANEL.
SELF-DIAGNOSTIC MODE. Next : CLR REPLACE THE BOARD A.
PRESS CLR BUTTON TO PROCEED TO
THE NEXT STEP.
2) PRESS THE KEYS IN ORDER THE DISPLAY SHOWS Key AND THE DEFECTIVE RESULTS:
KEYS AS DESCRIBED BELOW. MACHINE BEEPS. DOES NOT DISPLAY THE NAME
qREVERSE STITCH BUTTON BEEPS WHEN ENTER THE KEY OF BUTTON OR DOES NOT BEEP
wAUTO-LOCK BUTTON CHECK MODE. WHEN BUTTONS ARE PRESSED.
eUP/DOWN NEEDLE POSITION BEEPS WHEN BUTTONS OR KEYS
BUTTON ARE PRESSED. REPLACE:
rMODE KEY THE DISPLAY SHOWS THE NAME OF REPLACE THE TOUCH PANEL.
tSTITCH WIDTH KEY + PRESSED BUTTON OR KEY. REPLACE THE BOARD A.
ySTITCH WIDTH KEY
uSTITCH LENGTH KEY + Step2 Key
iSTITCH LENGTH KEY
PRESS THE REST OF KEYS IN
ORDER FROM LEFT TO RIGHT,
STARTING FROM THE HIGHEST PRESS CLR BUTTON TO PROCEED TO
COLUMN TO THE LOWEST THE NEXT STEP.
COLUMN.
3) MOVE THE BOBBIN WINDER TO THE DISPLAY SHOWS Switch AND DEFECTIVE RESULTS:
THE RIGHT. THE MACHINE BEEPS. DOES NOT DISPLAY THE NAME
BOBBIN OF BUTTON OR DOES NOT BEEP
MOVE THE BOBBIN WINDER TO THE DISPLAY SHOWS ON AND
WINDER THE LEFT. BEEPS WHEN BOBBIN WINDER IS WHEN BUTTONS ARE PRESSED.
SPINDLE MOVED TO THE RIGHT.
THE DISPLAY SHOWS OFF AND REPLACE:
BEEPS WHEN BOBBIN WINDER IS REPLACE THE BOBBIN WINDER.
MOVED TO THE LEFT. REPLACE THE BOARD A.
Step3 Switch
SP : OFF

THE NEXT STEP.
4) LOWER THE BUTTONHOLE THE DISPLAY SHOWS Sensor AND DEFECTIVE RESULTS:
BUTTONHOLE LEVER. THE MACHINE BEEPS. THE DISPLAY DOES NOT CHANGE
CENSOR PULL, AND PUSH THE BUTTON- WHEN THE BUTTONHOLE OR SHOW THE CORRECT.
HOLE LEVER, THEN CHECK THE LEVER IS PULLED, THE SCREEN RESULTS WHEN THE
DISPLAY. DISPLAYS "H". BUTTONHOLE LEVER IS PULLED
OR PUSHED.
WHEN THE BUTTONHOLE LEVER IS
POSITIONED IN CENTER, THE REPLACE OR ADJUST:
SCREEN DISPLAYS "L". REPLACE THE BUTTONHOLE
LEVER SENSOR.
WHEN THE BUTTONHOLE LEVER IS REPLACE THE BOARD A.
PUSHED, THE SCREEN DISPLAYS "H".
Step4 Sensor
BH:L BS:L FS:L
UPPER-SHAFT TURN THE HANDWHELL WHEN NEEDLE IS IN THE HIGHEST DEFECTIVE RESULTS:
CENSOR TOWARD YOU TO MOVE THE POSITION, THE SCREEN SHOWS: THE DISPLAY DOES NOT CHANGE
NEEDLE FROM HIGHEST TO [BS:H FS:L] OR SHOW THE CORRECT.
THE LOWEST POSITION. RESULTS WHEN THE NEEDLE IS
CHECK THE SCREEN. WHEN NEEDLE IS IN THE LOWEST MOVED.
POSITION, THE SCREEN SHOWS:
[BS:L FS:H]
REPLACE OR ADJUST:
REPLACE THE UPPER SHAFT
WHEN NEEDLE IS IN NEITHER THE
SENSOR.
HIGHEST NOR THE LOWEST POSI-
REPLACE THE BOARD A.
TIONS.
[BS:L FS:L]
THE NEXT STEP.
10
DEFECTIVE RESULTS /
TESTS CORRECT RESULTS REPLACEMENT AND
ADJUSTMENT
TURN THE HANDWHEEL THE DISPLAY SHOWS VeloSen. DEFECTIVE RESULTS:
5) CLOCKWISE TO MOVE THE BEEP SOUND. THE VALUE DOES NOT CHANGE.
VELOCITY NEEDLE FROM HIGHEST TO THE VALUE DECREASES WHEN
SENSOR THE LOWEST POSITION. Step5 VeloSen THE FOOT CONTROL IS
(DC MOTOR) 000 DEPRESSED.
REPLACE:
THE VALUE SHOULD BE 365 TO 375 REPLACE THE DC MOTOR.
WHEN THE HANDWHEEL IS ROTATED REPLACE THE BOARD A.
ONCE.

THE NEXT STEP.
6) SET THE SPEED CONTROL TO THE DISPLAY SHOWS Volume AND DEFECTIVE RESULTS:
THE LEFTMOST POSITION. THE MACHINE BEEPS. THE VALUE DOES NOT CHANGE.
SLIDE VOLUME
THEN SLIDE THE SPEED THE VALUE DOES NOT MATCH.
Step6 Volume
CONTROL LEVER FROM LEFT WITH THE CORRECT RESULTS.
TO RIGHT, THEN RETURN TO 255
LEFT.
WHEN THE SPEED CONTROL LEVER REPLACE:
IS AT LEFT, THE SCREEN DISPLAYS REPLACE THE DC MOTOR.
000 TO 010. REPLACE THE BOARD A.
WHEN THE SPEED CONTROL LEVER
IS AT RIGHT, THE SCREEN DISPLAYS
255 TO 250.
PRESS CLR BUTTON TO PROCEED
TO THE NEXT STEP.
7) DEPRESS THE FOOT CONTROL THE DISPLAY SHOWS FootCont AND DEFECTIVE RESULTS:
FULLY, THEN RELEASE THE THE MACHINE BEEPS. THE VALUE DOES NOT CHANGE.
FOOT CONTROL
FOOT CONTROL. THE VALUE DECREASES WHEN
Step7 FootCont THE FOOT CONTROL IS DE
210 PRESSED.
WHEN THE FOOT CONTROL IS NOT REPLACE:

DEPRESSED, THE SCREEN SHOULD REPLACE THE FOOT CONTROL.
DISPLAY 000 TO 016. REPLACE THE BOARD A.
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 DEFECTIVE RESULTS:

8) TURN THE HANDWHELL
THE MACHINE BEEPS. THE VALUE DOES NOT CHANGE.
TOWARD YOU TO MOVE THE
ZIGZAG WIDTH THE NEEDLE IS NOT CENTERED.
NEEDLE FROM HIGHEST TO THE NEEDLE IS CENTERED.
MOTOR THE LOWEST POSITION. REPLACE:
CHECK THE SCREEN. Step8 Stm MEM REPLACE THE ZIGZAG WIDTH
BM Phase MOTOR.
FEED MOTOR THE FEED MOTOR IS INITIALIZED.
(THE STITCH LENGTH IS 0) DEFECTIVE RESULTS:
THE VALUE DOES NOT CHANGE.
Step8 Stm MEM
FM Phase REPLACE:
REPLACE THE FEED MOTOR.
PRESS CLR BUTTON TO PROCEED REPLACE THE BOARD A.
TO THE NEXT STEP.
DEFECTIVE RESULTS:
DEPRESS THE FOOT CONTROL THE DISPLAY SHOWS SewMotor
9) THE MOTOR DOES NOT START, OR
TO CHECK THE SEWING SPEED. AND THE MACHINE BEEPS.
ROTATES UNSTABLY.
DC MOTOR
Step9 SewMotor REPLACE:
REPLACE THE DC MOTOR.
* PRESS THE CLR BUTTON TO RETURN TO STEP 1. END THE SELF DIAGNOSTIC TESTS.
11
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:
SCREWS (C)
TOP COVER (D)

SCREW (C)
FACE COVER (B)
SCREW (A)
12
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)
SCREW (A)
SCREW (A)
13
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).
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)
BED COVER (E) SCREW (B)

SCREW (A)
DROP LEVER
2 SCREWS (D)
14
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.
TO ATTACH:
SETSCREW (B)
SETSCREW (C)
SETSCREW (A)
HOOK
SETSCREW (D)
SETSCREW (E)
SETSCREW (F)
15
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.
TO ATTACH:
SETSCREW (E)
SETSCREW (A)
SETSCREW (D)
SETSCREW (B)
SETSCREW (C)
PRESSER FOOT LIFTER TWIST AND REMOVE THE ARM COVER

PART FROM PRESSER FOOT LIFTER
REAR COVER
16
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:
NEEDLE PLATE
SETSCREW (A)
FREE ARM COVER

SETSCREW (B)
17
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.
SETSCREW
ECCENTRIC PIN
NEEDLE PLATE HOLE
0.2 MM OR 0.2 MM OR
MORE MORE ECCENTRIC PIN POSITION
(OFF CENTER HEAD)
A=B
ADJUST THE NEEDLE DROP POSITION BY TURNING THE
ECCENTRIC PIN AS SHOWN
18
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.
1. REMOVE THE NEEDLE PLATE AND BOBBIN HOLDER.

TURN ON THE POWER SWITCH.
3. SELECT THE PATTERN (SIMPLE ZIGZAG). (MAXIMUM ZIGZAG WIDTH)
4. TURN THE HANDWHEEL TOWARD YOU UNTIL THE TIP OF HOOK MEETS THE RIGHT SIDE OF THE
NEEDLE.
5. LOOSEN THE SETSCREW (A).
6. ADJUST THE HEIGHT OF THE NEEDLE BAR BY MOVING THE NEEDLE BAR UPWARD OR DOWNWARD
WITHOUT TURNING IT. (MAKE SURE THAT THE NEEDLE SETTING GROOVE OF THE NEEDLE BAR IS IN
THE FRONT).
7. TIGHTEN THE SETSCREW (A).
8. INSERT THE BOBBIN HOLDER, THEN ATTACH THE NEEDLE PLATE.
SETSCREW (A)
NEEDLE SETTING GROOVE
TIP OF HOOK MEETS RIGHT

SIDE OF NEEDLE
NEEDLE #14 HOOK RACE
1.6-2.0 MM
UPPER EDGE OF
NEEDLE EYE
HOOK RACE UNIT
19
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.
1 REMOVE THE NEEDLE PLATE AND BOBBIN HOLDER.

2 TURN ON THE POWER SWITCH, SET THE STRAIGHT STITCH PATTERN NO.2 (LEFT NEEDLE POSITION).
3 REMOVE THE BED COVER.
4 TURN THE HANDWHEEL TOWARD YOU, AND SET THE NEEDLE BAR AT THE LOWEST POSITION.
5 LOOSEN THE SETSCREWS ON THE LOWER SHAFT TIMING GEAR.
6 RAISE THE NEEDLE BAR BETWEEN 3.25 - 3.55 MM FROM THE LOWEST POSITION OF THE NEEDLE BAR.
7 TURN THE LOWER SHAFT TIMING GEAR UNTIL THE TIP OF HOOK MEETS WITH THE RIGHT SIDE OF
NEEDLE.
8 TIGHTEN THE SETSCREWS ON THE LOWER SHAFT TIMING GEAR.
9 ATTACH THE BED COVER, BOBBIN HOLDER AND NEEDLE PLATE.
SETSCREW
LOWER SHAFT GEAR
NEEDLE #14 MATCH THE TIP OF

HOOK AT THE RIGHT
SIDE OF NEEDLE
3.253.55 MM
LOWER NEEDLE POSITION
20
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 " ".
2. REMOVE THE NEEDLE PLATE (A) AND BOBBIN HOLDER (B), INSERT THE TEST PIN (C) INTO THE
NEEDLE BAR AND PUSH IT UP UNTIL IT STOPS, THEN TIGHTEN THE NEEDLE CLAMP SCREW.
3. REMOVE THE BED COVER (SEE PAGE14).
ADJUSTMENT:
1. LOOSEN THE SETSCREWS (D) AND (E), THEN LIGHTLY LOOSEN THE SETSCREW (F).
2. TURNING THE HANDWHEEL TOWARD YOU SLOWLY BY HAND, MOVE THE HOOK SETPLATE UP OR
DOWN TO ADJUST THE CLEARANCE BETWEEN THE TEST PIN (C) AND THE POINT OF THE HOOK TO
-0.10 TO +0.05 MM. REPEAT THE PROCEDURE FOR BOTH THE LEFT AND RIGHT NEEDLE POSITIONS.
3. TIGHTEN THE SETSCREWS (D), (E) AND (F) SECURELY.
4. CHECK THE BACKLASH OF THE HOOK DRIVE GEAR AND THE LOWER SHAFT GEAR.
IF THE BACKLASH IS TOO LARGE OR SMALL, IT NEEDS TO BE ADJUSTED (SEE PAGE 22).
5. INSTALL THE BED COVER.
6. REMOVE THE TEST PIN (C), THEN INSTALL THE BOBBIN HOLDER (B) AND THE NEEDLE PLATE (A).
TEST PIN (C)
POINT OF HOOK
NEEDLE PLATE (A)
0.10 TO +0.05MM
BOBBIN HOLDER (B)
SETSCREW (F)
HOOK SET
PLATE
SETSCREW (E)
SETSCREW (D)
21
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. IF THE PLAY EXCEEDS 0.8 MM, ADJUST AS FOLLOWS.
ADJUSTMENT:
1. REMOVE THE BED COVER (SEE PAGE 14)
2. LOOSEN THE SETSCREW.
3. TURN THE LOWER SHAFT BUSHING (ECCENTRIC BUSHING) CLOCKWISE (B) IF THERE IS TOO MUCH
PLAY IN THE HOOK RECE.
TURN THE LOWER SHAFT BUSHING (ECCENTRIC BUSHING) COUNTERCLOCKWISE (A) IF THERE IS
TOO LITTLE PLAY IN THE HOOK.
4. TIGHTEN THE SETSCREW SECURELY AFTER ADJUSTMENT AND INSTALL THE BED COVER.
NOTE:
AFTER ADJUSTING THE BACKLASH, BE SURE TO CHECK THE NEEDLE TO HOOK TIMING AND THE
FEED DOG HEIGHT.
BACKLASH ALLOWANCE
POINT OF HOOK RACE
CHECK THE
BACKLASH
GROOVE
HOOK GEAR
LOWER SHAFT GEAR GROOVE OF LOWER SHAFT BUSHING

B A
22
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.

2. TURN ON THE POWER SWITCH.
3. REMOVE THE BED COVER.
4. TURN THE HANDWHEEL TOWARD YOU TO SET THE FEED DOG AT THE HIGHEST POSITION.
5. LOOSEN THE SETSCREW(A) AND NUT(B).
6. ADJUST THE FEED DOG HEIGHT BY TURNING THE ADJUSTING SCREW (C).
7. TIGHTEN THE NUT (B) AND SETSCREW (A).
PRESSER FOOT
0.80-0.90 MM
FEED DOG
SURFACE OF THE
NEEDLE PLATE
E (TO RAISE)
D
SETSCREW (A)
(TO LOWER)
NUT (B)
ADJUSTING SCREW (C)
23
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).

2. TURN ON THE POWER SWITCH, SELECT THE PATTERN NO. 2 AND SET THE MACHINE AT THE
MAXIMUM ZIGZAG WIDTH.
3. TURN THE HANDWHEEL TOWARD YOU SLOWLY WITH YOUR HAND UNTIL THE NEEDLE START TO
SEWING. LOOSEN THE SETSCREW AND TURN THE UPPER SHAFT SHIELD PLATE IN THE DIRECTION
OF;
* A. IF THE SWING POINT IS HIGHER THAN 7.5 MM.
* B. IF THE SWING POINT IS LOWER THAN 6.3 MM.
4. POSITION THE UPPER SHAFT SHIELD PLATE AS CLOSE AS POSSIBLE TO THE LEFT.
(IT SHOULD NOT TOUCH THE UPPER SHAFT SENSOR).
5. CHECK THE SWING POINT BY TURNING THE HANDWHEEL, THEN TIGHTEN THE SETSCREW.
6. ATTACH THE FRONT COVER.
NEEDLE #14
SURFACE OF NEEDLE PLATE
6.37.5 MM
UPPER SHAFT SHIELD PLATE

SETSCREW
UPPER SHAFT SENSOR
24
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).
2. LOWER THE PRESSER FOOT LIFTER, AND SET THE THREAD TENSION DIAL AT "9".
THEN LOOSEN THE SET SCREW (A).
3. WHILE PUSHING THE TENSION RELEASE PLATE (2) IN THE DIRECTION OF "A", MOVE
THE TENSION RELEASE PLATE (1) UNTIL IT TOUCHES TENSION DISK SUPPORTER.
IN THIS CONDITION, TIGHTEN THE SET SCREW (A).
4. RAISE THE PRESSER FOOT LIFTER, AND CHECK THE TENSION RELEASE MECHANISM.
5. SET THE THREAD TENSION DIAL AT "0".
LOWER THE PRESSER FOOT LIFTER.
MOVE THE TENSION RELEASE PLATE (2) BACK AND FORTH. IN THIS CONDITION,
THE TENSION DISK SUPPORTER SHOULD NOT MOVE.
6. ATTACH THE TOP COVER, BELT COVER AND FRONT COVER (SEE PAGES 12, 13 AND 15).
TENSION RELEASE PLATE (1)
SETSCREW (A)
TENSION DISK SUPPORTER SETSCREW (A)
A
TENSION DISC SUPPORTER
TENSION RELEASE PLATE (2) TENSION DISK
TENSION RELEASE LEVER
25
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. IF NOT (IF THERE IS UNEVENESS BETWEEN FORWARD
FEEDING AND BACKWARD FEEDING), THEN MAKE AN ADJUSTMENT AS FOLLOWS.
1. TURN THE POWER SWITCH ON, AND SELECT PATTERN NO.3 ( ).
2. SET THE SLIT OF THE FEED BALANCING DIAL (C) AT THE STANDARD SETTING MARK '' ''
ON THE FRONT COVER.
3. PUT THE PAPER BETWEEN THE FOOT AND FEED DOG AND LOWER THE PRESSER BAR
LIFTER.
4. TURN THE HANDWHEEL, AND CHECK THE NEEDLE MARKS '' A '' AND '' B ''.
5. REMOVE BASE CUP ( D ).
6. IF THE LENGTH OF A IS BIGGER THAN THE LENGTH OF B, TURN THE ADJUSTING SCREW ( E ) IN
THE DIRECTION OF '' F ''.
IF THE LENGTH OF A IS SMALLER THAN THE LENGTH OF B, TURN THE ADJUSTING SCREW ( E ) IN
THE DIRECTION OF '' G ''.
7. ATTACH THE BASE CUP ( D ).
FEED BALANCING DIAL ( C )
STANDARD
SETTING MARK
INDICATION LINE
BASE CUP (D)
ADJUSTING
F G
A SCREW ( E )
A 1 A 1 1
A 3 B
2
A 2 3 B
A 2
3 B
A=B A>B A<B
26
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. IF THE TENSION IS OUT OF THE STANDARD RANGE, ADJUST AS FOLLOWS.
1. REMOVE THE FRONT COVER UNIT (SEE PAGE 15).
2. PULL THE ADJUSTING PLATE SPRING (D) AWAY FROM THE LEAD SCREW (D) AND ADJUST
BY TURNING THE LEAD SCREW (E).
IF THE TENSION IS STRONG, TURN THE LEAD SCREW IN DIRECTION "B".
IF THE TENSION IS WEAK, TURN THE LEAD SCREW IN THE DIRECTION "C".
3. ATTACH THE FRONT COVER UNIT.
ADJUSTING PLATE SPRING (D)
LEAD SCREW (E)
THREAD TENSION DIAL AT ''4'' NEEDLE THREAD

POLYESTER SEWING THREAD
#50 (WHITE)
FIG.1
27
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]".
2. REMOVE THE FACE COVER AND LOOSEN SETSCREW(A).
3. LOWER THE BUTTONHOLE LEVER. POSITION THE BUTTONHOLE LEVER GUIDE SO THE SCREEN
DISPLAYS "L". TIGHTEN SETSCREW (A).
TO ADJUST THE BUTTONHOLE SENSOR POSITION:

4. INSTALL THE BUTTONHOLE FOOT (R).
5. LOWER THE BUTTONHOLE LEVER TO ITS LOWEST POSITION, AND INSERT A 1.6 MM THICKNESS
GAUGE.
6. TURN THE ADJUSTING SCREW TO THE LEFT UNTIL THE SCREEN DISPLAY CHANGES FROM "L"
TO "H".
7. THEN, TURN THE ADJUSTING SCREW TO THE RIGHT UNTIL THE SCREEN DISPLAY CHANGES
FROM "H" TO "L".
8. CHECK IF THE LCD SCREEN SHOWS "H" WHEN THE CLEARENCE OF THE BUTTONHOLE FOOT IS
1.4 MM AND "L" WHEN THE CLEARENCE IS 1.8 MM.
9. TURN OFF THE POWER SWITCH.
10.INSTALL THE FACE COVER.
NOTE
IF THERE IS ANY LINT IN THE BUTTONHOLE SENSOR SLIT, CLEAN OUT WITH A SWAB.
LEFT (LCD SCREEN) RIGHT

Step4 Sensor Step4 Sensor Step4 Sensor
< <
BH:H BS:L FS:L BH:L BS:L FS:L BH:H BS:L FS:L
(3) (2) (1)
LEFT RIGHT
SENSOR PLATE (E)

BH LEVER GUIDE (B)
SETSCREW (D)
BH SENSOR
SETSCREW (A)
BH LEVER (C) (1.6 MM)
BH FOOT "R"
28
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.
1. OPEN THE FACE COVER AND RAISE THE PRESSER FOOT.

LOOSEN THE SETSCREW TO ADJUST THE PRESSER FOOT HEIGHT (6.0 MM) AND THE PRESSER
FOOT ALIGNMENT.
2. TIGHTEN THE SETSCREW FIRMLY.
3. CLOSE THE FACE COVER.
SETSCREW 4X8
PRESSER BAR
LIFTER
[HEIGHT OF PRESSER FOOT]

PRESSER FOOT
[PRESSER FOOT ALIGNMENT]
NEEDLE PLATE
SHOULD BE
PARALLEL
FEED DOG
29
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.
NOTE:
AFTER CHANGING THE NEEDLE THREAD TENSION UNIT, CHECK THE MECHANICAL ADJUSTMENT, "TENSION
RELEASE MECHANISM".
SCREW (A)
NEEDLE THREAD TENSION UNIT (C)
SCREW (B)
30
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.
2. LOOSEN THE SCREW AND REMOVE THE THREADER PLATE (FIG. A).
TO CHANGE THE NEEDLE THREADER:

1. IF THE HOOK OF THE THREADER PLATE TOUCHES LEFT OR RIGHT SIDE OF THE NEEDLE EYE,
LOOSEN THE SCREW AND ADJUST THE HOOK POSITION (FIG. B).
2. IF THE HOOK OF THE THREADER PLATE TOUCHES THE TOP OR BOTTOM SIDE OF THE NEEDLE
EYE, LOOSEN THE SCREW AND ADJUST THE HOOK POSITION (FIG. C).
TO CHANGE THE THREADER PLATE (FIG. A)
THREADER KNOB
THREADER PLATE
SCREW
HOOK
ADJUST THE DIRECTION OF LEFT OR RIGHT

(FIG. C) ADJUST THE DIRECTION OF LEFT OR RIGHT
(FIG. B)
POSITION SETTING
THREADER PLATE
PLATE
31
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. GRASP THE CONNECTOR DIRECTORY WITH YOUR FINGERS AND PULL.
DO NOT PULL ON THE LEAD WIRE, AS THIS WAY DAMAGE THE CONTACT SLEEVE INSIDE
THE CONNECTOR.
2. WHEN DISCONNECTING THE MACHINE SOCKET AND POWER TRANSFORMER
CONNECTORS, PULL THEM WHILE PUSHING THEM TOWARD THE A BOARD TO UNLOCK
THEM.
TO INSTALL:
4. TO INSTALL, FOLLOW THE ABOVE PROCEDURE IN REVERSE.
NOTE:
WHEN INSTALLING BOARD "A" IN THE MACHINE.
THE TRANSFORMER WIRE SHOULD NOT PASS OVER THE CAPACITOR WHEN BOARD "A" IS
INSTALLED.
IF THE CORD IS RESTING ON THE CAPACITOR, IT MAY INTERFERE THE PATTERN
SELECTOR BUTTON AFTER THE FRONT COVER IS INSTALLED.
PRINTED CIRCUIT BOARD F"
SETSCREW
SETSCREW
PRINTED CIRCUIT
BOARD "A"
SETSCREW
SETSCREW
CAPACITOR
SLIDE VOLUME THE TRANSFORMER

CONNECTOR CORD SHOULD NOT
PASS OVER THE
CAPACITOR WHEN
BOARD "A" IS
INSTALLED.
SETSCREWS
SETSCREWS
32
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:
PRINTED CIRCUIT "F" BOARD

CONNECTOR
PRINTED
CIRCUIT
BOARD F
SETSCREWS
(2)
33
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.
TO ATTACH:
6 FOLLOW THE PROCEDURE ABOVE IN REVERSE.
SLIDE VOLUME
CONNECTOR
SLIDE VOLUME
CS RINGS (2)
34
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.
TO ATTACH:
3. SET THE MOTOR IN MACHINE AND REPLACE SCREW (A) AND (B).
4. INSERT THE MOTOR CONNECTOR INTO THE CONNECTOR POST (E) ON THE A-BOARD.
5. REPLACE THE MOTOR BELT.
6. MOVE THE MOTOR MOUNTING BLANKET (C) UP AND DOWN WHILE APPLYING APPROXIMATELY
300 GRAMS PRESSURE IN THE MIDDLE OF THE BELT, IT SHOULD DEFLECT 7 TO 9 MM WHEN SET
PROPERLY.
7. TIGHTEN THE SETSCREWS.
8. ATTACH THE FRONT COVER.
BELT
PRESSURE 300G
BELT DEFLECTION:
7~9 MM
DC MOTOR
SETSCREWS (2)
SETSCREWS (2)
35
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".
3. REMOVE THE FUSE (PRY UP THE FUSE WITH A SCREWDRIVER).
FUSE NO. PART NO. TYPE/SPECIFICATION

F1 000-144-605 TSD-2.5A-250V
5.2 X 20 MM 2.5A TIME-LAG FUSE
NOTE:
1. REPLACE THE PRINTED CIRCUIT BOARD "A" IF YOU NOTICE ANY BROWNING,
DISCOLORATION, OR OTHER ABNORMALITIES.
2. ONLY INSTALL FUSES WITH THE CORRECT RATING.
IF THE FUSE IS LOOSE, BEND THE FUSE CLIPS INWARD TO SECURE THE FUSE.
PRINTED CIRCUIT BOARD "A"
FUSE
NUT
FUSE HOLDER
F1
AC 250V 2.5A
COVER OF PRINTED SETSCREWS (4)

CIRCUIT BOARD "A"
36
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.
NOTE:
PULL OUT THE CORD IN FRONT OF THE ARM TO PREVENT IT FROM CONTACTING
WITH THE LOWER SHAFT OR OTHER MOVING PARTS, AND SECURE IT TO THE FEED
MOTOR CORD WITH A BINDER.
SETSCREW
SETSCREW
MACHINE
SOCKET
37
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.
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 ANY MOVING PARTS.
TRANSFORMER
SETSCREW
SETSCREW
38
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).
4. REMOVE THE TWO SETSCREWS (C) AND REMOVE THE ZIGZAG WIDTH MOTOR.
TO INSTALL:
5. TO INSTALL THE ZIGZAG WIDTH MOTOR, FOLLOW THE ABOVE PROCEDURE IN REVERSE.
NOTE:
1. THE SETSCREW OF ZIGZAG ROD SHOULD BE TIGHTENED TO 5~7 KGF OF TORQUE.
2. CHECK TO ENSURE THAT THE UPPER SHAFT SENSOR MOUNTED ON THE ZIGZAG WIDTH
MOTOR DOES NOT INTERFERE WITH THE UPPER SHAFT SHIELD PLATE.
3. ADJUST THE NEEDLE DROP POSITION (SEE PAGE 19).
ZIGZAG WIDTH MOTOR SETSCREW (A) 2 SETSCREW (B)

PROTECTOR PLATE BINDER
SETSCREW (A) ZIGZAG WIDTH

MOTOR
ZIGZAG WIDTH SETSCREW (B)
SETSCREW (C)
ZIGZAG WIDTH
MOTOR SETSCREW (C)
39
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.
CUT OFF THE CORD BINDER.
TO INSTALL:
TO INSTALL THE FEED MOTOR, FOLLOW THE ABOVE PROCEDURE IN
REVERSE.
NOTE:
ADJUST THE STRETCH STITCH PATTERNS (SEE PAGE 26).
ACCESS SETSCREW (B)

THROUGH THIS HOLE
BINDER
SETSCREW (B)
SETSCREW (A)
SNAP RING
FEED MOTOR (E-3)
SNAP RING (E-3)
40
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.
3. TIGHTEN THE SETSCREW.
4. INSTALL THE FRONT COVER.
TO CONFIRM:
TURN THE POWER SWITCH ON.
BOBBIN
THE LED DISPLAYS WINDING WHEN THE BOBBIN WINDER SPINDLE IS SET THE BOBBIN
WINDING POSITION, AND DISPLAYS SEWING STITCH PATTERN SELECTION WHEN THE BOBBIN
WINDER IS RETURNED TO THE SEWING POSITION.
BOBBIN
WINDING
SETSCREW
APPROX.
0.7 TO 1.3mm BOBBIN WINDING
SWITCH FIXING
PLATE
BOBBIN WINDER ARM
41
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.
GREASE:
USE WHITE GREASE SUCH AS MOLYCOTE EM-40M AT THE POINTS (L& M) INDICATED BY
THE WHITE ARROWS.
D
F
H
K
J M L I
42

DC 5100

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SERVICE MANUAL

LOCATE AND IDENTIFY THE PARTS ............................................................................................................... 1

LOCATE AND IDENTIFY THE PARTS

THREAD TAKE-UP LEVER SCREEN BRIGHTNESS

UP/DOWN NEEDLE POSITION

HOOK COVER PLATE RELEASE

BOBBIN WINDER SPINDLE

HANDWHEEL PRESSER FOOT LIFTER

FEED DOG DROP LEVER

MACHINE SOCKETS NOMENCLATURE PLATE

WINDING THE BOBBIN

INSERTING THE BOBBIN

PLACE THE BOBBIN IN THE BOBBIN HOLDER WITH THE

GUIDE THE THREAD INTO THE NOTCH (A) ON THE FRONT

CONTINUE TO DRAW THE THREAD LIGHTLY UNTIL THE

CHECK THE THREADING BY REFERRING TO THE CHART

THREADING THE MACHINE

EACH CONNECTOR SHOULD BE CONNECTED AS FOLLOWS;

GENERAL TROUBLE SHOOTING PROCEDURE

(MACHINE DOESNT WORK WELL)

IS NEEDLE SET OK?

MECHANICAL ELECTRICAL CANT JUDGE

ELECTRIC QUICK CHECK

CONDITION CAUSE HOW TO FIX REFERENCE

1. SKIPPING 1. NEEDLE IS NOT INSERTED INSERT THE NEEDLE PROPERLY.

2. NEEDLE IS BENT OR WORN. CHANGE THE NEEDLE.

3. INCORRECTLY THREADED. RETHREAD.

4. NEEDLE OR THREAD ARE USE THE RECOMMENDED

5. SEWING ON STRETCH USE A #11 BLUE TIP NEEDLE.

6. INAPPROPRIATE NEEDLE SEE MECHANICAL ADJUSTMENT P. 19

7. INAPPROPRIATE NEEDLE SEE MECHANICAL ADJUSTMENT P. 20

8. INAPPROPRIATE NEEDLE SEE MECHANICAL ADJUSTMENT P. 21

2. FABRIC NOT 1. INCORRECT FEED DOG HEIGHT. SEE MECHANICAL

2. FEED DOG IS IN DOWN RAISE THE FEED DOG.

3. THREAD ON BOTTOM SIDE OF MAKE SURE TO BRING BOTH

4. FEED DOG TEETH ARE WORN. CHANGE THE FEED DOG.

CONDITION CAUSE HOW TO FIX REFERENCE

3. BREAKING 1. INITIAL SEWING SPEED IS START WITH MEDIUM SPEED.

3. NEEDLE IS BENT OR DULL. REPLACE WITH A NEW NEEDLE.

4. UPPER THREAD TENSION IS ADJUST NEEDLE THREAD TENSION P. 27

5. NEEDLE SIZE IS USE APPROPRIATE NEEDLE FOR

6. NEEDLE EYE IS WORN. CHANGE THE NEEDLE.

7. NEEDLE HOLE IN NEEDLE REPAIR THE HOLE OR REPLACE

4. BREAKING 1. INCORRECTLY THREADED THREAD BOBBIN CORRECTLY.

3. LINT IS STUCK INSIDE THE CLEAN THE BOBBIN HOLDER.

4. THREAD QUALITY IS CHANGE TO A HIGH QUALITY

5. THREAD IS JAMMING CLEAR OUT THE JAMMING THREAD.

5. NEEDLE 1. NEEDLE IS HITTING THE SEE MECHANICAL P. 18

3. NEEDLE IS HITTING THE HOOK. SEE MECHANICAL ADJUSTMENT P. 21

4. THE FABRIC MOVES WHILE SEE MECHANICAL ADJUSTMENT P. 24

5. FABRIC IS BEING PULLED TOO GUIDE THE FABRIC GENTLY

CONDITION CAUSE HOW TO FIX REFERENCE

6. NOISY 1. BACKLASH BETWEEN HOOK SEE MECHANICAL ADJUSTMENT P. 22

2. LOWER SHAFT GEAR IS ELIMINATE THE LOOSENESS.

3. INAPPROPRIATE BELT SEE REPLACING DC MOTOR AND P. 35

4. NOT ENOUGH OIL. OIL ALL MOVING PARTS. P. 42

7. DEFORMATION 1. INAPPROPRIATE FEED SEE MECHANICAL ADJUSTMENT P. 26

3. UPPER THREAD TENSION SEE MECHANICAL ADJUSTMENT P. 27

SELF DIAGNOSTIC TESTS

THE SEWING MACHINE LIGHT DOES NOT LIGHT UP.

THE LCD SCREEN DOES NOT DISPLAY.

THEN PRESS THE 01 BUTTON WITHIN 3 SECONDS

TO ENTER THE SELF-DIAGNOSTIC MODE.