Bernina B 590 Service And Maintenance Manual
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Bernina B 590 Service And Maintenance Manual

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Service- and Maintenance Manual
Of the 5 Series (VIO type)
B 590
B 500
B 570
B540
B 535
BERNINA International AG
Seestrasse 161
CH-8266 Steckborn
Schweiz
Seite 1 von 172
DRAFT – VERSION

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  • Page 1 Service- and Maintenance Manual Of the 5 Series (VIO type) B 590 B 500 B 570 B540 B 535 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 1 von 172 DRAFT – VERSION...

  • Page 2: Table Of Contents

    1.8 Technical specifications of 5 Series ..................14 Chapter 2 – Electronics and Wiring ................16 2.1 BERNINA B 590 (B 570 QE, B 535, B 520 & B 500 Embroidery Only) Block Diagram ..16 2.2 PCBA-Power ........................17 2.3 PCBA-CPU-Module (ARM9) General Information ...............
  • Page 3 5.6.4 Main feed mechanical balance - basic setting................. 104 5.6.5 Upper feed (Dual Feed)-/main feed synchronization (pinning position) .......... 105 5.6.6 Upper feed-dog (Dual Feed) mechanical balance – Basic setting ..........106 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 3 von 172 DRAFT –...
  • Page 4 1b Machine firmware data and technical information ................121 1c Machine operating hours data ......................122 1d Stitch counter data ..........................122 1e BSR (BERNINA Stitch Regulator) data ....................122 1f Machine servicing data ......................... 123 1g Saving customer data .......................... 123 1h Customer related data (Customer Information) ...................
  • Page 5 9.5.1 Measures to be taken before the servicing ..................168 9.5.2 Measures to be taken after the service ................... 168 9.5.3 Functional check ..........................169 9.5.4 Maintenance checklist BERNINA 590, 570 QE, 540, 520, 500............170 9.5.5 Embroidery module ......................... 171 Chapter 10 – Document Revision History ................172...

  • Page 6: Chapter 1 - General Information

    This service manual is only available in electronic format. It can be downloaded from BERNINA Infogate at http://infogate.bernina.com under ‘Service Manual’ in the ‘Tech. Service’ register. If you don't have access to Infogate, contact your local BERNINA importer. They'll be glad to be of assistance.
  • Page 7 The capacitors require 30 seconds to discharge after the power supply has been switched off. We recommend to wait for the complete discharging of the capacitors before starting any servicing work on the PCBs. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...

  • Page 8: Esd-Related Note: Electrostatic Discharge (Esd)

    Electrostatic Discharge (ESD) 5. Treat faulty PCBs in the same manner as new ones to prevent consequential damage or harm. Note: For more information see 2.12 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 8 von 172...

  • Page 9: Tools And Gauges

    1.4 Tools and gauges (commercially available, not available from Bernina): Calliper, multimeter, TORX screwdrivers sizes 6, 8, 10, 10 with 200mm shaft length, 15, 20, 25, 25 with 200mm shaft length, angled Torx sizes 6 and 10, combination spanners in sizes 10mm and 8mm, open-...
  • Page 10 Distance plate Adjusting the needle height 730475.51.00 Distanzplatte Einstellen der Nadelhöhe Plaque-étalon de distance Réglage de la hauteur de l’aiguille Basic position of the BERNINA dual feed Synchroplate Grundposition Obertransportfuss 032798.50.00 Synchroplatte Position de base pour BERNINA dual Plaque de synchronisation...
  • Page 11 Ø1.5, 2.3, 3.2) (Size 3.2) Helpful Tools for BERNINA Sewing and Embroidery Systems Hilfreiche Werkzeuge für BERNINA Näh- und Sticksysteme Trousse à outils secourable pour les maschine à coudre informatisée de BERNINA Spring balance gauge Tension of thread regulator spring 006038.50.00...

  • Page 12: Handling Adjustments

    Throughout the whole manual the following abbreviations have been used. We have reserved the right not to explain individual abbreviations within the text. Abbreviation: Stands for: BERNINA Dual Feed (upper feed) BERNINA Stitch Regulator Direct Current EEPROM Electronically Erasable Programable Read Only Memory (elektrisch löschbarer, programmierbarer nur Lesespeicher)

  • Page 13: Cleaning

    Drive area: • Drive motor/carbon dust • Toothed-belt discs, and motor pulley • Hook drive Electronics area • All sensors, light barriers, switches, electronic components BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 13 von 172 DRAFT – VERSION...

  • Page 14: Technical Specifications Of 5 Series

    Stitching speed, min./max. 100 - 1000 100 - 1000 100 – 1000 100 – 1000 100 – 1000 Sideways Motion BERNINA Dual Feed (upper feed) BERNINA Stitch Regulator (BSR) port Embroidery module connection Automatic thread cutter Embroidery speed, max. 1000 SPM...
  • Page 15 Number of buttonhole types (incl. eyelets) Button sewing-on program Number of utility stitch patterns Number of decorative stitch patterns Embroidery design packages Alphabets Number of embroidery motifs included BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 15 von 172 DRAFT – VERSION...

  • Page 16: Chapter 2 - Electronics And Wiring

    Chapter 2 – Electronics and Wiring Plug diagram and brief descriptions of electronic components 2.1 BERNINA B 590 (B 570 QE, B 535, B 520 & B 500 Embroidery Only) Block Diagram BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 16 von 172 DRAFT –...

  • Page 17: Pcba-Power

    2.2 PCBA-Power BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 17 von 172 DRAFT – VERSION...

  • Page 18: Pcba-Cpu-Module (Arm9) General Information

    'old' PCBA and add to new base PCBA. • Data 2.3.1 PCBA-CPU-Module/ARM9 Note: If a PCBA-CPU-module requires early replacement, please refer to chapter 8.3. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 18 von 172 DRAFT – VERSION...

  • Page 19: Pcba-Base General Information

    PCBA. Do not remove or plug in any connections when the sewing computer is switched on or connected to the power supply. 2.4.1 PCBA-Base with feed-dog drop detection BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 19 von 172 DRAFT –...

  • Page 20: Pcba-Position Hall

    2.5 PCBA-Position Hall 2.6 PCBA-Threader BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 20 von 172 DRAFT – VERSION...

  • Page 21: Pcba-Cover Including Display And Touch Screen

    2.7 PCBA-Cover including display and touch screen 2.7.1 PCBA-Front cover (B 590, B 570 QE, B 540, B 535 & B 500 Embroidery Only) 2.7.2 PCBA-Stitching head (PCBA-RET) (B 590, B 570 QE, B 540, B 535 & B 500 Embroidery Only) BERNINA International AG...

  • Page 22: Pcba-Lower-Thread Observer (Lto)

    Connecting • According to picture Task • Recognition of presser feet and buttonhole foot signal via sensors. 2.10 PCBA Embroidery module detection (B 590, B 570 B 540 B 535) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 22 von 172...

  • Page 23: Handling Of Electronic Components

    Electronic components that have been manipulated or repaired by oneself are excluded from the repair- /replacement process. They will be disposed of. Bernina International AG reserves the right to charge the original price (of the new component) for electronic components that have been manipulated, repaired by oneself or improperly packaged.

  • Page 24: Chapter 3 - Troubleshooting

    1. FW update via alternative access (see Does machine start up to 8.2)? black starting screen with 2. Machine keeps asking for FW update red BERNINA logo? (loop). 3. EEPROM is corrupted or inexistent • Switch machine off. •...

  • Page 25: Operating Voltage Functional Test

    PCBA-Base. necessary. • Check the connectors for deformations. Replace if necessary. • Check PCBA-Power functioning. Replace if necessary. • Replace PCBA-Base. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 25 von 172 DRAFT – VERSION...
  • Page 26 • Check LED 1-2 Repair note: • Replace PCBA-Power. access • Replace PCBA-Power. • Replace PCBA-Base. • Replace PCBA-Base. • Replace PCBA-CPU-Module • Replace PCBA-CPU-Module BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 26 von 172 DRAFT – VERSION...

  • Page 27: Upper-Thread Sensor

    • The signal can be tested in Service Program Test 4f (upper-thread sensor). • Hook spring to actuating lug. • Check regulator spring position and unwinding force (see 5.11) • Replace PCBA-Stitching head (RET) (see 4.2.8). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 27 von 172 DRAFT – VERSION...

  • Page 28: Lower-Thread Sensor

    With the 5 Series (VIO), it isn’t possible to wind the lower thread wrongly or insert the bobbin into the bobbin case the wrong way It works the same as with the 7 Series. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 28 von 172 DRAFT –...

  • Page 29: Touch Screen Calibration

    View from below Exceptions in the 5 Series (VIO): The narrow, touchscreen-supplying ribbon cable has the blue stabilizing film at the top. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 29 von 172 DRAFT – VERSION...

  • Page 30: Update Failed

    Typically occurs with machines from early production, or when several updates have been skipped. 1. Start normal customer updating process. 2. After rebooting, the black screen with the red BERNINA logo stays, or keeps reappearing. 3. Switch machine off. Connect USB stick containing the relevant firmware for machine. Load firmware from USB stick (see 8.2).
  • Page 31 2. Switch machine off. 3. Connect USB data stick containing the relevant firmware for machine. 4. Switch machine on. Firmware updating process starts automatically. 5. Reboot machine manually after ‘successful updating’ message has appeared. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 31 von 172 DRAFT –...

  • Page 32: Sewing-Off Guidelines

    • Is the row of stitching straight? • Is the stitch formation on both sides of the fabric regular? • Do the threads interlock in the middle of the fabric? • Is the seam free of skipped stitches? BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 32 von 172 DRAFT –...
  • Page 33 • Is the interlocking of the needle thread and bobbin thread on the wrong side of the fabric regular? • Does no puckering occur? • Is the seam free of skipped stitches? BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 33 von 172 DRAFT –...
  • Page 34 3. Honeycomb stitch or leaf pattern default settings 4. Decorative stitch (401) in max. stitch width 5. Neatening of fabric edge with zigzag stitch width 3.0 stitch length 1.0 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 34 von 172 DRAFT – VERSION...
  • Page 35 • Does the bobbin thread show on the right side of the fabric? It shouldn’t. • Does no puckering occur? (With thin fabrics, a stabilizer must be used). • Is the seam free of skipped stitches? BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 35 von 172...

  • Page 36: Personal Notes Regarding Troubleshooting

    ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 36 von 172 DRAFT – VERSION...

  • Page 37: Chapter 4 - Removal And Refitting Of Components

    (pict 2). • Refit fastening screw in thread-redirection/pre- tensioner area and retighten carefully (pict 3). • Insert service cover into respective openings, then slide to right (pict 1) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 37 von 172...

  • Page 38: Front Cover

    - the screw that holds the front cover and rear cover together. • Picture 5 - Remove slide-on table anchoring screw e (T15). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 38 von 172...
  • Page 39 Um die USB Stecker nicht von der LPB-Basis abzureissen muss das Verdeck vorne zuerst am Freiarm ausgehängt werden. • Picture 9 - Unplug all power-supplying ribbon cables connecting the touchscreen and PCBA-Front cover 1, display 2, and EMV 3. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 39 von 172 DRAFT –...
  • Page 40 • Picture bottom right in picture 6b - Refit and retighten fastening screw (T10) f left of the bobbin door. • Refit lower-thread sensor as outlined in pictures 6, 6a, and 6b. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 40 von 172 DRAFT –...

  • Page 41: Rear Cover

    Picture 1 - Refit and retighten rear slide- on table anchoring screw (T15) e. • Picture 1 - Retighten screw d. • Picture 1 - Refit and retighten screw c incl. washer. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 41 von 172 DRAFT –...

  • Page 42: Freearm Cover

    • Refit all the covers (see 4.1). Important! Take care not to interfere with the lower- thread sensor wires to avoid damaging them. • Refit lower-thread sensor (see 4.2.9) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 42 von 172 DRAFT – VERSION...

  • Page 43: Base-Plate Cover

    • Only after refitting the rear cover and front cover, slide base-plate cover into final position and retighten fastening screws b. Refit the screw covers a into the left and right long hole. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 43 von 172 DRAFT –...

  • Page 44: Electronics, Sensors, Switches, Magnets

    • Picture 3 - In the yellow-circled areas, pull housing apart to unlock snap fits. Remove protective cover. Note: It is best to remove the protective cover while the housing is still fastened to the machine. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 44 von 172...
  • Page 45 • Picture 1 - Refit wheel, sliding it onto pinion. • Refit the covers (see 4.1). Note: Test run the machine after refitting the front cover. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 45 von 172...

  • Page 46: Pcba-Cpu-Module (Arm9) General Information

    7 Series, and the 5 Series (VIO), the slot for the small backlighting wire is still there, but not on the PCBA-Base for the 5 Series (VIO). • Note the LEDs on PCBA-CPU-Module (ARM9), see pict. below. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...

  • Page 47: Pcba-Cpu-Module (Arm9)

    • Picture 1 - Refit and retighten screw a. Note: On fitting a new or repaired PCBA-CPU-Module (ARM9), it is necessary to load the required firmware for the respective model. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 47 von 172...

  • Page 48: Pcba-Base With Feed-Dog Drop Detection

    Assembly: • Attach EEPROM 2 to base. • Take care to fit EEPROM in the correct position (markings must match) and avoid bending the contacts. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 48 von 172 DRAFT – VERSION...

  • Page 49: Pcba-Position Hall

    • Picture 1 - Hook feed-dog drop 1 in behind PCBA-Base. Position the whole unit and fasten with four screws • Picture 1 - Reconnect all plugs. • Refit all covers (if appropriate). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 49 von 172 DRAFT –...

  • Page 50: Pcba-Threader

    • Picture 3 - Refit PCBA-Base connector. • Picture 2 - Reconnect basting solenoid wire. • Picture 1 - Refit four links of protective casing cover. • Refit head cover (if appropriate). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 50 von 172...

  • Page 51: Pcba-Front Cover Including Display And Touchscreen

    Color 036391.70.00 Faceplate cpl. with touchscreen and display black 036391.70.01 Faceplate cpl. with touchscreen and display silver 036391.70.02 Faceplate cpl. with touchscreen and display white BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 51 von 172 DRAFT – VERSION...

  • Page 52: Pcba-Ret (B 590, B 570 Qe, B 540, B 520 & B 500 Embroidery Only)

    4.2.8 PCBA-RET (B 590, B 570 QE, B 540, B 520 & B 500 Embroidery Only) See ESD-related note Disassembly: • Remove the covers (see 4.1) • Picture 1 - Remove SSU slide and knobs. • Picture 2 - Disconnect PCBA-RET flat ribbon cable.

  • Page 53: Pcba-Lower Thread Sensor Cpl

    • Insert guiding pin on the left of the lower-thread sensor into guiding rail (red circle, pict. 1). • Take care that wires are lain correctly (picts 3 and 4) • Close bobbin door. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 53 von 172...

  • Page 54: Sensor Support Abc (Presser Foot Recognition)

    Take care that sensor support 3 doesn't catch edges while fitting it. Note: 4l. Calibrate buttonhole foot with slide 3A in Check ABC sensor for functioning in Service Program Service Program BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 54 von 172 DRAFT – VERSION...

  • Page 55: Head Frame And Frame Arm Led Sewing Light

    • Picture 2 - Bring wire into position and rethread into harness. Refit two clips d. • Picture 1 - Lay wires. Replug connector a. • Refit covers (if appropriate). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 55 von 172...
  • Page 56 • Picture 2 - With clip e bring wire into position and rethread into harness. Refit two clips d. • Picture 1 - Lay wires. Replug connector a. • Refit covers (if appropriate). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 56 von 172 DRAFT –...

  • Page 57: Pcba-Embroidery Module Detection

    • Picture 1 - Lay PCBA-Embroidery module detection unit wire in such way that it won’t be damaged when refitting the cover. Reconnect plug a. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 57 von 172 DRAFT – VERSION...

  • Page 58: Electromechancial/Mechanical Components

    Picture 4 - Tighten the 3 securing screws 2 (T20) only so much that the hook race ring can still be moved in x-axis direction. Hook race ring movement is locked for all other directions. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 58 von 172 DRAFT –...
  • Page 59 • Picture 6 - The hook drive shaft end protrudes ca. 4.5mm from the hook bearing. Use 3.0mm pin b to lock hook drive in loop lift position. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 59 von 172...
  • Page 60 Replace hook if it is badly scratched or has broken hook tips. • For lubrication of hook refer to lubrication diagram (see BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 60 von 172...

  • Page 61: Main Feed-Dog And Feed-Dog Carrier

    • Refit stitch plate. • Attach needle and presser foot. Note: The main feed dog could be removed also after removing the main feed dog carrier. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 61 von 172 DRAFT – VERSION...

  • Page 62: Replacing The Hook Driver Drive Belt

    • Refit clutch carriage (siehe 4.3.11) • Adjust clutch carriage and thread cutter (see 5.7) • Refit covers (see 4.1), stitch plate, needle and presser foot if appropriate. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 62 von 172...

  • Page 63: Stitch Plate Carrier With Integrated Thread-Cutting Unit

    • Picture 5 – Remove the blade fastening screw d (T8, M2.5X3mm) Move thread catcher slightly to the right. • Picture 6 – Pull out the blade slightly to the right and up. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 63 von 172...
  • Page 64 Note regarding servicing: • When servicing the machine, the thread cutter must always be removed for cleaning purposes. • The blade is a wear part and therefore available as an individual part. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 64 von 172 DRAFT –...

  • Page 65: Replacing The Blade Of Built-In Thread-Cutter Unit

    030475.51.01 remove the screw d (T8) • Picture 6 – With the help of a small screwdriver bring the blade backwards until it can be hold and pulled out with tweezers. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 65 von 172...
  • Page 66 • Picture 9 – Complete test 6e (press green check button 7 times). • Picture 10 – Refit stitch plate, needle, and presser foot and close the bobbin door. • Sew-off, also testing the thread cutter. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 66 von 172...

  • Page 67: Base Shaft

    • Picture 2 – Rehook tension springs x, y, and z. Check for proper fitting. Note: It is important to check base shaft for correct functioning of timing, loop lift, thread cutting etc. Adjust if necessary. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 67 von 172 DRAFT –...

  • Page 68: Crank Shaft And Stitch Length Stepping Motor

    • Adjusting the crankshaft see 5.6.4 Main feed mechanical balance - basic setting. • Refit PCBA-Base. Refit all connectors (see 4.2.4). • Refit all covers (if appropriate). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 68 von 172 DRAFT – VERSION...

  • Page 69: Replacing Base Shaft And Vertical Shaft Connecting Belt

    Picture 1 – Push feed-dog carrier and advance link B in direction of arrow. Then slide eccentric shaft C out in direction of arrow. • Picture 1 – Remove feed-dog carrier B and advance link. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 69 von 172...

  • Page 70: Upper Feed Crank

    • Picture 2 – Refit shoe G and tension spring A. • Adjustment (see 5.6.6). • Picture 1 – Refit winder unit and adjust it (see 5.13). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 70 von 172 DRAFT – VERSION...

  • Page 71: Upper Feed (Dual Feed)

    • Picture 1 – Remove upper-feed carrier O. Assembly: • Picture 1 – Refit upper-feed carrier. Slightly tighten countersunk screws to fasten carrier and special washers. • Adjustment (see 5.6.5). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 71 von 172 DRAFT – VERSION...

  • Page 72: Clutch Carriage

    • In this position, retighten connecting strap screws 2 (2 X T10). • Rehook tension spring 1. • Check and adjust base shaft synchronization (see 5.5.1) • Function-check solenoid (see Service Program test 6d). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 72 von 172 DRAFT –...

  • Page 73: Adjusting The Thread-Cutter And Stitching-Start Solenoid

    • Move solenoid bracket ca. 0.3mm to left. Then retighten screw a (pict. C). • Start machine in Service Program. Run tests 6d and • Refit the covers (see 3.1). • Sew-off including thread-cutting. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 73 von 172...

  • Page 74: Thread Take-Up Cover With Automatic Upper-Thread Tensioning Unit

    • Carefully reinsert the two stranded wires (black/white) into the small cable duct. • If nothing else has to be taken care of, refit the covers (see 4.1) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 74 von 172...

  • Page 75: Needle-Bar Support

    033145.70.00 while keeping catch 2 pressed. • Rough-set the needle-bar guide and secure setscrew b (T6 M3x4). • Rehook spring 1. • Refit needle-bar support (see 3.3.7) • Adjust threader (see 4.9). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 75 von 172...

  • Page 76: Needle Clamp

    Needle stop pin 036687.50.02 Needle stop pin 036687.50.03 Needle stop pin 036687.50.04 Needle stop pin 036687.50.05 Needle stop pin 036687.50.00 Needle stop pin 036687.50.07 Needle stop pin BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 76 von 172 DRAFT – VERSION...

  • Page 77: Threading Mechanism

    Position dowel 8 in such way that the pressure spring sits in the entry of the dowel 8 (pict. a). • Rehook tension spring 10. • Rehook tension spring 9. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 77 von 172...

  • Page 78: Threader Head

    • Push threader head c onto threader bar in correct position. • Release needle threader holder b. • Insert needle. • Functional check. • Adjust threader if necessary (see 5.9). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 78 von 172 DRAFT – VERSION...

  • Page 79: Thread Tension

    Then refit thread tension. • Picture 1 - Refit and retighten screw b. • Picture 5 - Using distance gauge 735386.50.00, reset to mechanical basic setting. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 79 von 172...

  • Page 80: Thread Take-Up Lever And Thread Regulator Spring

    • Refit screw 17 (T10 M3x5). Retighten slightly. • Adjust thread regulator spring (see 5.11 • Retighten screw 17 (T10 M3x5). • Refit head cover. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 80 von 172 DRAFT – VERSION...

  • Page 81: Main Motor

    2 (black negative pole '-'). Note: The positive pole can be identified by the salient • Refit drive belt and wheel. • Adjust belt tension (see 5.1.2). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 81 von 172...

  • Page 82: Stitch Length Stepping Motor

    734149.50.00 and 734150.50.00 • Start machine in Service Program. • Machine with touchscreen Select test (stepping motors pinning position). Size BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 82 von 172 DRAFT – VERSION...

  • Page 83: Presser-Foot Pressure Stepping Motor

    • If nothing else has to be taken care of, refit the covers. Note: Since the stepping motors don’t have connectors attached to the motors, they must be replaced fully and including the wires when wires are damaged. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 83 von 172...

  • Page 84: Stitch-Width Stepping Motor

    B in such way that each side has the same amount of teeth when pinning it at 9.0mm left and right. • Picture 1 - Remove 3.0mm pinning tool. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 84 von 172...

  • Page 85: Chapter 5 - Adjustments

    5.0mm above corner c of frame bar. • Untighten screw b (T20). Then use adjusting spanner 733019.70.00 to turn the bearing until the specified tension value has been reached. • Retighten screw b. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 85 von 172 DRAFT –...

  • Page 86: Drive Motor Belt Tension

    • Remove the two motor fastening screws a and b (T20 M4X12 u-washer 4.2x14x1.5). • Turn motor clockwise until specified value has been reached. Turn motor counterclockwise to slacken belt tension. • Retighten fastening screws a and b. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 86 von 172 DRAFT –...

  • Page 87: Hook Drive Belt Tension

    (pict. 1). • Untightening screw d allows for moving the belt tensioner up and down. Moving up slackens the tension, moving down tightens the tension (pict. 2). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 87 von 172...

  • Page 88: Head-Frame Plate Position

    • Raise presser foot ca. 1mm from stitch plate. • Use screw d (T20 M4x16) to set distance: o Turning it clockwise moves the foot forward. o Turning it counterclockwise moves the foot backward. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 88 von 172 DRAFT –...

  • Page 89: Position Of Head-Frame Plate/Stitch Plate In X-Direction

    • Raise presser foot ca. 1mm from stitch plate. • Slightly untighten two screws e (T20 M4x16). • Use setting excenter 031563.50.00 to bring head-frame plate into position. • Retighten two screws e. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 89 von 172...

  • Page 90: Presser-Foot Adjustment

    • Slightly untighten setscrew b (T8). • Slide presser foot bar up or down until the distance is 0.5mm +0.2. Ensure that presser foot and stitch plate are parallel. • Retighten setscrew b. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 90 von 172 DRAFT –...

  • Page 91: Presser-Foot Fixation

    Sewing-/embroidery machines - Presser-foot sole and stitch plate must be parallel. o Embroidery machines - Stitch hole in embroidery foot 26 and stitch hole in stitch plate must be centred. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 91 von 172...

  • Page 92: Needle Settings

    • The distance should be ca. 0.4mm in front of needle 130/705 Nm 100 and ca. 0.6mm behind the needle. • Retighten lock nut f. 0.6 mm 0.4 mm BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 92 von 172...

  • Page 93: Needle Distribution

    • Retighten screw b. Adjusting embroidery machines • Slightly untighten screw e (T10). • Set needle to center (pict. C). • Retighten screw e. 001361.70.00 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 93 von 172 DRAFT – VERSION...

  • Page 94: Zigzag Stitch Width Limiter

    Move base body of gauge to right until needle bar is risen by 734571.70.01 007937.50.00 2.618mm (pict. B). • Front view - Base shaft should be pinnable using pinning tool 0079937.50.00 (pict. C). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 94 von 172 DRAFT – VERSION...

  • Page 95: Base Shaft-/Load Lock Screw Distance

    • The distance should be 0.15mm. Adjustment: • Turn screw f (T10) to set 0.15mm distance between base shaft and load lock. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 95 von 172 DRAFT – VERSION...

  • Page 96: Loop Lift

    • Retighten second setscrew c2 in direction of rotation. • Check again and repeat setting if required. • Recheck loop lift. Front cover connected Recheck: • Start machine in Service Program. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 96 von 172 DRAFT – VERSION...
  • Page 97 • Move gauge to right until the needle bar is risen by 2.625mm (loop lift value) and stops. • Hook tip must be flush with left needle edge. Adjustment: • See 5.5.3 above BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 97 von 172...

  • Page 98: Needle Penetration In Y Directions

    Turn eccentric pin b (T6 Torx wrench) to bring stitch plate into specified position. • Retighten screw a (T6). Note: We recommend to use a magnifying glass to ensure accurate setting. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 98 von 172...

  • Page 99: Needle Height

    Available sizes of needle stop pins Item no. Height in mm labelled 036687.50.00 n.a. 036687.50.01 n.a. 036687.50.02 n.a. 036687.50.03 n.a. 036687.50.04 n.a. 036687.50.05 n.a. 036687.50.06 n.a. 036687.50.07 n.a. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 99 von 172 DRAFT – VERSION...

  • Page 100: Needle Height Without Basting Device

    • The needle bar represents 'target’ c and must be set to level 2 of distance plate b. • Retighten needle-bar clamp screw. • Check functioning of threader (see 5.9) • Refit heas cover (if appropriate). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 100 von 172 DRAFT –...

  • Page 101: Presser-Foot Settings

    Note: The adjusting plate is pressure springed! • Push the feed-dog carrier up to the required height by hand. • Retighten screw c. • Recheck setting. • Repeat adjustment if necessary. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 101 von 172...
  • Page 102 • On the right, move eccentric shaft e into required position with open-end wrench 6. • Retighten three setscrews d (T8). • Recheck setting. • Repeat adjustment if necessary. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 102 von 172...

  • Page 103: Main Feed-Dog Position Within Stitch Plate In X-Direction

    • Feed-dog must be equidistant from each side of the stitch plate. Adjustment: • Untighten two setscrews a (T6). • Move feed-dog into the specified position. • Retighten two setscrews a (T6). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 103 von 172...

  • Page 104: Main Feed Mechanical Balance - Basic Setting

    001356.50.00 (pict. C). • Remove pinning tools. • Refit PCBA-Base (see 4.2.4) • Balance fine-adjusting in Service Programm Test 6b BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 104 von 172...

  • Page 105: Upper Feed (Dual Feed)-/Main Feed Synchronization (Pinning Position)

    • Upper feed-dog must sit flush against front of synchronizing plate without play or clamping. Adjustment: • Untighten two screws i (T10). • Bring upper feed-dog g into specified position. • Retighten two screws i (T10). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 105 von 172...

  • Page 106: Upper Feed-Dog (Dual Feed) Mechanical Balance - Basic Setting

    5.6.6 Upper feed-dog (Dual Feed) mechanical balance – Basic setting Check: • Start machine in Service Program. • Carry out test 6b BERNINA Duel Feed Balance Rough-adjustment: • Turn main feed-dog stitch-length crank to maximum stitch 1.5mm length. • The distance between crown gear and adjusting hub should be 1.5mm.

  • Page 107: Clutch Carriage/Thread Cutter

    Move solenoid casing to right up to stop. • Now move solenoid casing ca. 3mm to left. Retighten screw a. • Start machine in Service Program, and run Test 0.3mm BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 107 von 172 DRAFT – VERSION...

  • Page 108: Clutch Carriage Alignment

    • Retighten two screws (T10) on link between clutch carriage and cutting-unit release lever. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...

  • Page 109: Clutch Carriage Timing

    • Use 3.0mm pinning tool 007937.50.00 to pin base shaft in loop lift position. • Untighten clutch-ring setscrew d (T10). • Position setting gauge 734258.52.00 onto clutch ring. • Position clutch ring at base collar. • Retighten clutch-ring setscrew d (T10). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 109 von 172...

  • Page 110: Thread Cutter

    Untighten thread-guide plate screw c (T8 angled Torx wrench) and thread-stop nut d (ring wrench 5). • Untighten two thread-guide plate screws e (T8, angled Torx wrench). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 110 von 172 DRAFT – VERSION...

  • Page 111: Hall Position Synchronization

    • Click ‘Checked position reached’ bar. A green check button appears to the right of the bottom bar. • Click green check button to exit Service Program. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 111 von 172...

  • Page 112: Threader

    Untighten needle bar guide adjusting screw 17 (T8). • Center needle bar bore within clutch-bolt clearance 4. • Retighten needle bar guide adjusting screw 17 (T8). Refit basting solenoid housing. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 112 von 172 DRAFT – VERSION...

  • Page 113: Time Of Clutch Release

    • Run machine at highest speed to test basting solenoid in left and right needle positions. Note: If functional test fails in one, some or all needle positions, recheck the setting of the buffer position and the needle bar guiding and adjust as required. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 113 von 172 DRAFT –...

  • Page 114: Thread Regulator

    5.11 Thread regulator Checking the tension power: • Thread an approx. 30cm long thread into thread regulator. • Attach the two thread ends to the BERNINA tension spring scales (006038 50.00). • Slowly move the scales up. • On moving the regulator spring, the tension value must be between 14 g and 17g.

  • Page 115: Thread Tension

    5.12.1 Upper thread tension • 6j Automatic upper-thread tension • Use a cotton thread DMC 50 BLANC (recommendation by BERNINA, see Service Information in Infogate, Ref: 18249) to thread machine up to and including thread take-up. Step 1: •...

  • Page 116: Lower-Thread Tension (Basic Setting)

    • Turn screw counterclockwise (to left) to slacken . • Turn screw clockwise (to right) to tighten. 398142.03.0 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 116 von 172 DRAFT – VERSION...

  • Page 117: Winder

    • Picture 4 - Turn screw b (T10) in or out as appropriate. Note: Incorrectly or unevenly filled bobbins can affect the stitch quality and impair the functioning of the lower thread sensor. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 117 von 172 DRAFT – VERSION...

  • Page 118: Lower-Thread Sensor Position

    If the lower-thread indicator doesn't work flawlessly, check the state of the bobbin, especially the inner and outer reflectors on the bobbin. If the bobbin is in mint condition, replace the lower-thread sensor unit. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...

  • Page 119: Chapter 6 - Service Program

    • The machine can now be used normally. Basic position: Sections 1 to 11 are selected in the basic position of the Service Program. BERNINA 590, 570, 565, 540, 520, 500 Information Screen, symbols Location of sensors in the machine...
  • Page 120 Data entering field modes: a. Upper-case letters b. Lower-case letters c. Numbers, symbols, punctuation marks d. Special characters BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 120 von 172 DRAFT – VERSION...

  • Page 121: Section 1 - Service Information

    6.1 Section 1 – Service Information Machine basic data Machine firmware data and technical information Machine operating hours data Stitch counter data BSR (BERNINA Stitch Regulator) data Machine servicing data Saving customer data Customer related data (Customer Information) Dealer related data (Dealer Information)

  • Page 122: Machine Operating Hours Data

    • Stitches Embroidery (total number of enbroidery stitches) • Stitches since last Lubrication • Stitches since last Service 1e BSR (BERNINA Stitch Regulator) data Shows information’s about attached BSR Check: The BSR foot must be connected so see these informations: •...

  • Page 123: Machine Servicing Data

    • Save the customer settings = Save customer data onto data stick • Load the customer settings = Load customer data onto machine • Connect BERNINA USB data stick and select required button. • Remove the data stick after saving/loading of data has been confirmed.

  • Page 124: Customer Related Data (Customer Information)

    • A virtual keyboard opens on selecting a field, and data can be entered. • Dealer data can also be read and entered in .txt format from BERNINA USB data stick. Important: The file must be named dealerdata.txt (see example below).

  • Page 125: Log File

    The Log file can be saved here Check: • External saving of internal processes (log book) on a BERNINA USB data stick. • The log file contains processes and configuration data. Tip: • If firmware problems occur, send the log files, with a detailed description of the symptoms, to the importer/distributor by ticket system or email.

  • Page 126: Lcd (Screen Brightness)

    • Clean touch screen. • If necessary, replace faceplate (see 4.2.7). Important! Do not use any corrosive cleaning agents, such as alcohol, benzine, thinner or other. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 126 von 172 DRAFT – VERSION...

  • Page 127: Rgb (Red, Green And Blue) Screen

    • To return to section 2, press Repair note: • Check cables for deformation and/or wear and tear. • Replace PCBA-RET if a key won’t light up (see 4.2.8). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 127 von 172 DRAFT – VERSION...

  • Page 128: Led Sewing Light And Brightness

    Check correct positioning of PCBA-Threader. The PCBA Threader is held in position with a pin and fastening screw 007752.50.34 (T10) in the needle bar support. • If sensor doesn’t respond, replace PCBA-Threader (see 4.2.6). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 128 von 172 DRAFT – VERSION...

  • Page 129: Presser-Foot Micro Switch

    • Repeat the test using a new bobbin. • Check cables for deformation and/or wear and tear. • Replace lower thread sensor. • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 129 von 172 DRAFT – VERSION...

  • Page 130: Feed-Dog Drop

    • To return to section 3, press Repair note: Signal doesn't respond: • Remove the covers (see 4.1). • Check mechanical function of feed dog drop. • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 130 von 172 DRAFT – VERSION...

  • Page 131: Bobbin Winder Micros Witch

    • Check if PCBA-Base sensor area is free of sewing dust or loose cables. • If the signal doesn't respond, replace the PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 131 von 172 DRAFT – VERSION...

  • Page 132: Section 4 - Signals

    6.4 Section 4 – Signals Stitch width and stitch length knob(s) Functions of keys and buttons on machine Start-/Stop Slide (SSU) Foot control Upper Thread Observer (UTO) BERNINA Stitch Regulator (BSR) PCBA-Position Speaker USB ports Basting solenoid Presser-foot recognition BSR foot interface...

  • Page 133: Functions Of Keys And Buttons On Machine

    • To return to section 4, press Repair note: • Check cables for deformation and/or wear and tear. • Replace PCBA-RET (see 4.2.8). • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 133 von 172 DRAFT – VERSION...

  • Page 134: Foot Control

    Check if regulator spring is properly set (see 5.11). • Check cables for deformation and/or wear and tear. • Replace PCBA-RET (see 4.2.8). • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 134 von 172 DRAFT – VERSION...

  • Page 135: Bernina Stitch Regulator (Bsr)

    4g BERNINA Stitch Regulator (BSR) Is used to check BSR sensor function Check: • Attach BSR foot. • Select test 4g. • Place fabric under the presser foot. • Lower presser foot. • Press the icon to start the test.

  • Page 136: Speaker

    If 'Test Failed' message appears: • Repeat the test using another USB cable. • Check host and client ports on machine. • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 136 von 172 DRAFT – VERSION...

  • Page 137: Basting Solenoid

    Check cables for deformation and/or wear and tear. • If the presser-foot recognition still fails to work, clean ABC sensor support. Replace ABC sensor support if necessary. • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 137 von 172 DRAFT – VERSION...

  • Page 138: Bsr Foot Interface

    Test BSR foot on a working sewing machine. • Check cables for deformation and/or wear and tear. • Replace Check BSR socket. • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 138 von 172 DRAFT – VERSION...

  • Page 139: Section 5 - Locations Of Stepping Motors In The Machine

    4.2.4). • Replace stitch-width stepping motor (see 4.3.22) Important! Disconnect machine from the power supply. Do not disconnect or reconnect when the machine is powered. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 139 von 172 DRAFT – VERSION...

  • Page 140: Presser-Foot Pressure Stepping Motor

    • Replace upper-thread tension stepping motor (see 4.3.17) Important! Disconnect machine from the power supply. Do not disconnect or reconnect when the machine is powered. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 140 von 172 DRAFT – VERSION...

  • Page 141: All Stepping Motors In Pinning Position

    • If the stepping motor doesn’t move, the fault might be with the motor itself, the wiring or the PCBA-Base. • Check cables and plugs for deformation and/or wear and tear. • eplace PCBA-Base (see 4.2.4). • Replace winder motor. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 141 von 172 DRAFT – VERSION...

  • Page 142: Stitch-Length Stepping Motor

    4.2.4). • Replace stitch-length stepping motor (see 4.3.20) Important! Disconnect machine from the power supply. Do not disconnect or reconnect when the machine is powered. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 142 von 172 DRAFT – VERSION...

  • Page 143: Section 6 - Adjustments

    Note: Ensure to carry out all crucial adjustments and calibrations by following the check list in section 11. Important! Do not run a threaded machine without fabric! BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 143 von 172 DRAFT – VERSION...

  • Page 144: Electronic Balance Calibration

    • The darning pattern must form square with a virtual straight top and bottom line (see picture). Adjust: • Turn balance adjusting cam a (T 10, blade length at least 110mm) until the pattern is stitched properly. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 144 von 172 DRAFT – VERSION...
  • Page 145 110mm) until the leaf pattern is stitched properly. Note: • Rotate balance cam a clockwise = the leaf pattern pulls together • Rotate balance cam a counterclockwise = the leaf pattern pulls apart. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 145 von 172 DRAFT –...

  • Page 146: Bernina Dual Feed Balance

    BERNINA Dual Feed balance Check: • Synchronization of feed-dog and upper feed motion (BERNINA Dual Feed BDF). Difference in length between the repeats: • Attach foot 1D. • Thread machine and place two-layered sewing-off cotton under the presser foot. • Feed-dog in the up position (normal sewing).

  • Page 147: Buttonhole Calibration

    • Check cables and plugs for deformation and/or wear and tear. • Replace ABC sensor board (see 4.2.10). • Replace PCBA-Base (see 4.2.4). User view in Setup menu: BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 147 von 172 DRAFT – VERSION...

  • Page 148: Thread Cutter Clamping Mechanism (Solenoid)

    • To return to section 6, press Repair note: • Check cables for deformation and/or wear and tear. • Replace complete clutch carriage (see 4.3.11). • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 148 von 172 DRAFT – VERSION...

  • Page 149: Thread Cutting

    6. • If the answer is No, press to leave the upper- thread tension settings and return to section 6. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 149 von 172...

  • Page 150: Resetting To Factory Settings (Reset All)

    6. Important! It is essential to save all the customers data on a BERNINA USB data stick before resetting to factory settings! See customer data saving in 1g. BERNINA International AG...

  • Page 151: Automatic Upper-Thread Tension

    (see 5.12.1). Important! • Gauging thread DMC 50 white can be ordered from BERNINA under item no. 652010.20.++. • Cotton thread is prone to dry out. Moisture loss reduces tensile strength and gliding properties of thread. 6k Test Tie On...

  • Page 152: Start-/Stop Slide (Ssu) Calibration

    Check slider for dust or stains and smooth mechanical running. • Check cables and plugs for deformation and/or wear and tear. • Replace PCBA-Front cover (see 4.2.7). • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 152 von 172 DRAFT – VERSION...

  • Page 153: Bsr Sewing Mode

    Service Program. Repair note: • Check BSR for dust or stains. • Replace BSR foot. • Replace Check BSR socket. • Replace PCBA-Base (see 4.2.4). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 153 von 172 DRAFT – VERSION...

  • Page 154: Magnetic Position Encoder Calibration

    Customer view embroidery mode Hoop recognition 7n Duration Run Embroidery Motors A detailed description of the Service Program section 7 can be found in the Embroidery Module Service- and Maintenance Manual. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 154 von 172...

  • Page 155: Section 11 - Check-Out Tests

    Buttonhole calibration, test 6c Lubrication and resetting the service stitches, test 1f On completion of the last test and confirmation with , check-out program returns to Service Program main menu. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 155 von 172...

  • Page 156: Chapter 7 - Lubrication Diagram

    Chapter 7 – Lubrication Diagram = Klüber OY 100 (002779.70.01) = Velocite 6 (033567.50.01) = Klübersynth UH1 14-1600 (002779.72.02) Max. 5 drops both both sides sides BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 156 von 172 DRAFT – VERSION...
  • Page 157 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 157 von 172 DRAFT – VERSION...
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  • Page 161: Lubrication Of Modified Hook Driver When Removed From Machine

    • Recheck if tensions springs are correctly hooked at both ends. (pict. 3 and 6) • To avoid cutting a new thread, find the proper thread with the screws. • Don’t tighten the screws too tight to avoid stiff running of the drive shaft. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...

  • Page 162: Chapter 8 - Firmware Update

    • The BERNINA 590, 570 QE, and 535 do not have the same firmware (FW). • Update files are available for downloading from Infogate. • Update files for BERNINA 590, 570 QE, 540, and 535 CANNOT be saved on the same BERNINA USB data stick.
  • Page 163 USB memory (root USB stick. memory. directory). Defective or incompatible Use a BERNINA USB stick. USB stick. Check functioning of USB stick on a Is the USB stick connected? Connect BERNINA USB Stick with updates and customer data to machine, wait for 10 seconds, then try again.

  • Page 164: Update Alternative Access

    This procedure might be necessary especially at the beginning of the introduction of the new 5 Series until all PCBA-CPU module spare parts will be used up in the markets. From the start of the 5 Series on, BERNINA International AG will only deliver PCBA-CPU modules with new-5-Series-compatible bootloaders.

  • Page 165: Chapter 9 - Maintenance Guidelines

    • Defined wear-and-tear parts are subject to a charge; the parts declared in the spare-parts-warranty extension (Bernina warranty provision) are excepted. • Compliance with maintenance intervals allows system functioning to be ensured and increases the service life of the sewing and embroidery machines.

  • Page 166: Calculation Table

    • Service entries must be made by the technician in the Service Program after maintenance or repair work. If not, the maintenance stitches will not reset to zero. • The same holds true for the cleaning-stitch reset. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...

  • Page 167: Wear-And-Tear-Parts Definition

    • In the case of intensive use for which the machine was not designed, increased wear-and-tear of parts cannot be ruled out. • In order to ensure continuously flawless operation of the sewing and embroidery machine, BERNINA recommends replacing the parts according to the table (9.4.2) once the tenth maintenance interval is reached.

  • Page 168: Maintenance Checklist

    • Read out the stitch and hour counter and enter on the Service Report. Customer data backup in Service Program 1g of the BERNINA 590, 570 QE, 540, 535, 500. Connect BERNINA USB data stick and select required button. Remove stick after confirmation by the machine.

  • Page 169: Functional Check

    • Needle bar support / needle bar Smooth running of the machine mechanical ease • Swing bearing of movement • Bevel gears • Bobbin case / hook • Drive belt tensions BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 169 von 172 DRAFT – VERSION...

  • Page 170: Maintenance Checklist Bernina 590, 570 Qe, 540, 520, 500

    9.5.4 Maintenance checklist BERNINA 590, 570 QE, 540, 520, 500 Front and rear cover Covers to be removed Base casing Stitch plate Hook Parts that must be removed Bobbin case Recommended parts according to Tear-and-Wear Parts Definition Free-arm area Needle bar / needle bar support...

  • Page 171: Embroidery Module

    For X/Y test pattern assessment refer to Service and Maintenance Manual of Embroidery Module Sewing-off Cleaning Covers Final check Is the set of accessories complete? BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 171 von 172 DRAFT – VERSION...

  • Page 172: Bernina International Ag Seestrasse 161 Ch-8266 Steckborn Schweiz Seite 2 Von

    Chapter 10 – Document Revision History Date Version Description Author November 2017 First German version After Sales Service November 2017 First English version as DRAFT After Sales Service BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 172 von 172 DRAFT – VERSION...

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