Janome 415 Servicing Manual
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Janome 415 Servicing Manual

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SERVICING MANUAL
415
419S/423S

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  • Page 1 SERVICING MANUAL 419S/423S...

  • Page 2: Troubleshooting

    TROUBLESHOOTING PROBLEM CAUSE REMEDY 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.
  • Page 3 PROBLEM CAUSE REMEDY REFERENCE 3. BREAKING 1. INITIAL SEWING SPEED IS START WITH MEDIUM SPEED. UPPER TOO FAST. THREAD 2. THREAD PATH IS USE THE PROPER THREAD INCORRECT. PATH. 3. NEEDLE IS BENT OR DULL. REPLACE WITH A NEW NEEDLE. 4.
  • Page 4 PROBLEM CAUSE REMEDY REFERENCE 6. NOISY 1. BACKLASH BETWEEN SEE MECHANICAL P. 13 OPERATION SHUTTLE HOOK GEAR AND ADJUSTMENT “CLEARANCE LOWER SHAFT GEAR IS TOO BETWEEN NEEDLE AND HOOK GREAT. (NO. 2).” 2. LOWER SHAFT GEAR IS ELIMINATE THE LOOSENESS. LOOSE.

  • Page 5: Table Of Contents

    CONTENTS TROUBLESHOOTING ................... 1–3 SERVICE ACCESS FACE COVER / TOP COVER .............. BELT COVER ..................BASE ....................FRONT COVER ..................MECHANICAL ADJUSTMENT TOP TENSION ..................BOBBIN TENSION ................PRESSER BAR HEIGHT AND ALIGNMENT ........NEEDLE SWING .................. NEEDLE DROP ..................CLEARANCE BETWEEN NEEDLE AND HOOK (NO.

  • Page 6: Service Access

    SERVICE ACCESS FACE COVER FACE COVER (TO REMOVE) REMOVE THE FACE COVER BY REMOVING THE CAP (A) AND SCREW (B). (TO ATTACH) ATTACH THE FACE COVER WITH THE SCREW, AND THEN, REPLACE THE CAP. TOP COVER TOP COVER (TO REMOVE) REMOVE THE FACE COVER.

  • Page 7: Belt Cover

    SERVICE ACCESS BELT COVER BELT COVER REMOVE THE FACE COVER AND TOP COVER (SEE PAGE 4). LOOSEN SCREW (A). TAKE THE BELT COVER OUT. (TO ATTACH) FOLLOW THE ABOVE PROCEDURE IN REVERSE. BASE BASE (TO REMOVE) REMOVE THE FACE COVER, TOP COVER (SEE PAGE 4) AND BELT COVER. REMOVE 6 SCREWS (B).

  • Page 8: Front Cover

    SERVICE ACCESS FRONT COVER PATTERN SELECTOR DIAL FRONT COVER (TO REMOVE) REMOVE THE FACE COVER, TOP COVER, BELT COVER AND BASE (SEE PAGES 4-5). REMOVE THE PATTERN SELECTOR DIAL. LOOSEN SETSCREWS (A) AND (B), AND THEN, REMOVE THE FRONT COVER BY REMOVING SETSCREWS (C) AND (D).

  • Page 9: Mechanical Adjustment

    MECHANICAL ADJUSTMENT TOP TENSION TO CHECK: THE STANDARD UPPER THREAD TENSION SHOULD BE 65–95 g WHEN PULLING THE THREAD (COTTON THREAD #50) IN THE DIRECTION OF (A) WITH THE TENSION DIAL AT “3.” (MAKE SURE THE FOOT IS LOWERED.) IF THE TENSION IS OUT OF THE STANDARD RANGE, ADJUST IT AS FOLLOWS: ADJUSTMENT PROCEDURE: REMOVE THE TOP COVER (SEE PAGE 4).

  • Page 10: Bobbin Tension

    MECHANICAL ADJUSTMENT BOBBIN TENSION TO CHECK: SET THE BOBBIN IN THE BOBBIN CASE AND PASS THE THREAD (COTTON #50) THROUGH THE TENSION SPRING. THE BOBBIN THREAD TENSION SHOULD BE 45–55g WHEN PULLING THE THREAD IN THE DIRECTION OF (A). IF THE TENSION IS OUT OF THIS RANGE, ADJUST IT AS FOLLOWS: ADJUSTMENT PROCEDURE: IF THE BOBBIN THREAD TENSION IS TOO TIGHT, TURN THE ADJUSTING SCREW (B) IN THE DIRECTION OF (C).

  • Page 11: Presser Bar Height And Alignment

    MECHANICAL ADJUSTMENT PRESSER BAR HEIGHT AND ALIGNMENT TO CHECK: RAISE THE PRESSER FOOT LEVER (A). THE DISTANCE BETWEEN THE PRESSER FOOT (C) AND THE NEEDLE PLATE (D) SHOULD BE 6.0 MM (0.24"). ADJUSTMENT PROCEDURE: REMOVE THE FACE COVER (SEE PAGE 4). RAISE THE PRESSER FOOT LEVER AND LOOSEN THE SCREW (B) ON THE PRESSER BAR HOLDER.

  • Page 12: Needle Swing

    MECHANICAL ADJUSTMENT NEEDLE SWING TO CHECK: WHEN SEWING THE ZIGZAG PATTERN (WITH MAXIMUM ZIGZAG WIDTH), IF THE NEEDLE BAR STARTS MOVING SIDEWAYS WHILE THE NEEDLE IS IN THE FABRIC, ADJUST THE NEEDLE SWING ACCORDING TO THE FOLLOWING PROCEDURE. ADJUSTMENT PROCEDURE: SET THE PATTERN SELECTOR DIAL WITH MAXIMUM ZIGZAG WIDTH, AND REMOVE THE TOP COVER (SEE PAGE 4).

  • Page 13: Needle Drop

    MECHANICAL ADJUSTMENT NEEDLE DROP TO CHECK: WHEN THE NEEDLE SWINGS IN MAXIMUM ZIGZAG WIDTH, THE DISTANCE BETWEEN BOTH ENDS OF THE NEEDLE HOLE ON THE NEEDLE PLATE AND THE NEEDLE DROP POSITIONS SHOULD BE EQUAL. IF NOT, ADJUST AS FOLLOWS: ADJUSTMENT PROCEDURE: REMOVE THE FACE COVER (SEE PAGE 4).

  • Page 14: Clearance Between Needle And Hook (No. 1)

    MECHANICAL ADJUSTMENT CLEARANCE BETWEEN NEEDLE AND HOOK (ADJUSTMENT METHOD NO. 1) TO CHECK: THE CLEARANCE BETWEEN THE NEEDLE AND SHUTTLE RACE SHOULD BE –0.05 TO +0.10 MM. IF NOT, ADJUST AS FOLLOWS: ADJUSTMENT PROCEDURE: REMOVE THE TOP COVER (SEE PAGE 4). SET THE PATTERN SELECTOR DIAL AT ( ), STITCH WIDTH CONTROL AT ( 0 ).

  • Page 15: Clearance Between Needle And Hook (No. 2)

    MECHANICAL ADJUSTMENT CLEARANCE BETWEEN NEEDLE AND HOOK (ADJUSTMENT METHOD NO.2) TO CHECK: USE THIS ADJUSTMENT METHOD NO. 2 WHEN METHOD NO.1 CANNOT BE USED. THE CLEARANCE BETWEEN THE NEEDLE AND SHUTTLE RACE SHOULD BE –0.05 TO +0.10 MM. ADJUSTMENT PROCEDURE: SET THE PATTERN SELECTOR DIAL AT ( ), STITCH WIDTH CONTROL AT ( 0 ).

  • Page 16: Feed Dog Height

    MECHANICAL ADJUSTMENT FEED DOG HEIGHT TO CHECK: LOWER THE PRESSER FOOT. TURN THE HANDWHEEL TOWARD YOU TO BRING THE FEED DOG TO ITS HEIGHEST POSITION. THE HEIGHT OF THE FEED DOG FROM THE NEEDLE PLATE SHOULD BE 0.75 TO 0.90 MM. IF IT IS NOT IN THE RANGE, ADJUST AS FOLLOWS.

  • Page 17: Needle Bar Height

    MECHANICAL ADJUSTMENT NEEDLE BAR HEIGHT TO CHECK: WHEN THE TIP OF SHUTTLE HOOK MEETS THE LEFT SIDE OF THE NEEDLE IN ASCENDING TRAVEL OF THE NEEDLE FROM ITS LEFT AND LOWEST POSITION, THE DISTANCE BETWEEN THE TOP OF THE NEEDLE EYE AND THE TIP OF THE SHUTTLE HOOK SHOULD BE IN THE RANGE OF 2.9–3.5MM.

  • Page 18: Needle Timing To Shuttle

    MECHANICAL ADJUSTMENT NEEDLE TIMING TO SHUTTLE TO CHECK: THE HEIGHT OF THE NEEDLE POINT FROM ITS LOWEST POINT SHOULD BE IN THE RANGE OF 1.45–1.95 MM WHEN THE TIP OF THE SHUTTLE HOOK MEETS THE LEFT SIDE OF THE NEEDLE AT THE LEFT NEEDLE POSITION IN ASCENDING TRAVEL. ADJUSTMENT PROCEDURE: SET THE PATTERN SELECTOR DIAL AT ( ), STITCH WIDTH CONTROL AT "0".

  • Page 19: Buttonhole Feed Balance

    MECHANICAL ADJUSTMENT BUTTONHOLE FEED BALANCE TO CHECK: WHEN SEWING A BUTTONHOLE, THE STITCHES ON EACH SIDE OF THE BUTTONHOLE SHOULD BE OF THE SAME STITCH DENSITY. A RANGE OF 9–12 STITCHES IN THE “BACKWARD FEEDING” (RIGHT SIDE ROW) AGAINST 10 STITCHES IN THE “FORWARD FEEDING” (LEFT SIDE ROW) IS CONSIDERED ACCEPTABLE.

  • Page 20: Feed Balance On Stretch Stitch

    MECHANICAL ADJUSTMENT FEED BALANCE ON STRETCH STITCH TO CHECK: IF THE STRETCH STITCH PATTERNS ARE DISTORTED WHEN SETTING THE STITCH LENGTH CONTROL AT "S.S." (THERE IS A DIFFERENCE BETWEEN FORWARD FEEDING AND BACKWARD FEEDING, ADJUST AS FOLLOWS: ADJUSTMENT PROCEDURE: REMOVE THE TOP COVER (SEE PAGE 4). SET THE PATTERN SELECTOR DIAL AT ( ), AND THE STITCH LENGTH CONTROL AT "S.S."...

  • Page 21: Bartack Feed Of Buttonhole

    IF THE PAPER IS FED FORWARD, TURN THE ADJUSTING SCREW IN THE DIRECTION OF (C). IF THE PAPER IS FED BACKWARD, TURN THE ADJUSTING SCREW IN THE DIRECTION OF (D). ATTACH THE TOP COVER. (FOR MODEL 415) ADJUSTING SCREW FORWARD FEEDING BACKWARD FEEDING...

  • Page 22: Disengagement Of Cam Follower

    MECHANICAL ADJUSTMENT DISENGAGEMENT OF CAM FOLLOWER TO CHECK: IF THE CLEARANCE BETWEEN THE CAM FOLLOWER AND THE TOP CONVEX OF THE ZIGZAG CAM IS NOT ENOUGH, THE PATTERN SELECTOR DIAL IS BLOCKED OR WILL NOT SELECT THE CORRECT PATTERN. ADJUSTMENT PROCEDURE: SET THE PATTERN SELECTOR DIAL AT ( ) AND THE STITCH WIDTH CONTROL AT ( 5 ).

  • Page 23: Needle Swing In Straight Stitch Sewing

    MECHANICAL ADJUSTMENT NEEDLE IN STRAIGHT STICH SEWING TO CHECK: IF THE NEEDLE SWINGS WHEN RUNNING THE MACHINE WITH ZIGZAG STITCH ( AT WIDTH "0", CORRECT IT AS FOLLOWS: AT THE STRAIGHT STITCH SEWING, ADJUST IT AS FOLLOWS: SET THE PATTERN SELECTOR DIAL AT ( ) AND STITCH WIDTH CONTROL AT (0).

  • Page 24: Buttonhole Length

    MECHANICAL ADJUSTMENT (FOR MODEL 419S/423S) BUTTONHOLE LENGTH TO CHECK: BUTTONHOLE SHOULD BE ABOUT 3 MM LONGER THAN THE LENGTH SET BY R FOOT. IF THE BUTTONHOLE LENGTH IS OUT OF STANDARD RANGE, CHECK AND ADJUST AS FOLLOWS. ADJUSTMENT PROCEDURE: REMOVE THE FACE COVER (SEE PAGE 4). TURN THE ADJUSTING SCREW IN THE DIRECTION OF (A) IF THE BUTTONHOLE STITCH LENGTH IS LONGER THAN THE STANDARD, OR IN THE DIRECTION OF (B) IF THE BUTTONHOLE STITCH LENTH IS SHORTER THAN THE STANDARD.

  • Page 25: Motor Belt Tension

    MECHANICAL ADJUSTMENT MOTOR BELT TENSION TO CHECK: IMPROPER BELT TENSION MAY CAUSE NOISE, OVERLOAD OF MOTOR, SLOW RUNNING OR MOTOR BELT JUMPING. THE BELT DEFLECTION SHOULD BE 7MM –9MM WHEN PRESSING THE MIDDLE OF THE MOTOR BELT WITH APPROXIMATELY 300 GRAMS OF PRESSURE. ADJUSTMENT PROCEDURE: REMOVE THE BELT COVER (SEE PAGE 5).

  • Page 26: Wiring

    WIRING (FOR 110-120V) FROM MOTOR FROM LAMP SOCKET (FOR 220-240V) FROM LAMP SOCKET FROM MOTOR...

  • Page 27: Parts List

    PARTS LIST MODEL (423S, 419S)
  • Page 28 PARTS LIST...
  • Page 29 PARTS LIST PART DESCRIPTION 303602006 TOP COVER UNIT 303009007 TOP COVER 730501011 THREAD GUIDE PLATE UNIT 000160102 ADJUSTABLE NUT 4 735016307 BOBBIN WINDER STOPPER 000101828 SETSCREW 4X16 000071013 PLAIN WASHER 000061205 303010001 CARRYING HANDLE 730015002 HANDLE FIXING PLATE PIN 730016003 HANDLE FIXING PLATE 000107204 TAPPING SCREW 3X12B...
  • Page 30 PARTS LIST (120V)
  • Page 31 PARTS LIST PARTS DESCRIPTION 303626006 FRONT BRACKET UNIT (AUSTRALIA, U.K. & CONTINENTAL EUROPE) 303627007 FRONT BRACKET UNIT (U.S.A. & CANADA) 303018010 FRONT BRACKET (AUSTRALIA, U.K. & CONTINENTAL EUROPE)) 303068015 FRONT BRACKET (U.S.A. & CANADA) 303019000 TENSION RELEASE LEVER 000013903 SNAP RING CS-4 000101404 SETSCREW 4X6 303021108...
  • Page 32 PARTS LIST...
  • Page 33 PARTS LIST KEY PARTS DESCRIPTION 303604008 NEEDLE BAR SUPPORTER UNIT 303020107 NEEDLE BAR SUPPORTER 730022002 NEEDLE BAR SUPPORTER PIN 673022002 SPRING WASHER 000070609 PLAIN WASHER 6 000002507 SNAP RING E-4 000111902 HEXAGONAL SOCKET SCREW 3X4 303605009 NEEDLE THREADER SHAFT UNIT 303016007 NEEDLE THREADER SHAFT 000003508...
  • Page 34 PARTS LIST...
  • Page 35 PARTS LIST KEY PARTS DESCRIPTION 303608002 UPPER SHAFT (UNIT) 102073003 SCREW 102063000 SCREW 000111304 HEXAGONAL SOCKET SCREW 5X5 553245008 HEXAGONAL SOCKET SCREW 000111108 HEXAGON SOCKET SCREW 4X6 743029009 FELT 731312005 FELT 732003003 UPPER SHAFT REAR BUSHING 738634007 CRANK ROD UNIT 735064001 CRANK ROD PIN 000024206...
  • Page 36 PARTS LIST...
  • Page 37 PARTS LIST KEY PARTS DESCRIPTION 303625005 ZIGZAG MECHANISM UNIT 303625108 ZIGZAG MECHANISM UNIT (MODEL 419S) 303028002 INDEX SPRING 303051004 INDEX SPRING 000078319 SETSCREW 3X6 000101404 SETSCREW 4X6 000115205 TP SCREW 4X6 000081005 SETSCREW 4X8 810220003 SETSCREW 303052005 PATTERN SELECTOR DIAL 303610100 FEED REGULATOR UNIT 303029003...
  • Page 38 PARTS LIST...
  • Page 39 PARTS LIST KEY PARTS DESCRIPTION 640603104 HOOK RACE UNIT 640503000 HOOK RACE UNIT 532096007 HOOK 000111304 HEXAGONAL SOCKET SCREW 5X5 647515006 BOBBIN CASE UNIT 102261000 BOBBIN 640018003 HOOK DRIVER SHAFT BUSHING 626045407 735064001 CRANK ROD PIN 000110107 HEXAGONAL SOCKET SCREW 5X5 WP 738023007 LOWER SHAFT CRANK 647142008...
  • Page 40 PARTS LIST...
  • Page 41 PARTS LIST KEY PART DESCRIPTION 730611004 FEED ROCK SHAFT UNIT 730057006 FEED ROCK SHAFT 647066007 FEED DOG BASE 647134007 FEED DOG BASE SHAFT 648019008 FEED DOG BASE SLIDING PLATE 102021202 SETSCREW 000002507 SNAP RING E-4 000111108 HEXAGON SOCKET SCREW 4X6 730184003 FEED DOG 730183002...
  • Page 42 PARTS LIST...
  • Page 43 PARTS LIST KEY PARTS NO. NO. DESCRIPTION 739503308 MACHINE SOCKET UNIT (AUSTRALIA, U.K. & CONTINENTAL EUROPE) 739505403 MACHINE SOCKET UNIT (U.S.A. & CANADA) 000060802 NUT 739037007 MACHINE SOCKET COVER 000107802 TAPPING SCREW 3X10B 000103509 SETSCREW 4X10 303615002 MOTOR UNIT (AUSTRALIA & U.K.) 303616003 MOTOR UNIT (U.S.A.
  • Page 44 PARTS LIST...
  • Page 45 PARTS LIST PARTS DESCRIPTION 303870018 ACCESSORY SET 653802002 SCREW DRIVER 741814003 OIL 102261000 BOBBIN 647808009 SEAM RIPPER/BUTTONHOLE OPENER 540401026 NEEDLE SET 740801004 AUTOMATIC BUTTONHOLE FOOT 743815000 HEMMER FOOT 611406002 ZIPPER FOOT 674401002 HEM GUIDE 042870102 FOOT CONTROL (AUSTRALIA) 033870104 FOOT CONTROL (U.S.A. & CANADA) 042870401 FOOT CONTROL (U.K.) 042870308 FOOT CONTROL (NETHERLANDS) 303800051 INSTRUCTION BOOK (ENGLISH)

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