SERVICE MANUAL

PARTS LIST

MODEL : DC4030
 DC4030

CONTENTS
SERVICE ACCESS (1) FACE COVER ........................................................................... 2
SERVICE ACCESS (2) BED COVER ............................................................................. 3
SERVICE ACCESS (3) FRONT COVER ........................................................................ 4
SERVICE ACCESS (4) REAR COVER ........................................................................... 5
PRESSER BAR HEIGHT AND ALIGNMENT .................................................................. 6
NEEDLE DROP POSITION ............................................................................................ 7
NEEDLE TO HOOK TIMING ........................................................................................... 8
NEEDLE BAR HEIGHT ................................................................................................... 9
NEEDLE CLEARANCE TO SHUTTLE.......................................................................... 10
BACKLASH (BETWEEN LOWER SHAFT GEAR AND HOOK DRIVE GEAR) ............. 11
FEED DOG HEIGHT ..................................................................................................... 12
ZIGZAG SYNCHRONIZATION ..................................................................................... 13
NEEDLE THREAD TENSION ....................................................................................... 14
STRETCH STITCH FEED BALANCE ........................................................................... 15
REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE............ 16
ADJUSTING BUTTONHOLE LEVER POSITION ......................................................... 17
CONNECTOR DIAGRAM ............................................................................................. 18
SELF DIAGNOSTIC TESTS .................................................................................. 19 - 22
REPLACING PRINTED CIRCUIT BOARD A ................................................................ 23
REPLACING PRINTED CIRCUIT BOARD F AND SLIDE VOLUME ............................ 24
REPLACING DC MOTOR AND ADJUSTING MOTOR BELT TENSION ..................... 25
REPLACING THE FUSES ............................................................................................ 26
REPLACING MACHINE SOCKET (UNIT) .................................................................... 27
REPLACING THE TRANSFORMER............................................................................. 28
REPLACING THE ZIGZAG WIDTH MOTOR ................................................................ 29
REPLACING THE FEED STITCH MOTOR .................................................................. 30
ADJUSTING THE BOBBIN WINDER SWITCH ............................................................ 31
PARTS LIST ........................................................................................................... 32 - 51

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 DC4030
SERVICE ACCESS (1)

FACE COVER

TO REMOVE:
1. Remove the 2 setscrews and remove the face cover.

TO INSTALL:
2. Follow the above procedure in reverse.

Setscrew

Face cover

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 DC4030
SERVICE ACCESS (2)

BED COVER

TO REMOVE:
1. Set the drop lever to the left and remove the 3 setscrews, remove the bed cover.

TO INSTALL:
2. Set the drop lever to the left and install the bed cover.
Secure the bed cover with the 3 setscrews.

Setscrew

Drop lever
Setscrew Bed cover

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 DC4030
SERVICE ACCESS (3)

FRONT COVER

TO REMOVE:
1. Remove the bed cover and needle plate (see page 3).
2. Loosen the setscrew (A), remove the setscrew (B), (C), (D), (E), (F), (G), and (H).
(Remove setscrew (I) and lamp set plate (2) when the setscrew (A) is hard to access.)
3. Disconnect the connector from the board "A", then remove the front cover.
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. Follow the above procedure in reverse.
NOTES: 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. Insert the connector at the right angle. Then push it straight down until it locks in place.

Setscrew (B) Setscrew (C)

Lamp set plate (2)
Setscrew (I)

Setscrew (D) Setscrew (E)

Setscrew (A)

Setscrew (H)

Setscrew (F) Setscrew (G)

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 DC4030
SERVICE ACCESS (4)

REAR COVER

TO REMOVE:
1. Remove the front cover (see page 4).
2. Remove the setscrews (A), (B), and (C), then remove the rear cover.
* 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.

Setscrew (A)
Setscrew (C)

Setscrew (B)
Presser foot lifter

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 DC4030
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 5.7-
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. 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
Presser bar lifter

[Height of presser foot]

Presser foot
[Presser foot alignment]

Needle plate

6.0 mm
Should be parallel

Feed dog

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 DC4030
MECHANICAL ADJUSTMENT

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, check the needle drop position by setting the stitch pattern at straight " " and
the zigzag width at maximum " ".
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 (A),
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.

Setscrew (A)
Eccentric pin

Needle plate hole

Eccentric pin position

(Off -center head)

0.2 mm or more 0.2 mm or more

Adjust the needle drop position by turning the
eccentric pin as shown
A=B

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 DC4030
MECHANICAL ADJUSTMENT

NEEDLE TO HOOK TIMING

When the machine is set the straight stitch pattern " " (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 " " (left needle position).
3. Remove the bed cover (see page 3).
4. Turn the handwheel toward you, and set the needle bar at the lowest position.
5. Loosen the 2 setscrews on the lower shaft gear.
6. Raise the needle bar 3.4 mm from the lowest position of the needle bar.
7. Turn the lower shaft gear until the tip of hook meets with the right side of needle.
8. Tighten the 2 setscrews on the lower shaft gear.
9. Attach the bed cover, bobbin holder and needle plate.

Needle plate

2 setscrews

Bobbin holder

Lower shaft gear

Match the tip of hook at

the right side of needle

Needle #14

3.4 mm

Lower needle position

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 DC4030
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 position.

1. Remove the needle plate and bobbin holder.

2. Turn on the power switch.
3. Select the pattern " " (left needle position).
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.

Needle plate
Setscrew (A)

Bobbin holder

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

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 DC4030
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 (see page 3), and replace the needle with the test pin.
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 hinge screw (C).
2. Turn the handwheel toward you, and adjust the clearance between test pin and the point of the hook in
the left and right needle position to –0.1 to +0.05 mm 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 (see page 11).
5. Attach the bed cover, needle plate and bobbin holder, and remove the master needle.

Needle plate

Bobbin holder
Test pin

Point of hook
–0.1 to +0.05 mm

Hinge screw (C)

Hook set plate

Setscrew (B)
Setscrew (A)

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 DC4030
MECHANICAL ADJUSTMENT

BACKLASH (BETWEEN LOWER SHAFT GEAR AND HOOK DRIVE 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
exceeds 0.8 mm, adjust as follows.

ADJUSTMENT:
1. Remove the bed cover (see page 3).
2. Loosen the setscrew.
3. Turn the lower shaft bushing (eccentric bushing) clockwise (B) if there is too much play in the hook.
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 shuttle hook

Check the backlash

Groove

Setscrew

Shuttle hook gear

Lower shaft gear Groove on the lower shaft bushing

B A

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 DC4030
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 foot pressure adjusting lever is set at "3" and the presser foot is lowered.

1. Set the pressure foot pressure adjusting lever at "3" and lower the presser foot.
2. Turn on the power switch.
3. Remove the bed cover (see page 3).
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

Presser foot pressure

adjusting lever
Feed dog Surface of the
needle plate

To raise

Setscrew (A) To lower

Nut (B)
Adjusting screw (C)

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 DC4030
MECHANICAL ADJUSTMENT

ZIGZAG SYNCHRONIZATION

The needle should start swing 8.2 mm above the surface of the needle plate when the machine is set for
zigzag stitching.

1. Remove the front cover (see to page 4).

2. Turn on the power switch, select the pattern no. 5 and set the machine at the maximum zigzag width.
3. Turn the handwheel toward you slowly with your hand until the needle start to swing. Loosen the
setscrew and turn the upper shaft shield plate in the direction of;
* A. If the swing point is higher than 8.2 mm.
* B. If the swing point is lower than 8.2 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

8.2 mm

Upper shaft shield plate

Setscrew

Upper shaft sensor

A

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 DC4030
MECHANICAL ADJUSTMENT

NEEDLE THREAD TENSION

The standard tension should be 75 to 90 grams when the tension dial is set at "A" (auto), 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 "A" and check the thread tension.
2. Remove the face cover (see page 2).
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 "A" 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.
Set the thread tension dial at "A"

Thread (polyester sewing

thread (#50 white))

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 DC4030
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
" ", the 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 " ".
2. Set the slit of the feed balancing dial to the standard setting mark " " on the front cover.
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. If A>B, turn the adjusting screw counterclockwise "C".
5. When A<B, turn the adjusting screw clockwise "D".

Standard setting
mark

Feed balancing dial

Setscrew

C D

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 DC4030
MECHANICAL ADJUSTMENT

REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE

If the hook of the threader plate is damaged, change and adjust the part as follows:

TO CHANGE THE THREADER PLATE:

1. Push down the needle threader knob and pull the threader plate supporter (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 hole, 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 hole, loosen setscrew (D)
and adjust the hook position (FIG.3)

Replacing the needle threader cover

(with the threader plate attached
FIG. 1

Pin (B) Vertical adjustment

FIG. 3
Threader plate
supporter (A)

Setscrew (D)

Adjustment of left or right direction

FIG. 2

Threader plate View from "X"

Setscrew (C)
Nut

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 DC4030
ADJUSTING BUTTONHOLE LEVER POSITION

TO ADJUST THE BUTTONHOLE LEVER GUIDE:

1. Enter adjusting mode, by turning the power switch on while pressing the "Start/Stop" and "Auto-lock"
buttons. Press the #4 key within 3 seconds. The LCD screen shows "BH sensor [H] or [L]".
2. Open 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. Attach the buttonhole foot (R).
5. Lower the buttonhole lever to its lowest position, and insert a 1.6 mm thickness gauge into the button-
hole foot.
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 1.4 mm thickness gauge is inserted and "L" when the
1.8 mm thickness gauge is inserted.
9. Turn off the power switch.

NOTE
If there is any lint in the buttonhole sensor slit, remove the setscrew (B), clean out with a swab.

1. Turn the power switch on 2. Press the start/stop button 3. Press the auto-lock button.
while pressing the start/stop to select menu item "2".
button & auto-lock button.

Setscrew (B)
Buttonhole
lever guide
Buttonhole sensor

Setscrew (A) Adjusting screw

BH lever

Clearance
1.6 mm

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 DC4030

CONNECTOR DIAGRAM

REFER TO THE DIAGRAM FOR LOCATING THE CONNECTOR POST ON THE CIRCUIT
BOARD
A: Buttonhole sensor (BLK) H: Power transformer (secondary circuit) (RED)
B: Sewing light (WHT) I: Printed circuit board “F” (BLK)
C: Upper shaft sensor (BLK) J: Bobbin winder switch (BLU)
D: Feed motor (BLK) K: Presser foot lifter switch (BLK)
E: Zigzag width motor (WHT) L: Slide volume (WHT)
F: DC motor (WHT) M: Machine plug (secondary circuit) (WHT)
G: Power transformer (primary circuit) (BLK) N: Receptacle (primary) (WHT)

J L I

C A

M
B

H
D

N G

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 DC4030

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 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.
* 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 needle up/down 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".

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 NO.2 NO.3

Turn the power switch on while Press the reverse button five Press the needle up/down button.
simultaneously pressing the times to select menu item "6".
needle up/down button and the
reverse button.

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 DC4030

SELF DIAGNOSTIC TESTS

STEP AND PROCEDURE CORRECT RESULTS DEFECTIVE RESULTS
ITEMS TO
CHECK

Turn on the power switch while * Beep sounds when the buttons are * No beep sound.
01)
simultanously pressing the needle up/ pressed. * Does not enter self-diagnos-
7-segment
down button and the start/stop button. * LED displays " 8.8", and blinks in 1- tic mode.
LED
Press the start/stop button five times to sec. Intervals. * LED does not blink on or off.
select menu item "6".
Press the needle up/down button: The 1. Replace board "A".
LED
LED indicates "01" for one second.
If you don't press the reverse button
within 2.5 seconds, the machine
automatically reverts to normal sewing
mode.

02) Press needle up/down button, LED LED displays "Ld", and LEDs blink in 1- * LED does not blink.
Mode LED displays "02" for one second. sec. Intervals.
The pattern selector buttons blink column
by column. 1. Replace board "A".
The start/stop button lights in green and
red alternat ively.

LED

03) Press needle up/down button, LED * LED indicates "--". * LED display is different from
displays "03" for one second. that shown to the left.
Switch LED
Press buttons 01 to 20.

20 1. Replace board "A".

16 17 18 19 * Button number is displayed when the

button is pressed.
01 02 03

04 05 06

07 08 09

10 11 12

13 14 15

04) Press needle up/down button, LED * LED indicates "II". * LED display is different from
Bobbin displays "04" for one second. that shown to the left.
(At left position) 1. Adjust bobbin winder switch
winder
* Move the bobbin winder spindle to position.
switch
the right. 2. Replace bobbin winder
(At right position)
* Return it to the left. switch.
3. Replace board "A".

05) * LED indicates "UP". * LED display is different from

Press needle up/down button, LED
that shown to the left.
Presser foot displays "05" for one second.
(At up position) 1. Adjust presser foot lifter
lifter switch
switch position.
2. Replace bobbin winder
(At down position) switch.
3. Replace board "A".

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 DC4030

SELF DIAGNOSTIC TESTS

STEP OPERATION CORRECT CONDITION DEFECTIVE CONDITION

06) Press needle up/down button, LED * LED indicates "L" or "H". LED display is different from
Buttonhole displays "06" for one second. LED that shown to the left.
sensor
1. Lower the buttonhole lever. 1. Adjust the buttonhole
sensor position.
* When the buttonhole lever
2. Move the buttonhole lever back and
is pulled, LED displays "H". 2. Replace buttonhole
forth.
sensor.
* When the buttonhole lever
is free (positioned in the
3. Replace board "A".
center), LED displays "L".

* When the buttonhole lever

is pushed, LED displays "H".

07) Press the needle up/down button, * LED indicates "H.L". * LED display is different from
Upper shaft LED displays "07" for one second. LED that shown to the left.
sensor
* Turn the handwheel toward you to
raise and lower the needle to its highest 1. Adjust upper shaft shield
* When the needle is at
and lowest position. plate.
the highest position,
LED displays "HL".
2. Replace upper shaft sensor.
* When the needle is at
the lowest position, 3. Replace board "A".
LED displays "LH".

* When the needle is halfway,

LED displays "LL".

08) * Press the needle up/down button. * LED displays "00" first and the * LED displays different from that
Sewing LED displays "08" for one second. indicates value increases as you turn shown to the left.
the handwheel.
speed
* Turn the handwheel clockwise by hand 1. Replace motor.
sensor
and check the counter value displayed. (When the value
reaches 100, it will 2. Replace board "A".
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.

09) * Press the needle up/down button. * LED indicates "00". * LED display is different from
Slide LED displays "09" for one second. that shown to the left.
volume (At left position)
* Slide the speed control lever from the 1. Replace slide volume.
left to the right, then return it to the left.
(At right position)
2. Replace board "A".

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 DC4030

SELF DIAGNOSTIC TESTS

STEP OPERATION CORECT CONDITION DEFECTIVE CONDITION

Press needle up/down button, * LED indicates "00". * LED display is different from that
10)
the LED displays "10" for one LED shown to the left.
Foot
controller second.

Depress the foot controller down 1. Replace foot control.

When the foot control is not
all the way and release.
depressed, LED should
2. Replace machine socket.
display "F0" to "FF"
(hexadecimal value).
3. Replace board "A".
When the foot control is fully
depressed, LED should
display "05" to "2F".

When the control is

disconnected, LED should
show "00" to "04".

11) Press the needle up/down * LED displays "bs". * LED display is dtfferent from that
Zigzag width button, the LED displays "11" for LED shown to the left.
motor one second.

* Press the start/stop button.

Zigzag width motor is set to the initial If LED displays "E1", replace the
position. (Needle centered) width motor or board "A".

Feed Turn the handwheel toward you to * LED displays "FS". * LED display is different from
motor lower the needle to its lowest LED that shown to the left.
position, then press start/stop
button.

Feed motor is set to the initial position. If LED displays "E2", replace
(Stitch length : 0) motor or board "A".

12) Press needle up/down button, LED * LED indicates "dc". Machine does not run, LED
DC motor indicates "12" for one swcond. * Machine runs at the speed set by displays "Lo".
* Press foot control. the speed control lever.
LED

1. Replace DC motor.
Full left: 80 ~100 SPM
Full right: 800 ~840 SPM 2. Replace board "A".

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

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 DC4030
REPLACING PRINTED CIRCUIT BOARD A

TO REMOVE:
1. Remove the front cover (see page 4).
2. Unplug the connectors from the board "A".
3. Remove the 8 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 theconnector.
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 Printed circuit board "F"

Setscrew Setscrew

Printed circuit board "A"

Setscrew

Capacitor

Setscrew The transformer cord should not

pass over the capacitor when
board "A" is installed.

Setscrew

Setscrew

Setscrew

Setscrew

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 DC4030
REPLACING PRINTED CIRCUIT BOARD F
AND SLIDE VOLUME
REPLACING THE SLIDE VOLUME
TO REMOVE:
1. Remove the front cover unit (see page 4).
2. Unplug the slide volume connector.
3. Remove the 2 CS rings (A), CS ring (B), 2 CS rings (C), 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 (see page 4).
6. Unplug the printed circuit board "F" connector and remove the four CS rings.
7. Remove the 2 setscrews and remove the printed circuit board "F".
TO INSTALL:
8. 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.

Printed circuit board "F"

Slide volume connector
connector 2 CS rings (A)

Printed circuit board "F"

2 CS rings (C)

Setscrews (2)

Slide volume control

CS ring (B)

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 DC4030
REPLACING DC MOTOR AND ADJUSTING
MOTOR BELT TENSION
TO REMOVE:
1. Remove the front cover and rear cover (see pages 4 and 5).
2. Unplug the DC motor connector.
3. Remove the 2 setscrews, then remove the DC motor and belt.

TO INSTALL:
4. Lightly tighten the 2 setscrews.
5. 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 2 setscrews
firmly.
6. Install the front cover and rear cover.

Belt

Pressure 300g

Belt deflection:
7~9 mm

DC motor Setscrews (2)

25
 DC4030
REPLACING THE FUSES

REPLACING THE FUSES

TO REMOVE:
1. Remove the front cover (see page 4).
2. Remove the four setscrews and remove 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. PART NO. TYPE/SPECIFICATION

F2, F3 000-144-605 TSD-2.5A-250V
5.2 X 20 MM 2.5 A TIME-LAG FUSE
F1 000-182-904 3.15A-250V
5.2 X 20 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 holder inward to secure the fuse.

Printed circuit board "A"

F1 AC250V 3.15A

F2. AC250V 2.5A F3. AC250V 2.5A Fuse

Fuse holder

Printed circuit board "A" case

Setscrews (4)

26
 DC4030
REPLACING MACHINE SOCKET (UNIT)

REPLACING THE MACHINE SOCKET

TO REMOVE:
1. Remove the front cover and rear cover (see pages 4 and 5).
2. Remove the 2 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 (unit)

27
 DC4030
REPLACING THE TRANSFORMER

REPLACING THE TRANSFORMER

TO REMOVE:
1. Remove the front cover (see page 4).
2. Remove the 2 setscrews and remove the transformer.

TO INSTALL:
3. To install the transformer, follow the above procedure in reverse.

NOTE
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

28
 DC4030
REPLACING THE ZIGZAG WIDTH MOTOR

REPLACING THE ZIGZAG WIDTH MOTOR

TO REMOVE:
1. Remove the front cover and rear cover (see pages 4 and 5).
2. Remove the two zigzag rod setscrews (A). Disconnect the connector from the board "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 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 7).

Setscrew (B)

Setscrew (B)

Zigzag rod setscrew (A)

Setscrew (B)

Zigzag width motor

Setscrew (B)

29
 DC4030
REPLACING THE FEED STITCH MOTOR

REPLACING THE FEED MOTOR

TO REMOVE:
1. Remove the front cover and rear cover (see pages 4 and 5).
2. Remove the snap ring (E-3). Disconnect the connector from the board "A".
3. Remove the two setscrews (A), (B) and remove the feed motor.

TO INSTALL:
4. To install the feed motor, follow the above procedure in reverse.

NOTE
Adjust the stretch stitch feed balance (see page 15).

Setscrew (B)

Setscrew (A)

Snap ring (E-3)

30
 DC4030
ADJUSTING THE BOBBIN WINDER SWITCH

TO ADJUST THE BOBBIN WINDING SWITCH

1. Remove the front cover (see page 4).

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 LCD indicates when the bobbin winder spindle is set the bobbin winding position. The LED
indicates when the bobbin winder is returned to the sewing position.

LED

Setscrew

Approx.
0.7 to 1.3 mm Bobbin winder arm
Switch fixing (Bobbin winding)
plate

31
 DC4030

PARTS LIST

27
26 27
8
7

6 25
5
4 3
6

24
9 19
20
10 21
12
15 23

14
28 18
13

11

16
17

29 22

32
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 843640304 Face cover (unit)

2 843095102 Face cover
3 840602006 Thread cutter (unit)
4 724025006 Face plate sticker
5 731067002 Face plate spring
6 000161206 Setscrew 3x10 (B)
7 100411207 Lump sticker
8 366501102 Face cover hinge (unit)
9 000081119 Setscrew 4x6
10 843632602 Rear cover (unit)
11 843077603 Rear cover
12 650503506 Tread guide (unit)
13 000014409 Snap ring CS-8
14 827503005 Top cover thread guide (unit)
15 000162001 Setscrew 2.6x5 (B)
16 827006003 Rear cover set plate
17 000120203 Setscrew 3x8 (B)
18 659067005 Spool pin
19 810220003 Setscrew
20 000104119 Setscrew 4x20
21 000161309 Setscrew 3x12 (B)
22 000103509 Setscrew 4x10
23 000119601 Setscrew 4x25 (B)
24 822020503 Spool holder (large)
25 751100000 Handle
26 843005002 Handle set plate
27 000081005 Setscrew 4x8
28 843501106 Extension table (unit)
29 647009002 Bed rubber base

33
 DC4030

PARTS LIST

17
18

1 4
6 2
13
3 12

4
7
11
9 5

14
8

10
16
18 4
15

19
20

21

34
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 843623507 Front base plate (unit)

2 844096003 Front base plate
3 843502004 Printed circuit board E-1 (unit)
4 000101105 Setscrew 3x4
5 844040013 BH sensor set plate
6 845029008 Insulation paper
7 843625004 BH lever (unit)
8 000002105 Snap ring E-3
9 830057010 BH lever guide
10 000103808 Setscrew 3x5
11 827029013 Cord guide plate
12 652203004 Setscrew 3x3.5
13 829016002 Sticker
14 843055007 Lamp set plate (2)
15 843508206 Lump socket (uint)
16 000115308 TP setscrew 2x8
17 827106004 Set plate
18 000081005 Setscrew 4x8
19 000026002 Wedge base lamp 12V 5W
20 843038004 Lump set plate (1)
21 000101507 Setscrew 3.5x5

35
 DC4030

PARTS LIST

37
34
35
31
33
4
4
6 32
5
1
2
26
9 29 3
20
8
18
25
21 7
7
28
24
23

19 22
27
16 36
29
17
15
13 30
10 12

11

14

41
37 39 38

40
21

36
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 842636108 Needle bar supporter (unit)

2 827026010 Needle bar supporter
3 730022002 Needle bar supporter pin
4 000002507 Snap ring E-4
5 000070609 Washer
6 673022002 Spring washer
7 000111902 Hexagonal socket screw 3x4
8 827098002 Washer
9 842637006 Threader shaft (unit)
10 842638007 Threader plate (unit)
11 755064106 Threader guard plate
12 842088006 Thread retension plate
13 844095002 Threader plate
14 755096004 Setscrew
15 755095003 Nut
16 840036025 Threader shaft
17 000003508 Spring pin 2x8
18 000125105 Guide pin E-2x16-CH
19 842090001 Threader shaft spring
20 842096007 Threader lever spring
21 000002105 Snap ring E-3
22 842622008 Threader positioning setting plate (unit)
23 842053002 Threader positioning setting plate
24 734102009 Threader positioning setting block
25 000097602 Setscrew 2x4
26 842091002 Threader guide plate
27 844036027 Threader lever plate
28 842092003 Threader lever
29 000078319 Setscrew 3x6
30 653503103 Needle bar (unit)
31 843652000 Needle bar connecting stud (unit)
32 639516002 Needle bar connecting stud (unit)
33 843543007 Needle ber crank (unit)
34 650040005 Felt
35 650041006 Spring
36 829027006 Supporter guide plate
37 000111201 Hexagonal socket screw 4x4
38 102408089 Needle HA-14
39 842625001 Supporter guide pin (unit)
40 827083004 Pin
41 844038018 Supporter spring

37
 DC4030

PARTS LIST

35

27 36 39

16
37
1 38
18

19
2 20 50
41
21 40
4 51
3
30
5 28
22 29

9
17
23

8
26 34 42
49
7
6

10 24
13
11
34
15 43
13
12 48
14 25

33 44
46 47
34
46
31
45
32 45

38
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 750036012 Hook cover plate

2 102261000 Bobbin
3 627569209 Bobbin holder (unit)
4 681009101 Needle plate setscrew
5 756604303 Needle plate (unit)
6 832235010 Hook cover plate holder (Left)
7 825015010 Hook cover plate holder (right)
8 825016000 Hook cover plate holder release button
9 825017001 Hook cover plate holder spring
10 820374004 Setscrew 2x2.3
11 000122504 Pin D3x10CH
12 827011001 Reverse rotation stopper
13 810220003 Setscrew
14 627567001 Rotation stopper (unit)
15 000122700 Pin D2.5x6-LC
16 652201002 Washer
17 507086006 Presser bar
18 826006000 Presser spring
19 826055004 Washer
20 826056005 Spring
21 735028003 Presser bar bracket
22 000111500 Hexagonal socket screw 4x8
23 829515006 Presser foot unit
24 804509000 Presser foot holder (unit)
25 832523007 Zigzag foot (unit)
26 647112009 Thumb screw
27 652104004 Presser bar bushing
28 829013009 Presser adjusting lever
29 829014000 Presser adjusting plate
30 820090003 Hinge screw
31 827036002 Arm thread guide
32 000115205 TP setscrew 4x6
33 827037003 Front panel set plate
34 000081005 Setscrew 4x8
35 827622012 Zigzag rod (unit)
36 827055018 Zigzag rod
37 827088009 Zigzag rod spring
38 820373003 Setscrew 2x3
39 000078319 Setscrew 3x6
40 678084007 Eccentric pin
41 653037008 Washer
42 827608207 Presser base plate (unit)
43 827020036 Presser base plate
44 827082003 Foot regulating plate
45 000066303 Hexagonal bolt 4x6
46 000070908 Washer 4
47 735029004 Presser foot lifter
48 827022005 Tension release lever (1)
49 827023006 Tension release lever (2)
50 840623302 Switch base (unit)
51 000103808 Setscrew 3x5
39
 DC4030

PARTS LIST

12

5 11
9 8 10
3
4 2 1 8

16
9 20
6 7

15 16

13 18 19
17 21

14
23

24 26 22

25

40
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 820511108 Thread take-up lever

2 650062003 Thread take-up lever pin
3 000111201 Hexagonal socket screw 4x4
4 000002806 Snap ring E-6
5 807606007 Upper shaft (unit)
6 000111706 Hexagonal socket screw 5x8
7 000110901 Hexagonal socket screw 5x4
8 000111304 Hexagonal socket screw 5x5
9 731384008 Felt
10 830095010 Upper shaft shielding plate
11 820102009 Washer
12 000081005 Setscrew 4x8
13 673062004 Upper shaft bushing
14 756017004 Upper shaft gear
15 000020501 Spring pin 3x22
16 000024206 Spring pin 3x30
17 502064003 Clutch ring
18 502065004 Clutch spring
19 844050016 Belt wheel
20 000030205 Snap ling E-8
21 844077008 Handwheel
22 650071005 Timing belt
23 653139012 Timing belt
24 843525302 Thread tension (unit)
25 000101703 Setscrew 4x12
26 000101404 Setscrew 4x6

41
 DC4030

PARTS LIST

9
10

8
4 7
6
11
4 1
5 12
3

1
3

2
9 13

15
14
16 9
17

19 23
20 24
18

27

26

28
25

21
22

42
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 820166001 Lower shaft ring

2 735143005 Felt
3 000038502 Washer
4 000111201 Hexagonal socket screw 4x4
5 650078002 Lower shaft bushing (front)
6 753183025 Feed lifting cam
7 686035008 Feed lifting cam spring
8 650955002 Lower shaft gear
9 000111304 Hexagonal socket screw 5x5
10 823026111 Feed cam
11 000149600 Setscrew 3x14
12 827613009 Lower shaft (unit)
13 650079003 Lower shaft bushing (rear)
14 822112008 Felt holder (1)
15 822070003 Felt (1)
16 820161006 Feed lifting pin
17 843601004 Bed cover (unit)
18 843001008 Bed cover
19 753005000 Drop lever
20 000013903 Snap ring CS-5
21 000101703 Setscrew 4x12
22 000120203 Setscrew 3x8 (B)
23 827601107 Arm leg (unit)
24 827002102 Arm leg
25 735002001 Rubber base
26 000097901 Setscrew 5x18
27 000061412 Nut
28 000066808 Setscrew 6x14

43
 DC4030

PARTS LIST

23 5
3 4 2
6
21
11

22

12
9
8
6 7
24
10 12

25
20
16

20
15
13
20
17

14

18 20
19 12

44
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 807602405 Front cover (unit)

2 807001707 Front cover
3 807020001 Pattern indicating window
4 807004009 Slide volume lever
5 653507082 Slide volume (unit)
6 000014306 Snap ring CS-3
7 807005206 S/S button
8 807006207 Button (1)
9 807019100 Pattern indicating window frame
10 000014007 Snap ring CS-4
11 807503003 Printed circuit board F (unit)
12 000120203 Setscrew 3x8 (B)
13 807013104 Button (5)
14 807008209 Button (3)
15 807009200 Button (4)
16 807603200 Printed circuit board A (unit)
17 807507007 Printed circuit board A (unit)
18 842063108 Board A case cover
19 843021107 Board A case
20 000161206 Setscrew 3x10 (B)
21 000071013 Washer 4
22 735016307 Bobbin winder stopper
23 000101828 Setscrew 4x16
24 843014004 Nut
25 827069004 Front cover set plate (lower)

45
 DC4030

PARTS LIST

1
9 12
7 8
3

4 10 11

5 11
5

13
24
4
6 14
5
15
25 21
11
18
26 38
27 19

28 16
30 29 40
22
33 31 23
20 17
32

39
36
37

37 5
34
29
41 37
35
37

46
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 827615300 Feed rock shaft (unit)

2 840005003 Feed dog
3 000104005 Setscrew 3.5x8
4 738055008 Center pin
5 000111304 Hexagonal socket screw 5x5
6 650085002 Spring
7 625508008 Feed adjuster (unit)
8 823110009 Felt
9 625144002 Feed shaft bushing (front)
10 650175000 Screw base
11 000111201 Hexagonal socket screw 4x4
12 820387000 Ring
13 840603306 Feed shaft (unit)
14 827042012 Feed shaft
15 827043105 Feed adjusting arm (1)
16 825261002 Feed adjusting arm (2)
17 000115906 TP setscrew 3x12
18 810207004 Spring washer
19 589040002 Spring
20 827086100 Feed adjusting arm screw
21 000160102 Adjustable nut 4
22 000071013 Washer
23 000036407 Washer FT50
24 650092002 Feed shaft bushing (rear)
25 827614033 Shuttle race (unit)
26 820123006 Shuttle race shaft
27 820124007 Oil string (1)
28 820125008 Oil string (2)
29 000038409 Washer
30 650623008 shuttle body (unit)
31 627191000 Hook bottom plate
32 820374004 Setscrew 2x2.3
33 627190010 Magnet
34 627192001 Washer
35 625102008 Washer
36 650094004 Shuttle race shaft base
37 000081005 Setscrew 4x8
38 827040009 Hook gear cover
39 000107204 Setscrew 3x12 (B)
40 823106002 Shuttle race set plate
41 000070506 Washer 4

47
 DC4030

PARTS LIST

14
19
18
1

17

3
2
20
15
4

9
21
16
5
22

5
12

13
23
6

4 24

5
25

10
7 7 26

8 27

9
11

48
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 807605006 Stepping motor (unit)

2 807505005 Printed circuit board P (unit)
3 844052007 Connecting arm
4 000002105 Snap ring E-3
5 000081005 Setscrew 4x8
6 844602215 Feed motor (unit)
7 000115205 TP setscrew 4x6
8 846512202 Transformer (unit)
9 000101404 Setscrew 4x6
10 843645505 DC motor (unit)
11 000115700 TP setscrew 4x10
12 843034000 Set plate
13 652611009 Idler (unit)
14 844628033 Bobbin winder (unit)
15 827506008 Bobbin winder (unit)
16 823119008 Bobbin winder arm spring
17 844075039 Clutch releasing arm
18 000120203 Setscrew 3x8 (B)
19 652093009 Setscrew
20 843628007 Switch base plate (unit)
21 753507203 Buttonhole select switch
22 843067002 Switch set plate
23 845504404 Machine socket (unit)
24 000107802 Setscrew 3x10 (B)
25 000103509 Setscrew 4x10
26 000101817 Setscrew 4x16
27 000188209 Nylon clip

49
 DC4030

PARTS LIST
1

2 3 4

5 6 7

8 9 10

11 12 13 14

15 16 17 18

50
 DC4030

PARTS LIST

KEY PARTS
NO. NO. DESCRIPTION

1 807870015 Accessory set

2 822801001 Overedge foot
3 822804118 Satin foot
4 825817009 Blind hem foot
5 102261000 Bobbin
6 540401026 Needle case (unit)
7 653802002 Screw driver
8 802424004 Lint brush
9 647808009 Seam ripper
10 822019509 Small spool holder
11 802422002 Quilter
12 753801004 Buttonhole foot
13 829801002 Zipper foot
14 822808008 Overedge foot
15 830335004 Power supply cord
16 043271133 Foot control
17 807800058 Instruction book
18 479714000 Cover

51