Challenge 1640 Sewing Machine Manual

The Challenge 1640 is a versatile mechanical sewing machine with 40 built-in stitches, one-step buttonhole, automatic needle threader, drop-in bobbin system, adjustable stitch length and width, free arm capability, built-in LED light, and variable speed control. Powered by 120V AC, 60Hz. Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Accessories 7. Basic Sewing Operations 8. Maintenance Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Mechanical sewing head, built-in stitch patterns, automatic needle threader, drop-in bobbin system, free arm, accessory storage.

FeatureDescription
Built-in stitches40 different stitch patterns including utility, decorative, and stretch
One-step buttonholeAutomatic buttonhole creation with precise sizing
Automatic needle threaderEasy threading with built-in threading mechanism
Drop-in bobbin systemTop-loading bobbin with clear cover for easy monitoring
Free arm capabilityConvertible for sewing sleeves and cuffs
Variable speed controlAdjustable sewing speed with foot pedal
Built-in LED lightBright illumination of sewing area
Stitch length/width adjustmentCustomizable stitch dimensions
Reverse stitchingReinforce seams with reverse stitch button
Accessory storageBuilt-in compartment for feet and accessories

Installation

Unpack and inspect contents. Place on stable sewing table.

  1. Remove machine from packaging: Lift carefully from carrying case.
  2. Position machine: Place on sturdy table with adequate workspace.
  3. Connect foot pedal: Plug into machine's foot control port.
  4. Connect power: Plug power cord into machine and wall outlet.
  5. Install accessories: Attach standard presser foot and thread machine.

WARNING! Machine contains sharp needles; handle with care. Ensure stable placement to prevent tipping.

First-Time Setup

Prepare machine for first use with proper threading and bobbin winding.

  1. Wind bobbin: Place thread on spool pin, wind bobbin using bobbin winding system.
  2. Install bobbin: Place wound bobbin in drop-in bobbin case with thread pulling counterclockwise.
  3. Thread upper thread: Follow numbered threading path on machine; use automatic needle threader.
  4. Select first stitch: Choose straight stitch for initial testing.
  5. Test sew: Use scrap fabric to test machine operation and tension.

CAUTION! Keep fingers away from needle area during operation. Always turn off when threading.

Specifications

Controls and Settings

Access stitch selection via dial controls. Front Panel: Stitch selector dial, stitch length dial, stitch width dial, reverse stitch button.

Additional Controls: Power switch, bobbin winder, thread tension dial, presser foot lever, hand wheel.

Stitch Selection: Turn dial to choose from 40 built-in patterns. Stitch Length: Adjust from 0-4mm for different fabric types. Stitch Width: Adjust from 0-5mm for zigzag and decorative stitches. Tension Control: Dial adjustment for perfect stitch formation. Reverse Stitch: Hold button for backstitching at beginning and end of seams.

Connecting Accessories

Various presser feet and accessories for different sewing techniques.

  1. Turn off machine before changing accessories.
  2. Raise presser foot lever to highest position.
  3. Align presser foot shank with machine ankle.
  4. Lower presser foot lever to lock in place.
  5. Test accessory function on scrap fabric.

Tip: Always use correct presser foot for specific techniques (zipper foot for zippers, buttonhole foot for buttonholes).

Basic Sewing Operations

Fundamental sewing techniques and machine functions.

  1. Straight Stitching: Select straight stitch pattern, adjust length as needed.
  2. Zigzag Stitching: Select zigzag pattern, adjust width for finishing edges.
  3. Buttonholes: Use one-step buttonhole function with buttonhole foot.
  4. Decorative Stitches: Choose from built-in decorative patterns.
  5. Free Arm Sewing: Remove accessory tray for sewing sleeves and cuffs.
  6. Reverse Stitching: Hold reverse button to reinforce seams.
  7. Variable Speed: Control sewing speed with foot pedal pressure.
  8. Needle Positioning: Use hand wheel to precisely position needle.

WARNING! Never pull fabric while sewing; let feed dogs move fabric. Keep fingers clear of moving needle.

Maintenance Features

Automatic needle threader: Push lever to thread needle easily. Drop-in bobbin: Easy loading with clear view window. Built-in LED: Consistent lighting for precise sewing.

Care & Cleaning

Unplug before cleaning. Remove lint and dust from bobbin area and feed dogs regularly.

CAUTION! Use only sewing machine oil for lubrication. Do not use household oils. Keep machine covered when not in use.

Regulatory Information

UL Listed: Certified for electrical safety in household use. Copyright © 2025 Challenge Sewing Machines; trademarks of Challenge Manufacturing Co. For support, visit www.challengesewing.com or contact 1-800-555-SEWING.

Troubleshooting

SymptomPossible CauseCorrective Action
Thread breakingIncorrect threading/tensionRethread machine; adjust tension; check for burrs on needle.
Needle breakingWrong needle/bent needleReplace needle; ensure correct insertion; check for hitting pins.
Uneven stitchesTension issuesAdjust upper and bobbin tension; rethread completely.
Machine not feedingFeed dogs loweredRaise feed dogs; clean feed dog area of lint.
Bobbin thread bunchingIncorrect bobbin threadingRemove and rethread bobbin; ensure correct direction.

Maintenance: Oil moving parts every 6 months with sewing machine oil only.

Service: 1-800-555-SEWING; www.challengesewing.com

Challenge 1640 Sewing Machine Manual © - All Rights Reserved 2025