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Servicing Manual & Parts List
Model 5100

TABLE OF CONTENTS
WHAT TO DO WHEN ................................................................................................. 1-3 SERVICE ACCESS (1) FACE COVER ......................................................................... 4 SERVICE ACCESS (2) BED COVER ........................................................................... 5 SERVICE ACCESS (3)(4) FRONT COVER ............................................................... 6-7 SERVICE ACCESS (5) REAR COVER ......................................................................... 8 MECHANICAL ADJUSTMENT PRESSER BAR HEIGHT AND ALIGNMENT ................................................................ 9 NEEDLE DROP POSITION ........................................................................................ 10 NEEDLE TO SHUTTLE TIMING ................................................................................. 11 NEEDLE BAR HEIGHT ............................................................................................... 12 NEEDLE CLEARANCE TO SHUTTLE ....................................................................... 13 BACKLASH (BETWEEN LOWER SHAFT GEAR AND SHUTTLE HOOK GEAR) ..... 14 FEED DOG HEIGHT ................................................................................................... 15 ZIGZAG SYNCHRONIZATION ................................................................................... 16 NEEDLE THREAD TENSION ..................................................................................... 17 STRETCH STITCH FEED BALANCE ......................................................................... 18 REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE ......... 19 CONNECTOR DIAGRAM ........................................................................................... 20 SELF DIAGNOSTIC TESTS ....................................................................................... 21 SELF DIAGNOSTIC SHEET .................................................................................. 22-25 REPLACING PRINTED CIRCUIT BOARD A .............................................................. 26 REPLACING SLIDE VOLUME AND PRINTED CIRCUIT BOARD F .......................... 27 REPLACING DC MOTOR AND ADJUSTING MOTOR BELT TENSION .................... 28 REPLACING THE FUSES .......................................................................................... 29 REPLACING MACHINE SOCKET (UNIT) .................................................................. 30 REPLACING THE TRANSFORMER .......................................................................... 31 REPLACING THE ZIGZAG WIDTH MOTOR .............................................................. 32 REPLACING THE FEED STITCH MOTOR ................................................................ 33 ADJUSTING BUTTONHOLE LEVER POSITION ....................................................... 34 ADJUSTING THE BOBBIN WINDER SWITCH .......................................................... 35 OILING ........................................................................................................................ 36 PARTS LIST ........................................................................................................... 37-54

MODEL 5100

WHAT TO DO WHEN
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. Presser foot pressure is too weak. 7. Inappropriate needle bar height.

Insert the needle properly. Change the needle. Rethread. Use the recommended sewing needle and thread.

Use a #11 blue tip needle. Adjust the presser bar level to make the pressure stronger. See mechanical adjustment "Needle bar height". See mechanical adjustment "Needle to shuttle timing". See mechanical adjustment "Clearance between needle and hook". p. 12

8. Inappropriate needle to shuttle timing. 9. Inappropriate needle to shuttle clearance.

p. 11

p. 13

2. Fabric not moving

1. Presser foot pressure is too weak. 2. Incorrect f.d. Height.

Adjust the presser bar level to make the pressure stronger. See mechanical adjustment "feed dog height". Raise the feed dog Level. Make sure to bring both needle and bobbin thread under the foot when starting sewing. Change the feed dog. p. 15

3. Feed dog Is in down position. 4. Thread on bottom side of fabric is jammed up.

5. Feed dog teeth are worn.

1

MODEL 5100

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. p. 17

Use appropriate needle for fabric and thread in use. Change the needle. Repair the hole or replace the needle plate. Thread bobbin correctly. Adjust the position of stopper.

4. Breaking bobbin thread

1. Incorrectly threaded bobbin. 2. Too much thread is around on the bobbin. 3. Lint is stuck inside the bobbin holder. 4. Thread quality is too low. 5. Thread is jamming around the bobbin.

Clean the shuttle.

Change to a high quality sewing thread. Clear out the jamming thread.

5. Needle breaks

1. Needle is hitting the needle plate.

See mechanical adjustment "needle drop position". Change the needle. See mechanical adjustment "Clearance between needle and hook".

p. 10

2. Needle is bent or worn. 3. Needle is hitting the shuttle.

p. 13

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 "Zigzag synchronization".

p. 16

Guide the fabric gently while sewing.

2

MODEL 5100

CONDITION

CAUSE

HOW TO FIX

REFERENCE

6. Noisy operation

1. Backlash between shuttle hook gear and lower shaft gear is too great. 2. Lower shaft gear is loose. 3. Inappropriate belt tension.

See mechanical adjustment "Backlash (lower shaft gear)".

p. 14

Eliminate the looseness. See part removal and replacement "driving motor (DC motor)". Oil all moving parts. p. 28

4. Not enough oil.

p. 36

7. Deformation pattern

1. Inappropriate feed balance.

See mechanical adjustment "Stretch stitch feed balance".

p. 18

2. Inappropriate zigzag synchronization. 3. Upper thread tension is too strong.

See mechanical adjustment "Zigzag synchronization". See mechanical adjustment "Needle thread tension".

p. 16

p. 17

3

MODEL 5100

SERVICE ACCESS (1)
FACE COVER
TO REMOVE: 1. Remove the cap. 2. Remove the setscrew (A) and remove the face cover. TO INSTALL: 3. Insert the three ribs and the hook on the face cover into the rear cover . Tighten the setscrew (A) and attach the cap.

Face cover

Setscrew (A)

Ribs

Cap

Hook

4

MODEL 5100

SERVICE ACCESS (2)
BED COVER
TO REMOVE: 1. Set the drop lever to the left and remove the three setscrews (A), remove the bed cover. TO INSTALL: 2. Set the drop lever to the left and install the bed cover. Secure it in place with the three setscrews (A).

Setscrew (A)

Setscrew (A)

Bed cover

Drop lever

Setscrew (A)

5

MODEL 5100

SERVICE ACCESS (3)
FRONT COVER
TO REMOVE: 1. Remove the face cover and bed cover (see pages 4 and 5). 2. Loosen the setscrews (A) and then remove the setscrew (B), (C), (D), (E) and (F). 3. Remove the front cover (see page 20) and disconnect each switch connector. NOTES: TO DISCONNECT THE CONNECTORS: Grasp the connector directly with your fingers and pull. Do not pull on the lead wire, as this may damage the contact sleeve inside the connector. TO INSTALL: 4. To install the front cover, follow the above procedure in reverse. NOTES: TO CONNECT THE CONNECTORS: 1. Insert each connector into the connector post (on the printed circuit board) which has the same color as that of the connector. 2. Insert the connector at the right angle. Then push it straight down until it locks in place.

Setscrew (C)

Setscrew (D)

Setscrew (A) Setscrew (B) Front cover Setscrew (F)

Setscrew (E)

6

MODEL 5100

SERVICE ACCESS (4)
HOW TO REMOVE THE FRONT COVER
1. Remove the hooks on the front cover and the rear cover (indicated by the white arrows) and the hook on the base. 2. Remove the feed balancing dial. 3. Remove the machine socket, and then remove the front cover. * Remove the setscrews (G) and (H) from the rear cover to remove the machine socket easily,

Machine socket

Feed balancing dial

Setscrew (G)

Setscrew (H)

7

MODEL 5100

SERVICE ACCESS (5)
REAR COVER
TO REMOVE: 1. Remove the front cover (see pages 6 and 7). 2. Loosen the setscrews (A), (B), (C), (D) and (E). * To remove the cover, detach the presser foot lifter section first, with the presser foot lifter in the down position. TO INSTALL: 3. Follow the above procedure in reverse.

Rea cover Setscrew (B)

Presser foot lifter

Setscrew (A)

Setscrew (C) Setscrew (D) Setscrew (E)

8

MODEL 5100

MECHANICAL ADJUSTMENT
PRESSER BAR HEIGHT AND ALIGNMENT
When the presser foot is raised, the clearance between the presser foot and the needle plate should be 6.0 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. Remove 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. Install the face cover.

Setscrew 4x8 Presser bar lifter

[Height of presser foot] Presser foot [Presser foot alignment]

Needle plate

6.0 mm

Should be parallel

Feed dog

9

MODEL 5100

MECHANICAL ADJUSTMENT
NEEDLE DROP POSITION
Set the stitch pattern at " "; the standard needle drop position should be at the center of the needle plate ", the distance between both ends of the needle hole on

hole. When the needle swings in maximum zigzag width "

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, remove 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 install the face cover.

Setscrew 3x4 Eccentric pin

Needle plate hole

Eccentric pin position (Off -center head)

Adjust the needle drop position by turning the eccentric pin as

0.2 mm or more

0.2 mm or more

A=B

10

MODEL 5100

MECHANICAL ADJUSTMENT
NEEDLE TO SHUTTLE 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 thestraight 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

3.25-3.55 mm Lower needle position

11

MODEL 5100

MECHANICAL ADJUSTMENT
NEEDLE BAR HEIGHT
The distance between the upper edge of needle eye and the tip of the hook should be in the range of 1.6-2.0 mm when the tip of hook meets the right side of the needle in ascending travel of needle from its left and lowest poosition. 1. Remove the needle plate and bobbin holder. 2. 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

Hook race unit

Upper edge of needle eye

12

MODEL 5100

MECHANICAL ADJUSTMENT
NEEDLE CLEARANCE TO SHUTTLE
The clearance between the needle and the tip of hook should be -0.1 to +0.05 mm. PREPARATION: 1. Remove the needle plate, bobbin holder, and bed cover, and replace the needle with the test pin (B). 2. Turn the power switch on, and select pattern " " (simple zigzag). (Maximum zigzag width) ADJUSTMENT PROCEDURE: 1. Loosen the screws (A), (B), (C), then slightly tighten the hing screw (C). 2. Turn the handwheel toward you, and adjust the clearance between master needle and the point of the hook in the left and right needle position to 0.1 to +0.05 mm by moving the hook in the left and right by moving the hook set plate up or down. 3. Tighten the setscrews (A), (B), (C). 4. Check the backlash of the hook drive, gear and lower shaft gear. If the backlash is too great or not enough, adjust the backlash in accordance with "to adjust the backlash of hook drive gear and lower shaft gear". 5. Attach the bed cover, needle plate and bobbin holder, and remove the master needle.

Test pin (D)

Point of hook 0.1 to +0.05 mm

Hinge screw (C)

Hook set plate (E)

Setscrew (B) Setscrew (A)

13

MODEL 5100

MECHANICAL ADJUSTMENT
BACKLASH (BETWEEN LOWER SHAFT GEAR AND SHUTTLE 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 play excess 0.8 mm, adjust as follows. ADJUSTMENT: 1. Remove the bed cover (see page 5). 2. Loosen the setscrew. 3. Turn the lower shaft bushing (eccentric bushing) clockwise (B) if there is too much play in the shuttle hook. Turn the lower shaft bushing (eccentric bushing) counterclockwise (A) if there is too little play in the shuttle 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 shuttle timing and the feed dog height.

Backlash allowance

Point of shuttle hook Check the backlash

Setscrew

Groove

Shuttle hook gear Lower shaft gear Groove on the lower shaft bushing

B

A

14

MODEL 5100

MECHANICAL ADJUSTMENT
FEED DOG HEIGHT
The highest position of the feed dog should be between 0.8 to 0.9 mm from the surface of the needle plate when the pressure dial is set at "3" and the presser foot is raised. 1. Set the pressure dial at "3" and 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

(to raise)

Setscrew (A) Nut (B)

(to lower)

Adjusting screw (C)

15

MODEL 5100

MECHANICAL ADJUSTMENT
ZIGZAG SYNCHRONIZATION
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 7). 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

B

A

Upper shaft sensor

16

MODEL 5100

MECHANICAL ADJUSTMENT
NEEDLE THREAD TENSION
The standard tension should be 75 to 90 grams when the tension dial is set at "4", measured with a #50 white polyester thread being pulled at approximately 110 mm/sec. If the tension is outside the standard range, adjust as follows: ADJUSTMENT: 1. Set the thread tension dial to "4" and check the thread tension. 2. Remove the face cover (see page 4). 3. If the tension is outside the standard range, turn the dial to find a position where the correct tension is obtained. 4. Insert a screwdriver into the slit on the shaft and push it until the tension dial is disengaged from the shaft. 5. While holding the shaft in place with the screwdriver, turn the dial back to position "4" and engage it with the shaft. 6. Remove the screwdriver. 7. Check the thread tension to confirm that it is correct, then install the face cover.

Shaft

Pull the thread at a speed of approx. 110 mm/sec. In the direction of arrow. Thread (polyester sewing thread (#50 white))

Set the thread tension dial

17

MODEL 5100

MECHANICAL ADJUSTMENT
STRETCH STITCH FEED BALANCE
When a stretch stitch pattern is sewn with the feed balancing dial position set at the standard setting mark " stitch pattern should look like the one marked with a " " (A=B) in the diagram below. If forward and backward feeding is unbalanced (A.B or A,B), adjust as follows. ADJUSTMENT PROCEDURE: 1. Turn the power switch on and select the stitch pattern " ", the

". " on the front cover.

2. Set the slit of the feed balancing dial to the standard setting mark " 3. Put a piece of paper under the presser foot and lower it.

Turning the handwheel toward you, and check the needle mark at "A" and "B". 4. Remove the cap. 5. If A>B, turn the adjusting screw counterclockwise "C". 6. When A
Feed balancing dial

Standard setting mark

Indication line

Cap

Adjusting screw

F

G

18

MODEL 5100

MECHANICAL ADJUSTMENT
REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE
If the hook of the threader plate is damaged, change or adjust the part as follows: TO CHANGE THE THREADER PLATE: TO REMOVE: 1. Push down the needle threader knob and pull the needle threader plate (A) down to remove it (see FIG 1). 2. To install the needle threader plate, line the groove up with the pin (B) and push it up to snap fit. TO ADJUST THE THREADER PLATE POSITION: 1. If the hook on the threader plate touches the left or right side of the needle guide, loosen setscrew (C) and adjust the hook position (FIG 2). 2. If the hook on the threader plate touches the top or bottom side of the needle guide, loosen setscrew (D) and adjust the hook position (FIG.3)

Replacing the needle threader cover (with the threader plate attached

FIG. 1

Pin (B) Threader plate supporter (A) Threader knob Needle hole Hook

Vertical adjustment

FIG. 3

Adjustment of left or right direction FIG. 2

Setscrew (D)

Threader plate

View from "X"
Setscrew (C)

Nut
Threader position set plate

X

19

MODEL 5100

CONNECTOR DIAGRAM
Refer to the diagram for locating the connector posts to which each connectors should be connected. NOTE: TO DISCONNECT THE CONNECTORS: 1. Grasp the connector directly with your fingers and pull. Do not pull the lead wire, as this may damage the contact sleeve inside the connector. 2. When disconnecting the machine socket and power transformer connectors, pull them while pushing them toward the printed circuit board to unlock them. NOTE: TO CONNECT THE CONNECTORS: 1. Be sure that the color of each connector corresponds to the color of the connector post on the printed circuit board (PCB) to which it is connected. 2. Position the connector correctly, then push it straight down until it locks in place.

Slide volume Bobin winder switch Printed circuit board "F"

Lamp Upper shaft sensor

Machine socket (Secondary)

Buttonhole sensor

Zigzag width motor

Feed motor

Power transformer (Secondary) DC motor

Machine plug (Primary circuit)

Power transformer (Primary circuit)

20

MODEL 5100

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. * Connect the foot controller to the machine. NOTE: * Be careful: The sewing machine may start running in 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. * You can skip steps in the diagnostic procedure and go directly to the test you want to perform. (Enter self-diagnostic mode, then press the #01 button until the step number of the required test is indicated.) PRELIMINARY TEST: Turn on the power switch. If any of following problems occur, take the recommended 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 machine socket. 5. Replace the power transformer. * The sewing machine light does not light up. 1. Replace the lamp. 2. Replace printed circuit board "A". * The display shows " " to " ", 1. Replace the printed circuit board "A".

TO ENTER THE SELF-DIAGNOSTIC MODE:
If you do not press the next button within 2.5 sec, the machine will revert to normal sewing mode. Should this occur, start over again from step no. 1.

NO.1
Turn the power switch on while simultaneously pressing the #01 button and the #16 button.

NO.2
Press the #16 button five times to select menu item "6".

NO.3
Press the #01 button.

21

MODEL 5100

SELF DIAGNOSTIC SHEET
STEP AND ITEMS TO CHECK
Turn on the power switch while simultanously pressing the #01 button 7-segment led and the #16 button. Press the #16 button five times to select menu item "6". Press the #01 button: The led indicates "01" for one second. If you don't press the #16 button within 2.5 seconds, the machine automatically reverts to normal sewing mode.

PROCEDURE

CORRECT RESULTS

DEFECTIVE RESULTS

01)

* Beep sounds when the buttons are pressed. * Led displays " 8.8", and blinks in 1-sec. Intervals. LED

* No beep sound. * Does not enter self-diagnostic mode. * Led does not blink on or off. 1. Replace board "A".

02)
Mode led

Press #01 button, led displays "02" for one second.

7- segment led displays "Ld" 3 mode leds blink in 1-sec. Intervals. LED

* Led does not blink.

1. Replace board "A".

03)
Switch

Press #01 button, led displays "03" for one second. Press buttons S1 to S3.

* Led indicates "--".

* Led display is different from that shown to the left.

Button S1 S2 S3

* Button number is displayed when the button is pressed.

1. Replace board "A".

04)
Bobbin winder switch

Press #01 button, led displays "04" for one second. * Move the bobbin winder spindle to the right. * Return it to the left.

* Led indicates "II".

(At left position)

(At right position)

* Led display is different from that shown to the left. 1. Adjust bobbin winder switch position. 2. Replace bobbin winder switch. 3. Replace board "A".

05)
Not applicable to this model

Skip this step by pressing the #01 button.

22

MODEL 5100

STEP 06)
Buttonhole sensor

OPERATION
Press #01 button, led displays "06" for one second. 1. Lower the buttonhole lever. 2. Move the buttonhole lever back and forth.

CORRECT CONDITION

DEFECTIVE CONDITION
Led display is different from that shown to the left. 1. Adjust the buttonhole sensor position. 2. Replace buttonhole sensor. 3. Replace board "A".

* When the buttonhole lever is pulled, led displays "H". * When the buttonhole lever is free (positioned in the center), led displays "L". * When the buttonhole lever is pushed, led displays "H".

07)
Upper shaft sensor

Press the #01 button, led displays "07" for one second.

* When the needle is at the highest position, led displays "LH".

* Led display is different from that shown to the left.

* Turn the handwheel toward you to raise and lower the needle to its highest * When the needle is at and lowest position. the lowest position, led displays "LH". * When the needle is halfway, led displays "LL".

1. Adjust upper shaft shield plate. 2. Replace upper shaft sensor. 3. Replace board "A".

08)
Sewing speed sensor

* Press the #01 button. Led displays "08" for one second.

* Led displays "00" first and the indicates value increases as you turn the handwheel.

* Led displays different from that shown to the left. 1. Replace motor. 2. Replace board "A".

* Turn the handwheel clockwise by hand and check the counter value displayed (When the value by the leds. reaches 100, it will return to "00" and one mode led lights up. For example, 2 mode leds and "78" means "278".) The maximum value should be 370 to 390.

23

MODEL 5100

STEP 09)
Slide volume

OPERATION
Press #01 button, led displays "09" for one second. Slide the speed control lever from the left to the right, then return it to the left.

CORECT CONDITION

DEFECTIVE CONDITION

When the speed control lever is at the left, * Led display is different from that led displays "00". shown to the left. 1. Replace slide volume. The indicated value 2. Replace board "A". (hexadecimal) increases as you move thew speed control lever to the right, and finally it shows "FF" when the lever reaches the right-most position.

10)
Foot controller

Press #01 button, the led displays "10" for one second. Depress the foot controller down all the way and release.

When the foot control is not depressed, led should display "F0" to "FF" (hexadecimal value). When the foot control is fully depressed, led should display "05" to "2F". When the control is disconnected, led should show "00" to "04".

* Led display is different from that shown to the left.

1. Replace foot control. 2. Replace machine socket. 3. Replace board "A".

11)
Zigzag width motor

Press the #01 button, the led displays "11" for one second. * Press the #16 button.

* Led displays "bs".

* Led display is dtfferent from that shown to the left.

Zigzag width motor is set to the initial position. (Needle centered)

If led displays "E1", width motor or board "A".

Feed motor

Turn the handwheel toward you to * Led displays lower the needle to its lowest position, then press #16 button. Feed motor is set to the initial position. (Stitch length : 0)

* Led display is different from that shown to the left.

If led displays "E2", replace motor or board "A".

24

MODEL 5100

STEP 12)
DC motor

OPERATION

CORECT CONDITION

DEFECTIVE CONDITION
Machine does not run, led displays "Lo".

Press needle up/down button, led * Led indicates "dc". indicates "12" for one swcond. * Machine runs at the speed set by * Press foot control. the speed control lever.

Full left: 80 ~100 SPM Full right: 800 ~840 SPM

1. Replace DC motor. 2. Replace board "A".

THE END OF TEST: All of test is finished, turn off the power switch.

25

MODEL 5100

REPLACING PRINTED CIRCUIT BOARD A
TO REMOVE:
1. Remove the front cover (see page 6-7). 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 directly with your fingers and pull. Do not pull on the lead wire, as this may 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.

Slide volume connector Setscrew

Printed circuit board "F" Setscrew

Printed circuit board "A"

Setscrew

Capacitor Setscrew The transformer cord should not pass over the capacitor when board "A" is installed.

Setscrew

Setscrew

26

MODEL 5100

REPLACING SLIDE VOLUME AND PRINTED CIRCUIT BOARD F
REPLACING THE SLIDE VOLUME
TO REMOVE: 1. Remove the front cover unit (see page 6-7). 2. Unplug the slide volume connector. 3. Remove the four cs ring (A), (B) and remove the side volume. TO INSTALL: 4. To install the slide volume, follow the above procedure in reverse. * Secure the lead wire on the board using the cs rings, as shown. * Check to ensure that the slide volume moves smoothly back and forth.

REPLACING PRINTED CIRCUIT BOARD "F"
TO REMOVE: 5. Remove the front cover unit. 6. Unplug the printed circuit board "F" connector and remove the three cs rings (B), (C). 7. Remove the two setscrews and remove the printed circuit board "F". TO INSTALL: To install the printed circuit board "F". Follow the above procedure in reverse. * Secure the lead wire on the board using the cs ring, as shown. * Each button (needle up/down button, start/stop button, reverse button) should "click" when pressed.

Slide volume connector

Printed circuit board "F" connector CS rings (B)

CS rings (C) Printed circuit board "F"

Setscrews (2)

CS rings (A)

Slide volume control

27

MODEL 5100

REPLACING DC MOTOR AND ADJUSTING MOTOR BELT TENSION
TO REMOVE: 1. Remove the front and rear covers (see page 6 - 8). 2. Remove the two setscrews, then remove the DC motor and belt. TO INSTALL: 3. Lightly tighten the two screws. 4. Put the motor belt on the pulley and adjust the belt deflection to about 7 to 9 mm by pressing the middle of the motor belt with your finger (with approximately 300 grams of pressure). Then, tighten the screws firmly. 5. Install the front and rear covers.

Belt

Pressure 300g Belt tension: 7~9 mm

DC motor Setscrew

28

MODEL 5100

REPLACING THE FUSES
REPLACING THE FUSES
TO REMOVE: 1. Remove the front cover (see page 6-7). 2. Remove the four setscrews and lift off the cover on printed circuit board "A". 3. Remove the fuse. (Pry it out with a screwdriver). TO INSTALL: 4. Follow the above procedure in reverse. FUSE NO. F1, F3 F2
PART NO. 000-144-605 000-182-904

TYPE/SPECIFICATION TSD-2.5A-250V 5.2 X 20 MM 2.5 A TIME-LAG FUSE 3.15A-250V 5.2 X20 MM 3.15A TIME-RUG 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. 3. If the fuse is loose, bend the fuse clips inward to secure the fuse.

Printed circuit board "A"

F3. AC250V 2.5A

F2. AC250V 3.15A

F1. AC250V 2.5A

Fuse

Fuse holder Printed circuit board "A" case Setscrews (4)

29

MODEL 5100

REPLACING MACHINE SOCKET (UNIT)
REPLACING THE MACHINE SOCKET
TO REMOVE: 1. Remove the front and rear cover (see page 6 - 8). 2. Remove the two screws 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

30

MODEL 5100

REPLACING THE TRANSFORMER
REPLACING THE TRANSFORMER
TO REMOVE: 1. Remove the front cover (see page 6-7). 2. Remove the two setscrews and remove the transformer. Cut off the binder. 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 with any moving parts.

Transformer

Setscrew

Setscrew

31

MODEL 5100

REPLACING THE ZIGZAG WIDTH MOTOR
REPLACING THE ZIGZAG WIDTH MOTOR
TO REMOVE:

1. Remove the front and rear cover (see page 6 - 8).
2. Remove the two zigzag rod setscrews (A). 3. Remove the two setscrews (B) and remove the zigzag width motor. TO INSTALL: 4. 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 kg 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 10).

2 setscrew (A)

Zigzag width motor

Zigzag width setscrew (A) Setscrew (B)

Zigzag width motor Setscrew (B)

32

MODEL 5100

REPLACING THE FEED STITCH MOTOR
REPLACING THE FEED MOTOR
TO REMOVE: 1. Remove the front cover and rear covers (see page 6 - 8). 2. Remove the snap ring (E-3). 3. Remove the two setscrews and remove the feed motor. TO INSTALL: 4. To install the feed motor, follow the above procedure in reverse. NOTE Adjust the stretch stitch patterns (see page 18).

Access setscrew (B) through this hole

Snap ring (E-3) Feed motor Setscrew

Snap ring (E-3)

33

MODEL 5100

ADJUSTING BUTTONHOLE LEVER POSITION
TO ADJUST THE BUTTONHOLE LEVER GUIDE:
1. Set the machine in buttonhole sensor adjusting mode. (See below. The led should display "H" or "l".) 2. Remove the face cover and loosen setscrew (A). 3. Lower the buttonhole lever. Loosen the setscrew and position the buttonhole lever guide so the led 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 clearance gauge. 6. Turn the adjusting screw to the left until the led display changes from "l" to "H". 7. Next, turn the adjusting screw to the right until the led display changes from "H" to "l". 8. Check the led. When the clearance of the buttonhole foot is 1.4 mm, the led displays "H"; when the clearance is 1.8 mm, the led displays "l". 9. Turn off the power switch, and install the face cover. NOTE If there is any lint in the buttonhole sensor slit, clean out with a swab.

TO ENTER ADJUSTING MODE:

1. Turn the power on while pressing the #01 button and #16 buttonsimultaneoudly. (Hold both buttons down until the led displays the adjusting mode.)

2. Press the #16 button to select "2".

3. Press the needle #01 button.

Setscrew (B) Buttonhole sensor

Buttonhole lever guide

Setscrew (A) Setscrew (B)

Adjusting screw

BH lever Clearance 1.6 mm

34

MODEL 5100

ADJUSTING THE BOBBIN WINDER SWITCH
TO ADJUST THE BOBBIN WINDING SWITCH
1. Remove the front cover (see page 6-7). 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. The led displays when the bobbin winder spindle is set the bobbin winding position, and bobbin winder is returned to the sewing position. when the

Setscrew

Approx. 07. To 1.3 mm Switch fixing plate

Bobbin winder arm (Bobbin winding)

35

MODEL 5100

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.

A

C B

D F E G

K

JML

I
36

H

MODEL 5100

PARTS LIST
22 21 22

6 5

1

20 19 2 7 9 12 11 13 14 15 16 18

25

10

3 4 8

23

27

26

24 17 6

37

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

PARTS NO.
843647002 843128105 840602006 827099003 000101817 653006101 843646001 843126103 650503702 000014409 827503005 000162001 659067005 810220003 000104119 000161309 000103509 000119601 822020503 751100000 843005002 000081005 843127001 647009002 843129106 827006003 000120203

DESCRIPTION
Face cover unit Face cover Thread cutter unit Face cover reflection plate Setscrew 4x16 Cap Rear cover unit Rear cover Upper thread guide unit Snap ring CS-8 Top cover thread guide unit Tapping screw 2.6x5 (B) Spool pin Setscrew Setscrew 4x20 Tapping screw 3x12 (B) Tapping 4x10 Setscrew 4x25 (B) Spool holder (large) Carrying handle Carrying handle fixing plate Setscrew 4x8 Extension table Bed rubber cushion Decoration plate Rear cover fixing plate Setscrew 3x8 (B)

38

MODEL 5100

PARTS LIST
1 4 2 5 7 4 10 8 6 9 4 11 13 14 22 16 17 23 35 34 30 31 42 18 20 19 15 14 3

12

37 39 18 40

38

27

21 24 29 46 47 28 25 26 36 41 32

33

21

42 45 44 8

48 43

39

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

PARTS NO.
843604203 843008005 843502004 000101105 843009006 000103808 843625107 000002105 830057010 843007004 843508000 000115308 000026002 000081005 840647003 827026010 730022002 000002507 000070609 673022002 000111902 840033000 000101105 840034001 840037004 000078319 840646002 755643002 840035002 000125105 827098002 734625003 734101008 734102009 000097602 653503103 653612003 653504001 650040005 650041006 829027006 000111201 102408089 827083004 827092006 840036003 000003508 842625001

DESCRIPTION
Front bracket unit Front bracket E-1 board (printed circuit board) unit Setscrew 3x4 Sensor fixing plate Setscrew 3x5 Buttonhole lever unit Snap ring E-3 Buttonhole lever guide Lamp fixing plate Lamp socket unit TP setscrew 2x8 Wedge base lamp 12V 5 W Setscrew 4x8 Needle bar supporter unit Needle bar supporter Needle bar supporter pin Snap ring E-4 Washer 6 Washer Hexagonal socket screw 3x4 Needle threader frame Setscrew 3x4 Needle threader lever Needle threader lever guide Setscrew 3x6 Needle threader shaft unit Needle threader cover unit Threader spring Pin Washer Threader position set plate unit Threader position set plate Threader position set holder Setscrew 2x4 Needlr bar unit Needle bar crank rod unit Needle bar crank rod unit Felt Spring Needle bar supporter guide plate Hexagonal socket screw 4x4 Needle HA1-14 Supporter guide pin Spring Needle threader shaft Spring pin 2x8 Supporter guide pin unit

40

MODEL 5100

PARTS LIST

1 18 2 4 5 20 21 3 19

28 29

30 31 35

32

43 9 22 34 33 7 6 8 24 25 10 13 15 14 26 16 27 38 13 37 39 23 40 36 42 40

11 12

41

17

41

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

PARTS NO.
750036012 102261000 627569106 681009101 756604107 752005007 825015010 825016000 825017001 820374004 000122504 827011001 810220003 627567001 000122700 827037003 000115205 802021007 802022008 730026006 735028003 000111500 827021004 660509008 660106001 827036002 000081005 827622012 827055018 827088009 820373003 000078319 678084007 653037008 827608403 827020047 827082003 000066303 000070908 000081005 735029200 827022005 827023006

DESCRIPTION
Hook cover plate Bobbin Bobbin holder unit Needle plate setscrew Needle plate unit Hook cover holder (left) Hook cover holder (right) Hook cover plate release button Spring Tapping screw 2x2.3 Needle plate position adjusting pin Needle plate nut holder Setscrew Bobbin holder stopper unit Pin Front cover fixing plate Setscrew 4x6 Presser bar bushing (upper) Snap retainer Presser bar spring Presser bar supporter Hexagonal socket screw 4x8 Presser bar Presser foot unit Setscrew Arm thread guide Setscrew 4x8 Zigzag width rod unit Zigxag widht rod Zigzag width rod spring Setscrew 2x3 Setscrew 3x6 Eccentric pin Washer Presser base plate unit Front base Presser foot positioning plate Bolt 4x6 Washer Setscrew 4x8 Presser bar lifter Tension release lever (1) Tension release lever (2)

42

MODEL 5100

PARTS LIST
13 12 23 3 1 6 10 9 11

4

2

23 7 8 19 5 28 17 14 20 15 25 16 26 21 24 18 22 17

27

43

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

PARTS NO.
820511108 650062003 000111201 000002806 652512009 843643101 000111706 000110901 000111304 000172602 830095010 820102009 000081005 673062004 756017004 650071005 000024206 502064003 502065004 844050016 653139012 000030205 731384008 844077008 843538009 000101404 000101703 000020501

DESCRIPTION
Thread take-up lever unit Thread take-up pin Hexagonal socket screw 4x4 Snap ring E-6 Needle bar crank pin unit Upper shaft unit Hexagonal socket screw 5x8 Hexagonal socket screw 5x4 Hexagonal socket screw 5x5 Setscrew 5x8 Upper shaft shield plate Washer Setscrew 4x8 Upper shaft rear metal Upper shaft timing gear Timing belt Spring pin 3x30 Clutch ring Clutch spring Belt wheel Timing belt Snap ring E-8 Felt Handwheel Thread tension unit Setscrew 4x6 Setscrew 4x12 Spring pin 3x22

44

MODEL 5100

PARTS LIST
9 8 10

4 4 3 1 3 2 5 1

7 6

11

12

13 14 15 9

16 17 19 20 18 26 25 24 22

23

27

21

28

45

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

PARTS NO.
820166001 735143005 000038502 000111201 650078002 753183025 686035008 650955002 000111304 751148000 000115009 751612206 650079003 822112008 822070003 820161006 843601004 843001008 753005000 000013903 000101703 827601107 827002102 735002001 000097901 000061412 000066808 000120203

DESCRIPTION
Lower shaft ring Felt Washer 8x0.5 Hexagonal socket screw 4x4 Lower shaft bushing (front) Feed lifting cam Feed lifting cam spring Lower shaft timing gear Hexagonal socket screw 5x5 Feed cam TP setscrew 3x8 Lower shaft unit Lower shaft bushing (rear) Felt holder (1) Felt (1) Pin Bed cover unit Bed cover Drop feed lever Snap ring CS-5 Setscrew 4x12 Arm leg unit Arm leg Rubber cushion Setscrew 5x18 Nut Setscrew 6x14 Tapping screw 3x8 (B)

46

MODEL 5100

PARTS LIST
1 7 20 5 21 3 9 6 13 15 14 14 16 17 19 12 11 8 11 6 10

4

2

18 11

14

47

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

PARTS NO.
843648003 843132102 843137107 843133000 653507082 000014306 000103107 843134104 843135105 849507100 000120203 843136106 843014004 000161206 827069004 843610408 843527108 843020106 843021107 000071013 735016307

DESCRIPTION
Front cover unit Front cover Pattern indication window Slide knob Slide volume unit Snap ring CS-3 Setscrew 4x14 Button Button F-board (printed circuit board) Tapping screw 3x8 (B) Indication changing button Nut Tapping screw 3x10 (B) Front cover fixing plate (bottom) A-board (printed circuit board unit) A-board (printed circuit board) Case lid for A-board Casw for A-board Washer Bobbin winder stopper

48

MODEL 5100

PARTS LIST
1 8 3 2 15 11 4 12 5 25 35 36 17 19 20 42 23 14 32 37 38 39 33 34 29 40 39 5 39 39 22 18 21 12 12 16 24 7 10 9 13

6 4 28 41 31

26

27

29 30

5

49

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

PARTS NO.
834527100 840005003 000104005 738055008 000111304 650085002 650612004 000036603 823110009 625144002 650175000 000111201 820387000 000036407 840603007 840006004 000160102 825261002 589040002 827043105 810207004 827086007 000115906 650092002 827614033 820123006 820124007 820125008 000038409 650623008 627191000 820374004 627192001 625102008 827040009 823106002 000107204 650094004 000081005 000070506 627190010 000071013

DESCRIPTION
Feed lock shaft unit Feed dog Setscrew 3.5x8 Screw center Hexagonal socket screw 5x5 Spring Feed regulator unit Thrust washer FT 50x0.5 Felt Bushing (front) Washer Hexagonal socket screw 4x4 Ring Thrust washer FT 50 Feed shaft unit Feed shaft Adjustable nut 4 Feed shaft arm (2) Buttonhole feed adjusting spring Feed shaft arm (1) Spring washer Feed arm screw Setscrew TP 3x12 Bushing (rear) Hook unit Hook driver shaft Hook shaft oil felt (1) Hook shaft oil felt (2) Washer 6x0.5 Shuttle body unit Hook race bottom plate Setscrew 2x2.3 Washer Plain washer Hook gear cover Hook base plate Setscrew 3x12 (B) Hook shaft base Setscrew 4x8 Plain washer 4 Magnet Plain washer

50

MODEL 5100

PARTS LIST
20 14 1 15 2 5 17 19 18 12

16 3 27 3 3 10 4 3 13

7

3

26 9 11 8 21 25 6

24 23

3

24

22

51

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

PARTS NO.
843608001 843505007 000081005 829020009 000101404 000053008 843606009 000115205 000002105 843512007 000115205 827506008 823119008 652093009 843628007 843067002 753507203 844075039 000120203 844628033 843615001 000115700 841514405 000103509 652611009 843034000 000188209

DESCRIPTION
Zigzag width motor unit P-board (printed circuit bord) Setscrew 4x8 Transfomer supporter Setscrew 4x6 Cord binder Stitch length motor unit TP setscrew 4x6 Snap ring E -3 Power transfomer unit TP setscrew 4x6 Bobbin winder unit Bobbin winder arm spring Hinge screw Switch base plate unit Switch base plate Buttonhole selector switch unit Clutch releasing arm Setscrew 3x8 (B) Bobbin winder (unit) Motor unit TP setscrew 4x10 Machine socket unit Setscrew 4x10 Idler unit Base plate Nylon clip

52

MODEL 5100

PARTS LIST
1 2 3 4 5

6

7

8

9

10

11

12

13

14

15

16

53

MODEL 5100

PARTS LIST
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PARTS NO.
843870246 822808008 829801002 822804118 753801004 102261000 639804000 653802002 647808009 822019509 829803004 625031500 102403109 033570318 843800658 653524007

DESCRIPTION
Accessory set Overcast foot (M) Zipper foot (E) Satin stitch foot (F) Automatic buttonhole foot (R) Bobbin Needle set Screwdriver Seamripper Small spool holder Spool stand Additional spool pin Felt Foot control Instruction book Power supply cord

54