SERVICE MANUAL 895900-22TABLE OF CONTENTS A, HOW TO REMOVE THE FRONT COVER B, HOW TO REFIT THE FRONT COVER ‘ADJUSTMENTS, HOOK AXLE POSITION AND HOOK GEAR PLAY GAP BETWEEN NEEDLE AND HOOK (NEEDLE CLEARANCE) NEEDLE CENTERING . NEEDLE BAR SWING FEED DOG HEIGHT FEED TIMING AND FEED DOG LIFTER TIMING HOOK TIMING HEIGHT AND ORIENTATION OF NEEDLE BAR HEIGHT AND ORIENTATION OF PRESSER BAR AUTOMATIC FEED (STRETCH STITCH) BUTTONHOLE BALANCING BOBBIN WINDING LOWER TENSION UPPER TENSION * ZIGZAG TIMING * MOTOR BELT TENSION = * TIMING BELT TENSION = * STITCH INDICATOR POSITION Mode? 1600 REPLACEMENT OF STITCH INDICATOR ROPE Model 1600 * Note : For these adjustments the front cover has to be removed. 02.92HOW TO REMOVE THE FRONT COVER 1) Remove light cover and screw 2) Remove screw "B" that holds spool pin. 3) Set stitch selector dial at @) and pull dial out (for model 1600, First unscrew the 2 screws of the dial with a 2mm hexagonal wrench). Remove front panel by pulling it towards you with your fingers. 4) Lay machine down and remove base and screws " 5) Remove forward/reverse adjusting knob by sliding it towards the right and placing a thin screwdriver between knob and shaft. 6) Pull lock down with a small screwdriver. Turn flywheel to raise thread take-up lever to its highest position. 7) Push left lower corner strongly; hook holding front cover will come off, Lift front cover up slowly.1) 2) 3) 4) 5) 6) 7) 8) 9) HOW TO REFIT THE FRONT COVER Turn flywhee? to raise thread take-up lever to its highest position, Lower presser foot. Move stitch width lever, connected to zigzag unit to the left. Set stitch width cursor on front cover at " Refit front cover so that tension releasing lever fits between notch of tension guide. Press left lower position of cover strongly; it will snap into place. Check thread tension release and stitch width mechanisms before fitting screws. Tighten screws "A", "BY and "D". Press lock upwards. Insert forward/reverse adjusting knob with its hook facing to the rear. Refit base, light cover, front panel and stitch selector dial at @) Tighten both screws of stitch selector dial (only for Model 1600).HOOK AXLE POSITION AND HOOK GEAR PLAY Remove : Needle plate, needle, sewing foot and bobbin case. Check : a) That hook has no axial play. (Too much play could cause noisy running and too little play could sTow down the machine). b) That gap at the tip of hook is between 0 and 0,5 mm. Adjustment of hook axle position 1) Lay machine down, remove bed lid and loosen screw 2) Push on top of hook axle "B", just enough to eliminate play but without binding effect. Tighten screw "A" while pushing. 3) Check if there is no axial play. Adjustment of hook gear play 4) Loosen slightly 3 screws "C" to move base "D" with friction. 5) Adjust backlash by moving base "D" up or down. Tighten screws "C" temporarily. 6) Set needle plate and check that feed dog does not touch needle plate. If it touches, rotate base "D" slightly. 7) Tighten screws "C" securely. Then check needle clearance (adjustment [2]). A O2 amGAP BETWEEN NEEDLE AND HOOK (NEEDLE CLEARANCE) 2 If the needle hits the hook, it could be the cause of needle and thread breakages. If the gap is too big, it will cause skipping of stitches. Check and adjust as follows + Check + 1) Remove sewing foot, needle plate and bobbin case. 2) Set stitch selector dial at (@) and stitch width cursor at "0". 3) Fit gauge 100'240, 4) Turn flywheel forwards and check that hook grazes gauge slightly or bend it less than 0.1 mm Adjustment 5) Remove light cover and lock screw cap. 6) Loosen (do not remove) lock screw 7) Adjust gap by turning adjusting nut "B" with a 10 mm wrench : If gap is too big, turn nut upwards. If needle is hitting hook, turn nut downwards. 8) Tighten lock screw and re-check gap. 9) Replace bobbin case, needle plate, Tight cover and lock screw cap. too20 rs. z Awa) Soe yes > ‘ \ a = 0.10 mm maxiNEEDLE CENTERING 1) Set stitch selector dial at (@) and stitch width cursor at " 2) Remove sewing foot, light cover and thread guide plate. 3) Loosen screw "A" located on left side of needle bar. Turn eccentric pin "B" either to the left or the right so that needle is in correct position. 4) Tighten screw "A" and recheck position of needle bar swing. Note : It is very important that the eccentric pin "B" is positioned so that the needle bar guide rod "C" is shifted away from the head block when the needle is in the center position, as illustrated below.NEEDLE BAR SWING Check = 1) Set stitch selector dial at G) and stitch width at maxinum. 2) Turn handwheel forwards and check that there is an equal gap between the needle and both sides of the needle plate slot. If, not, adjust as follows : Adjustment : 1) Check, and if necessary do adjustment ], Needle centering. 2) Remove front cover (procedure[A]). 3) Turn screw "A" on the cam assembly either to the left or the right to obtain the correct needle swing position, as illustrated below. Note : Do not turn the nut holding the screw A", since it is a self, locking nut preventing the screw to turn by itself.FEED DOG HEIGHT If the feed dog does not protrude sufficiently above the needle plate, it will cause insufficient and/or uneven feed of the fabric. The feed dog should protrude above the needle plate about 0.75-0.85 mm. If not, it should be adjusted as follows : 1) Remove bed lid by removing its screw and sliding it to the left. 2) Lower presser foot lifter. Turn flywheel until feed dog is at its highest position. 3) Loosen lock nut "A", Adjust height of feed dog so that it protrudes above needle plate about 0.75-0.85 mm by turning inner screw "B" clockwise or counter-clockwise. 4) Tighten lock nut "A". 5) Re-check adjystment by turning flywheel; then check feed timing (adjustment [5]). Adjusting Serew 8 . 0.75-0.85 mm PAAVANAAVATAYANFEED TIMING AND FEED DOG LIFTER TIMING Ls | FEED TIMING Set at maximum stitch length. Place thread take-up lever at its highest position. Check When turning flywheel slowly forwards, feed dog must stil] move forwards for 1 mm while thread take-up lever is going down. Adjustment : 1) Remove bed Tid by removing its screw and sliding it to the left. 2) Guide lines on lower shaft and feed cam must be aligned. 3) If not, loosen both screws "A" on the feed cam, Turn feed cam to align guide lines, then tighten screws "A", Guide Lines FEED DOG LIFTER TIMING (UI Check + Turn flywheel forwards until needle bar is at its lowest position. The guide line on feed rocking cam must be directly underneath lower shaft. If not, adjust as follows : Adjustment, 4) Loosen both screws "B" on lower shaft belt pulley. 5) Replace needle bar at its lowest position and turn lower shaft to position guide Tine correctly. 6) Tighten both screws "B" on Tower shaft belt pulley. 7) Then check hook timing (adjustment [6]). EE as Set Strews: Guide LineHOOK TIMING Check the hook timing as per the following procedure : 1) Set stitch selector dial at () and stitch width lever at "0 Remove needle plate and bobbin case. Fit gauge 100'240. 2) Turn flywheel forwards until needle bar is at its lowest position. Fit gauge 101360 so that it touches cradle, then turn flywheel slowly forwards until sliding part of gauge is fully compressed. 3) Check if tip of hook is in a position that corresponds to a timing of 2.30 to 2.50 mm, as shown on sketch. If not, adjust as follows : 4) Remove bed lid by removing its screw and sliding it to the left. Remove gauge 101'360 to be able to loosen both screws "A" on lower shaft gear. 5) Refit gauge 101'360 and proceed according to point 2). 6) Turn hook by hand until its tip is in axis of gauge and tighten temporarily one screw "A". 7) Turn flywhee! enough backwards to eliminate any gear play, then forwards to check timing according to point 3). 8) When correct timing is obtained, tighten both screws machine and check height and orientation of needle bar jo vono LIL 7 re 100240 —I Set Screws A © 2.5 mmHEIGHT AND ORIENTATION OF NEEDLE BAR Check + 1) Set stitch selector dial at G@) and stitch width cursor at 2) Remove needle plate, bobbin case and needle. 3) Fit gauge 100'230, When turning flywheel forwards, point of hook should just graze gauge 100'230, Caution : When turning flywheel backwards, gauge touches point of hook Do not force to avoid damaging point of hook. Adjustment : 4) Remove light cover. Place needle bar at its lowest position, then loosen screw " so that needle bar can slide with friction, slightly, 5) Turn flywheel forwards to set point of hook at "12 o'clock", (if necessary, slide needle bar upwards). 6) Slide needle bar so that gauge rests on point of hook and set groove of needle bar so that it is facing you. 7) Turn flywheel forwards until needle bar is at its lowest position and tighten screw "A". 8) Check height of needle bar according to point 3) and reassemble machine.HEIGHT AND ORIENTATION OF PRESSER BAR Ls | Check : 1) Fit metallic sewing foot, raise presser bar. 2) Set feed dog below needle plate. 3) Check that 5.5 mm gauge can just be inserted between sewing foot and needle plate. Adjustment : 4) Remove light cover and light bulb. 5) Loosen screw "A" and place gauge between sewing foot and needle plate. 6) Lower presser bar so that it touches gauge while aligning presser foot edge parallel to feed dog slot of needle plate, then tighten screw "A". 7) Presser bar lifter must have a slight play in down position.AUTOMATIC FEED (STRETCH STITCH) Check + 1) Set stretch stitch shown on sketch, stitch width cursor at maximum and stitch length dial at 2) Set forward/reverse adjusting knob located on right side of machine at horizontal position. 3) Sew on a medium cotton fabric. If stitch is too open or too close, adjust as follows : Adjustment : 4) Locate position of stitch selector dial and remove it by pulling it towards you. Remove front panel by pulling it towards you with your fingers. 5) If stitch is too open, turn adjusting screw "B" to the right; if stitch is too close, turn screw in opposite direction. Note : Adjust step by step but never loosen locking nut of screw " 6) Attach front panel and insert stitch selector dial in correct position. a SS unscrew SS Ss ——s & SS tomoriom — SS 2% a Tum ScrewB ><> — BBQ Tone Let BtBUTTONHOLE BALANCING Check + 1) Fit buttonhole foot, set stitch length knob at center of buttonhole mark. Set stitch selector dial at buttonhole position and stitch width cursor at " 2) Set forward/reverse adjusting knob "A", located on right side of machine, at horizontal position, 3) Sew a buttonhole on a medium cotton fabric. Adjustment 4) Locate position of stitch selector dial and remove it. Remove front panel and refit stitch selector dial in correct position. 5) If the reverse stitch is longer than the forward stitch, turn adjusting screw "B" to the left. If the reverse stitch is shorter than the forward stitch, turn screw to the right. Note : Adjust step by step but never loosen locking nut of screw 6) Reassemble machine, Make sure that stitch selector dial is correctly positioned. Buxenhole Adjusting screw Turn Screw B oe To the Right see Tothe Let 4 i Tun SerewBOBBIN WINDING A, If bobbin winds unevenly, adjust as follows : 1) Remove cap at the rear of arm. 2) Loosen (do not remove) screw that holds bobbin winder. 3) If bobbin winds like shown on illustration "A", tilt bobbin winder to the left, 4) If it winds like "BY, tilt it to the right. 5) Tighten screw securely and refit cap, 8. If bobbin is overfilled or not filled sufficiently, adjust bobbin winder stop as follows : 1) If bobbin is overfilled, loosen screw left. of stop and push latter to the 2) If it is not filled sufficiently, push it to the right. 3) Tighten screw "C" and check that winding stops 1 mm from edge of bobbin.LOWER TENSION Check : 1) Remove slide cover. 2) Use preferably an Nm 50/3 silk thread or an Nm 60/2 embroidery thread. 3) Insert a 80 % wound bobbin, Measure the tension by pulling thread slowly through needle plate slot with tension spring balance 101'670. There must be a tension of about 20 - 25 g. Adjustment + 4) If necessary, adjust with screw "A" Turn clockwise to increase tension or counter-clockwise to decrease ite Decrease Increase 12UPPER TENSION | 13 Use preferably an Nm 50/3 silk thread or an Nm 60/2 embroidery thread. Check : _ Set tension wheel at "4" and thread machine according to illustration. Lower presser bar and pull thread downwards slowly, with tension spring balance 101'670. There must be a tension fl D of about : ~ 140 - 150 g with Nm 50/3 silk thread. ~ 130 - 140 g with Nm 60/2 embroidery thread. If value is too far off, adjust basic tension as follows Adjustment 1) Remove front cover (procedure [A]) 2) Remove the 3 screws "A" of thread tension regulator. 3) Loosen lock nut "B", 4) Turn nut "C" clockwise to increase tension and counter-clockwise to decrease it. There must be a tension of about 80 g. 5) Tighten screw "B", then reassemble machine.ZIGZAG TIMING Check : 1) Set stitch selector dial at (@)_ and stitch width at maximum. 2) Run machine at full speed and observe one of the shiny spots on needle clamp, which must describe a single arch. If not, proceed as follows : Adjustment : 3) Reiove front cover (procedure fp, Loosen the 3 screws "A" on worn "3, 4) With one screw "A", hold worm "B" against ring "C" while turning upper shaft to another position and tighten screw temporarily. 5) Check according to step "2". Tighten the 3 screws "A", once the single arch has been obtained. 6) Refit front cover (procedure [BMOTOR BELT TENSION When the belt tension is too slack, it will cause noise and when it is too tight, it will slow down the machine. 1) Remove foot control and front cover (procedure [A]). Check a) That belt does not touch casing or other parts. b) That belt has a flexibility of 5 ~ 6 mm when average pressure is applied laterally. Adjustment + 2) If not, loosen both screws "A" and push motor downwards. Tighten one of the screws temporarily and adjust position of motor according to points a) and b). Tighten both screws "A" and check whether machine runs perfectly at full speed. 3) Check timing belt tension (adjustment [16] ).TIMING BELT TENSION 16 First adjust motor belt tension (adjustment ds then : 1) Check + That belt has a flexibility of 4 - 5 mm when average pressure is applied laterally. Adjustment : 2) If not, loosen screw " tightening screw "A", Push idle pulley downwards while Check flexibility of belt and readjust, if necessary. 3) Check whether machine runs perfectly at full speed, then reassemble it (procedure deSTITCH INDICATOR POSITION Mode? 1600 Check + 1) Turn the stitch selection dial and check that the red mark of stitch indicator should fit in the window of selected stitch pattern. Adjustment : 2) Remove the stitch selection dial and front panel. 3) Refit the stitch selection dial and turn it until the screws "A" comes to visible. 4) Loosen the screws "A". Turn the rope winder "B" right or left and adjust the positioning of stitch indicator. 5) The correct position is located, tighten the screws "A". 6) Refit front cover and stitch selector dial. Stitch Indicator EStTQ} Uy aH UEVEEREPLACEMENT OF STITCH INDICATOR ROPE Model 1600 [18 | To replace the stitch indicator rope, and adjust the indicator position, proceed as follows t 1) Turn the stitch selection dial clockwise to it's stop position, (right row of the buttonhole). 2) Remove front cover (procedure A). 3) Remove the 2 set screws "A" holding the cap for the indicator rope winder. 4) Remove the indicator rope from the winder 5) Attach the stitch indicator "C" to the new rope, and position it so that the correct rope length is obtained on both sides, as illus~ traded below. c — = — (Bes ~—| et——\\ \\ 6) Turn the indicator rope winder "B", so that pin is positioned at 8 o'clock.