1. Service Manual
Edited by: Greg Stavros
Revised: 10/31/13

3. Table of Contents
Required Tools and Gauges …………………………………………………………………...
Base Plate and Bed Cover Removal ………………………………………………………….
Belt Cover Removal …………………………………………………………………………….
Top Cover Removal …………………………………………………………………………….
Front Panel Removal …………………………………………………………
Parts of the Front Panel ………………………………………………………………………..
Printed Circuit Board ‘A’ Removal ……………………………………………………………..
Printed Circuit Board ‘A’ Connection Diagram ……………………………………………….
Communications Module (Wi-Fi) Removal & Installation …………………………………..
LCD Removal ……………………………………………………………………………………
Printed Circuit Board ‘A’ Installation …………………………………………………………..
Thread Tension Unit Removal & Adjustments …………………………………………….....
Free Arm Cover Removal ……………………………………..……………………………….
Needle Plate Micro Switch Adjustments …………………………………..………………….
Automatic Thread Cutter Removal, Adjustments and Installation ………...……………….
Free Arm Cover Installation ……………………………………………………………………
Rear Cover Removal …………………………………………………………………………...
Auxiliary Power Supply and Switching Power Supply Removal ………………………
Presser Foot Step Motor and Sensor Removal & Adjustments ……………………………
DC Motor Removal, Adjustment and Installation …………………………………………….
Feed Dog Drop Step Motor Removal & Adjustments ……………………………………….
Front Cover Installation ………………………………………………………………………...
Needle Position Front-to-Back ………………………………………………………………...
Reset All to Defaults ……………………………………………………………………………
Needle Position Left-to-Right ………………………………………………………………….
Feed Dog Height ……………………………………………………………………………......
Presser Bar Height ……………………………………………………………………………...
Needle-to-Feed Timing …………………………………………………………………………
Needle Bar Height ………………………………………………………………………………
Needle-to-Hook Timing …………………………………………………………………………
Needle-to-Hook Clearance …………………………………………………………………….
Hook Gear Backlash ……………………………………………………………………………
Needle Threader Removal, Adjustments and Installation …………………………………..
Presser Foot Lifter Stopper …………………………………………………………………….
Presser Foot Lifter Sensor Height …………………………………………………………….
Presser Foot ‘P’ Height …………………………………………………………………………
Presser Foot Pressure ………………………………………………………………………….
Remaining Bobbin Thread Sensor ……………………………………………………………
Knee Lifter ……………………………………………………………………………………….
Feed Balance ……………………………………………………………………………………
Buttonhole Balance ……………………………………………………………………………..
Positions of Bobbin Stoppers ………………………………………………………………….
Touch Screen Calibration ………………………………………………………………………
Error Codes ……………………………………………………………………………………...
Top Cover Installation …………………………………………………………………………..
Belt Cover Installation …………………………………………………………………………..
Bed Cover and Base Plate Installation ………………………………………… 1 2 3
4-5
6-7 8
9-10 11
12-13 14
15-16
17-22
23-24 25
26-28 29
30-31
32-34
35-38 39
40-43
44-45 46 47 48
49-52 53
54-55
56-57
58-59 60 61
62-65 66
67-70
71-72 73
74-75 76 77 78 79
80-81
82-84
85-86 87 88

5. Required Tools and Gauges
Phillip’s Head Screwdriver (150mm) - #SD150
Needle Nose Pliers
Phillip’s Head Screwdriver (Fine Tip) - #PHLDRVSP1
Large, Flathead Head Screwdriver - #DRIVER2
Multi-use Step Gauge - #860G001
1.5mm Hexagon Screwdriver - #TLHS15
2.0mm Hexagon Screwdriver - #TLHS20
Bobbin Stopper Position Gauge #
2.5mm Hexagon Screwdriver - #TLHS25
Thin, Short or Long, Flathead Screwdriver - #PREDVR
1.5mm Hexagon Key - #TLHW15
2.0mm Hexagon Key - #TLHW20
9mm Gauge Set - #
2.5mm Hexagon Key - #TLHW25
4 1/2” Curved Scissors - #
5-7mm Gauge Set - # 1

7. Base Plate and Bed Cover
Removal
1. Remove the accessory box.
2. Carefully lay the machine on its back. Remove the 5 set screws that hold the base plate to the machine then remove the plate. 1 2
3. Locate & remove the 2 set screws that hold the bed cover to the machine.
4. Pull down on the end of the bed cover then slide it outwards towards the end of the machine. 2

8. Belt Cover
Removal
1. Lift up on the handle and loosen the small washer screw directly under the handle on the right-hand side.
2. Remove the 3 caps then the Phillip’s set screws behind these caps. The middle screw is a self-tapping screw which means it screws into plastic.
3. Remove the 2 washer screws that hold the bottom of the belt cover to the machine.
4. To remove the belt cover, firmly pull the belt cover straight out, not on an angle. 3

9. Top Cover
Removal
1. Lift the handle up and remove the small screw directly under the left side of the handle.
2. Lift up the top cover lid. Carefully pull up & remove the bobbin winder cutter. Locate the large Phillip’s screw to the right of the bobbin winder stopper. Remove this screw completely and lay it in the foot holder.
3. Remove the set screw directly underneath the horizontal spool pin. Remove this screw completely and lay it in the foot holder.
4. With the top cover lid closed and the handle up, start to lift up on the back side of the top cover. 4

10. Top Cover
Removal
5. Continue to lift up and bring the top cover towards the back, left-hand side of the machine to free it from the handle.
6. Unplug the bobbin winder connection from the ‘U1’ board. 5

11. Front Cover
Removal
1. Open the face plate. Locate and loosen the small Phillip's washer screw directly above the metal thread guide that is holding the front panel to the casting.
2. On the left-side of the machine, locate and loosen the washer screw on the top of the machine directly above the tension unit.
3. Loosen the washer screw directly above the hand wheel.
4. Loosen the washer screw located directly below the auxiliary power supply deep within the machine. 6

12. Front Cover
Removal
5. Loosen the 2 washer screws that hold the bottom of the front cover to the machine.
6. To remove the front cover, start by pulling the right side of the cover.
7. While pulling on the right side of the cover, use a large screwdriver to push down on one of the two holes of the casting directly behind the upper shaft. This is where the rear cover meets the front cover.
8. Unplug the 13 connections that only hold the front panel to the machine. Remember to grab the wires as a group for each connection and never a single wire. 7

13. Parts of the Front Panel1 2 3 4 5 6
1. Circuit Board ‘L2’ (Horizontal LED Light)
2. Circuit Board ‘F’
3. Circuit Board ‘L1’ (Horizontal LED Light)
4. Slide Volume (Speed Control)
5. Circuit Board ‘K’
6. Circuit Board ‘A’
Presser Foot Up/Down
Needle Up/Down
Lockstitch
Reverse
Start/Stop
Thread Cutter
Needle Threader
Bobbin Winder
Horizontal LED Light 8

14. Printed Circuit Board ‘A’
Removal
1. Gently push the grey connector upwards to release the cables then lift the cables upwards to unplug them.
2. Peel off the 3 pieces of tape on the 2 sets of wires.
3. Very carefully pull the LCD display cable directly upwards. Be very careful as this cable and connection are extremely sensitive.
4. Carefully hook your finger under the loop of the brown flexible cable and pull upwards. Do not grab the black-colored connector, as this is soldered to the board. 9

15. Printed Circuit Board ‘A’
Removal
5. Remove the 4 set screws that hold the ‘A’ case to the front panel.
6. Peel off the tape that holds the Wi-Fi connector to the ‘A’ board.
7. Gently pull the Wi-Fi connector directly upwards to unplug it.
8. Remove the 4 screws that hold the ‘A’ board to the case. 10

16. Printed Circuit Board ‘A’
Connection Diagram
1. Printed Circuit Board ‘K1’ Relay
(Flexible Cable)
2. Printed Circuit Board ‘K1’ Relay
3. Printed Circuit Board ‘K1’ Relay
(6-pin)
4. Not Used
5. Printed Circuit Board ‘U1’ Relay
(24-pin)
6. Printed Circuit Board ‘U1’ Relay
(26-pin)
7. Auxiliary Power Supply
8. Switching Power Supply
9. Printed Circuit Board ‘U2’ Relay
(20-pin)
10. Knee Lifter Potentiometer
11. Printed Circuit Board ‘U2’ Relay
(14-pin)
12. Printed Circuit Board ‘U2’ Relay
(18-pin)
13. LCD (Display)
14. Touch Panel (TTP)
15. LCD Module
16. DC Motor
17. Printed Circuit Board ‘B’ (USB)
18. Foot Controller
19. Upper Shaft Sensor
20. Not Used
21. Speaker
22. Communications Module (Wi-Fi) 1 22 2 21 3 20 4 19 5 6 18 17 7 8 16 15 9 14 13 12 11 10 11

17. Communications Module
Removal & Installation
Nuts
Spacers
Screws
1. If the Wi-Fi is not working, you may need to replace the communications module which is attached to the ‘A’ board. This module is held in by 2 sets of screws, washers and nuts. Remove both screws while holding the nuts in place. Be careful not to lose the spacers.
2. Carefully remove the module by pulling directly upwards.
3. To replace the unit, align the new module with the connection on the ‘A’ board.
4. Push the board downward to ‘snap’ it into place. Do not push it down on an angle.
When replacing the screws, spacers and nuts, do not over-tighten the screws or it can crack the board. 12

18. Communications Module (Wi-Fi)
Removal & Installation
5. Place the ‘A’ board into the case. Carefully attach the Wi-Fi connector onto the communications module.
Do not push it down on an angle or it can damage the connector and/or connection.
6. Reattach the tape to secure the connector in place.
7. Replace the 4 screws that hold the ‘A’ board to the case. 13

19. LCD Unit
Removal
1. Peel off the tape that holds the LCD module down onto the front panel.
2. Remove the 4 set screws that hold the LCD unit to the front panel.
3. As you remove and attach the LCD, guide the plugs thru the access hole.
Be very careful not to pinch the wires.
4. After verifying no wires are pinched or caught between the LCD unit and the front panel, replace the 4 screws that hold the LCD in place. 14

20. Printed Circuit Board ‘A’
Installation
1. Replace the 4 set screws that hold the ‘A’ board unit to the front panel.
2. Reconnect the touch panel cable. Grasp the end of the connector, not the flexible cable itself, or the cable may get damaged. If it splits or gets folded, the LCD may not respond to touch.
3. Reconnect the LCD display cable by inserting the connector directly downwards.
This cable is very sensitive. Do not connect the cable on an angle or it may damage the connection on the ‘A’ board.
4. Replace the 3 pieces of tape that hold the wires of the 2 plugs in place. 15

21. Printed Circuit Board ‘A’
Installation
5. Before attaching the two flexible cables, push the brown connectors upwards.
6. Insert the flexible cables into position. Make sure the cables are not inserted on an angle.
7. After ensuring the cables are fully inserted, push the brown connectors downward to lock the cables in place. 16

22. A B .8mm Thread Tension Unit Removal & Adjustments
1. Before working on the tension unit, turn the large, white gear so that the silver bracket is not on the white bump on the back of this gear.
2. The clearance between the silver bracket and the black bracket that physically opens the tension discs should be .8mm. This is called the ‘thread tension release bracket’. A B
.8mm
This is a close-up of the thread tension release bracket.
3. To make an adjustment, loosen screw ‘A’ and pivot the bracket left or right to make the proper clearance. You may need to loosen screw ‘B’ if you need more clearance between the two brackets. 17

23. Thread Tension Unit Removal & Adjustments
4. To reset the upper tension to factory specifications, turn the silver, flat-head screw on the side of the unit towards the plus (or counter-clockwise) until it stops. Do not over-turn this screw. Now set it by turning the screw clockwise 16 ‘clicks’. You should see about 2 vertical lines on the small
5. If a replacement is needed, first remove the screw at the top of the machine directly behind the large, white gear.
6. Remove the second screw at the bottom of the unit.
This is the larger of the two screws. Do not remove the smaller screw which holds the check spring in place. 18

24. Thread Tension Unit Removal & Adjustments
7. Cut the 3 zip ties that hold the unit to the front of the machine.
8. Remove the screw and cable tie.
9. Cut the last remaining zip tie on the side of the machine directly above the hand wheel.
10. Remove the set screw and metal, protective plate. 19

25. Thread Tension Unit Removal & Adjustments
11. In order to gain access to the tension unit connection, unplug the black connector that is wrapped in black tubing.
12. Lastly, unplug the tension unit connector.
13. When the thread check sensor shield plate is in it’s home position, it should be as close to the center of the sensor as possible and almost touching the back of the sensor.
If an adjustment needs to be made, reshape the position of the sensor unit itself, not the shield plate. In order to do this, carefully reshape the large, silver bracket that holds the sensor in place using a pair of pliers. Be careful not to pinch the wires. 20

26. Thread Tension Unit Removal & Adjustments
14. When the machine is in normal sewing mode, the embroidery/thread cutting sensor shield plate should be barely out of the sensor.
15. Turn the large, white gear so the silver bracket is on the ‘bump’. When you enter embroidery mode, the tension unit will calibrate to this setting keeping the tension discs open and the shield plate within the sensor. It will then calibrate when you start embroidering.
16. When the silver bracket is on the bump of the gear, the shield plate will then enter the sensor. The shield plate should be in the center of the sensor. If an adjustment needs to be made, you need to reshape the position of the sensor unit itself, not the shield plate. In order to do this, carefully reshape the large, silver bracket that holds the sensor in place using a pair of pliers. Be careful not to pinch the wires. 21

27. Thread Tension Unit Removal & Adjustments
17. Notice the shield plate is going thru the middle of the sensor. 22

28. Free Arm Cover
Removal
1. Remove the presser foot, shank and needle. Then, raise the presser bar up and the needle bar to the highest position.
2. Since the needle plate is normally released by the bed cover, we need another way to remove it. Locate the pin with a spring & c-clip just to the left of the silver, feed cam fork on the bottom of the machine.
3. Using the butt-end of your screwdriver, firmly push the pin towards the top of the machine. This will release the needle plate from the machine.
4. Remove the silver, flat-head post on the inside of the free arm and the Phillip’s screw on the end of the free arm. 23

29. Free Arm Cover
Removal
5. Carefully pull the cover towards the end of the machine then start to lift up.
6. As you are pulling the cover towards the end of the machine, lift up on the cover to release it from the bed of the machine. 24

30. Needle Plate Micro Switch
Adjustments
11.5mm
1. Reattach the needle plate.
2. The top of the surface of the micro switch bracket and the bottom surface of the needle plate should be 11.5mm.
3. If an adjustment is needed, loosen the 1.5mm set screws and move the micro switch up or down accordingly. Tighten the 2 screws and recheck the position.
4. If the needle plate does not seat on the machine properly, is not snug or you get the “Warning – Attach needle plate” error, you may have to adjust the positions of either or both springs on the underside of the needle plate. 25

31. Automatic Thread Cutter
Removal, Adjustments and Installation
1. In order to remove the thread cutter unit from the machine, remove the two large Phillip’s set screws on the end of the cutter. As you remove the screws, the thread cutter will want to fall, so make sure you hold it in your hand.
2. To separate the thread cutter unit from the step motor, remove the 2 remaining, large Phillip’s set screws. As you remove the screws, silver supporting posts will fall from the unit.
OIL
3. This picture shows the parts when they are separated.
4. Clean the thread cutter from lint and debris from both the top and underside of the cutter.
Put one small drop of oil on the underside of the long extending blade. 26

32. Automatic Thread Cutter
Removal, Adjustments and Installation
Setting plate
Cutting blades
Screw for adjusting the plate
Screw
5. If the extending blade jams or does not slide smoothly, loosen the small Phillip’s screw that holds the setting plate in place and move the plate so it is as close to the long blade as possible without it touching.
6. If the thread cutter is cutting too short or too long, loosen the small screw that holds the small cutting blades in place. If you pivot the blades towards the back of the machine, it will cut the thread longer and shorter if you pivot the blades towards the front of the machine.
Vertical cutting blade plate
7. If the thread cutter cuts the bobbin thread but does not cut the top thread, you need to adjust the position of the large plate that sticks straight up.
If you are not sure which plate, pull the long, extending blade outwards then back in. The plate you want to adjust is the one that does not move and is stationary. 27

33. Automatic Thread Cutter
Removal, Adjustments and Installation
9. Be sure to clean the step motor gears thoroughly from thread & lint. Putting a small amount of lithium grease on the gears will help the cutter run smoother and quieter.
10. When reattaching, the black post of the step motor must fit into the access hole of the thread cutter.
11. Attach the silver posts and matching set screws that hold the thread cutter to the step motor. Tighten the 2 screws. To ensure the thread cutter is properly together. Push the long extending blade all of the way out then back in again. It should move smoothly and you should only feel the tension of the step motor.
12. Place the entire unit onto the machine and replace the two large Phillip’s set screws. 28

34. Free Arm Cover Installation
1. While pushing down on the end of the free arm, slide the cover inward to lock it into place. To ensure proper installation, pull up on the end of the cover. It should not lift up freely.
2. Attach the needle plate ensuring it snaps down properly and the free arm gap is even on both sides of the plate.
3. While pushing the free arm cover down, replace both the silver, flat-head post on the inside of the free arm and the Phillip’s screw on the end of the free arm. 29

35. Rear Cover
Removal
1. Remove the two long screws on the back of the machine towards the top.
2. Remove the two short screws towards the bottom of the machine directly to the right of the serial tag.
3. Unplug the face plate LED wire.
4. Loosen both washer screws that hold the rear cover to the machine. 30

36. Rear Cover Removal 5. Bend the retaining bracket outwards.
6. Unplug the two wire wrapped in black tubing. These two sets of wires are blue and white.
7. As you remove the rear cover, push the inside section downwards so the cover does not damage the presser foot step motor wires. 31

37. Auxiliary Power Supply and Switching Power Supply
Removal
1. Disconnect the large plug that connects to the auxiliary power supply by pushing the tab inwards and pulling out at the same time.
2. Disconnect the second, large plug by pushing the tab inwards and pulling out at the same time.
3. Remove the 2 small set screws that hold the auxiliary power supply to the machine.
4. Locate the switching power supply connector. This is a 3-pin connector with brown, orange, and red wires. 32

38. Auxiliary Power Supply and Switching Power Supply
Removal
Metal shield plate
5. Feed this wire out of both cord guides.
6. Remove set screw and metal shield plate from the machine.
7. Remove the screw that holds the top of the switching power supply to the machine.
8. Remove the middle screw. 33

39. Auxiliary Power Supply and Switching Power Supply
Removal
9. Now, remove the last screw at the bottom of the power supply.
10. Disconnect the plug towards the top of the unit and remove the power supply. 34

40. Presser Foot Step Motor and Sensor
Removal & Adjustments
1. First, unwrap the coiled cord guide.
2. Unplug the large, black connector.
3. Unplug the 2- and 3-pin, black & white connectors. 35

41. Presser Foot Step Motor and Sensor
Removal & Adjustments
4. Unplug the large, white connector.
5. Unwrap the wires.
6. Remove the screw and cord guide.
7. Using a large, flat-head screwdriver, remove the 2 set screws that hold the presser foot step motor sensor in place.
It is important to use a flat-head screwdriver. These screws are very tight. 36

42. Presser Foot Step Motor and Sensor
Removal & Adjustments
8. Remove the 4 screws on each corner of the presser foot step motor. The screw on the upper-left corner also holds the retaining bracket in place.
9. As you remove the step motor unit, a spring and washer will come off with it, A new step motor will come with these parts.
10. Keep the large, white gear in the machine. Discard this gear that comes with the new step motor unit. 37

43. Presser Foot Step Motor and Sensor
Removal & Adjustments
11. Attach the new presser foot step motor sensor unit but keep the 2 screws slightly loose. Looking in from the back of the machine at the top, you must align the sensor so the shield plate is closer to the right-side of the sensor. This means you will move the sensor unit towards the left to make the shield plate closer to the right-side of the sensor.
Incorrect Position
Incorrect Position 38

44. Removal, Adjustment and Installation
DC Motor
Removal, Adjustment and Installation
1. Locate and remove the 2 Phillip's screws that hold the motor to the machine.
2. Lift the motor up and slide the belt off the motor pulley. Unplug the DC motor from the front panel if it still connected. The wire is wrapped in clear tubing. Remove the motor from the machine.
3. Attach the new motor to the machine. Push the DC motor up to attach the belt and replace the 2 large washer screws.
4. Adjust the position of the motor so the motor belt has 5mm deflection with about 200 grams of pressure while pushing in the middle of the belt. 39

45. Feed Dog Drop Step Motor
Removal & Adjustments v v
1. Remove the 3 set screws, metal bracket, and thrust washer that hold the metal rail in place. Be sure to hold the rail in place when you remove the last screw, as it will fall.
2. Remove the small, black, Phillip's screw on the end of the free arm. The metal bracket and thrust washer will come off with the screw. v
3. Unplug the base unit connector that plugs into the ‘U2’ board.
4. Remove the 2 large Phillip's screws and washer that hold the front arm sole to the machine. 40

46. Feed Dog Drop Step Motor
Removal & Adjustments
5. Remove the 2 large screws and washer that hold the rear arm sole to the machine. Make sure you hold the base cover in place as you remove the last screw. Carefully slide the base cover off of the machine.
6. Now that you have the feed dog drop step motor exposed, remove the 2 large screws that hold it to the machine.
7. Unplug the feed step motor from the ‘U2’ board. 41

47. Feed Dog Drop Step Motor
Removal & Adjustments
8. Remove the large c-clip that holds the silver bracket & spring in place.
9. Remove the large bracket and spring from the step motor unit.
Before
After
10. Expand the spring outward so it will provide more pressure for the silver bracket to push on the microswitch. Now, reattach the spring, large bracket, and c-clip. 42

48. Feed Dog Drop Step Motor
Removal & Adjustments
Raised, white line
11. Turn the gear so the bracket is resting on the flat spot of the gear. Once the silver bracket touches the white line of the gear, you should hear a ‘click’ of the micro switch.
12. If you do not hear a click, you will have to adjust the position of the micro switch. Loosen the screw that holds the micro switch bracket in place and move the bracket to the left or right accordingly then tighten the screw.
13. To reattach the step motor, align the post of the motor unit into the cutout of the feed dog driving plate. 43

49. Front Cover Installation
1. Align the front panel with the machine. Plug the 13 connections back into the ‘A’ board. It’s best to start from the bottom-inside, work your way across, then up.
2. Tighten the screw on the top of the machine directly above the tension unit.
3. Tighten the small Phillip's washer screw directly above the metal thread guide that is holding the front panel to the casting.
4. Tighten the washer screw directly above the hand wheel. 44

50. Front Cover Installation
5. Tighten the washer screw that is deep within the machine directly below the auxiliary power supply.
6. Tighten the washer screws that hold the bottom of the front panel to the machine.
7. Ensure the front & rear covers are attached properly with no gaps between the covers. 45

51. Needle Position Front-to-Back
1. Turn the hand wheel towards you to bring the needle down.
2. When the needle just enters the needle plate hole, stop turning the hand wheel. The needle should be as close to center (front-to-back) as possible.
3. If an adjustment is needed, loosen the 2mm hex screw that holds the needle bar positioning pin in place.
4. Pivot the needle bar front-to-back to align it accordingly to the needle plate. As you are firmly holding the needle bar in place, tighten the screw. 46

52. Reset All to Defaults
Before making any other adjustments, reset the machine’s settings to factory defaults.
1. The customer may have changed settings that make change the way the machine works. To reset the machine to factory specifications, press the ‘SET’ key.
2. Press the down arrow to the last page.
3. Press ‘Yes’ under the ‘Reset All to Defaults’ option then ‘OK’ to save it. 47

53. Needle Position Left-to-Right
1. Press the center needle, straight stitch key to center the needle.
2. The needle should be as close to the center of the needle plate (left-to-right) as possible.
3. If an adjustment is needed, locate the 1.5mm hex locking screw and large, flat-head, eccentric screw.
4. Loosen the 1.5mm hex screw then turn the eccentric screw to align the needle bar with the needle plate. Tighten the 1.5mm hex screw. 48

54. .8 - .9mm above the surface and level with the needle plate.
Feed Dog Height
.8mm - .9mm above the surface of the needle plate in their highest position
mm above the surface and level with the needle plate.
1. When the feed dog is in its highest position, it should be mm above and level with the needle plate. It should not point upwards or downwards.
2. Using the feed dog height gauge, set the gauge with ‘A’ facing up at the front of the feed dog. Rotate the hand wheel towards you. If the feed dog is too low, it should not grab and move the gauge.
3. Now flip the gauge so side ‘B’ is facing up and rotate the hand wheel towards you. If the feed dog is too high, it should grab and move the gauge. Check both the front and rear feed dog. 49

55. Feed Dog Height
.8mm - .9mm above the surface of the needle plate in their highest position
4. To adjust the rear section of the feed, locate the locking set screw towards the rear of the machine on the end of the free arm, directly above the thread cutter step motor. Loosen this locking screw.
5. Turn this small adjusting screw clockwise to raise and counter-clockwise to lower the rear section of the feed dog. Do not loosen the hexagon nut. Do not tighten the locking set screw yet. When you adjust the rear section of the feed dog, you will likely have to adjust the front. 50

56. Feed Dog Height
.8mm - .9mm above the surface of the needle plate in their highest position
This is a counter-threaded set screw.
Turn it clockwise to loosen.
6. To adjust the front section of the feed dog, locate and loosen the washer set screw set deep within this access hole directly above the thread cutter unit.
This is a counter-threaded set screw.
Counter-threaded set screw
Empty-threaded, 2mm hole
7. To make an adjustment, locate the small, empty-threaded access hole on the feed dog height plate. 51

57. Feed Dog Height
.8mm - .9mm above the surface of the needle plate in their highest position
8. Temporarily borrow a 2mm hex screw from the lower shaft collar.
9. Now, insert it into the empty-threaded hole. Turn it clockwise to raise and counter-clockwise to lower the front-section of the feed dog.
This is a counter-threaded set screw.
Turn it counter-clockwise to tighten.
10. Recheck the height using the feed dog height gauge. If the adjustments are correct, firmly tighten the 2 locking set screws.
11. Replace the 2mm hex screw back into the lower shaft collar. 52

58. Presser Bar Height
6mm when the presser bar is in it’s normal, up position with the standard zigzag foot attached
6mm
1. Lower the feed dog by pressing the key. Press the presser foot up/down button to lower the presser bar then raise the presser bar manually by lifting the presser foot.
2. Slide the gauge under the foot directly where it snaps onto the shank. The gauge should slide snuggly and should not have any up or down ‘play’.
3. If an adjustment needs to be made, locate and loosen the 2mm set screw on the presser bar block. Grab the presser bar and move it up or down accordingly then lightly tighten the screw. Recheck using the gauge.
4. Before tightening the screw completely, check the angle of the presser foot. The foot should be aligned with the feed dogs. Once verified, firmly tighten the screw. 53

59. Needle-to-Feed Timing
1. Turn the hand wheel towards you and stop when the tip of the needle is flush with the top of the needle plate. At this point the feed dog should also be flush with the top of the needle plate.
2. To make an adjustment, loosen the Phillip's screw that holds the idler which provides tension on the timing belt. Push the idler out of the way.
3. Slide the timing belt off of the lower shaft gear.
4. Turn the hand wheel towards you so the tip of the needle is touching the surface of the needle plate. Never turn the hand wheel backwards. The needle bar should be going downward in its sewing motion. 54

60. Needle-to-Feed Timing
5. Turn the lower shaft towards you so the feed dogs are level with the top of the needle plate when going in their downward rotation. Never turn the gear backwards. The feed dog should be going downward in its sewing motion.
6. While firmly holding the hand wheel in place with one hand, slide the timing belt onto the lower shaft with the other hand. Place the idler back into position and tighten the screw. While pushing on the middle of the belt, there should be about 7mm deflection.
Incorrect
Incorrect 55

61. needle bar is in its highest position using a Janome needle.
Needle Bar Height
The tip of the needle should be 8.8mm above the surface of the needle plate when the
needle bar is in its highest position using a Janome needle.
1. Select straight-stitch, center needle position then remove the needle plate.
2. Attach the needle bar height gauge with the black post sticking out towards you. Be sure the gauge is inserted completely into the needle bar.
Make sure the tip of the hook is touching the flat spot of the gauge at all times.
3. Turn the hand wheel towards you so the needle bar is all of the way up and the tip of the hook race is under the right bobbin stopper.
4. Insert the 9mm radial timing gauge. Make sure the tip of the hook is touching the flat spot of the gauge at all times. This is necessary for both proper timing checks and adjustments. 56

62. needle bar is in its highest position using a Janome needle.
Needle Bar Height
The tip of the needle should be 8.8mm above the surface of the needle plate when the
needle bar is in its highest position using a Janome needle.
5. As you continue to turn the hand wheel towards you to bring the needle bar down, the gauge should very lightly skim the top of the gauge. There should not be a gap between the gauges and the needle bar height gauge should not hit the radial gauge enough to shift the needle bar sideways.
6. If an adjustment needs to be made, locate and loosen the 2mm hex screw on the block that holds the needle bar in place. This is the larger of the two blocks on the needle bar. Raise or lower the needle bar accordingly. Do not twist the needle bar left or right. Recheck the adjustment. 57

63. Needle-to-Hook Timing
The tip of the hook should be 1.6mm-2.0mm above the top of the eye of the needle when
the hook touches the right-side of the needle in its sewing motion.
Make sure the tip of the hook is touching the flat spot of the gauge at all times.
1. Remove the needle bar height gauge and install the needle-to-hook timing gauge. Make sure this timing needle gauge is fully inserted.
2. Make sure the tip of the hook touches the flat end of the gauge at all times. This is necessary for both proper timing checks and adjustments.
3. Turn the hand wheel towards you to bring the needle bar down.
4. When the needle touches the top of the radial gauge, it should touch the middle of the red line of the gauge. If the needle hits before or after the line on the gauge, an adjustment must be made. Keep in mind there is .5mm tolerance. 58

64. Needle-to-Hook Timing
The tip of the hook should be 1.6mm-2.0mm above the top of the eye of the needle when
the hook touches the right-side of the needle in its sewing motion.
5. To make an adjustment, locate the two 2.5mm hexagon screws holding the timing gear to the lower shaft.
6. Using a 2.5mm hex screwdriver, loosen both screws. While holding the hand wheel, use your screwdriver as leverage to adjust hook timing and lightly tighten the 1 screw.
7. Make sure the tip of the shuttle hook is touching the flat spot of the radial gauge and recheck timing. If the adjustment is correct, securely tighten the both hex screws on the timing gear. Remove the gauges. 59

65. Hook-to-Needle Clearance
0mm – 0.05mm when the tip of the hook is behind the needle
1. Attach a new, size 14 needle. With the machine off, push the needle bar to the left. Turn the hand wheel to bring the tip of the hook directly behind the needle. The distance between the back of the needle & the tip of the hook should be mm.
2. Loosen the 2 of the 3 screws that hold the large silver plate onto the machine. Push the plate closer or away from the needle to make the necessary adjustment. Tighten the 2 screws.
3. If it is difficult to see the clearance by eye, use a flathead screwdriver and push against the front of the needle. There should be no deflection. The hook should not deflect the needle either. Check for deflection by turning the hand wheel very quickly and listen for any ‘tings’. 60

66. Hook Gear Backlash .8mm of “Play”
1. Hold the hook race with your hand and wiggle it left & right. The hook race should have .8mm of backlash, or “play”. Check it in 3 different spots by turning the hand wheel so the hook race turns 1/3 each time.
2. If an adjustment is needed, locate and loosen the 2mm hexagon set screw that holds the lower shaft eccentric bushing in place.
3. Using a small flathead screwdriver, move the bushing either upwards or downwards. Moving the bushing upwards will give the hook more backlash, or “play”, and downwards will give it less backlash. Lightly tighten the hex screw. Do not move the bushing left or right and do not touch the hand wheel while the screw is loose.
4. Recheck hook backlash. Check it in 3 different spots by turning the hand wheel so the hook race turns 1/3 each time. If the adjustment is correct, tighten the 2mm set screw. Do not over-tighten the screw as this will cause a bind in the lower shaft. 61

67. Removal, Adjustments and Installation
Needle Threader
Removal, Adjustments and Installation
1. Turn the machine off. While holding down the start/stop & reverse buttons, turn on the machine to enter the test mode.
2. Press ‘Needle Thread’ to enter the needle threader adjusting menu.
3. Press ‘Down’. This will lower the needle threader completely.
4. Verify the hook of the needle threader is going thru the eye of the needle perfectly. If the hook is too high or low or the hook touching the sides of the eye of the needle, it may not thread the needle. 62

68. Removal, Adjustments and Installation
Needle Threader
Removal, Adjustments and Installation
5. If the height is off, loosen the 2mm hex screw on the needle bar. This is the smaller of the two blocks on the needle bar. Move the block upwards or downwards accordingly. Do not rotate the block left or right.
6. If the hook is too far to the left or right of the eye of the needle, loosen the small, Phillip’s screw on the threader unit. Move the threader hook left or right accordingly then tighten the screw.
7. Each time you make any adjustment, recheck the threader position by pressing ‘Init’ to calibrate the threader, then ‘Down’ to recheck the position. 63

69. Removal, Adjustments and Installation
Needle Threader
Removal, Adjustments and Installation
8. This picture shows the parts separately.
9. This shows the threader parts together. If a replacement is needed, you will need to order the ‘hook holder unit’ # which is the threader hook.
10. If the threader hook is not going thru the eye of the needle enough, an adjustment must be made.
11. Press ‘Dn’ twice then press ‘Set’ to save it. 64

70. Removal, Adjustments and Installation
Needle Threader
Removal, Adjustments and Installation
12. To check the adjustment, you must press ‘’Init’ to calibrate the motor then ‘Down’ to engage the unit.
13. It is important not to have the threader too far into the hook as it will deflect the needle and cause threader issues.
14. Once finished, press ‘X’ to exit the needle threader test menu. 65

71. Presser Foot Lifter Stopper
The distance between the bottom of the presser bar casting and the bottom surface of the
presser bar bushing must be 22mm
1. Turn the machine off and completely lower the presser bar by turning the large, white gear. Keep turning it until it won’t turn anymore.
2. At the top of the presser bar is a black collar. This is the presser foot lifter stopper.
22mm
3. The distance between the bottom surface of the presser bar casting and the bottom surface of the stopper should be 22mm. 66

72. Presser Foot Lifter Sensor Height
13mm above the surface of the needle plate using the standard ‘A’ foot
1. Turn the machine off. While holding down the start/stop & reverse buttons, turn on the machine to enter the test mode.
2. Press ‘Foot Sensor’.
3. Press ‘OFF’ to turn off the presser foot step motor.
4. Turn the large, white gear to raise the presser bar all the way up. 67

73. Presser Foot Lifter Sensor Height
13mm above the surface of the needle plate using the standard ‘A’ foot
5. Insert the presser bar height gauge with the groove-side down. Turn the white gear to lower the presser bar until the gauge is lightly snug against the foot.
6. Locate the 2mm hex screw on the back of the presser foot step motor sensor. This is the adjusting screw for the height of the sensor.
7. Look in from the side of the machine by the face plate. Use a small, flat-head screwdriver to push down on the silver bracket directly below the 2mm hex screw. 68

74. Presser Foot Lifter Sensor Height
13mm above the surface of the needle plate using the standard ‘A’ foot
8. Slowly turn the 2mm hex adjusting screw clockwise to bring the screw down.
9. Keep turning the screw until the screw just barely touches the silver bracket. Over-turning this screw will damage the bracket and possibly crack the sensor. 69

75. Presser Foot Lifter Sensor Height
13mm above the surface of the needle plate using the standard ‘A’ foot
10. Press ‘Start’. This will activate the sensor.
11. The screen will change from ‘Error’ to ‘Reading’
12. Now turn the 2mm hex adjusting screw counter-clockwise.
13. Continue turning the screw until ‘Sensor1’ says ‘H’ and ‘Sensor2’ reads ‘L’. At this point, the machine will beep and display ‘OK’. Press ‘X’ to save the setting into the machine’s memory. 70

76. Presser Foot ‘P’ Height
1.8mm above the surface of the needle plate using the standard ‘P’ foot
1. Press ‘Foot Up/Down’ on the main menu.
2. Now press ‘Offset’ to enter the ‘P’ foot menu and attach the ‘P’ foot.
1.7mm
1.9mm
3. Make sure the ‘P’ foot height gauge is not underneath the foot. Press ‘1.7mm’. The ‘P’ foot will lower, touch the needle plate then raise up 1.8mm.
4. To verify the height is correct, insert the gauge under the foot. The thinner section of the gauge (1.7mm) should slide under the foot, but should stop when it touches the thicker section (1.9mm). 71

77. Presser Foot ‘P’ Height
1.8mm above the surface of the needle plate using the standard ‘P’ foot
5. If the gauge doesn’t slide at all or completely slides under the foot, you must make an adjustment.
6. Press ‘+’ so ‘UP Offset Step’ changes to any number close to 80. This will also raise the ‘P’ foot small increments at a time.
1.7mm
1.9mm
7. Remove the gauge from under the ‘P’ foot.
Press ‘–’ only once to lower the ‘P’ foot once increment at a time. For each step, insert the gauge to check the adjustment. The gauge must not be under the foot each time you press ‘–’. You must end this adjustment with ‘–’ not ‘+’. Press ‘Set’ to save it, then ‘1.7mm’ to recheck.
8. To verify the height is correct, insert the gauge under the foot. The thinner section of the gauge should slide under the foot, but should stop when it touches the thicker section.
If you lower the ‘P’ foot as much as it will go and the thicker section of the gauge still slides under the foot, you need to adjust presser foot pressure. 72

78. Presser Foot Pressure
1. Press ‘Adjust’ to enter the presser foot pressure menu.
2. Make sure the gauge is not under the ‘P’ foot. Press ‘Adjust’.
3. The presser bar will lower. ‘Adjust Step’ will change from ‘0’ and display a new number.
4. Press the ‘+’ or ‘–’ key so ‘Adjust Step’ displays ‘1000’. Now press ‘Set’ to save the setting. When finished, press ‘X’.
Repeat steps 1-8 in “Presser Foot ‘P’ Height”. 73

79. Remaining Bobbin Thread Sensor
1. Press ‘Bobbin’ to enter the remaining bobbin thread sensor menu.
2. Insert the empty bobbin into the bobbin case.
3. Press ‘Key’ to get the value then press ‘Empty’ to save it into the memory bank.
4. Insert the half-empty bobbin gauge into the bobbin case. 74

80. Remaining Bobbin Thread Sensor
5. Press ‘Key’ to get the value then press ‘Half’.
6. Now insert the full bobbin gauge.
7. Press ‘Key’ to get the value then press ‘Full’ to save it into the memory bank.
8. Press ‘OK’ to permanently save it into the machine’s memory then ‘X’ to exit the menu. 75

81. Knee Lifter 1. Press ‘Knee Lifter’ and insert the knee lifter.
2. ‘Sensor’ will display a value. Press ‘MEM1’ to save the number.
3. Now, push the knee lifter all the way to the right and press ‘MEM2’ while holding it.
4. Press ‘OK’ to save it into the machine’s memory, then ‘X’ to exit the menu. 76

82. Feed Balance Perfectly balanced stitches
1. Turn the machine off then back on like normal. Before making any adjustments, make sure the customer’s balance screw is vertical and not turned in either direction.
Stitches are too far apart
Stitches are too close together
2. On the bottom of the machine is a black bracket. The 2mm hex screw is the adjusting screw. Turn this screw with small adjustments at a time. Turning the screw clockwise will make the stitch longer. Turning it counter-clockwise will make the stitch shorter.
Turn the machine off then back on again to reset the feed step motor after each adjustment. 77

83. Buttonhole Balance 1. Lower the buttonhole lever all the way down.
2. Follow the lever all the way up and it turns into a black shield plate with a slit. The slit should be as close to the center of the sensor as possible but may be slightly tweaked to make a symmetrical buttonhole.
Improperly adjusted buttonhole.
3. If an adjustment is needed, locate the 1.5mm hex screw sticking out of a silver locknut. Turn this screw clockwise to move the shield plate towards the back of the sensor and counter-clockwise to move it towards the front of the sensor. These are very fine adjustments.
Perfectly adjusted buttonhole. 78

84. Positions of Bobbin Stoppers
1. With the bobbin case in the machine, turn the hand wheel backwards. The bobbin case will turn slightly and provide a gap between itself and the right stopper. The gap should be .8mm. The stoppers must also be aligned properly.
2. Remove the bobbin case and insert the bobbin stopper position gauge # There should be no ‘play’ on the gauge and the gauge should not push the spring of the right stopper inwards.
3. This picture shows an improperly adjusted right bobbin stopper. Notice the spring is pushed inwards.
4. To make an adjustment, loosen the 2 set screws that hold the stoppers in place and adjust the positions accordingly then firmly tighten the screws. 79

85. Touch Screen Calibration
1. While holding down the needle up/down button, turn on the machine.
2. Using a touch panel stylus, press the center of the first crosshair towards the left-hand side of the touch screen.
3. Press the center of the second crosshair in the middle of the screen.
4. Press the center of the third crosshair towards the right-hand side of the screen. 80

86. Touch Screen Calibration
5. Press the center of the fourth crosshair at the top of the screen.
6. Press the center of the last crosshair at the bottom of the screen.
7. When the machine displays “FINISH” at the top of the screen, turn the machine off. The machine has already saved the calibrations into its memory.
8. If the machine displays “NG”, turn the machine off and repeat steps 1-6 up to 3 times. If it continues to give this error, check the brown, flexible cable at the bottom of the ‘A’ board. If it is connected properly with no damage, replace the LCD unit. 81

87. Error Codes The bobbin winder is not pushed to the left (engaged).
The bobbin winder connection is not plugged in.
See page #85
The customer may have jammed the machine.
There may be a bind in the machine.
The DC motor or upper shaft sensor may be dirty or need to be adjusted or replaced.
The machine ran out of thread.
There is a problem with the thread check sensor on the tension unit.
See pages #17-22
The bobbin is almost empty.
The remaining bobbin thread sensor needs to be adjusted in the test mode.
See page #74-75 82

88. Error Codes The needle plate was just attached.
There is a problem with the needle plate micro switch.
See pages #23-25
The needle plate was just attached.
The presser foot up/down micro switch needs to be adjusted.
See page #23-25
The buttonhole lever is not lowered all the way down before sewing a buttonhole.
The shield plate is not in the center of the sensor.
The buttonhole sensor connection is not plugged in.
See pages #78
The embroidery unit was connected or disconnected while the machine is on. Turn the machine off then back on again to reset the machine. 83

89. Error Codes
This is a universal error for a step motor or micro switch not calibrating correctly when the machine is turned on. With the machine off and the embroidery unit attached, perform the following:
1. Remove the belt cover, top cover and base plate, then open the face plate.
2. Open the embroidery arm. Slowly and firmly push the carriage unit all the way to the left and all the way towards the back.
4. Raise the needle bar to its highest position then to the left.
5. Lower the needle threader manually half-way down by turning the white gear directly behind the threader cover.
Now, turn the machine on:
The X- and Y-carriages on the embroidery unit should return to their home positions.
The needle bar should center itself.
The needle threader should calibrate.
The tension unit should calibrate.
The presser bar should lower, raise, then drop slightly.
The feed dog drop step motor should calibrate.
The remaining bobbin thread step motor should calibrate.
The automatic thread cutter should calibrate.
If you still receive the error, check which step motor did not calibrate. If you do not receive the error, turn the hand wheel to bring the needle bar down which will then calibrate the feed step motor. If you now get the error, this will point you to this step motor.
Once you find the step motor that is not working properly, check the connections, pinched wires, or the position of the micro switch for that specific step motor. If everything looks fine, replace the malfunctioning unit. 84

90. Top Cover Installation
1. Before replacing the top cover, plug the bobbin winder connector into the ‘U1’ board on the back of the machine.
2. With the handle up, carefully place the top cover into position. Lower the handle then lift up on the top cover lid. Make sure the clips lock together.
3. Push down on the back of the top cover to ensure it is seated properly.
Be careful not the pinch any wires especially the bobbin winder connector.
4. Lift up the top cover lid. Replace the set screw directly underneath the horizontal spool pin. 85

91. Top Cover Installation
5. Replace the bobbin winder cutter and the large Phillip’s screw to the right of the bobbin winder stopper.
6. Lower the top cover lid, lift the handle up and replace the small screw directly under the left side of the handle. 86

92. Belt Cover Installation
1. To replace the belt cover, insert the cover straight inward, not on an angle.
2. Replace the 3 Phillip’s set screws followed by the caps. The middle screw is a self-tapping screw which means it screws into plastic.
3. Lift up on the handle and tighten the small washer screw directly under the handle on the right-hand side.
4. Replace the 2 washer screws that hold the bottom of the belt cover to the machine. 87

93. Base Plate and Bed Cover
Installation 2 1
1. Carefully lay the machine on its back. Insert the bed cover into position while the cover is pulled down on the end.
2. After ensuring the cover aligns correctly with the front & rear covers, replace the 2 set screws that hold the bed cover to the machine.
3. Replace the 5 set screws that hold the base plate to the machine.
4. Replace the accessory box. 88