Page 1 Service- and Maintenance Manual BERNINA 7 Series BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 1 of 225...
Page 2: Table Of Contents
Tools and gauges ........................... 10 Abbreviations / Names used ......................13 Cleaning and disinfection ....................... 14 Technical Details of 7 Series since 2015 ..................15 Kapitel 2 - Electronics and Wiring .................. 17 PCBA-Base – General Information ....................17 PCBA-Base ............................ 17 PCBA EMC screen connection ......................
Page 3 Dual feed ..........................112 Thread Take-Up ........................113 Base Shaft..........................114 Restraint-guided thrust link ...................... 115 Stitch length of crank shaft ....................... 117 Stitch length stepping motor ....................119 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 3 of 225...
Page 4 1b Machine soft- and firmware data ......................160 1c Machine Operating Time Data ......................161 1d Machine Stitch Counter Data ....................... 161 1e BSR (BERNINA Stitch Regulator) Data ....................161 1f Machine Servicing Data ........................162 1g Saving customer data ........................... 163 1h Customer data ............................
Page 5 4b Functions of Keys and Buttons on machine ..................178 4c Start-/Stop Slide (SSU) ......................... 178 4d Foot control ............................179 4f Upper thread observer .......................... 179 4g BERNINA Stitch Regulator (BSR) ......................180 4h PCBA-Position ............................180 4i Speaker ..............................182 4j USB Host Interface ..........................182 4k Basting Solenoid ...........................
Page 6 Measures to be taken before the service ..................220 Measures to be taken after the Service ..................220 Functional check .......................... 221 Maintenance Checklist BERNINA 7 Series .................. 222 Embroidery module ........................223 Kapitel 10 - Document Revision History ..............224...
Page 7: Chapter 1 - General Information
When settings are carried out in the correct order, the machine will function flawlessly. It is important that only devices approved and distributed by BERNINA® are connected to the machine ports. When servicing or repairing, always use genuine parts and original accessories, either those delivered with the machine or purchased afterwards.
Page 8: Warning: Dangerous Voltage Levels
The capacitors require 90 seconds to discharge after the power supply has been switched off. We recommend waiting for the complete discharging of the capacitors before starting any servicing work on the PCBs. Caution! High voltage BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 8 of 225...
Page 9: Esd-Related Note: Electrostatic Discharge
4. Only use conductive ESD-capable plastic/foil pouches and ESD transport boxes for dispatching electronic components – even if the components might be faulty 5. To prevent consequential damage or harm, treat faulty PCBs in the same manner as new ones. Electrostaticdischarge_ESD BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 10: Tools And Gauges
Tools and gauges Commercially available (not available from BERNINA): Vernier caliper, multimeter, TORX screwdriver: No. 6, 8, 10 and 10 with 200 mm blade length; 15, 20 and 20 with 200 mm blade length, 25; angled torx no. 6 and 10, 10 mm ring wrench, 6 mm flat wrench.
Page 11 Helpful Tools for BERNINA machine Item no. Description Application Picture 0013565.0.00 Pinning tool short Pinning positions 0027335.0.00 Pinning tool long Pinning positions Alignment of head plate to 0315635.0.00 Eccentric key 2.0 mm the stitch plate 0079375.0.00 Pinning tool 3.0 mm...
Page 12 / Voltage tests Weight for setting the upper 0087097.2.00 Setting weight (5-pieces-set) thread tension 7304755.1.00 Distance gauge Needle bar height setting Disassembling & 0304755.1.00 Torx screwdriver reassembling aide BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 12 of 225...
Page 13: Abbreviations / Names Used
Throughout the whole manual the following abbreviations have been used. We have reserved the right not to explain individual abbreviations within the text. Abbreviations Englisch BERNINA Dual Feed BERNINA Stitch Regulator Direct Current EEPROM Electronically Erasable Programable Read Only Memory...
Page 14: Cleaning And Disinfection
Apply the liquid to a cloth and clean the surface immediately • Then use a second cloth to dry the surface • Don't forget the corresponding accessories and the power cables BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 14 of 225...
Page 15: Technical Details Of 7 Series Since 2015
Technical Details of 7 Series since 2015 B 710, B 750 and B 780 not included in this Service Manual Features BERNINA 790 BERNINA 770 BERNINA 770 BERNINA 740 Plus QE Plus Technical Line voltage 100 - 240 Volt 100 - 240 Volt...
Page 16 DC / 36 Volt Stitching speed, min./max. 100 - 1000SPM 100 - 1000SPM 100 - 1000SPM Sideways feed BERNINA Dual Feed (BDF) BERNINA Stitch Regulator (BSR) connector Embroidery Module Interface Automatic thread cutter Embroidery speed, max. 1000 SPM 1000 SPM 1000 SPM...
Page 17: Chapter 2 - Electronics And Wiring
PCBA EMC screen connection The EMC screen connection is not included with the older CBA base. In this case, an additional EMC screen connection is attached. X-24 X-15 EEPROM X-40 0351657.0.00 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 17 of 225...
Page 18: Pcba-Cpu-Module (Arm9) - General Information
PCBA and add it to the new • Data one. Connectors • According to picture PCBA-CPU-Module / ARM9 X-1 PCBA- Base X-28 TFT screen Contact surfaces on PCBA base BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 18 of 225...
Page 19: Pcba Front Covers
Needle up/down (S-1) o Seam securing (S-2) o Pattern end (S-3) o Pattern begin (S-4) • Connecting PCBA-Left front cover with PCBA-RETand PCBA-Right Front PCBA-RET connector Sewing speed slide potentiometer BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 19 of 225...
Page 20: Pcba-Right Front Cover
(S-4). • Supply for LCD backlighting Key-function foil • Supply for LED freearm lighting Connection to PCBA base Connection to touchscreen Connection to LED free arm lighting BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 20 of 225...
Page 21: Pcba-Power
The cause must be identified and removed. Only a replacement fuse of the correct rating must be used. It is essential to test the functions on replacing the fuse. BERNINA International AG Seestrasse 161...
Page 22: Pcba Needle Threader
Light barrier 2 receives the A/B signal of the increment disc. This signal is used for motor Light barrier 1 control, among other things • Light barrier 3 includes various positions BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 22 of 225...
Page 23: Pcba-Ret
The PCBA-Feeddog Drop Detection contains: • Light barrier • Connector • Connector • According to picture Task • Reporting feed dog status (up/lowered) to CPU via PCBA base • BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 23 of 225...
Page 24: Pcba Lower Thread Observer (Lto)
The upper and lower position of the presser foot is recognized via the light barrier. The hall sensor together with the magnetic strip determines the presser foot position. Light barrier Hall sensor BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 24 of 225...
Page 25: Sensor Support Abc (Presser Foot Recognition)
Infrared (IR) LEDs • X-38 PCBA- Photo transistors base via harness Connector • According to picture Task • Recognition of presser feet and buttonhole foot signal via sensors Sensors BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 25 of 225...
Page 26: Cable Harness
6 Accessories connector white X 38 / / PCBA-Base 7 Dual Feed sensor white X 38 / / PCBA-Base 8 ABC sensor support white X 38 / / PCBA-Base BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 26 of 225...
Page 27: Bernina 7 Series Block Diagram
2.15 BERNINA 7 Series block diagram BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 27 of 225...
Page 28: 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 29: Chapter 3 - Trouble Shooting
Machine is stuck in a boot loop/ only starts up to BERNINA logo (see 3.1.9.9) Before commencing any work on the electronic side of the BERNINA Sewing Machines ensure all systems covering ESD are in place to ensure safe handling of all PCBA’s and cables. Delayed damage to prints can occur after repair if this is not done correctly.
Page 30: Information About The Three Main Pcbas
PCBA power supply to the PCBA base or the PCBA base is not working. Always check these indication lights for troubleshooting. Figure 1: PCBA base, LED indication lights, top left corner BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 31 3.1.3.2 Circuit board labelling Figure 2: PCBA base, Circuit Board Type and Revision Label indicates part number – PCBA Type and the revision number as shown above in blue. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 31 of 225...
Page 32: Pcba Cpu Module
- va374042_52370_Bernina790.bin (application) (3-Files) - vd374042_52370_Bernina790.bin (data) - xb021403_Universalbootloader.bin (bootloader) Table 1: Update files All 7-series machines have the new bootloader installed at production. Figure 3: Read the firmware version BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 32 of 225...
Page 33 Figure 5 describes the labelling location for PCBA CPU module. Rev. 0 to Rev. 4 are marked with a label and Rev. 5 is marked with laser engraving. Revisio Figure 5: Left: Labels for Rev. 0 – 4; Right: Laser engraved for Rev. 5 and later BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 34: Pcba Power Supply
Make sure thread cutter button moves freely this may require removal of the button pad to be cleaned and the surrounding area of the front cover. If the error is still present it may be required to replace PCBA-Ret. Use service mode test 4b to test buttons. BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 35 After switching on machine nothing is initialized and at the bottom left corner, written in red letters the message: “Error loading application ECC” or “Error loading application CRC” appears. Solution Force update firmware. If update fails, change PCBA CPU module BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 35 of 225...
Page 36: Troubleshooting
CPU) according to the block diagram The LCD cable and the touch cable are often confused. The LCD cable is the cable that goes straight to the PCBA CPU module board. The touch cable is smaller and is BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 37 If the function with a new sensor is still not given and all cables are good, change PCBA CPU module and then if still faulty change PCBA base 3.1.9.9 Machine is stuck in a boot loop/ only starts up to BERNINA logo • Check connection between PCBA base and PCBA CPU module. Remove the PCBA CPU module, lightly blow out its slot with air and reseat (USE NO SOLVENTS TO CLEAN) •...
Page 38: Flow Charts
Please switch-off the machine and unplug the power cable before plugging in/unplugging any other cables or changing any PCBAs. Damage to the machine and/or PCBAs may occur if done otherwise. BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 39 Set needle bar BDC (bottom dead center) • Switch-on (restart) machine Go to: «3.1.10.3 Not Booting to black start- booting to black SP: 5 screen with red BERNINA start screen» logo? Check all SMs in SP Go to: «3.1.10.4 Has application Application not started? starting»...
Page 40 3.Test: Try a new LCD (replace if necessary) working 4.Test: Try a new PCBA module (replace if necessary) 5.Test: Change PCBA base Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 40 of 225...
Page 41 Remove front cover • working Switch-on machine Both LEDs on PCBA module flashing? Switch-off machine Plug-in LCD and PCBA cover cables Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 41 of 225...
Page 42 4. Test: Change PCBA P-print 5. Test: Change PCBA base 6. Test: Change PCBA module All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 42 of 225...
Page 43 Sensor ok? 4.Test: Try a new PCBA module (replace if necessary) 5.Test: Change PCBA base All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 43 of 225...
Page 44 4. Test: Try a new PCBA module (replace if necessary) 5. Test: Replace PCBA base All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 44 of 225...
Page 45 7. Test: Replace PCBA base Switch-on machine SP: 4c Check SS slider in SP SS slider working? All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 45 of 225...
Page 46 6.Test: Try a new PCBA module (replace if necessary) 7.Test: Replace PCBA base Check relevant button in SP: 4b All tests Is button performed & working? machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 46 of 225...
Page 47 3. Test: Exposed metal (wires) 2. Test: Replace PCBA base 4. Test: Replace SM All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 47 of 225...
Page 48 Press F/C (more than 5s) «gears» Make sure there is no bind message on (e.g. cutter stuck) screen? All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 48 of 225...
Page 49 2. Test: Try a new PCBA module (replace if necessary) 3. Test: Change PCBA base All tests performed & machine still not working Return to «Overview» Write a ticket BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 49 of 225...
Page 50 3. Test: Try changing PCBA module (replace if necessary) 4. Test: Replace PCBA base All tests performed & machine still not working Write a ticket Return to «Overview» BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 50 of 225...
Page 51 4. Change PCBA needle threader machine still not 5. Test: Try a new PCBA module (replace if working necessary) 6. Replace PCBA base Return to «Overview» Write a ticket BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 51 of 225...
Page 52 USB and then read it from the USB Test successful? A)with a BERNINA USB stick 1. Test: Try another BERNINA USB stick 2. Test: Check USB host port on the Read and write machine (USB A port) 3. Test: Replace PCBA-Base SP: 4g &...
Page 53: Thread Cutter: Possible Faults
• Stitch plate support must be checked for bent sheet metal parts Solution • Check clutch carriage for mechanical damage. See iPortal info no. 063984 https://iportal.bernina.com/ • Check locking pin for mechanical damage. See iPortal info no. 080650 https://iportal.bernina.com/ •...
Page 54: Excessive Sources Of Noise
Check the thread path for residual threads, remove residual threads and other dirt o Check the thread path for technical defects, replace the identified parts o Carry out appropriate setting as described in the Service Manual BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 55: Thread Detection
The brake spring is not correctly inserted in the bobbin case. A full bobbin must be lifted from the bobbin case around the wall thickness of the bobbin • The reflectors of the bobbin are damaged and the bobbin thread indicator detects no more movement BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 56: Alternative Access To Touchscreen Calibration
• Access is achieved by simultaneously pressing the needle position keys and switching the machine on • The touch screen can now be calibrated as per instructions above BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 56 of 225...
Page 57: Eeprom Is Missing Or Is Incorrectly Programmed
PCBA base under certain circumstances Solution Insert the EEPROM correctly as described in the service manual, replace the EEPROM and possibly the PCBA base. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 57 of 225...
Page 58: Pop-Up Messages Upon Starting The Machine In Customer Mode
Message • The automatic thread cutter (on thread catcher) needs to be cleaned (see also SP Solution • Carry out cleaning based on the instruction on the screen BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 58 of 225...
Page 59: Machine Requires Maintenance
• Reset the counter Machine requires maintenance Message • It is time for regular maintenance. Please contact your specialized BERNINA dealer to make an appointment (see also SP Solution • Carry out maintenance on the machine • Reset the counter...
Page 60: Update Failed
USB memory. level of the USB memory (root No valid updates on USB stick directory). Defective or incompatible USB Use a BERNINA USB stick. stick Check functioning of USB stick on a PC. Is the USB stick connected?
Page 61: Other Reasons For Faulty Fw Update
Case 1: Boot loader too old Generally happens on machines from earlier production, or after some updates have been skipped. Update process can be started normally Upon starting, the black screen with the red BERNINA logo freezes or keeps appearing Solution •...
Page 62: Case 4: The Eeprom Is Replaced And The Wrong Machine Identification Has Been Loaded
Insert USB stick with the right FW for the machine • Switch on machine, the FW update process starts automatically • A restart after the update must be manually carried out BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 62 of 225...
Page 63: Sewing-Off Guideline
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 8266 Steckborn Switzerland Page 63 of 225...
Page 64: Zigzag Stitch (Default Settings)
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 8266 Steckborn Switzerland Page 64 of 225...
Page 65: Honeycomb Stitch (Default Settings)
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 8266 Steckborn Switzerland Page 65 of 225...
Page 66: Standard Buttonhole (Default Settings, Max. Length 20.0 Mm)
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 8266 Steckborn Switzerland Page 66 of 225...
Page 67: Chapter 4 - Removal And Refitting Of Components
• Screw in screw b (T20 M4x66) • Refit the four screws a (T20 M4x16) • Refit screw b (T20 M4x66) See iPortal info no. 100440 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 67 of 225...
Page 68: Front Cover
Refit and retighten screws c *The EMC screen connection is not included with the older PCBA base. In this case, an additional EMC screen connection is attached. 0351657.0.00 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 68 of 225...
Page 69: Free Arm Cover
Press the Free Arm Cover slightly up, so that it abuts the free arm cover • Tighten screw e (T10 M4x8) • Refit and retighten two screws (f) (T15) • Attach lower thread observer (see 4.2.20) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 69 of 225...
Page 70: Free Arm Cover Plate
Refit and retighten screw b • Attach the Free Arm Cover and bobbin door Take care not to interfere with the lower-thread observer wires to avoid damaging them. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 70 of 225...
Page 71: Base Plate Cover
Secure belt cover with two screws a (T10) on fixing plate • Tilt machine to refit fastening screw b (T20) on base plate underside • Refit handwheel 1 onto main shaft BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 71 of 225...
Page 72: Electronics And Sensors
Replug PCBA-RET/front left PCBA-Cover properly • Refit button (marked with a yellow arrow in the upper picture) • Attach the covers (see 4.1) See iPortal info no. 100153 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 72 of 225...
Page 73: Stitch-Length And Stitch-Width Adjusting Knobs
Rewind the winder wires around wire harness 2. Then reconnect PCBA base plug 1 (see 5.14) • Attach the covers (see 4.1) See iPortal info no. 100153 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 73 of 225...
Page 74: Winder Motor
Remove winder unit (see 4.2.3) Replace entirely if necessary. Assembly • Refit complete winder unit (see 4.2.3) • Functional check (see 5.14) • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 74 of 225...
Page 75: Lc Display / Touchscreen
Stick self-adhesive copper foil tape over the severed copper foil to bridge the cut • Attach front right and front left PCBA cover to front cover (see 4.2.1) • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 75 of 225...
Page 76: Pcba-Ret/Rubber Key Pad/Ribbon Cable
Reposition PCBA-RET c and bridge b properly and slightly tighten 4 fastening screws 1 • Reconnect PCBA-RET c ribbon cable a to front left PCBA- Cover • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 76 of 225...
Page 77: Pcba-Base
Retighten three screws a • Reconnect all plugs (note the color coding, see next page) Ensure that no wires are within the FHS light barrier area 3 Is the EEPROM attached? BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 77 of 225...
Page 78 * For connector details see 2.18 cable harness LED 5 V LED 36 V X-1701 X-1503 X-1700 1702 X-17 X-3112 X-38 X-3111 X-30 X-2111 X-104 X-42 X-24 X-15 EEPROM X-40 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 78 of 225...
Page 79: Pcba-Cpu-Module
The current state of the firmware must be checked after assembly of the new PCBA-CPU-module. If it is not the latest version, the firmware must be updated (via updating procedure). BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 79 of 225...
Page 80: Eeprom (Electrically Erasable Programmable Read-Only Memory)
Assembly • Attach EEPROM 2 to base • Note the installation position (markings must match) and do not bend the contact feet EEPROM fitting position Markings must match. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 80 of 225...
Page 81: Free Arm Led Sewing Light
(see 4.1) Risk of short circuit: To avoid the risk of a short circuit, attach a strip of electrical insulation tape to the bottom of the stand of the machine. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 81 of 225...
Page 82: Pcba Power Including Pcba Housing
Refit PCBA cover 1, PCBA housing and air duct 2, taking care not to interfere with the main switch and power plug • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 82 of 225...
Page 83: Pcba-Power
ESD protective gasket into slot • Tighten the 3 fastening screws a (T10) to secure PCBA-Power in the housing • Refit PCBA-Power and housing (see 4.2.10) • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 83 of 225...
Page 84: Head Frame Led Sewing Light
• Fit the left LED sewing light into the socket and use small screwdriver (T10) 0304755.0.00 to tighten the fastening screw 1 • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 84 of 225...
Page 85: Overlift Presser Food Switch (Presser Foot Height Sensor)
Attach the covers (see 4.1) Some 7 Series models have no magnetic strip and hall sensor. In that case the presser-foot height sensor 4 must positioned exactly in the centre of the rear actuating lug and secured with screw 3 max 1.6mm...
Page 86: Pcba Needle Threader
Start machine in Service Program, select (test • Carry out presser foot height calibration • (Select test 6c), carry out buttonhole calibration See iPortal info no. 051105 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 86 of 225...
Page 87: Pcba-Dual-Feed Sensor
• Disconnect plug 8 Assembly • Lower dual feed • Position PCBA-Accessories-Interface 8 • Retighten two screws a • Reconnect plug 8 • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 87 of 225...
Page 88: Embroidery Module Interface
• Secure on base plate with angled torx (T8) PCBA- EMB connection • PCBA-EMB is float-mounted. • Replug PCBA EMB connector • Attach base plate cover (see 4.1.6) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 88 of 225...
Page 89: Lower Thread Observer Unit
Click lower thread observer a into place on hook race cover holder c shaft b (fig. 1) • Insert guiding pin on the left of the lower-thread observer into guiding rail (red circle, fig. 1) • Close the bobbin door BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 89 of 225...
Page 90: Mechanical Components
Remove the three screws 2 (T20) from the Hook Guideway • Carefully remove the Hook Guideway Take care not to lose the calotte washers. See iPortal info no. 100633 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 90 of 225...
Page 91 Assembly, see (Hook Guideway without guide pins) Assembly, see (Hook Guideway without guide pins) Assembly, see (Hook Guideway with guide pins) See iPortal info no. 100561 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 91 of 225...
Page 92 Front view of frame, without groove marking, installation Front view of frame, without groove marking, (marked in yellow), machined installation surface surface not machined installation surface not machined (marked in red) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 92 of 225...
Page 93 Tighten screws 4, remove feed dog height gage 398024.03.1+ and setting gage 3 • Continue with the assembly of the hook driver 398024.03.1+ See iPortal info no. 100238 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 93 of 225...
Page 94 Then tighten three screws of the Hook Guideway 1 => 2 => 3 • The Hook Guideway is now locked in all directions • Remove setting gage 7345417.2.00 • Continue with the assembly of the hook driver BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 94 of 225...
Page 95 Check: The mark on the white plastic belt wheel must be exactly flush with the freearm frame lug mark. • Hook in tension spring connector between 5 clutch carriage and belt tensioner See iPortal info no. 100536 and 100095 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 95 of 225...
Page 96 Replace hook if it is badly scratched or has a broken hook tip • Lubrication of hook according to lubrication diagram (see 7.8) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 96 of 225...
Page 97: Stitch Plate Support With Integrated Thread Cutter Unit
Remove screw 4 (T8) • Move the thread catcher slightly to the right and pull the blade up and out See iPortal info no. 071949 and 100111 on https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 97 of 225...
Page 98: Blade Change On Mounted Thread Cutter Unit
Slip a sewing needle between the first and second plate. This will make it easier to pull out the knife. At the same time it'll mark the correct position for reinsertion of the new knife BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 99 • Close bobbin door. Then complete test 6e • Refit stitch plate, attach presser foot and insert new needle; then carry out a sewing and thread cutting test BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 99 of 225...
Page 100: Thread Tension
Remove the two screws (T20), fig. 3 • Carefully remove the whole upper thread tension unit from the rubber cushion, taking care not to remove the rubber cushion from its bore (fig. 4) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 101 • When done, reattach all covers • Start machine in Service Program, select (test • Carry out electronic upper thread tension adjustment BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 101 of 225...
Page 102: Mechanical Basic Setting Of The Thread Tension
Retighten upper screw of thread take-up lever cover • When done, reattach covers • Start machine in Service Program, select (test • Carry out electronic upper thread tension adjustment BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 102 of 225...
Page 103 The side measured with 9.95 mm of the distance gage 735386.50.00 must go up very easily over the tension spring BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 103 of 225...
Page 104: Clutch Carriage
Reattach connecting strap between clutch carriage and thread-cutter release lever and two screws (2) (T10) • Pin the thread catcher of the thread cutting unit with 3.0 mm pinning tool a 0079375.0.00 See iPortal info no. 080650 and 100561 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 104 of 225...
Page 105 Check if the solenoid on the clutch carriage is properly set (see 5.8.1 • Check the distance between the spring and clutch lever (see 5.8.4) See iPortal info no. 063984 and 047286 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 105 of 225...
Page 106: Hook Driver Belt Pulley
5.2.3) • Remove setting gages • Check the setting of the base shaft on the hook driver belt pulley (see 5.6.1) • Attach clutch carriage (see 4.3.6) 0079375.0.00 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 106 of 225...
Page 107: Needle Bar Support
7 • Slide needle bar support 12 to front, then to the left and out of thread take-up crank • Remove support 13 behind the needle bar support BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 107 of 225...
Page 108 Refit zigzag support with screw f and spring 8 • Rehook spring 8 • Remove calibration tool 14 • Set needle distribution (see 4.4.2) • Attach the covers (see 4.1) build-in BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 108 of 225...
Page 109: Needle Bar
Use feeler gauge 8 to press spring 3 down, then slide needle clamp 5 over needle bar 7 in direction of arrow as indicated • Retighten needle height screw b • Refit needle clamp screw a BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 109 of 225...
Page 110: Threader Mechanism
Reposition dowel 8 so that pressure spring sit’s in the groove of the dowel 8 (see picture a) • Rehook tension spring 10 • Rehook tension spring 9 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 110 of 225...
Page 111: Main Motor
Position motor back into motor bracket • Retighten screw a including u-washer and serrated washer • Refit drive belt and ventilation fan • Set belt tension (see 4.1.2) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 111 of 225...
Page 112: Dual Feed
Reconnect all plugs, lay cable in duct and close. • Refit right LED housing • Set dual feed in X-direction (see 4.6.2) • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 112 of 225...
Page 113: Thread Take-Up
Retighten setscrew b on the flat of crank 5 so that there is no play or clamping • Attach needle bar support, thread tension and covers (see 4.1) See iPortal info no. 071665 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 113 of 225...
Page 114: Base Shaft
It should now be possible to pin the base shaft with the 3.0 mm pinning tool 007937.5.00 against the lift cam • Set belt tension between main shaft and base shaft (see 5.2.1) • Check loop lift (see 5.6.2) 007937.5.00 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 114 of 225...
Page 115: Restraint-Guided Thrust Link
Loosen screw 9 (T8) of bearing pin, then remove bearing pin 14 • Pull lift-/advance 16 link out, lifting it away from you and taking care not to lose the pressure spring BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 115 of 225...
Page 116 7345625.0.00 • Mount circlip 8 • Turn handwheel and check for ease of running BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 116 of 225...
Page 117: Stitch Length Of Crank Shaft
Remove circlip e for toothed segment • Push toothed segment a to the right • Remove circlip f on the belt pulley • Extend crank shaft with small belt pulley BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 117 of 225...
Page 118 Remove pinning tools • Attach PCBA base (see 4.2.7) • Attach the covers (see 4.1) • Start machine in Service Program, select (test • Carry out balance fine-setting 0027335.0.0 0027335.0.0 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 118 of 225...
Page 119: Stitch Length Stepping Motor
Place 0.3 mm feeler gauge 9 under stop 7 of drive gear pinion 6 • Set stop 7 of drive gear pinion 6 against rubber buffer 8 and retighten setscrew b • Remove feeler gauge 9 • Refit stepping motor BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 119 of 225...
Page 120: Sideways-Motion Stepping Motor
Attach free arm cover, be aware of clearance from the stitch plate (see 4.1.5) • Attach Free Arm Cover (see 4.1.4) • Install the rear cover (see 4.1.2) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 120 of 225...
Page 121: Presser-Foot Pressure Stepping Motor
Replug stepping motor connector • Replug PCBA-Threader connector • Start machine in Service Program, carry out (test • Install the rear cover (see 4.1.2) • Attach head cover (see 4.1.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 121 of 225...
Page 122: Stitch-Width Stepping Motor
Retighten setscrew c • Complete test 5e • Remove pinning tool 6 and feeler gage 7 • Set needle distribution (see 4.4.2) • Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 122 of 225...
Page 123: Presser Foot Pressure - Toothed Rack Bearing
Position entire toothed rack bearing at rear head plate and retighten three screws a • Slide pinion 5 over shaft • Attach wheel 3 including washer and circlip 4 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 123 of 225...
Page 124: Chapter 5 - Settings
For servicing, we recommend that you always use the accessories included with the machine or purchased specifically for the machine afterwards. These are the following: power cable, foot control, buttonhole foot, embroidery module and hoop, BSR foot, and other accessories. BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 125: Belt Tensions
Loosen screw b (T20), then use setting spanner 7330197.0.00 to turn the bearing until the specified tension value has been reached. • Retighten screw b Clockwise turning --˃ Belt tension tightens BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 125 of 225...
Page 126: Drive Motor
If these markings are no longer available, the belt tensioner should be flush up to max. -1 mm under the free arm surface Setting • Loosen screw 6 • Set belt tension • Retighten screw 6 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 126 of 225...
Page 127: Head-Frame Plate Position
Use 3/8-inch markings on stitch plate for reference Setting • Slightly untighten screws a (T20) • Apply angled eccentric key 0315635.0.00 at eccentric engagement bore b to position head frame plate • Retighten screws a BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 127 of 225...
Page 128: Presser-Foot Settings
Ensure that presser foot and stitch plate are parallel • Retighten screw b The presser foot height is read by the PCBA-Dual feed sensor and does therefore not require mechnical setting as with previous models. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 128 of 225...
Page 129: Presser-Foot Fixation
• Ensure that presser foot sole and stitch plate are parallel - align if required • Use 3/8-inch markings on stitch plate for reference • Retighten screw c BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 129 of 225...
Page 130: Needle Settings
It must not be used for the setting of the needle/hook 0.6 mm 0.4 mm distance. Setting of needle/hook distance (see 5.6.3) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 130 of 225...
Page 131: Needle Distribution
Retighten screw b Test • Attach Revers Pattern Foot #1D • Set to maximum stitch width • Needle mustn't touch the right or left side of the stitch plate BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 131 of 225...
Page 132: Zigzag Stitch Width Limiter
Start machine in Service Program, select (test • Needle bar support mustn't touch the zigzag stitch width limiter a Setting • Loosen screw b (T10) • Position limiter a • Retighten screw b BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 132 of 225...
Page 133: Mechanical Synchronization, Hook Settings, Needle Settings
For machines without feed dog (only embroidery machines), use setting gage 7342585.2.00. To do so, place the setting gage on the coupling ring. Setting gage should meet the frame 734258.52.00 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 133 of 225...
Page 134 (see 4.3.7) • Should it not be possible to pin the hook driver with pinning tool 0079375.0.00: → Check the assembly of the hook driver (see 4.3.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 134 of 225...
Page 135: Loop Lift
(sewing direction). The two toothed wheels must run smoothly (no play, no clamping) • Use gauge to remove clamp • Tighten second screw counterclockwise (sewing direction) • Check again and repeat setting if required BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 135 of 225...
Page 136: Needle / Hook Distance
Carefully nudge stitch plate into the required position with the aid of an angled torx (T6) • Retighten screw a (T6) We recommend to use a magnifying glass to ensure accurate setting. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 136 of 225...
Page 137: Needle Height
The needle bar is in nominal position c, at level 2 of distance plate b Setting If the distance plate b deviates from its nominal position c = 2, the needle positioning pin d needs to be replaced. This is to applay for all 7 Series machines. • Remove the distance gauge a •...
Page 138: Feed-Dog Settings
Without sideways motion feeding • Turn handwheel until feed-dog at its highest point • Untighten screws (e) (T6) • Push feed dog into the specified position • Tighten screws (e) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 138 of 225...
Page 139: X-Direction Positioning Against Main Feed Dog
Without sideways motion feeding • Untighten screw c (T10) • Use eccentric key 0013617.0.00 in eccentric engagement bore d to set the lateral positioning • Retighten screw c BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 139 of 225...
Page 140: Leveling Of Main Feed Dog (0.9-1.0 Mm)
Turning clockwise > feed dog level is lowered. Turning counterclockwise > feed-dog level is lifted. • Retighten screw d (T8) and check the height using gage 3980240.3.1+ • Repeat setting if necessary BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 140 of 225...
Page 141: Main Feeding Balance - Mechanical Basic Setting
The first tooth d of drive gear b must gear into the first gap of the toothed segment e • Use spring pressure to reposition calotte bearing h to the left into the motor holding plate BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 141 of 225...
Page 142 Retighten screw g to fix drive gear b at stop c • Remove pinning tools • Refit PCBA-Base • Start machine in Service Program, select (test • Carry out balance fine-setting BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 142 of 225...
Page 143: Feed Dog/Dual Feed Synchronization
Setting • Loosen screw g (T10) • Move dual feed into the specified position • Retighten screw g • Remove Synchroplate and pinning tools BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 143 of 225...
Page 144: Dual Feed Balance - Basic Mechanical Setting
Turn setting screw a until the distances between the drive belt flange and the setting hub are even • Carry out BDF Balance fine setting in Service Program BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 144 of 225...
Page 145: Clutch Carriage/Thread Cutter
Attach air tube ( see 4.2.11 • Reattach free arm cover plate, free arm cover, rear cover and head cover ( see 4.1 • Test sew and test thread cutting BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 145 of 225...
Page 146: Clutch Carriage
• With the lever in this position, retighten the two screws (T10) on the connecting strap between clutch carriage and cutting unit release lever BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 147: Timing Of Clutch Carriage
Set down setting gage 7342585.2.00 on coupling ring • Position the coupling ring at the collar of the base • Tighten the setscrew d (T8) of the coupling ring BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 147 of 225...
Page 148: Distance Between Spring And Clutch Lever
Refit and retighten screw c (T8 angled torx) and nut d (open-end or ring wrench 5) on thread guide plate/thread stop • Carry out a manual functioning check See iPortal info no. 063984 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 148 of 225...
Page 149: Synchrinising Disc
Between 22.5° and 27.5°. • Place synchronizing disc against circlip • Retighten screw a (not too hard) • Remove loop lift gauge See iPortal info no. 065493 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 149 of 225...
Page 150: Threader
The threader head can be properly set by moving it up, or down • Retighten needle bar guide setting screw 17 (T8) and check 7341015.0.00 setting. Refit basting solenoid housing BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 150 of 225...
Page 151: Basting Device
Loosen needle bar guide setting screw 17 • Center needle bar bore within clutch-bolt clearance 4 • Retighten needle bar guide setting screw 17 (T8). Refit basting solenoid housing 734101.50.00 BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 151 of 225...
Page 152: Checking The Timing Of Disengagement
Run machine at highest speed to test basting magnet in left and right needle positions If functional test fails in one, some or all needle positions, recheck the setting of the cushioner position and the needle bar guiding and set as required. BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 153: Thread Regulator
Check tension • Thread thread regulator with a 30cm long bit of thread • Attach the two thread ends to the BERNINA tension spring scales (0060385.0.00) • Slowly move the scales up • On moving the regulator spring, the tension value must be 12 – 15 g...
Page 154: Thread Tension
Add another 10 grams (2 x 5 grams), see picture 4. The gauge should move down very slowly. If required, set using the multifunction knob a • Touch to save the setting • The "Successful" message appears together with the tension settings BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 154 of 225...
Page 155: Lower Thread Tension (Basic Setting)
• Turn screw counterclockwise (to left) to slacken • Turn screw clockwise (to right) to tighten • See iPortal info no. 079853 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 155 of 225...
Page 156: Winder
• Turn screw b (T10) inwards or outwards accordingly Incorrectly or unevenly filled bobbins can affect the stitch quality and impair the functioning of the lower thread observer BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 156 of 225...
Page 157: Position Of Lower Thread Observer
If the lower thread observer does not 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 indicator unit. BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 158: Chapter 6 - Service Program
2 = Area: Monitor 3 = Area: Sensors 4 = Area: Signals 5 = Area: Motors 6 = Area: Settings 7 = Area: Embroidery 11 = Area: Final module check BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 158 of 225...
Page 159 Selecting a keyboard a: Upper case letters b: Lower case letters c: Numbers, special characters and punctuation marks d: Special marks BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 159 of 225...
Page 160: Menu 1 - Service Information
Menu 1 – Service Information Machine basic data Machine soft- and firmware data Machine operating time data Machine stitch counter data BSR (BERNINA Stitch Regulator) data stitch counter Machine Servicing Data Saving customer data Customer data Dealer data Log data...
Page 161: Machine Operating Time Data
Total number of stitches using BSR • Total number of embroidery stitches • Stitches since last lubrication • Stitches since last service 1e BSR (BERNINA Stitch Regulator) Data What to test The BSR foot must be attached and connected. • Serial Number • Chassis Number •...
Page 162: Machine Servicing Data
Service interval • The stitch counter triggers a reminder after 3’000’000 stitches: Please take your machine to a BERNINA dealer for servicing. Reset • Remember to always reset the counter (cleaning interval) after servicing or repairing...
Page 163: Saving Customer Data
• Load the Customer settings = Loading of customer data to the machine Connect BERNINA USB memory stick and select required button. Remove the stick after saving of data has been confirmed. 1h Customer data What to test •...
Page 164: Dealer Data
• Dealer data can now be entered • Dealer data can also be read and entered in .txt format from a BERNINA USB memory stick. Important: The file must be named "dealerdata.txt" (see example below) • The dealer-related data will automatically appear on the screen when a maintenance reminder is...
Page 165: Reset Thread Cutter Counter
Customer requirement: Clean thread cutter • The counter triggers a note for the customer upon 1000 thread cuts – "The automatic thread cutter (with thread catcher) must be cleaned" (see 3.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 165 of 225...
Page 166: Menu 2 - Display, Buttons
LED sewing light and brightness 2a Touchscreen Calibration What to test • Touch 'Calibrate' to start the test • To calibrate the touchscreen, use the BERNINA stylus to touch the 3 crosses as required • Touch to save and return •...
Page 167: Lc Display (Screen)
White blank screen to find dirt or stains • Touch to return Repair notes • Clean LCD and touchscreen Never use alcohol, petrol, spirits or any corrosive fluids, or abrasive pastes or abrasive cleaners! BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 167 of 225...
Page 168: Rgb (Red, Green And Blue) Screen
The start / stop button will light up green or red respectively • Touch to return Repair notes • Check cables for deformation and/or wear and tear • Replace PCBA-RET if any of the buttons don’t light up BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 168 of 225...
Page 169: Led's And Brightness
Check all connectors • Check cables for deformation and/or wear and tear • Check connectors P-38 and P-3111 on the PCBA-Base • Replace the LED’s • Replace the PCBA-Base BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 169 of 225...
Page 170: Menu 3 - Sensors (Mounting Locations In The Machine)
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 the sensor does not respond, replace the PCBA needle threader (see 4.2.15) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 170 of 225...
Page 171: Presser Foot Height Sensor
Incorrect reading of presser foot height! "0" will be displayed if the presser foot sits on the stitch plate in most cases. • Check the basic setting of the presser foot height in Service Program (see BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 171 of 225...
Page 172: Lower Thread Observer
Check the sensors for dust and stains • Repeat the test using a new bobbin • Check cables for deformation and/or wear and tear • Replace lower thread observer • Replace PCBA base BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 172 of 225...
Page 173: Feed Dog Drop
Pull PCBA-Detection out a little ▪ Unplug PCBA-Base connector ▪ Replug PCBA-Base connector ▪ Attach PCBA detection in the required position and retighten fastening screw (T20) ▪ Attach the covers (see 4.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 173 of 225...
Page 174: Dual Feed Recognition Sensor
If the sensor does not respond, replace the PCBA dual feed sensor. ( see 4.2.17 • The support ABC sensor (presser foot recognition, see 4.2.16) might also be affected BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 174 of 225...
Page 175: Bobbin Winder Switch
• Switch off bobbin • Touch to return Repair notes • Check cables for deformation and/or wear and tear • Replace winder • Replace PCBA base (see 4.2.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 175 of 225...
Page 176: Free Hand System Fhs
• Check if in the area of the sensor on the PCBA-Base no cables are exposed • If the signal is not activated, replace PCBA base (see 4.2.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 176 of 225...
Page 177: Menu 4 - Signals
Stitch width and stitch length knob(s) Functions of keys and buttons on machine Start/stop slide (SSU) Foot control (normal) 4e PS2 interface, intended for production only Upper thread observer BERNINA stitch regulator (BSR) PCBA position Speaker USB host interface Basting solenoid 4l Presser-foot recognition...
Page 178: Functions Of Keys And Buttons On Machine
The bar will fill accordingly • Touch to return Repair notes • Check cables for deformation and/or wear and tear • Replace PCBA-RET (see 4.2.6) • Replace PCBA-Left Front Cover (see 4.2.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 178 of 225...
Page 179: Foot Control
Check if the regulator is properly hooked and if it actuates the actuating lug • Check if the regulator spring is properly set (see 4.11) • Replace PCBA-RET (see 4.2.6) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 179 of 225...
Page 180: Bernina Stitch Regulator (Bsr)
4g BERNINA Stitch Regulator (BSR) What to test • Attach BSR foot • Select test 4g • Lower presser foot • Press the icon to start the test • Place fabric under the presser foot • Move the fabric in different directions •...
Page 181 Turn synchronizing disk until signal 1 blanks • Position: between 25° and 27,5° • Retighten screw a slightly Attention! Don't tighten screw a of synchronizing disk too tight. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 181 of 225...
Page 182: Speaker
If 'Test Failed' message appears • Repeat the test using another USB cable • Check the client and host ports on the machine • Replace PCBA-Base (see 4.2.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 182 of 225...
Page 183: Basting Solenoid
'Successful' appears • Touch to return Repair notes • Check plugs and cables for deformation and/or wear and tear • Replace basting solenoid • Replace PCBA-Base (see 4.2.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 183 of 225...
Page 184: Presser-Foot Recognition
For example Feet 1C, 20C, 40C 5.5 mm feet e.g.: Feet 2A, 5, 16, 18 Straight stitch foot Darning foot e.g.: Feet 13, 35, 38, 43, 53 5.5 mm Dual feed foot BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 184 of 225...
Page 185 Press the presser foot indicator (marked in red) at top left • The currently attached presser foot will be displayed in the box top left, along with all other feet on further 6 pages BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 186: Bsr Foot Interface
Repair notes • Check BSR plug and connector • Check cables for deformation and/or wear and tear • Replace BSR foot • Replace PCBA-Accessories Connector (see 4.2.18) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 186 of 225...
Page 187: Menu 5 - Stepping Motors (Mounting Locations In The Machine)
Swap connectors with the presser-foot pressure stepping motor to check if the fault is with the motor or the PCBA-Base Disconnect from the power supply. Do not disconnect or reconnect when the machine is powered. BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 188: Presser Foot Pressure Stepping Motor
Disconnect from the power supply. Do not disconnect or reconnect when the machine is powered. Do not use the stitch length or dual feed stepping motors for testing, as these run with higher electricity BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 189: Pinning Positions Of All Stepping Motors
Touch to return Repair notes • Check plugs and cables for deformation and/or wear and tear • Replace PCBA-Base (see 4.2.7) • Replace the winder motor (see 4.2.4) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 189 of 225...
Page 190: Stitch Length Stepping Motor
• Replace PCBA-Base (see 4.2.7) • Replace stitch length stepping motor (see 4.3.18) Disconnect from the power supply. Do not disconnect or reconnect when the machine is powered. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 190 of 225...
Page 191: Sideways Motion Stepping Motor
Swap connectors with the stitch length stepping motor to check if the fault is with the motor or the PCBA base Disconnect from the power supply. Do not remove or refit anything when the machine is powered. BERNINA International AG Seestrasse 161 8266 Steckborn...
Page 192: Menu 6 - Settings
In order to ensure the carrying out of all crucial settings and calibrations, follow the check list in menu 11 Do not run a threaded machine without fabric! BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 192 of 225...
Page 193: Electronic Balance
The basic value is 0, the setting ranges from +4 to -4 • Touch to save and return Information on correction direction • button = forward, button = backward BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 193 of 225...
Page 194 The number 9 must be sewn closed What to set • Turn balance cam a (T10) to set until the 9 is stitched properly Turn CW Turn CCW BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 194 of 225...
Page 195 Information on correction direction • Rotate the balance cam a clockwise = the leaf pattern pulls together • Rotate the balance cam a anticlockwise = the leaf pattern pulls apart  BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 195 of 225...
Page 196 Correct the sewing pattern according to the listed directions of rotation over the axis balance a • The height between the end points 1 and 2 should be equal, but end point 2 may be max. 1 mm higher Turn CW Turn CCW BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 196 of 225...
Page 197 Lower the presser foot. Press the permanent reverse button on the screen • Sew the pattern backward • The difference in length between the two stitch rows should not be larger than 7.0 mm BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 197 of 225...
Page 198 Turning setting screw a counterclockwise will shorten the left side of the diamond stitch pattern while the right side of the diamond pattern will be lengthened (see 4.6.4)  BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 198 of 225...
Page 199: Buttonhole Calibration
Check foot recognition in test 4l • Replace presser foot • Check plugs and cables for deformation and/or wear and tear • Replace sensor carrier ABC (see 4.2.18) • Replace PCBA-Base (see 4.2.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 199 of 225...
Page 200: Thread Cutter Clamping Mechanism (Magnet)
Check if the solenoid on the clutch carriage is properly set (see 5.8.1) • Check cables for deformation and/or wear and tear • Completely replace clutch carriage (see 4.3.6) • Replace PCBA-Base (see 4.2.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 200 of 225...
Page 201: Thread Cutter Cutting Process
Move to needle stop position up. Restore thread tension 220° Test done After setting the thread tension 220° • The message "After setting the thread tension" appears • Touch to return BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 201 of 225...
Page 202: Upper Thread Tension Reset To Default
If the answer is Yes, press to reset the upper-thread tension to default and to return to menu 6 • If 'No', press to return to menu 6. The tension values remain unchanged BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 202 of 225...
Page 203: Resetting To Factory Settings (Reset All)
If 'No', press to return to menu 6. The sewing settings remain unchanged IMPORTANT: It is essential to save all the customer's data on a BERNINA USB data stick before resetting to factory settings. Saving customer data (see test 1g).
Page 204: Automatic Upper Thread Tension
• Select the setting thread to be used (DMC 50, Belfil, Mettler or Amann) • A 'Successful!' message will appear on successfully completed setting • Touch to return BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 204 of 225...
Page 205: Start-/Stop Unit (Ssu) Slide Control Calibration
Touch to return Repair notes • Check slider for dust or dirt and smooth mechanical running • Replace PCBA front cover (see 4.2.1) • Replace PCBA-Base (see 4.2.7) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 205 of 225...
Page 206: Bsr Foot Sewing Program
The noise level of the machine can be evaluated • Touch to return Repair notes • Lubricate hook (see 7.1.8) • Check positioning of the Hook Guideway (see 4.3.1) BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 206 of 225...
Page 207: Menu 7 - Embroidery Module (Emb)
Cleaning and servicing intervals, test After completion and confirmation of the last test with , the check-out program will return to the main menu in the Service Program. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 207 of 225...
Page 208: Chapter 7 - Lubrication Diagram
Chapter 7 - Lubrication diagram = Klüber OY 100 (0027797.0.01) = Velocite 6 (0335675.0.01) = Klübersynth UH1 14-1600 (0027797.2.02) = Klübersynth GE 14-151 (0363327.0.10) Head frame BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 208 of 225...
Page 209: Main Feed Dog
Main feed dog BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 209 of 225...
Page 210: Threader Mechanism / Needle Drive
Threader mechanism / Needle drive BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 210 of 225...
Page 211: Toothed-Segment Needle-Bar Support
Toothed-segment needle-bar support Upper Thread Tension Unit BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 211 of 225...
Page 212: Dual Feed Crank Shaft
Hook drivers with plastic housing are maintenance-free and should not be relubricated 048554 • Hook drivers with sintered housing up to SN 608933276-57/08, see iPortal info no. https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 212 of 225...
Page 213: Feed-Dog Fork
Feed-dog fork Base shaft/lift cam and feed cam of main feed dog Feed-dog crank shaft BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 213 of 225...
Page 214: Chapter 8 - Firmware Update
The USB stick must be FAT32-formatted, so that the firmware update can be correctly ended. 1. Save the update files to a BERNINA USB stick (> 512 MB) https://iportal.bernina.com/ For BERNINA dealers www.bernina.com/downloads...
Page 215: Alternative Update Process
This starts the update process with the data check on the USB stick On completion of the manual update procedure, the machine must be started manually. BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland...
Page 216: 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 machines •...
Page 217: 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 8266 Steckborn Switzerland...
Page 218: 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 defect-free operation of the machine, BERNINA recommends replacing the parts according to the table (9.4.2) once the tenth maintenance interval is reached •...
Page 219: Operating-Time-Related Parts
Operating-time-related parts BERNINA 7 Series Art. # Article Maintenance Remarks interval 0336665.X.00 Link piece 2 / 4 / 6 / 8 / 10 0337347.X.01 Crank shaft 10 / 19 0334607.X.00 Crank shaft 10 / 19 Dual feed 0349215.X.00 Lift cam and feed cam...
Page 220: Maintenance Checklist
• Read out the stitch and hour counter and enter on the Service Report Customer data backup Service Program 1g. Connect BERNINA USB memory stick and select required button. Remove stick after confirmation by the machine. • Save the customer settings = Customer data saved onto the storage medium •...
Page 221: Functional Check
• Thread take-up crank • Needle bar support/needle bar Mechanical quality of the machine • Hook driver bearing • Bevel gears • Bobbin carrier / hook • Drive belt tensions BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 221 of 225...
Page 222: Maintenance Checklist Bernina 7 Series
Maintenance Checklist BERNINA 7 Series Front and rear cover Covers to be removed Free Arm Cover Stitch plate Hook Parts that must be disassembled or removed Bobbin carrier Recommended parts according to Tear-and-Wear Parts Definition Free-arm area Needle bar/needle bar support...
Page 223: Embroidery Module
Evaluation of test sample, (see 3.3) in the Service and Embroidering the test pattern Maintenance Manual of the embroidery module Cleaning Covers Final check Is the set of accessories complete? BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 223 of 225...
Page 224: Kapitel 10 - Document Revision History
5.8.4 Distance between spring and clutch lever 5.13.2 Lower thread tension (basic setting) Chapter 6 Reset thread cutter counter Chapter 9 9.2.1 When is a cleaning message displayed? BERNINA International AG Seestrasse 161 8266 Steckborn Switzerland Page 224 of 225...
Page 225 Attachment – document directory Chapter Document title iPortal info no. 3.1.1 Guide for fault rectification for electronics of 7 Series 079271 3.1.7.1 Complaints caused by PCBA needle threader 051105 3.2.1 Thread cutting block, prevention through improved clutch carriage 063984 Locking pin for automatic thread cutter 080650 3.7.4...

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