SERVICE MANUAL FOR

XL2600i
XL3500i
XL3600
BM3600
XL3750

9. 2006.
6. 2007.

CONTENTS
Disassembly Procedure
Disassembly Procedure......................................................................................1 - 1
Needle Bar-Presser Unit Disassembly ...............................................................1 - 5
Lower Shaft Unit Disassembly............................................................................1 - 7
Thread Tension Disassembly .............................................................................1 - 8
Z Dial Assy. Disassembly ...................................................................................1 - 9

Assembly Procedure
Assembly Procedure.........................................................................................1 - 10
Front Cover.......................................................................................................1 - 10
Rear Cover .......................................................................................................1 - 11
Thread Tension Assembly ................................................................................1 - 15
Needle Bar-Presser Unit Assembly (With Needle Thread)...............................1 - 16
Lower Shaft Unit Assembly...............................................................................1 - 18
Z Dial Assy. Assembly ......................................................................................1 - 21
An Exchange Method Of Outer Rotary Hook Assy...........................................1 - 22

Adjustment
Adjustment of the Timing Belt Tension ...............................................................2 - 1
Adjustment of the Motor Belt Tension.................................................................2 - 2
Adjustment of the Needle Bar Stopper ...............................................................2 - 3
Adjustment of the Needle Sidewise Movement (Needle Swing Timing).............2 - 4
Adjust of the down position back and forth for the presser foot..........................2 - 5
Adjustment of the Needle Swing.........................................................................2 - 6
Adjust of the down position of the straight line on the left base line (right / left) ...2 - 7
Adjustment of the down position of the bar track (BH ac) on the left base line (right / left) ...2 - 8
Adjustment of the Needle Bar Height .................................................................2 - 9
Clearance between the needle and the rotary hook point adjustment..............2 - 10
Adjustment of the Position of the Inner Rotary Hook Rotation Prevention Bracket.......2 - 11
Adjustment of the Upper Thread Tension.........................................................2 - 12
Adjustment of the Inner Rotary Hook (Lower Thread) Tension ........................2 - 13
Adjustment of the Thread Winding (Uneven Bobbin Winding and Amount of Thread Winding) ....2 - 14
Adjustment of the feed of the bar track (BH a). ..............................................2 - 15
Adjustment of the feed......................................................................................2 - 16
Adjustment of the feed......................................................................................2 - 17
Adjustment of the feed of the left over edging button hole (BH b)..................2 - 18
Adjustment of the BH length .............................................................................2 - 19

Disassembly Procedure
Disassembly Procedure
1. Remove the needle plate B.
2. Remove the one screw (taptite cup P M4 x 20) securing the face plate and then remove the face plate to the
front.
3. Pull out the selection dial on the front face of the front cover.
4. Remove the retaining ring E6, and then remove the feed dial.
5. Remove the screws fastening the front cover, one in the front (taptite bind B M4 10) and six in the back
(five giza tite M 5 16, and one giza tite M 3 25), to remove the front cover.
6. Remove the two screws (taptite, bind B M 4 14) to remove the thread conductor A assembly.
7. Remove the one screw (taptite, bind B M 4 14) to remove the thread conductor B assembly.
8. Pull out the reverse stitching knob.
5
5
2

5
8

4
6
6
6

7
5
3

1-1

Disassembly Procedure
9. Remove the feed connecting holder from the spring. (5 21 mm)
10. Remove the retaining ring E2.5 that links the BH change arm assy. and the BH connecting rod B.
11. Remove the three screws (giza tite 5 16), and then remove the selecting unit assy., selecting unit the two
washers and the spacer.
12. Remove the spring (6 15 mm) of the zigzag lever.
13. Remove the retaining ring E2.5 that links the Z linkage and the selection unit and E5 that links the Z linkage
and the needle bar supporter and then remove the Z linkage and the polyester slider.
14. Remove the two screws (giza tite 5 16) , and then remove the Z dial assy. and the zigzag lever.
15. Remove the two screws (giza tite 5 16) securing the lower shaft metal retainer to remove it.
16. Remove the screw (giza tite 5 16) for the feed transmission holder.
17. Remove the two screws (giza tite 5 16) holding the base plate assembly and remove the feed module.
18. Remove the screw (screw bind M3 20) holding the lamp and remove the lamp unit.
19. Remove the screw (taptite, bind B M4 14), and then remove the cord stopper.
20. Remove the screw (taptite, bind B M4 14), and then remove the cord clamp.

Disassembly
Procedure

C
B
C
D
C
D

D
J

A
A
H

A
A

A
A
K
9

E
E
G
G

G
E

1-2

Disassembly Procedure
21. Remove the screw (screw, bind M3 25) for needle clearance adjustment.
22. Remove the screw (screw, pan (S/P washer) M4 x 8) for the BH notch spring plate, and then remove the BH
notch spring plate and the BH spring.
23. Remove the two screws (giza tite 5 16, taptite, cup P M 4 x 20) of the BH change shaft holder A, and then
remove the BH change shaft holder A.
24. Remove the four screws (giza tite 5 16) securing the upper shaft metal retainer to remove it.
25. Loosen the screw (set screw, socket (FT) M 5 5) for the thread take-up lever crank and separate the upper
shaft assembly from the needle bar-presser unit assembly, and then remove the upper shaft assy.
26. Remove the tension belt from the upper shaft assembly.
27. Remove the two screws (giza tite 5 16) securing the needle bar-presser unit assembly and then remove the
needle bar-presser unit assembly.

L
N
N
M
R
R

P
O
O

O
O

1-3

Disassembly Procedure
28. Remove the one screw (giza tite 5 16) and remove the cord retainer and the bobbin winder spring.
29. Cut the band of the cord guide plate, remove the shield wire of the lamp unit.
30. Remove the two screws (taptite, bind B M 5 16) to remove the bobbin winder assy.
31. Remove the one screw (taptite, bind B M 4 14) to remove the shield wire clip.
32. Remove the two screws (bolt, (S/P washer) M 5 12) to remove the motor and the motor belt.
33. Remove the two screws (giza tite 5 16) to remove the two motor fixed plate.
34. Remove the two screws (screws, pan (S/P washer) M 4 30) to remove the three pole lamp socket.
35. Remove the two screws (taptite, bind B M 4 14) to remove the Plate apring, the adjusting plate, and the
adjusting screw.
36. Remove the spool pin spring and remove the spool pin.
37. Remove the one screw (giza tite 4 12) to remove the thread guide assembly.
38. Remove the one screw (taptite, pan B (S/P W) 3 12) to remove the bobbin presser.
Z

\
Z
[

Disassembly
Procedure

S
X

V
U

X
W

Y
Y

W
Y

Y
W
V
V
V

1-4

Disassembly Procedure
Needle Bar-Presser Unit Disassembly
1. Loosen the screw (set screw socket (CP) M 4 x 4) of the BH change arm, and then remove the BH change
arm.
2. Remove the retaining ring E2.5 of the BH change shaft assy., and then remove the BH change shaft assy.
3. Remove the needle bar crank rod, and then remove the polyester slider.
4. Remove the screw (screws pan (S/P washer) M 3 8) of the stud for thread take-up lever supporter by
pulling it out to the right, and them remove the thread take-up lever supporter, the dome spring washer and
the retaining ring E5.
5. Remove the thread take-up lever body and the needle bar crank from the thread take-up lever supporter.
6. Remove the screw and the spring at the top of the needle bar supporter and remove the needle bar supporter
from the base holder assembly.

3
5
6

1-5

Disassembly Procedure
7. Loosen the one screw (set screw, socket (FT) M 4 4) securing the needle bar clamp to remove the needle
bar assembly.
8. Remove the one screw (screw, bind M 2.6 4) of the thread positioning plate and remove the thread
positioning plate.
9. Remove the one screw (screws pan (S/P washer) M 3 8DA) at the bottom of the needle bar supporter and
remove the Z fine adjusting plate from the needle bar supporter.
10. Remove the screw (3.57L) to remove the thread take-up lever and the needle bar crank rod.
11. Loosen the screw (set screw, socket, (CP) M 5 8) securing the presser bar clamp to remove the presser bar
and the spring.
12. Remove the one screw (bolt, socket M 3 6) for the stopper to remove the stopper.
13. Remove the one screw (bolt, socket M 3 6) for the needle bar supporter stud holder to remove the needle
bar supporter stud holder assembly.
14. Remove the retaining ring E5 and remove the presser lifter.
15. Remove the retaining ring CS4 and remove the thread loosening lever and the spring.
16. Remove the one screw (screw, bind M 4 6) for the lamp holder to remove the lamp holder, and then
remove the one screw (screw, bind M 4 6) for the guard plate to remove the guard plate.
17. Remove the one screw (screw, bind M 4 6) for the BH shaft holder, and remove the retaining ring E3 for
the BH lever holder assy., and then the BH shaft holder and the BH lever holder assy.

Disassembly
Procedure

F
9

J
G

G
G

7
H

B
C

7
A

F
F

18. Remove the one screw (bolt socket M 3 x 6) for the needle holder stopper, and then remove the needle holder
stopper.
19. Remove the one screw (screw, bind M 4 6) for the BH change shaft holder B, and then remove the BH
change shaft holder B.
20. Remove the one screw (bolt socket M 3 x 6) for the BH lever stopper, and then remove the BH lever stopper.
21. Remove the reatainting ring E3 for the BH connecting rod A assy., and then remove the BH connecting rod
A assy.

1-6

Disassembly Procedure
Lower Shaft Unit Disassembly
1. Remove the two retainer ring E4 and loosen the screw (screw, bind 4 14) to remove the feed transmission
lever A and the feed transmission lever B.
2. Remove the two screws (screw M4) to remove the needle plate A.
3. Remove the inner rotary hook.
4. Remove the one screw (screws pan (S/P washer) M 3 6) and remove the inner rotary hook rotation
prevention bracket assembly.
5. Remove the two screws (screw, bind M 3 6) to remove the feed dog.
6. Loosen the three screw (set screw, socket (CP) M 4 4) for the shaft supporter and remove the rotary hook
assembly.
7. Remove the three retainer rings E3 for the vertical feed shaft and the retainig ring CS4 and then remove the
vertical feed shaft, the washer and the vertical lever.
8. Loosen the two screws (set screw, socket (CP) M 4 4) on the lower shaft set collar and then remove the set collar
and the washer, thrust.
9. Remove the one screw (screw, bind M 3 6) and remove the feed supporting plate and the feed supporting
plate B.
10. Remove the three screws (screw, bind M 3 6) to remove the metal retainer B.
11. Remove the metal and the washer, thrust.
12. Remove the retainer ring E6 from the timing pulley side of the lower shaft, loosen the two screws (set screw,
socket (CP) M 5 5), and then remove the timing pulley and the lower shaft bushing.
13. Remove the lower shaft assembly.
14. Remove the retainer ring E5 from the horizontal feed shaft and loosen the screw (set screw, socket (CP) M 3
6), and then remove the horizontal feed shaft.
15. Remove the two feed base tension spring.
16. Remove the two screws (screws, pan (S/P washer) M 4 22) and the two collar to remove the rotary hook
shaft receptacle.
17. Remove the retainer ring shaft CS3.5 and then remove the feed arm assy.
18. Remove the feed arm supporter.
19. Remove the feed adjusting shaft assy.
2

5
5

3
1
1

0
8

8
8
8

7 7

0
0

7
C

A
B

B
D

B
G

D
6

9
9
9

1-7

Disassembly Procedure
Thread Tension Disassembly
1. Remove the holding screw (screw, pan M 3 4) to remove the notch spring.
2. Set the thread tension dial to 9 and remove the thread tension dial shaft.
3. Remove the thread tension plate.
4. Remove the thread tension adjusting screw from the thread tension plate.
5. Remove the following items in the following order: the spring, the washer, the tension spring receptacle, the
thread release plate, the washer, plain, the thread tension disc B, and the thread tension disc A.
6. Remove the one screw (screws pan (S/P washer) M 3 18DA) and remove the thread take-up spring case
and the thread take-up spring.

Disassembly
Procedure

2
8

6
1
1

1-8

Disassembly Procedure
Z Dial Assy. Disassembly
1. Remove the two retainig ring E2.5, and then remove the Z dial connecting rod and the Z dial pin.
2. Remove the two retainig ring E4, and then remove the Z dial.
3. Remove the one screw (taptite, bind B M 3 6) and remove the notched spring.
4. Remove the retaining ring E2.5, and then remove the zigzag lever and the Z dial connecting rod.

1
3

2
3
1
1
4

1-9

Assembly Procedure
Assembly Procedure
Assemble and install the units first before attaching the front cover and the rear cover

Front Cover
1. Insert the thread tension dial of the thread conductor A assembly into the square hole of the front cover, and
secure with the two screws (taptite, bind B M 4 12).
2. Insert the tip of the wire of the thread conductor B assembly by aligning it against the positioning groove of
the front cover and secure with the screw (taptite, bind B M 4 12) that sets the protrusion of the thread
conductor B into the hole in the front cover.

1
2

1
1

1 - 10

Assembly Procedure
Rear Cover
1. Temporarily fasten the thread guide assembly with the one screw (giza tite 4 12).
2. Insert the spool pin into the rear cover and then attach the spool pin spring onto it.
3. Attach the adjusting plate, Plate apring, and the adjusting screw in this order and secure them with the two
screws (taptite, bind B M 4 10).
4. Attach the two motor fixed plate with the two screws (giza tite 5 16), and then attach the motor holder to
the motor, and then insert the motor fan while attaching the motor belt, and then attach the motor holder and
the cord guide plate with the two screw (bolt, (S/P washer) M 5 x 12).
5. Fasten the three pole socket assembly with the screw (screw, pan (S/P washer) M 3 6).
6. Route and connect the lamp unit harness and the motor harness, and then attach it with the screw of cord
clamp.
7. Secure the bobbin assembly with the two screws (taptite bind B M 5 16).
8. Fasten the cord retainer and the thread winding spring with the one screw (giza tite 5 16).

2
1

7
7

8
8

6
5
5

4
3

3
4

3
3
3
4

4
4
4

1 - 11

Assembly Procedure
9. Insert the BH change shaft assy. to the BH change shaft holder B on the needle-presser nuit, and then attach
the retaining ring E2.5.
10. Attach the needle bar-presser unit assembly to the rear cover with the two screws (giza tite 5 x 20), and then
Insert the BH change arm assy., and then temporarily fasten the screw (set screw socket (CP) M 4 x 4).
11. Insert the tension belt and the timing belt into the upper shaft assembly, and then attach the upper shaft
assembly to the rear cover while inserting the needle bar crank into the hole of thread take-up counter
weight.
12. Fasten the screw (set screw, socket (FT) M size 5 5) for the thread take-up lever crank at the cut face
position to connect the upper shaft assembly and the needle bar-presser unit assembly.
13. Attach the upper shaft bearing presser to the shaft bushing (two points) of the upper shaft assembly, and then
fasten the four screws (giza tite 5 x 16).

0
9

Assembly
Procedure

0
0

A
A
A
9

C
C

B
C

1 - 12

Assembly Procedure
14. Temporarily fasten the screw (screw bind M 3 x 25) for needle clearance adjustment.
15. Secure the lamp unit to the base holder assembly with the screw (screw bind M 3 x 20).
16. Rinse lower shaft of the feed module and the feed adjusting shaft, and then fit the feed module in the rear
cover and secure it with the two screws (giza tite 5 16) of the base plate assembly.
17. Attach the feed connecting holder with the screw (giza tite 5 16)
18. Place the lower shaft metal retainer on the lower shaft metal and fasten it with the two screws (giza tite 5 16).
19. Insert the hole of the BH change shaft holder A into the change shaft, and then attach it with the two screws.
20. Set the washer in the mounting position on the rear cover.
21. Put the worm pulley of the selection unit through the timing belt, and then adjust the pin of the feed
connecting lever and the hole of the feed rod, and then set it in the mounting position on the rear cover.
22. Insert the spacer into the hole of the lower left of the unit, and then attach the selecting unit with the three
screws (giza tite 5 x 16).
23. Attach the BH change shaft holder B to the BH change arm assy., and then attach the retaining ring E2.5.
24. Attach the zigzag lever to the groove of the zigzag link and the shaft of the lower needle holder, and then
attach the retaining ring E4 which connects zigzag link with the selecting unit.
25. Attach the Z dial assy. to the body, and then attach the zigzag lever and the Z dial assy. with the retaining
ring E2.5.
26. Attach Z dial assy. with the two screws (giza tite 5 x 16).
How to attach the Z dial assy.
Temporarily fasten the screw of the right side.
Turn the Z dial to [0].
Pull over the zigzag lever io the bottom, and pull over the Z dial assy. to the topside, and then lower the
zigzag lever along the groove of the zigzag link.
Fasten the screw of the left side when the roller of the zigzag lever located on the most inferior point of the
groove of the zigzag link.
Fasten the screw of the right side.

27. Attach the pull spring (6 15 mm) of the Z linkage.

28. Attach the spring.
29. Attach the BH spring and BH notch spring plate with the screw (screw pan (S/P washer) M 4 x 8).
O
Q

N
E
Q

R
R
N

S
D
J
S
J
E
L

K
L

R
K
G

H
F
F

1 - 13

Assembly Procedure
30. Attach the cord clamp with the screw (taptite bind B M 4 x 14).
31. Install the reverse stitching knob.
32. Tighten the screws for fastening the front cover, one in the front (taptite bind B M 4 x 14) and six in the back
(five giza tite 5 16, and one giza tite 3 32), to secure the front cover.
33. Attach the F dial, and then attach the retaining ring E6.
34. Attach the selection dial on the front face of the front cover.
35. Attach the face plate with the screw (taptite, cup P M 4 x 20).
36. Attach the.needle plate B.

T
V

Assembly
Procedure

1 - 14

Assembly Procedure
Thread Tension Assembly
1. Mount the following items in the following order: the tension disc A, the tension disc B, the washer, the
thread release plate, the tension disc washer, the washer, and the spring.
2. Mount the thread tension adjusting screw on the thread tension stud aligning it to the thread tension cam
groove in the thread tension dial.
3. Set the thread tension dial to 9 and attach the thread tension dial shaft.
4. Align the notch spring against the oval hole and secure it with the screw (screw, pan M 3 4).
5. Attach the thread take-up spring in the second hole from the bottom of the thread take-up spring case so that
the thread guard side fits between two protrusions of the spring case.
6. Insert the positioning protrusion of the thread take-up spring case assembly into the square hole of the thread
conductor B, shift it all the way up in the square hole, and secure it with the one screw (screw, pan (S/P
washer) M 3 18DA).

1 1

3
9
0

5
6

1 - 15

Assembly Procedure

1. After setting the lever spring in the letter V direction in the U-bend part of the thread loosening lever and
inserting into the base holder shaft, attach the retaining ring CS4. (The lever spring should be rested on the
base holder on the left side and on the upper side of the U-bend part on the right side.)
2. Insert the presser lifter in the presser lifter shaft and attach the retainer ring E4.
3. Align the U groove of the base holder against the protrusion of the needle bar stopper and temporarily fasten
it with the one screw (bolt, socket, M 3 6) from the back.
4. Set the screw (set screw, socket (CP) M 5 8) on the presser bar clamp, insert the presser bar into the base
holder, the presser bar clamp, and the spring in this sequence, and temporarily fasten the screw (set screw,
socket (CP) M 5 8).
5. Insert the needle holder rod A assy. into the hole of the base holder assy, and then attach it with retaining ring E3.
6. Align the positioning hole of the guard plate to the protrusion of the lamp holder, and then fasten the screw
(screws, bind M 3 4) from the rear side.
7. Align the positioning hole of the lamp holder to the protrusion of the base holder, and then fasten the screw
(screws, bind M 4 6) from the rear side.
8. Align the positioning hole of the BH change shaft holder B to the protrusion of the base holder, and then
fasten the screw (screws, bind M 4 6) from the rear side.
9. Insert the BH lever holder assy. into the hole of the BH shaft holder, and then attach the retaining ring E3.
10. Align the end of BH lever holder to the U groove of the BH change shaft holder A, and then align the
positioning hole of the BH shaft holder to the protrusion of the base holder, and then fasten the screw (screws,
bind M 4 6) from the rear side.6.Attach the retaining ring E5 to the stud for thread take-up lever supporter.
11. Attach the retaining ring E5 to the stud for thread take-up lever supporter.
12. Insert the dome spring washer into the stud for thread take-up lever supporter with its convex side facing the
retaining ring.
13. Insert the thread take-up lever supporter into the stud for thread take-up lever supporter.
14. Insert the stud for thread take-up lever supporter into the base holder and secure it with the one screw
(Phillips, pan head screw with spring and plain washers, size 3 8DB).
15. Insert the riveting stud for the Z fine adjusting plate from behind the needle bar supporter and temporarily
fasten it with the screw (Phillips, pan head screw with spring and plain washers, size 3 8DB).
16. Temporarily insert the needle bar into the needle bar supporter, run it through the thread positioning plate
and the needle bar block, and then attach the thread positioning plate withe the screw (screws, bind M 2.6
4) and temporarily fasten with the screw (set screw, socket (FT) M 4 4).
A
C
8

7
5
D

3
2

3
9
6

F
F

1 - 16

Assembly
Procedure

Needle Bar-Presser Unit Assembly (With Needle Thread)

Assembly Procedure
17. Set the needle bar supporter in the base holder, insert the push spring into the gap between the needle bar
supporter and the base holder, and force the needle bar supporter stud in.
18. Attach the lock nut to the needle bar supporter stud, turn it until it levels with the base holder, and then
tighten it.
19. Temporarily insert the needle bar supporter arm into the pin of the needle bar supporter.
20. Insert the needle bar supporter arm into the riveting pin for the needle bar supporter stud holder and attach
the retaining ring E2.
21. Insert into the U groove of the base holder of the needle bar supporter stud holder and temporarily fasten
with the one screw (bolt, socket M 3 6) approximately in the center of the oval hole of the needle bar
supporter stud holder.
22. Align the U groove of the needle holder stopper against the protrusion of the needle bar stopper and
temporarily fasten it with the one screw (bolt, socket, M 3 6) from the back.
23. Assemble with the thread take-up lever body and the needle bar crank and fasten with the Phillips, flat
countersunk head screw, size 3.57.
24. Insert the riveting stud of the thread take-up lever body for the thread take-up lever supporter into the thread
take-up lever supporter.
25. Insert the needle bar crank rod in to the needle bar crank and the needle bar clamp shaft.

M
H

N
O
G

G
O

J
I

K
L
K

1 - 17

Assembly Procedure
Lower Shaft Unit Assembly
1. Insert the push spring in the feed adjuster assembly which is then inserted into the shaft receptacle of the base
plate from the left.
2. Insert the feed arm receptacle to the end face of the base plate.
3. Snap on the retainer ring E6 in the retainer spring groove on the left of the lower shaft and attach the thrust
washer on the shaft from the left.
4. Insert the lower shaft assembly into the base plate.
5. Attach the lower shaft metal on the left of the lower shaft, set the metal retainer B, and secure with the three
screws (screws, bind M 3 6).
6. After attaching the thrust washer and the set collar on the left of the lower shaft, slide the set collar toward
the metal, and tighten the screw (set screw, socket (CP) M 4 4).

Assembly
Procedure

7. Insert the vertical feed shaft into the base plate, slide the vertical finger and the washer on the shaft, and
attach the retainer rings E3 on the inner left of the base plate as well as outside of the vertical finger (on both
the left and the right).

1
2

5
6

5
6 6

4
3

1 - 18

Assembly Procedure
8. Attach the polyslider first and then the feed arm B on the riveting stud of the feed arm A, and apply the
retainer ring shaft CS.
9. Insert the feed arms A and B assembly into the base plate from below, and place the feed regulator slide shaft
inside the feed adjuster.
10. After inserting the polyslider between the feed arm A and the base plate, insert the horizontal feed shaft from the left.
11. Snap on the retainer ring E5 to the horizontal feed shaft from inside of the base plate.
12. Slide the polyslider and the set collar on the horizontal feed shaft from the left, place them on the left hand
side, and tighten the two screws (set screws, socket, CP, size 4 4).
13. Tighten the screw (set screw, socket (CP) M 4 10) on the vertical adjuster.
14. Assemble the screw (set screw, socket (CP) M 4 10) with the lock nut, drive it into the feed base, and then
tighten the lock nut.
15. Slide the feed base on riveting stud of the feed arm A and snap on the retainer ring shaft CS to the shaft on
the left hand side.
16. Attach the vertical rod between the vertical adjuster and the vertical finger.
17. Attach the feed tension spring on the feed base and the base plate.
18. Align the protrusion of the feed auxiliary plate B against the groove in the feed auxiliary plate and fasten
with the screw (screws, bind M 3 4).
19. Attach the lower shaft metal to the right hand side of the lower shaft and snap on the retainer ring E6 in the
retainer ring groove on the inner side of the lower shaft.
20. Turn the lower shaft so that the spring pin of the lower shaft gear is at its lowest position and the horizontal
feed cam faces to the front. Slide the timing pulley D on the shaft with the pulley's screw head facing to the
right, position the pulley so that its screw (set screw, socket (CP) M 5 5) faces to the front and the other
screw to the top, and then temporarily tighten the screws.
21. Set the Class 2 nut 4 on the bottom side of the feed transmission lever and temporarily fasten with the screw
(screws, bind 4 14).
22. Attach the feed transmission lever to the feed adjuster shaft, snap on the retaining ring E4 in the retainer ring
groove on the right, slide the feed transmission lever toward the retainer ring, and temporarily fasten it.
L
D

D
F

L
K
I

B
B
8

8
H

H
H

1 - 19

J
J

Assembly Procedure
23. Temporarily insert the screw (set screw, socket (CP) M 4 4) in the rotary hood shaft receptacle and
temporarily fasten the rotary hood shaft receptacle with the screw (screw, pan (S/P washer) M 4 22).
24. While the spring pin of lower shaft gear facing down and the horizontal feed can facing to the front, insert the
rotary hook so that is reference point faces to the front and tighten the screw (set screw, socket (CP) M 4 4).
25. With a force of about 400g pushing on the outer rotary hook shaft, and then fasten the screw ((set screw, socket
(CP) M 4 4).
26. Verify that there is reasonable backlash between the rotary hook and the lower shaft. (The backlash along
the perimeter should be 0.8 mm max.)
27. Attach one end of the backlash eliminating spring to the same hole in the feed base as for the feed base
tension spring and the other end to the feed base plate.
28. Secure the feed dog with the screw (screw, bind M 3 6).
29. Set the inner rotary hook.
30. Temporarily fasten the needle plate A with the M4 screw.
31. Align the mounting hole of the inner rotary hook rotation prevention bracket against the protrusion and
temporarily fasten it with the screw (screw, pan (S/P washer) M 3 6).
T

Assembly
Procedure

T
R

(BM)

R
S

NO

N
U

(XL)

U
N

M
M

MO
M

1 - 20

Assembly Procedure
Z Dial Assy. Assembly
1. Pull over the notched spring to the end of upper side, and then fasten the one screw (taptite bind B M 3 x 6).
2. Insert the Z dial into the shaft, and attach the retaining ring E4.
3. Insert the Z dial pin into the Z dial and Z dial connecting rod, and attach the two retaining ring E2.5

2
1

3
2

1 - 21

Assembly Procedure
An Exchange Method Of Outer Rotary Hook Assy.
(Remove the front cover refer to Disassembly Procedure)
1. Remove the two screws (screw M4) to remove the needle plate A.
2. Remove the one screw (screw, pan (S/P washer) M3 x 6) to remove the inner rotary hook bracket assy.
3. Loosen the one screw (set screwsocket (CP) M4 x 4) of shaft supporter, and pull the outer rotary hook shaft.
4. Remove the outer rotary hook assy. while pushing the feed dog to the back side.
5. Insert outer rotary hook assy. so that the reference hole on the outer rotary hook faces the front, and tighten
the screw (set screw socket (CP) M4 x 4), and then hold the pin spring roll of lower shaft gear with the
bottom, and hold the feed cam with the rear.
6. Attach the inner rotary hook bracket assy. with the screw (screw, pan (S/P washer) M 3 6).
7. Attach the needle plate A with the screw (screw M4).

17
17

Assembly
Procedure

*Key point
After exchage, check the needle bar quantity of rise and needle bar height.

17
26

26

45

3
5

1 - 22

Adjustment
1. Adjustment of the Timing Belt Tension
When pulling on the middle portion of the timing belt with a force of 3 N (300 g), there should be a slack of
3 to 4 mm.
1 Loosen the screw (Screw, pan (S/P washer) M 4 8 DA) fastening the tension pulley holder.
2 Adjust the belt tension by moving the tension pulley holder up or down.
3 Tighten the screw (Screw, pan (S/P washer) M 4 8 DA) to secure the tension pulley holder.
4 Check the timing belt tension again.

Inspection and
Adjustment

Screw, pan (S/P washer) M4 8DA

Tension pulley holder

3 - 4 mm

3N(300g)
Tension guage

2-1

Adjustment
2. Adjustment of the Motor Belt Tension
When pulling on the middle portion of the motor belt with a force of 1 N (100 g), there should be a slack of 3
to 4 mm.
1 Loosen the two screws (Bolt, (S/P washer) M 5 12) fastening the motor holder.
2 Adjust the belt tension by moving the motor holder up or down.
3 Tighten the two screws (Bolt, (S/P washer) M 5 12) to secure the motor holder.
4 Check the motor belt tension again.

3 - 4 mm

1N(100g)

Tension guage

Bolt, (S/P washer) M5 12

2-2

Inspection and
Adjustment

Motor holder

Adjustment
3. Adjustment of the Needle Bar Stopper
The needle tip should not touch the needle plate when the needle bar is lowered and the needle bar support is
pushed to the right. The needle bar support should not contact the stopper when the needle is at the right
down position with the maximum zigzag width setting.
1 Turn the selection dial to [3].
2 Turn the dial to [5] to maximize the zigzag width.
3 Turn the pulley to lower the needle bar until the needle tip is level with the top face of the needle plate.
4 Loosen the screw (bolt, socket, size M3 x 6) securing the stopper.
5 Adjust the stopper position (left/right) so that the needle tip does not contact the needle plate when the needle
bar support is pushed to the right.
6 Tighten the screw (bolt, socket, size M3 x 6) to secure the stopper.
7 Turn the pulley to verify that the needle bar support does not contact the stopper when the needle is swung to
the right. If it contacts the stopper, repeat from step 1.

stopper

Needle bar
supporter

0.3 - 0.7 mm
Adjustment of the stopper position

2-3

Adjustment
4. Adjustment of the Needle Sidewise Movement (Needle Swing Timing)
When the needle sidewise movement move from the left base line to the right base line, the needle tip should
be 4.0 to 6.0mm from the fase of the needle plate.
1 Turn the selection dial to [3].
2 Turn the dial to [5] to maximize the zigzag width.
3 Loosen the two screws (set screw, socket (FT), size 4M x 4) securing the worm pulley.
4 Rotate the worm pulley, and adjust the position.
5 Tighten the two screws (set screw, socket (FT), size 4M x 4) to secure the worm pulley.

Inspection and
Adjustment

6 Turn the pulley to verify that needle swing timing is within the criteria.

Set screw, socket (FT) M4 4

Worm pulley

2-4

Adjustment
5. Adjust of the down position back and forth for the presser foot
1 Turn the selection dial to [3].
2 Turn the pulley to adjust height of the to needle the top face of the zigzag presser foot.
3 Adjust that to tarn the needle holder shaft of the needle unit with the flat-blade screwdriver so that the down
position back and forth to the needle hole of the zigzag presser foot in going on the center.
4 Check the down position back and forth to the needle hole of the zigzag presser foot on the needle is the
uppermost position.
* Check the gap between the needle and the zigzag presser foot (front and back) to 0.1 mm or more in both
front and back.

Needle holder shaft

Needle hole

Position of
needlepoint

2-5

Adjustment
6. Adjustment of the Needle Swing
When the Z dial is turned from 0 to 5 while the needle is at the right down position with the maximum zigzag
width setting, variation in needle down should be within 0.15 mm.
1 Turn the selection dial to [3].
2 Turn the dial to [5] to maximize
3 Turn the pulley to lower the needle bar until the needle tip is level with the top face of the needle plate when
the needle is at the right down position.
4 Loosen the screw at the Z adjustment nut.
5 Adjust the position of the needle with the Z adjustment nut so that the needle tip does not move when the Z
dial is turned from 5 to 0.
6 Tighten the screw.

Inspection and
Adjustment

7 Turn the Z dial from 0 to 5 and 5 to 0 to verify that variation in needle down is within the criteria.

2-6

Adjustment
7. Adjust of the down position of the straight line on the left base line (right / left)
1 Turn the Z dial to [5] to maximize the zigzag width.
2 Turn the pulley to adjust height of the needle to the top face of the needle plate on the left base line.
3 Compare the left and right gap [2] and [3] of the down position with the selection dial.
4 Loosen the screw, pan (S/P washer) M3 x 8 of the selecting unit assy.
5 Adjust the adjusting nut of the selecting unit with the wrench so that the down position of the straight line on
the left base line and the down position of the Z on the left base line is approximately same.
6 Tighten the screw, pan (S/P washer) M3 x 8 of the selecting unit assy.
7 Check the left and right gap of the down position of the straight line on the left base line for the down
position on the left base line.
* The gap should be 0.15 mm or less.

Adjusting nut

Dial [2]
Dial [3]

Needle hole

0.15 mm or less

2-7

Adjustment
8. Adjustment of the down position of the bar track (BH ac) on the left
base line (right / left)
The left and right gap of the down position of the bar track on the left base line should be 0.2 mm or less.
1 Turn the selection dial to [1].
2 Turn the Z dial to [5] to maximize the zigzag width.
3 Draw the BH lever to the bottom, and push the BH lever to the back side.
4 Remove the presser foot from the presser foot holder.
5 Turn the pulley unit the bar track down position to adjust height of the needle to the top face of the needle
plate on the left base line.
6 Loosen the screw, pan (S/P washer) M3 x 6 of the selecting unit assy.
7 Adjust the BHZ adjust plate of the selecting unit with flat-blade screwdriver (small) so that the down
position of the bar track on the left base line and the down position of the Z on the left base line is
approximately same.
8 Tighten the screw, pan (S/P washer) M3 x 6 of the selecting unit assy.

Screw, pan (S/P washer) M3 x 6

Inspection and
Adjustment

BH Z adjusting plate

2-8

Adjustment
9. Adjustment of the Needle Bar Height
When the rotary hook point is even with the perimeter of the needle (#14) after turning the pulley by hand
from the zigzag maximum left needle down position, the distance from the highest point of the needle hole to
the lower edge of the rotary hook point should be 1.0 to 1.4 mm.
1 Select the maximum zigzag width.
2 Turn the pulley until the perimeter of the needle is even with the rotary hook point near the left needle drop
position.
3 Loosen the screw (Set screw, socket, FT, M 4 4) on the needle bar clamp.
4 Adjust the needle bar height until the distance between the highest point of the needle hole and the lower
edge of the rotary hook point is 1.0 to 1.4 mm.
5 Tighten the screw (set screw, socket, FT, M 4 4) on the needle bar clamp.

Set screw, socket

(FT) M4 4

Right edge of needle

and tip coincide
Needle bar

1.0 - 1.4mm

2-9

Adjustment
10.Clearance between the needle and the rotary hook point adjustment
1 Turn the Z dial to [5] to maximize the zigzag width.
2 Turn the selection dial to [3].
3 Turn the pulley, and then stop the outer rotary hook tip at the back side position of the needle on the left base
line.
4 Loosen the screw bind M3 x 25 of the needle presser module.
5 Turn the adjusting screw with the wrench, and adjust the gap between the needle and the outer rotary hook
tip.
6 Tighten the screw bind M3 x 25 of the needle presser module.
7 Check the gap between the needle and the outer rotary hook tip.
* Iron-sintering outer rotary : The gap should be 0.25 mm or less, and without contact.
: The gap should be 0.1 to 0.3 mm.

Inspection and
Adjustment

* Plastic outer rotary

Adjusting screw

2 - 10

Adjustment
11.Adjustment of the Position of the Inner Rotary Hook Rotation Prevention
Bracket
1 Set the inner rotary hook in the rotary hook.
2 Loosen the bind screw securing the inner rotary hook rotation prevention bracket assy.
3 Adjust the position of the inner rotary hook rotation prevention bracket assy. so that the overlap distance
between the inner rotary hook and the rotation prevention bracket assy. is 2.4 to 2.7 mm and secure it with
the screw, pan (S/P washer ) M 3 6.

2.4 - 2.7mm
Screw, pan (S/P washer) M3 6

2 - 11

Adjustment
12.Adjustment of the Upper Thread Tension
The thread tension should be 0.38 - 0.43 N (38 - 43g) when pulled slowly using a tension gauge.
1 Raise the presser foot.
2 Set the thread tension dial to 4.
3 Thread a schappe spun sewing thread # 60 through the thread guide and the thread tension disc.
4 Lower the presser lifter.
5 Adjust the tightening amount of the thread tension adjusting screw so that the thread tension is 0.38 - 0.43 N
(38 - 43g) when pulled slowly using a tension gauge.

Inspection and
Adjustment

6 Apply a small amount of screw locking agent to the thread tension adjusting screw.

0.38 - 0.43N (38 - 43g)

Adjusting screw

2 - 12

Adjustment
13.Adjustment of the Inner Rotary Hook (Lower Thread) Tension
1 Set a bobbin (wound with a schappe spun sewing thread # 60) in the inner rotary hook and put a thread
through.
2 Adjust the tightening amount of the spring tension adjusting screw so that the thread tension is 0.10 to 0.12 N
(10 to 12 g) when pulled slowly using a tension gauge.

0.1 - 0.12N
(10 - 12g)

Shapesupan thread #60

Spring adjusting screws

2 - 13

Adjustment
14.Adjustment of the Thread Winding
(Uneven Bobbin Winding and Amount of Thread Winding)
1 Move the thread winding guide assy. up or down to adjust and correct for uneven bobbin winding. (Uneven
bobbin winding)

Inspection and
Adjustment

2 Rotate the bobbin presser to adjust the amount of thread winding. (As a guideline of thread winding amount,
a bobbin should be wound up to 80 to 90% of the external diameter of the bobbin.)

80 - 90%

2 - 14

Adjustment
15.Adjustment of the feed of the bar track (BH a).
The feed of the bar track should be 0 to 0.1 mm.
1 Turn the selection dial to [1].
2 Turn the Z dial to [5] to maximize the zigzag width.
3 Draw the BH lever to the bottom.
4 Switch on the sewing machine, and step on the foot controller and then stop it after drive the sewing machine
for a while.
5 Push the BH lever to the back side.
6 Turn the pulley until the bar track down position.
7 Attach the presser foot to the presser fool holder.
8 Set the broad cloth, and take down the presser foot.
9 Loosen the screw, pan (S/P washer) M3 x 6 of the selecting unit assy.
< Adjust the BHF adjusting plate A assy. with flat-blade screwdriver (small) so that the feed should be 0 to
0.1mm at the bar track BH a.
A Tighten the screw, pan (S/P washer) M3 x 6 of the selecting unit assy.

Screw, pan (S/P washer) M3 x 6

2 - 15

BH F adjusting plate A assy.

Adjustment
16.Adjustment of the feed
The feed should be 4.5 to 5.5mm when 11 stitches are sewn is feed [F] mode.
1 Turn the selection dial to [3].
2 Turn the feed dial to [F].
3 Loosen the screw bird M4 x 14 of feed connecting lever A.
4 Move the feed adjusting shaft back and forth to roughly adjust the feed to be with the criteria.
5 Tighten the screw bind M4 x 14 of the feed connecting lever A.

Inspection and
Adjustment

6 Fine-tune the feed with the adjustment screw.

Screw bind M4 x14

11P : 4.5 to 5.5 mm

Adjusting screw

Feed adjusting shaft

2 - 16

Adjustment
17.Adjustment of the feed
The feed should be 4.5 to 5.5 mm when 11 stitches are sewn in feed [F] mode
1 Turn the selection dial to [3].
2 Turn the feed dial to [F].
3 Loosen the binding screw of feed transmission lever A.
4 Move the axis back and forth to roughly adjust the feed to be within the criteria.
5 Tighten the feed transmission lever screw.
6 Fine-tune the feed with the adjustment screw.
*Key point
After adjusting the feed, be sure to check the feed for the super stitch 1 pattern and super stitch 2 pattern. If
the feed needs adjusting, follow the descriptions in sections 12 and 13.

Binding screw (3)

Fine-tune the feed with the adjustment screw (6)

2 - 17

Adjustment
18.Adjustment of the feed of the left over edging button hole (BH b)
The number of needles should be +10 to -4 for right over edging, when that sewed 20 mm with the left over
edging for BH.
1 Turn the selection dial to [1].
2 Turn the Z dial to [5] to maximize the zigzag width.
3 Turn the feed dial to [F].
4 Sandwich the button more than a diameter of 20 mm to the BH foot, and attach the BH foot to the presser
foot holder.
5 Repeat two pieces of broadcloth and sew it, and then check the number of the BH right over edging is 35 to
50 / 20 mm.
6 Draw the BH lever to the bottom, and push the BH lever to the back side.
7 Loosen the screw, pan (S/P washer) M3 x 6 of the selecting unit assy.
8 Repeat two pieces of broadcloth and sew it for BH, and align the BHF adjusting plate B assy. with flat-blade
screwdriver (small) so that fine-tune the gap of the number of the needles at the left over edging and the right
over edging for BH.

Inspection and
Adjustment

9 Tighten the screw, -pan (S/P washer) M3 x 6 of the selecting unit assy.

BH F adjusting plate B assy.

Screw, pan (S/P washer) M3 x 6

2 - 18

Adjustment
19.Adjustment of the BH length
The inside dimensions of a and c should be 21 to 23mm for the button of a diameter of 20mm.
1 Turn the electing dial to [1].
2 Turn the Z dial to [5] to maximize the zigzag width.
3 Turn the feed dial to [F].
4 Sandwich the button more than a diameter of 20 mm to the BH foot, and attach the BH foot to he presser foot
holder.
5 Draw the BH lever to the bottom, and push the BH lever to the back side.
6 Repeat two pieces of broadcloth and sew it for BH.
7 Measure the inside dimensions of the BH a and c.
8 Insert the hexagonal driver into the hole of the cover upper part, and then loosen the set screw socket (CP)
M4 x 4 of the BH change arm assy.
9 Adjust the BH length by moving the BH lever front or back.
* Shorten length

: Adjust the BH lever to the back side

* Lengthen length : Adjust the BH lever to the front side

0 Insert the hexagonal driver into the set screw socket (CP) M4 x 4 of the BH change arm assy. and then attach
it while pull over to the lower side.
A Check the inside dimensions of a and c for the button of a diameter of 20mm.
* The inside dimensions should 21 to 23mm.

80

Shoter
Longer

2 - 19

XL2600i/XL3500i/XL3600/BM3600/XL3750
10A06HF885S28/S29