SERVICE MANUAL & PARTS LIST
Contents
1. Needle bar supporter 0 05 TO 40 10 mm D 4 amp H F Figure D en Clearance between needle and needle plate should be at least 0 15 mm 13 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 1 Setthe pattern selector dial at CD E 2 Remove the rear cover See page 7 3 Loosen the screw A on the lower shaft bushing and slide the gear about 0 5 mm to the right to create some slack between the gears 4 Lower the needle and loosen the two shuttle race screws B Move the shuttle race unit axially either forward or backward to adjust the clearance between the needle and the shuttle race in the range of 0 05 to 0 10 mm 5 Setthe pattern select dial at turn the handwheel to check if the clearance between the needle and inner edges of the shuttle race spring at the left and right needle drops are equal If not adjust by turning the shuttle race unit 6 Tighten the two shuttle race screws B 7 Loosen the set screw on the lower shaft bushing and slide the gear back to the original position while adjusting the backlash 8 Tighten screw A firmly 9 Attach the rear cover NOTE The backlash play should be less than 0 32. PARTS DESCRIPTION NO NO 1 744004001 Needle plate 2 681009101 Setscrew 3 735950003 Lower shaft gear unit 4 000110107 Hexagonal socket screw 5x5 wp 5 000036201 Washer 8 0 5 6 735233003 Bushing 7 735061101 Feed lifting cam 8 000111304 Hexagonal socket screw 5x5 9 735236006 Lower shaft 10 102261000 Bobbin 11 822070003 Felt 12 735234004 Bushing 13 6390360038 Lower shaft crank arm 14 639037004 Pin 15 000001609 Snap ring E 5 16 735610101 Shuttle race body unit 17 532096007 Shuttle hook 18 647515006 Bobbin case unit 35 PARTS LIST PARTS LIST KEY PARTS DESCRIPTION NO NO 1 735612000 Feed rock shaft unit 2 735078008 Feed rock shaft 3 735079009 Feed bar 4 735080003 Feed bar shaft 5 000002507 Snap ring E 4 6 000111201 Hexagonal socket screw 4x4 7 735081004 Feed dog 8 735082005 Setscrew 9 735083006 Feed bar spring 10 735084007 Feed rock shaft center 11 735085008 Feed rock shaft center plate 12 000101404 Setscrew 4x6 13 301609007 Feed lifting arm unit 14 301027005 Feed lifting arm 15 000002806 Snap ring E 6 16 735276008 Ring 17 735087000 Feed lifting pin 18 735088001 Feed lifting roller 19 730061003 Feed lifting spring 20 735090006 Feed lifting shaft 21 000097200 Setscrew 4x12 22 739022009 Feed lifting shaft holder 23 000081119 Setscrew 4x6 24 743012009 Feed rod 25 743013000 Feed rod spring 26 102141003 Feed regulator slide block 27 735071104 Feed rock shaft co
3. Use A 11 blue tip needle See mechanical adjustment Needle bar height See mechanical adjustment Needle timing to shuttle See mechanical adjustment Clearance between needle and hook REFERENCE 2 Fabric not moving Incorrect feed dog height Thread on bottom side of fabric is jammed up Feed dog teeth are worn See mechanical adjustment Feed dog height Make sure to bring both needle and bobbin thread under the foot when starting sewing Change the feed dog PROBLEM 3 Breaking upper thread Initial sewing speed is too fast Thread path is incorrect Needle is bent or dull Upper thread tension is too strong Needle size is inappropriate for fabric Needle eye is worn Needle hole in needle plate is worn or burred REMEDY Start with medium speed Use the proper thread path Replace with a new needle Adjust upper thread tension correctly Use appropriate needle and thread for fabric in use Change the needle Repair the hole or replace the needle plate REFERENCE 4 Breaking bobbin thread Incorrectly thread bobbin case Too much thread is around on the bobbin Lint is stuck inside the hook race Thread quality is too low Thread is jamming around the bobbin Bobbin thread tension is too strong Thread bobbin case correctly Adjust the position of stopper Clean the hook
4. KEY PARTS DESCRIPTION NO NO 1 740007013 Lamp socket set plate 2 000081005 Setscrew 4x8 3 730024004 Needle bar supporter spring 4 000101404 Setscrew 4x6 5 743634003 Lamp socket unit 6 000009009 Lamp 240V 7 000053008 Cord tir band 8 301610001 Needle bar supporter unit 9 301032003 Needle bar supporter 10 730022002 Needle bar supporter pin 11 673022002 Wave washer 12 000070609 Plain washer 13 000002507 Snap ring E 4 14 000111304 Hexagonal socket screw 5x5 15 735119002 Zigzag rod 16 748021006 Washer 17 000111902 Hexagonal socket screw 3x4 18 678084007 Eccentric pin 19 730503116 Needle bar unit 20 000002806 Snap ring E 6 21 735504008 Needle bar crank pin unit 22 102408089 Needle HA 1 14 23 680504005 Needle bar connecting stud unit 24 000111201 Hexagonal socket screw 4x4 25 625506109 Thread take up lever unit 26 731511006 Thread take up pin unit 29 PARTS LIST 30 PARTS LIST KEY PARTS DESCRIPTION NO NO 1 304607004 Upper shaft unit 2 639113016 Clutch spring 3 000081005 Setscrew 4x8 4 650070509 Clutch cap 5 102073003 Setscrew 6 761052007 Setscrew K 000036717 Thrust washer 8 732025001 Upper shaft front bushing 9 639095000 Ring 10 000111304 Hexagonal socket screw 5x5 11 749011109 Worm 12 000111201 Hexagonal socket screw 4x4 13 000022802 Spring pin 14 731312005 Felt 15 304609006 Crank rod unit 16 304042005 Feed cam 17 743011008 Crank rod 18 304044007 Crank cam 19 30404300
5. race Change to a high quality sewing thread Clear out the jamming thread Adjust bobbin thread tension correctly 5 NEEDLE BREAKS Needle is hitting the needle plate Needle is bent or worn Needle is hitting the hook race The fabric moves while the needle is piercing it or the needle zigzags while in fabric Fabric is being pulled too strongly while sewing See mechanical adjustment Needle drop Change the needle See mechanical adjustment Clearance between needle and hook See mechanical adjustment Needle swing Guide the fabric gently while sewing PROBLEM 6 Noisy operation 1 Backlash between shuttle hook gear and lower shaft gear is too great Lower shaft gear is loose Inappropriate belt tension Upper shaft gear is loose Not enough oil REMEDY See mechanical adjustment Clearance between needle and hook NO 2 Eliminate the looseness See mechanical adjustment Motor belt tension Eliminate the looseness Oil all moving parts REFERENCE 7 Deformation of pattern Inappropriate zigzag synchronization Inappropriate disengagement of cam follower Upper thread tension is too strong Inappropriate feed balance See mechanical adjustment Needle swing See mechanical adjustment disengagement of cam follower Adjust upper thread tension correctly See mechanical adjust
6. 6 Crank cam plate 20 000161309 Tapping screw 3x12 21 000110107 Hexagonal socket screw 5x5 22 732003003 Upper shaft rear bushing 23 000172602 Setscrew 5x8 24 743029009 Felt 25 000030205 Snap ring E 8 26 743019006 Belt wheel 27 000023803 Spring pin 28 743630009 Handwheel unit 29 639097024 Handwheel 30 743030003 Balance weight 31 000121400 Tapping screw 3x14 B 31 PARTS LIST PARTS LIST KEY PARTS DESCRIPTION NO NO 1 735017308 Handle 2 740011009 Handle shaft 3 000002105 Snap ring E 3 4 740010008 Handle supporter 5 000081005 Setscrew 4x8 6 740602209 Bobbin winder base plate unit 7 735501005 Bobbin winder arm unit 8 740003101 Bobbin winder base plate 9 740042009 Bobbin winder arm spring 10 000002806 Snap ring E 6 11 736607016 Feed regulator unit 12 000160102 Adjustable lock nut 4 13 648010009 Setscrew 14 740096008 Feed regulating rod 15 735077007 Feed regulating body spring 16 735073003 Plain washer 17 000013800 Snap ring CS 6 18 745052007 Reverse link 19 000172602 Setscrew 5x8 20 670100006 Feed regulator spring 21 743667005 Zigzag mechanism unit 22 659013006 Index spring 23 000103808 Setscrew 3x5 24 743015002 Pattern selector dial 25 743208107 Dial ind plate 26 000172602 Setscrew 5x8 27 743014001 R button 28 739063002 R button spring 29 736015000 R button shaft 30 740624001 Handle shaft unit 31 000014007 Snap ring CS 4 33 PARTS LIST PARTS LIST KEY
7. ISENGAGEMENT OF CAM FOLLOWER To check Too narrow clearance between the cam follower and the top convex of zigzag cam may often cause difficulty in turning of the pattern selector dial this can also cause unintended patterns to become selected or make zigzag stitch in straight stitch setting Adjustment procedure 1 Remove the front cover See page 6 Mount the pattern selector dial and set it at pattern CD 5th as viewed from CH Turn the handwheel to put the cam follower onto the top convex of the zigzag cam Loosen the setscrew Push the convex part of the cam follower releasing arm in the direction of arrow until the cam follower releasing arm touches to position A of the pattern select cam and then tighten the setscrew NOTE After this adjustment check that the clearance between the zigzag cam and the cam follower is 0 3mm when the cam follower releasing arm has removed to position B by turning the pattern selector dial counterclockwise and also the clearance between the cam follower and the zigzag cam should be 0 3mm Remove the pattern selector dial and mount the front cover Setscrew Pattern select cam Convex part Position B Position A 20 MECHANICAL ADJUSTMENT MOTOR BELT TENSION To check 1 Too tight or too loose motor belt tension may create belt noise and also too tight motor belt tension can cause the machine to run slow and will overload the motor Too l
8. SERVICE MANUAL amp PARTS LIST MODEL IT1011 CONTENTS TROUBLESHOOTING ticas 1 3 SERVICE ACCESS FACE COVER BELT COVER ape teen gies 4 BASE PLATE citet ee dienen all 5 FRONFSOVER M EM 6 REAR COMER iii ade 7 MECHANICAL ADJUSTMENT TOP TENSION BOBBIN TENSION eren ne lehnen 9 PRESSER BAR HEIGHT AND ALIGNMENT 2 2 10 NEEDLE SWING ar are raader dede 11 NEEDLE DROP n 12 CLEARANCE BETWEEN NEEDLE AND HOOK ADJUSTMENT METHOD NO 1 13 CLEARANCE BETWEEN NEEDLE AND HOOK ADJUSTMENT METHOD NO 2 14 FEED DOG HEIGHT assistant 15 NEEDLE BAR HEIGHT een Eis 16 NEEDLE TIMING TO SHUTTLE a eat 17 BUT TONHOLE FEED BALANCE 5 tenet ita ias 18 BARTACK FEED OF BUT TONHOLE ocio 19 DISENGAGEMENT OF CAM FOLLOWER eee 20 MOTOR BELT TENSION Sucia be cese be t te Et geed 21 WIRING EA 22 PARTS LIST e en eo nl es 23 41 PROBLEM 1 Skipping stitches TROUBLESHOOTING Needle is not inserted properly Needle is bent or worn Incorrectly threaded Needle or thread are inappropriate for fabric being sewn Sewing on stretch fabric Inappropriate needle bar height Inappropriate needle to hook timing Inappropriate needle to hook clearance REMEDY Insert the needle properly Change the needle Rethread Use the recommended sewing needle and thread
9. e needle drop positions should be equal If not adjust as follows Adjustment procedure Remove the face cover See page 4 Set the pattern selector dial at maximum zigzag width Loosen the screw Turn the eccentric pin to adjust the needle drop Tighten the screw Attach the face cover NOTE Check the hook timing after this adjustment D gi oe o N o Screw Eccentric pin Both clearances should be equal 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 1 Remove the face cover See page 4 2 Set the pattern select dial at ci 3 Loosen screw A and move the needle bar supporter in the direction of the arrows to get a clearance between 0 05 to 0 10 mm If clearance is too wide move the needle bar supporter to direction B If clearance is too narrow move the needle bar supporter to direction C NOTE After this adjustment check that the clearance between the needle and needle plate is more than 0 15 mm as shown in figure D if not adjust the clearance between needle and shuttle race by using adjustment method above after readjust the clearance between needle and needle plate more than 0 15 mm 4 Attach the face cover Screw A Direction C e e Direction B
10. ew 3x8B 25 743004008 Extension table 26 743602035 Face cover unit 27 743005906 Face cover 28 000061319 Nut 29 724025006 Reflex sticker 30 739005006 Base plate 31 735616200 Rubber base unit 32 735002001 Rubber base 33 000097901 Flat screw 5x18 34 000103509 Setscrew 4x10 35 840602006 Thread cutter unit 25 PARTS LIST 26 PARTS LIST KEY PARTS DESCRIPTION NO NO 1 305604004 Presser bar base plate unit 2 735221008 Presser bar base plate 3 735222009 Needle drop adjusting plate 4 000101404 Setscrew 4x6 5 735025000 Needle bar supporter stopper 6 000138307 Bolt 4x8 7 735026001 Presser bar 8 735027002 Presser bar spring 9 735028003 Presser bar bracket 10 000111500 Hexagonal socket screw 4x8 11 735029004 Presser foot lifter 12 000001609 Snap ring E 5 13 735030008 Tension release lever 14 000013903 Snap ring CS 5 15 000081005 Setscrew 4x8 16 000070506 Washer 17 301612003 Presser foot unit 18 660106001 Thumb screw 19 739605002 Tension release arm unit 20 739017001 Tension release arm base 21 739018002 Tension release arm 22 739019003 Tension release spring 23 000002105 Snap ring E 3 24 743501000 Tension assembly unit 25 000103808 Setscrew 3x5 26 739016000 Top cover thread guide 27 000101703 Setscrew 4x12 28 611510000 Food hopler unit 29 301505002 Zigzag foot unit 27 PARTS LIST 28 PARTS LIST
11. ment Feed balance on stretch stitch Buttonhole feed balance SERVICE ACCESS FACE COVER 1 Remove the face cover by removing the setscrew BELT COVER 1 Loosen setscrew 2 Take the belt cover out SERVICE ACCESS BASE PLATE Base plate 1 Loosen the setscrews 2 Remove the base plate To attach 3 Mount the base plate by four setscrews SERVICE ACCESS FRONT COVER e Front Cover remove 1 Remove the face cover and remove the belt cover See page 4 2 Remove dial A 3 Loosen setscrews C D E F and and then remove the front cover by removing setscrews 1 AND J NOTE Remove the front cover in the order of K To attach 4 Mount the front cover in reverse procedure of the removing SERVICE ACCESS REAR COVER To remove 1 Remove the face cover and belt cover See page 4 NOTE Pull up the spool pins 2 Loosen setscrews A B C and D 2 pcs and then remove the rear cover by removing setscrews E F G and H NOTE Remove the rear cover in the order of X lower part gt Y upper part gt Z presser foot lifter part remove the bed cover together To attach 3 Mount the rear cover in reverse procedure of the re
12. mm and the lower shaft should turn smoothly After the adjustment check the hook timing Lower shaft bushing front Clearance should be equal cH o Needle Shuttle race screws B 2 Shuttle race spring MECHANICAL ADJUSTMENT FEED DOG HEIGHT To check 1 2 Lower the presser foot Turn the handwheel toward you until the needle bar comes to the feed dog above the needle plate should be 0 75 0 90 mm If itis not in the range adjust as follows Adjustment procedure 1 2 o e ZS Open the shuttle cover Lower the presser foot and turn the handwheel toward you until the feed dog comes to its highest point Loosen the screw A Turn the feed lifting pin to adjust the height of feed dog 0 75 0 90 mm Tighten the screw A Turn the handwheel toward you to recheck the height of feed dog Needle plate i e Screw A Feed lifting pin 15 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 5 mm Adjustment procedure 1 Remove the face cover Set the pattern selector dial at ci gt Open the shuttle cover Remove the shuttle race ring Turn the handwheel toward you until the tip of the shuttle h
13. moving 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 B with setting the tension dial at 3 make sure the foot should be lowered If the tension is out of the standard range adjust it as follows Adjustment procedure 1 Remove the front cover unit See page 6 2 Turn the adjusting nut in the direction of D when the upper thread tension is too tight Turn the adjusting nut C in the direction of E when the upper thread tension is too loose 3 Attach the front cover unit 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 45 550 when pulling the thread in the direction of If the tension is out of the range adjust it as follows Adjustment procedure 1 Turn the adjusting screw C in the direction of D when the bobbin thread tension is too tight 2 Turn the adjusting screw C in the direction of E when the bobbin thread tension is too loose MECHANICAL ADJUSTMENT PRESSER BAR HEIGHT AND ALIGNMENT To check 1 Raise the presser foot lever A 2 The distance between the presser foot D and the needle plate E should be 6 0 mm 0 24 Adjustment procedure 1 Remove the face cover See page 4 2 Remove the presser foot lever and l
14. nnecting pin 28 740013001 Drop feed selecting plate 37 PARTS LIST 38 PARTS LIST KEY PARTS DESCRIPTION NO NO 1 743611004 Motor assy 2 743025005 Motor set plate 3 024070108 Motor assy 4 000201209 TP screw 5x12 5 739503308 Machine socket unit 6 000060802 Nut 7 739037007 Machine socket cover 8 000103509 Setscrew 4x10 9 000107802 Setscrew 3x10 10 743017004 Belt cover 11 000115205 TP screw 4x6 12 650166008 Motor timing belt 39 PARTS LIST PARTS LIST KEY PARTS DESCRIPTION NO NO 1 743870380 Accessory set 2 102261000 Bobbin 3 647808009 Seam ripper 4 639804000 Needle set 5 611411000 Blind foot 6 611406002 Zipper foot 7 611413002 Slide buttonhole foot 8 042970402 Foot control 9 743801829 Instruction book 10 743812100 Cover 41
15. ook meets the left side of the needle Loosen the lower shaft crank arm screw A 7 Adjust the height of the needle bar by moving the needle bar upward or downward without turning it 8 Tighten the screw 9 Attach the shuttle race ring IREN Tip of shuttle hook meets left side of needle 2 9 3 5 mm Screw A lt gt Fi Needle bar 16 MECHANICAL ADJUSTMENT NEEDLE TIMING TO SHUTTLE To check The height of the needle point from its lowest point of travel should be in the range of 1 45 1 95 mm when the tip of the shuttle hook just meets the left side of the needle at the left needle position Adjustment procedure T ae D 9 10 11 Set the pattern selector dial at Ci Remove the base See page 5 Open the shuttle cover Remove the shuttle race ring Turn the handwheel toward you until the tip of the shuttle hook meets the left side of the needle Loosen the lower shaft crank arm screws A While holding the shuttle hook so it doesn t turn turn the handwheel toward you until the needle comes to its lowest position Then further turn the handwheel to raise the needle about 1 7 mm from its lowest position Tighten the screws A Turn the handwheel toward you to check if the height is in the range of 1 45 1 95 mm If it is not in this range repeat the above procedure Attach the shuttle race ring Attach the base Lower shaft crank arm L
16. oose motor belt tension may cause jumping of the belt teeth on the motor pulley 2 The correct motor belt tension is that the deflection of motor belt is about 7mm 0 28 9mm 0 36 when pushing the motor belt by finger at about 300 grams load Adjustment procedure 1 Remove the belt cover See page 4 2 Loosen the screws A and B 3 Move the motor up or down to adjust the deflection about 7mm 0 28 9mm 0 36 4 Tighten the screws A and B Deflection 7 9mm 21 WIRING 1 WIRING FOR MACHINE SOCKET UNIT From lamp socket From motor 22 PARTS LIST IT1011 PARTS LIST 24 PARTS LIST KEY PARTS DESCRIPTION NO NO 1 743617309 Rear cover unit 2 743003063 Rear cover 3 652205109 Spool pins 4 739064003 Bed rubber base 5 736007009 Spool pin spring 6 000161206 Tapping screw 3x10 7 735013005 Spool pin spring base 8 730006000 Spring 9 000101404 Setscrew 4x6 10 000061205 Nut 11 739004005 Bed cover 12 000115205 TP screw 4x6 13 000081005 Setscrew 4x8 14 000121905 Tapping screw 4x12 B 15 653006101 Cap 16 743608190 Front cover unit 17 743100706 Front cover 18 730501011 Thread guide plate unit 19 000160102 Adjustable locl nut 4 20 735016307 Bobbin winder stopper 21 000071013 Washer 22 000103107 Setscrew 4x14 23 740022003 Thread guard plate 24 000107307 Tapping scr
17. oosen the screw C on the presser bar holder Adjust the distance between the presser foot D and the needle plate D to 6 0 mm 0 24 3 Tighten the screw C securely Tighten the screw B to secure the lamp socket 5 Attach the face cover NOTE When you tighten the screw B make sure that both sides of the presser foot are parallel to the feed dog slots F on the needle plate gt 6 0 mm 10 MECHANICAL ADJUSTMENT NEEDLE SWING To check Adjust the needle swing according to the following procedure If the needle bar starts moving sideways while the needle is in the fabric at sewing the zigzag pattern with maximum zigzag width Adjustment procedure 1 Set the pattern selector dial with maximum zigzag width and remove the front cover See page 6 Loosen two screws Adjust the needle swing by turning the handwheel while holding the worm so as not to rotate it until the needle swing starts at 2 3 mm on the needle plate after the needle has come out of the right side of the needle hole Tighten two screws Mount the front cover NOTE After adjusting the needle swing check that the upper shaft worm and gear rotate smoothly without any backlash between them Gear Upper shaft worm 2 3 mm 11 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 th
18. ower shaft Y tal 1 45 1 95 mm A Lowest position 17 MECHANICAL ADJUSTMENT BUTTONHOLE FEED BALANCE To check When sewing buttonhole the stitches on each side of buttonhole should be the same stitch density The range of 9 12 stitches in the right side row backward feeding against 10 stitches in the left side row forward feeding is considered acceptable Adjustment procedure 1 Confirm the stitches by sewing buttonholes and remove the cap 2 Turn the adjusting screw in the direction of C in case of A right stitches are rough or in the direction of D in case of B left stitches are rough 3 Mount the cap A B D A gt 2 c NS SS Notch N E Forward feeding Backward feeding hc Adjusting screw NY 18 MECHANICAL ADJUSTMENT BARTACK FEED OF BUTTONHOLE To check If the material is feed forward or backward when sewing bartack on buttonhole make an adjustment as follows Adjustment procedure 1 Set the pattern selector dial at 2 and the stitch length dial at 4 2 Remove the front cover See page 6 3 Place a piece of paper under the foot and turn the handwheel If the paper is feed forward turn the adjusting screw in the direction of C If the paper is feed backward turn the adjusting screw in the direction of D 4 Attach the front cover D C Adjusting screw Stitch length dial 19 MECHANICAL ADJUSTMENT D
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