Page 1 Service- and Maintenance Manual of the 4 and 5 Series (VIO) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 1 von 218...
Page 2: Table Of Contents
Display shows lines or wrong colours ..................37 3.5.1.6 No/irregular presser foot detection ..................37 3.5.1.7 Machine is stuck in a boot loop/ only starts up to BERNINA logo .......... 37 3.5.2 Flow charts ..........................38 3.5.2.1 How to read flow charts ......................38 3.5.2.2...
Page 3 4.3.1 Hook and hook driver ......................88 4.3.1.1 Assembly of hook guideway with guiding pins (with front and rear and only rear calottes) → until 61/07 .......................... 90 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 3 von 218...
Page 4 4.3.13.1 Toothed Rack, machines with manual Presser Foot Pressure ..........109 4.3.14 Presser foot bar ........................110 4.3.15 Assembly unit BERNINA Dual Feed BDF ................111 4.3.15.1 Needle-bar support ....................... 113 4.3.15.2 Needle bar ..........................114 4.3.16 Needle clamp ........................115 4.3.17...
Page 5 1b Machine firmware data and technical information ................163 1c Machine operating hours data ......................164 1d Stitch counter data ........................... 164 1e BSR (BERNINA Stitch Regulator) data ................... 164 1f Machine servicing data ........................165 1g Saving customer data ........................165 1h Customer related data (Customer Information) ................
Page 6 Measures to be taken after the service ................. 212 9.5.3 Functional check ........................213 9.5.4 Maintenance checklist BERNINA Series 4 + 5 VIO .............. 214 9.5.5 Embroidery module ....................... 215 Chapter 10 - Document Revision History ..............216 Chapter 11 - Appendix – Document list ..............218...
Page 7: Chapter 1 - General Information
This service manual is only available in electronic format. It can be downloaded from BERNINA iPortal at BERNINA iPortal – Landing BERNINA iPortal page. If you don't have access to iPortal, contact your local BERNINA importer. They'll be glad to be of assistance. Disclaimer Masthead...
Page 8: Warning: Dangerous Voltage Levels
The capacitors require 30 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 CH-8266 Steckborn Switzerland...
Page 9: Esd-Related Note: Electrostatic Discharge (Esd)
5. Treat faulty PCBs in the same manner as new ones to prevent consequential damage or harm For more information (see 2.11 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 9 von 218...
Page 10: Tools And Gauges
Tools and gauges (Commercially available, not available from Bernina): Calliper, multimeter, TORX screwdrivers sizes 6, 8, 10, 10 with 20 0 mm shaft length, 15, 20, 25, 25 with 20 0 mm shaft length, angled Torx sizes 6 and 10, combination spanners in sizes 1 0 mm and 8mm, open-...
Page 11 Needle 130/705 H 100 (100) Needle penetration in Y-direction 7341015.0.00 Distance gauge Threaded head height 0327985.0.00 Synchroplate Basic position of the BERNINA dual feed 7330197.0.00 Adjusting spanner Adjusting the belt tension, setting the distance of the needle bar clamp 3980261.3.1+...
Page 12 Torx screwdriver T 10 Disassembling & reassembling aid No more available Timing gauge Set timing for clutch carriage Successor: 1043817.1.00 Helpful Tools for BERNINA Sewing and Embroidery Systems Part-No. Name Application Picture 0060385.0.00 Spring balance Tension of thread regulator spring 0319355.0.00...
Page 13: 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. Abbreviations Englisch BERNINA Dual Feed BERNINA Stitch Regulator Direct Current EEPROM Electronically Erasable Programable Read Only Memory...
Page 14: Cleaning
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 CH-8266 Steckborn Switzerland Seite 14 von 218...
Page 15: Technical Specifications Of 4 & 5 Series
100 – 1000 100 – 1000 100 – 1000 100 - 1000 Stitching speed, min./max. Sideways Motion BERNINA Dual Feed (upper feed) BERNINA Stitch Regulator (BSR) port Embroidery module connection Automatic thread cutter Embroidery speed, max. Embroidery file formats Long stitch and Basting stitch unit...
Page 16 100 – 1000 100 – 1000 100 - 1000 100 - 1000 Stitching speed, min./max. Sideways Motion BERNINA Dual Feed (upper feed) BERNINA Stitch Regulator (BSR) port Embroidery module connection Automatic thread cutter Embroidery speed, max. 1000 SPM 1000 SPM...
Page 17 262‘144 262‘144 262‘144 262‘144 262‘144 Number of colors Display backlight in white User interface Touch screen Touch screen Touch screen Touch screen Touch screen USB data stick/PC interface BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 17 von 218...
Page 18: Chapter 2 - Electronics And Wiring
Chapter 2 - Electronics and Wiring Block diagram and brief descriptions of electronic components Block Diagram BERNINA B 590 (BERNINA 4 and 5 Series equipement and function depend on model type). BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 18 von 218...
Page 19: Pcba-Power
Fuse (installed) Connection • Plug-in connection to PCBA base • Plug-in connection to power supply Purpose • Supplies the machine with voltage • Serves as overload protection (fuse) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 19 von 218...
Page 20: Pcba-Cpu-Module (Arm9) General Information
PCBA remove PCBA-CPU-module • Memory from the 'old' PCBA and add to new base PCBA. • Data 2.3.1 PCBA-CPU-Module/ARM9 If a PCBA-CPU-module requires early replacement, please refer to chapter 8.3. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 20 von 218...
Page 21: 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 Switzerland Seite 21 von 218...
Page 22: Pcba-Position Hall
Light barrier threader Connection • Plug-in connection to PCBA base • Plug-in connection to basting unit magnet Purpose • Recognition threader active • Triggers the basting unit magnet BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 22 von 218...
Page 23: Pcba-Cover Including Display And Touch Screen
Plug-in connection to PCBA sewing head • Plug-in connection to PCBA base • Plug-in connection to LCD Purpose • Registration of the entries via the buttons and controllers • Supply for LCD BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 23 von 218...
Page 24: Pcba-Stitching Head (Pcba-Ret)
Light barrier to upper thread indicator (is performed via the switching lug of the regulator spring) Purpose • Registration of the entries via the buttons • Recognition of upper thread See iPortal info no. 100294 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 24 von 218...
Page 25: Pcba-Lower-Thread Observer (Lto)
The ABC sensors support contains • Infrared (IR) LEDs • Phototransistors Connecting • According to picture Task • Recognition of presser feet and buttonhole foot signal via sensors. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 25 von 218...
Page 26: Pcba Embroidery Module Detection
2.10 PCBA Embroidery module detection The sensor circuit board ABC provides • Light Barrier • Connector Connection • See figure Purpose • The light barrier detects whether a embroidery module is connected BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 26 von 218...
Page 27: 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 28: Chapter 3 - Troubleshooting
No/irregular presser foot detection → refer to 3.5.1.6 Machine is stuck in a boot loop/ only starts up to BERNINA logo → refer to 3.5.1.7 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.
Page 29: Information About The Three Main Pcbas
Replace if generated directly on the 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 Switzerland Seite 29 von 218...
Page 30: Circuit Board Labelling
(see Table 1 and Figure 3). Table 1: Update files Content of the ZIP-File - va374042_52370_Bernina790.bin (application) (3-Files) - vd374042_52370_Bernina790.bin (data) - xb021403_Universalbootloader.bin (bootloader) Figure 3: Read the firmware version BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 30 von 218...
Page 31: Indication Lights
• Reload firmware via alternative • 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 Switzerland Seite 31 von 218...
Page 32: Circuit Board Labelling
Figure 4 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. Revision Figure 4: Left: Labels for Rev. 0 – 4; Right: Laser engraved for Rev. 5 and later BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland...
Page 33: Pcba Power Supply
Circuit board labelling Figure 5 describes the labelling location for PCBA power supply. The revision is marked blue. Revision Figure 5: PCBA power supply, circuit board type and revision BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 33 von 218...
Page 34: Errors
(which is located on the PCBA base). Visually check PCBA base for burnt parts or other indications for a fault. Before swapping the PCBA base try a new module print to rule out a fault on there. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...
Page 35: Stepper Error: Short To Ground Phase A/B
“Error loading application ECC” or “Error loading application CRC” appears. Solution: Force update firmware. If update fails, change PCBA CPU module See iPortal info no. 072611 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 35 von 218...
Page 36: Troubleshooting
If it doesn’t work after changing the LCD, change the PCBA CPU module and as a last step PCBA base. If at hand, use a front cover of another machine (only the same model!) to narrow down where the fault is coming from BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 36 von 218...
Page 37: Display Shows Lines Or Wrong Colours
➢ If still not working replace PCBA base. 3.5.1.7 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 CH-8266 Steckborn...
Page 39: Overview
Set needle bar TDC (top dead center) • Switch-on (restart) machine Go to: «Not booting Booting to black start- to black start SP: 5 screen with red BERNINA screen» logo? Check all SMs in SP Go to: «Application Has application not starting»...
Page 40: Not Booting To Black Start Screen
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 CH-8266 Steckborn Switzerland Seite 40 von 218...
Page 41: Application Not Starting
All tests performed & machine still not working 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 CH-8266 Steckborn Switzerland Seite 41 von 218...
Page 42: Errors And Warnings
Refer to ch. 6.6 SP: 6b Balance Calibrate electronic calibration balance warning? Calibration done but warning is still showing after restart? Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 42 von 218...
Page 43: Touch Not Working
4. Test: Try a new PCBA module (replace if necessary) 5. Test: Replace PCBA base Touch working? All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 43 von 218...
Page 44: Ss Slider
5. 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 CH-8266 Steckborn Switzerland Seite 44 von 218...
Page 45: Buttons
5.Test: Try a new PCBA module (replace if necessary) 6.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 CH-8266 Steckborn Switzerland Seite 45 von 218...
Page 46: Stepper Motors
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 CH-8266 Steckborn Switzerland Seite 46 von 218...
Page 47: Main Drive Not Working
3. Test: Replace PCBA base 4. Test: Try a new PCBA SMPS (replace if necessary) All tests Motor running performed & properly? machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 47 von 218...
Page 48: Applications (Service Program)
PCBA base 3. Test: Replace PCBA base 4. Test: Replace PCBA module All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 48 von 218...
Page 49: Applications 2 (Service Program)
5. Test: Try a new PCBA module (replace if necessary) 6. Test: Change PCBA base All tests performed & machine still not working Return to Write a ticket «Overview» BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 49 von 218...
Page 50: Applications 3 (Service Program)
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 CH-8266 Steckborn Switzerland Seite 50 von 218...
Page 51: Peripherals (Service Program)
USB and then load it from the USB Test successful? 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 4.
Page 52: Thread Cutter: Possible Faults
The distance between the thread catcher and thread guide plate is not correct Solution • Check the installation of the stitch plate support with integrated thread cutting unit (see 4.3.4) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 52 von 218...
Page 53: 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 CH-8266 Steckborn...
Page 54: 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 Switzerland Seite 54 von 218...
Page 55: 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...
Page 56: Touch Screen Calibration
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 CH-8266 Steckborn Switzerland Seite 56 von 218...
Page 57: Machine Doesn't Start After Repair
This also applies for the very narrow, EMC-properties-enhancing LCD cable. View from above 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 Switzerland Seite 57 von 218...
Page 58: Pop-Up Messages Upon Starting The Machine In Customer Mode
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 • Reset the counter BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 58 von 218...
Page 59: Machine Requires Maintenance
3.13.3 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 3.13.4 Error message even though embroidery module is connected Message •...
Page 60: Update Failed
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 61: Case 2: The Eeprom Needs To Be Replaced
Switch off machine, insert USB-Stick and load via the alternative update process (see 8.2) o After updating the boot loader, reload the FW onto the BERNINA USB-Stick o Carry out the update again with the complete update • A restart after the update via the alternative update process must always be manually carried out Updating via the alternative update process deletes all customer data.
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 CH-8266 Steckborn Switzerland Seite 62 von 218...
Page 63: Sewing-Off Guidelines
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 Switzerland Seite 63 von 218...
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 CH-8266 Steckborn Switzerland Seite 64 von 218...
Page 65 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 Switzerland Seite 65 von 218...
Page 66 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 Switzerland Seite 66 von 218...
Page 67: Chapter 4 - Removal And Refitting Of Components
Refit screw in thread-redirection/pre-tensioner area and retighten carefully (pict 3) • Insert service cover into respective openings, then slide to right (pict 1) See iPortal info no. 100253 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 67 von 218...
Page 68: Front Cover
Engage feed-dog drop to facilitate the removal of the front cover (red frame in picture 3) Remove the winder unit cover with the finger or the plug mounting tool 0319355.0.00 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 68 von 218...
Page 69 Picture 8 - Approximately in the centre of the frame arm, press the front cover to open the spring locks. Pull cover to front and out See iPortal info no. 075475 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland...
Page 70 Picture 5 - Refit and retighten slide-on table anchoring screw (T15) e • Refit lower-thread sensor as outlined in pictures 6, 6a, and 6b • Attach the winder unit cover BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 70 von 218...
Page 71: Rear Cover
(T15) e • Picture 1 - Retighten screw d • Picture 1 - Refit and retighten screw c incl. washer See iPortal info no. 075475 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 71 von 218...
Page 72: Freearm Cover
Picture 2 - Refit and retighten screw b 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 Switzerland Seite 72 von 218...
Page 73: Base-Plate Cover
Only after refitting the rear cover and front cover, slide base-plate cover into final position and retighten screws b. Refit the screw covers a into the left and right long hole BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 73 von 218...
Page 74: Electronics, Sensors, Switches, Magnets
Picture 3 - In the yellow-circled areas, pull housing apart to unlock snap fits. Remove protective cover 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 Switzerland...
Page 75 Picture 1 - Turn main motor in such way that the drive belt is slightly tensioned. Retighten the two screws a • Picture 1 - Refit wheel, sliding it onto pinion. Test run the machine after refitting the front cover BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 75 von 218...
Page 76: Pcba-Cpu-Module (Arm9) General Information
Series, and the 5 Series (VIO), the slot for the small backlighting wire is still there, but not on the PCBA- Base for the 4 & 5 Series (VIO) • Note the LEDs on PCBA-CPU-Module (ARM9), see picture below BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland...
Page 77: Pcba-Cpu-Module (Arm9)
• Picture 1 - Refit and retighten screw a 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 Switzerland Seite 77 von 218...
Page 78: Pcba-Base - With Feed-Dog Drop Detection
Take care to fit EEPROM in the correct position (markings must match) and avoid bending the contacts • Wrong way around fitted EEPROM destroys itself, and possibly the PCBA-Base BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 78 von 218...
Page 79: Pcba-Position Hall
• Picture 1 - Hook feed-dog drop 1 in behind PCBA-Base • Position the whole unit and fasten with four screws a • Picture 1 - Reconnect all plugs BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 79 von 218...
Page 80: 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 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 80 von 218...
Page 81: Pcba-Front Cover Including Display And Touchscreen
The faceplate is easiest to remove from front cover by unlocking the snap fits after PCBA-Front cover is removed from machine. With the new 5 Series (VIO) faceplate, touchscreen and LCD form one unit, and is only available as such BERNINA International AG Seestrasse 161 CH-8266 Steckborn...
Page 82: Pcba-Head
Position PCBA-Head properly, taking care not to jam the flat ribbon cable • Picture 2 - Refit PCBA-Head with three screws c • Picture 2 - Reconnect PCBA-Head flat ribbon cable BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 82 von 218...
Page 83: Pcba-Lower Thread Sensor (Lto)
Insert guiding pin on the left of the lower-thread sensor into guiding rail (red circle, picture 1) • Take care that wires are lain correctly (pictures 3 and 4) • Close bobbin door BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 83 von 218...
Page 84: Sensor Support Abc (Presser Foot Recognition)
Take care that sensor support 3 doesn't catch edges while fitting it. Note Check ABC sensor for functioning in Service Program 4l. Calibrate buttonhole foot with slide 3A in Service Program BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 84 von 218...
Page 85: Head Frame And Frame Arm Led Sewing Light
(marked in red) • Picture 2 - Bring wire into position and rethread into harness. Refit two clips d • Picture 1 - Lay wires. Replug connector a. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 85 von 218...
Page 86: Head Arm Sewing Light
• Picture 2 - With clip e bring wire into position and rethread into harness. Refit two clips d • Picture 1 - Lay wires. Replug connector a BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 86 von 218...
Page 87: Pcba-Embroidery Module Detection
Reconnect plug • Fix the cable harness with new copper foil b on the base plate BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 87 von 218...
Page 88: Electromechancial/Mechanical Components
• Picture 4, Remove the screws 1-3 (T20) from the hook race ring • Carefully remove hook race ring See iPortal info no. 100536 / 100633 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 88 von 218...
Page 89 • …. • …. See iPortal info no. 100563 / 077667 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 89 von 218...
Page 90: Assembly Of Hook Guideway With Guiding Pins (With Front And Rear And Only Rear Calottes) → Until 61/07
The gauge shaft must be pushed back by the spring automatically • Continue with the assembly hook driver BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 90 von 218...
Page 91 Tighten screws 4, remove feed dog height gage 398024.03.1+ and setting gage 3 • Continue with the assembly hook driver 398024.03.1+ Siehe iPortal Info-Nr. 100238 auf https://iportal.bernina.com/ Video: Assembly hok guideway without guiding pins BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 91 von 218...
Page 92: Assembly Hook Driver
• Picture 8 - Refit belt tensioner, adjust belt tension (see 5.1.3) See iPortal info no. 100536 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 92 von 218...
Page 93: Main Feed-Dog
Picture 2 – Refit main feed dog with 2 screws 1 (T10) • Adjust main feed-dog horizontal position (see 5.6.1) • Adjust main feed-dog height (see 5.6.2) • Refit stitch plate • Attach needle and presser foot BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 93 von 218...
Page 94: Replacing The Hook Driver Belt
Picture 2 – Refit thread cutter release link with screw 2, take care that the end of the release link fits into the slot of the thread catcher • Refit clutch carriage (see 4.3.11) • Adjust clutch carriage and thread cutter (see 5.7) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 94 von 218...
Page 95: Stitch Plate Carrier With Integrated Thread-Cutting Unit
Move thread catcher slightly to the right • Picture 6 – Pull out the blade slightly to the right and up See iPortal info no. 100111 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 95 von 218...
Page 96 The blade is a wear part and therefore available as an individual part Blade 0334285.1.00 • Use the small red T8-screw driver 0304755.1.01, only lightly tighten the screws • Only slightly tighten the screw BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 96 von 218...
Page 97: Replacing The Knife Of Integrated Thread-Cutter Unit
TORX screw driver T8 0304755.1.01 • Picture 6 – With a small screwdriver bring knife forwards until it can be hold and pulled out with tweezers BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 97 von 218...
Page 98 Picture 9 – Close bobbin door, and complete test (press 7 times the green key) • Picture 10 – Refit stitch plate, needle, and presser foot • Sew-off, also testing the thread cutter BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 98 von 218...
Page 99: Base Shaft
Adjust upper / base shaft tension (see 5.1.1) • Adjust base shaft and main shaft timing (see 5.5.1) • Adjust loop lift (see 5.5.3) • Adjust clutch carriage timing (see 5.7.3) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 99 von 218...
Page 100: Crank Shaft And Stitch Length Stepping Motor
Adjusting the crankshaft (see 5.6.3) Main feed mechanical balance - basic setting • Refit PCBA-Base. Refit all connectors See iPortal info no. 075054 / 075057 / 100062 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 100 von 218...
Page 101: Replacing Base Shaft And Upper Shaft Connecting Belt
733019.70.00 to turn spherical bearing in such way that drive belt slackens • Picture 3 - Slide drive belt H off base shaft, then over upper shaft drive wheel and out BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 101 von 218...
Page 102: Feed-Dog Carrier And Advance Link
Adjust main feed-dog horizontal position (see 5.6.1) • Picture 1 - Tighten two sets crews k • Adjust main feed-dog height (see 5.6.2) See iPortal info no. 080185 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 102 von 218...
Page 103: Upper Feed Crank
Picture 1 - Remove upper-feed carrier O Assembly • Picture 1 - Refit upper-feed carrier. Slightly tighten countersunk screws to fasten carrier and special supports • Adjustment (see 5.6.5) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 103 von 218...
Page 104: Clutch Carriage
Picture 2 – Refit connecting strap between clutch carriage and thread-cutter release lever, and retighten the two screws 2 T10 (M3X8) just slightly • Picture 2 – Rehook tension spring 1 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 104 von 218...
Page 105 2 T10 (M3X8) • Check and adjust base shaft synchronization (see 5.5.1) • Check and adjust the clutch carriage solenoid (see 5.7.1) • Function-check solenoid (see Service Program test BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 105 von 218...
Page 106: Upper-Thread Tension Unit With Thread Take-Up Cover
Tighten the three screws a, b and c T20 (M4X10 mm) • Remove the head cover H again • Carefully reinsert the two stranded wires (black/white) into the small cable duct BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 106 von 218...
Page 107: Toothed Rack, Machines With Stepper Motor Presser Foot Pressure
90° beneath the cables to the right and pull it out of the toothed rack segment • Picture 4, Unhook the pull spring at the toothed rack segment S, remove the toothed rack segment BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 107 von 218...
Page 108 • Picture 1 – Fix the cable channel N besides the housing of the PCBA-Threader F • Picture 1 – Fix plug E on PCBA-Threader F • Picture 1 – Attach the cable tie as before BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland...
Page 109: Toothed Rack, Machines With Manual Presser Foot Pressure
Fix the support presser foot pressure with 2 screws a T10 (M3X8) • Remove the pinning tool b from the adjustment plate • Reattach the cable tie • Reset the presser foot pressure to default setting BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 109 von 218...
Page 110: Presser Foot Bar
BDF support should be 2.5mm (Picture 5 rear view). As spacer, e.g. a 2.5 mm Allen can be used. • Setscrew m T8 (M4x10) • Check the synchronisation of the upper feed related to the main feed (see 5.6.4) 2.5 mm 2 mm BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 110 von 218...
Page 111: Assembly Unit Bernina Dual Feed Bdf
4.3.15 Assembly unit BERNINA Dual Feed BDF Disassembly • Picture 1, (front view), unhook the spring f at the BDF thrust reverser • Remove the sliding stone g • Picture 2, (rear view), Remove screw h T20 (M4X10). Therefore, the pull spring of the thrust reverse is released •...
Page 112 2.5mm. (Picture 8 rear view). As spacer, e.g. a 2.5 mm Allen can be used. • Setscrew m T8 (M4x10) • Check the synchronisation of the upper feed related to the main feed (see 5.6.4) 2.5 mm 2 mm BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 112 von 218...
Page 113: Needle-Bar Support
(see 5.4.2 • Adjust stitch-width stop (see 5.4.3) • Adjust threader head level (see 5.9) • Refit covers (see 4.1) • Carry out a functional check. Sewing-off (see 3.15) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 113 von 218...
Page 114: Needle Bar
• Picture 1 - .Refit basting device with screw c T10 • Refit needle-bar support (see 4.3.15.1) • Adjust threader (see 5.9) • Adjust basting device (see 5.10) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 114 von 218...
Page 115: Needle Clamp
0366875.0.01 Needle stop pin 0366875.0.02 Needle stop pin 0366875.0.03 Needle stop pin 0366875.0.04 Needle stop pin 0366875.0.05 Needle stop pin 0366875.0.00 Needle stop pin 0366875.0.07 Needle stop pin BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 115 von 218...
Page 116: Threading Mechanism
Allen key 1.5 • Picture 1 – Rehook tension spring 9 • Refit needle-bar support (see 4.3.15.1) • Adjust threader (see 5.9) • Adjust basting device (see 5.10) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 116 von 218...
Page 117: 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 Switzerland Seite 117 von 218...
Page 118: Thread Tension
Then refit thread tension • Picture 1 - Refit and retighten screw b • Picture 5 - Using distance gauge 7353865.0.00, reset to mechanical basic setting 7353865.0.00 7353865.0.00 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 118 von 218...
Page 119: Thread Take-Up Lever And Thread Regulator Spring
Retighten screw (T10) • Refit upper-thread tension unit (see 4.3.12) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 119 von 218...
Page 120: Thread Regulator Spring
The positive pole can be identified by the salient 3. • Refit drive belt and impeller. • Adjust belt tension (see 5.1.2) See iPortal info no. 075064 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 120 von 218...
Page 121: Presser Foot Pressure Stepping Motor
If nothing else has to be taken care of, refit the covers 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 Switzerland...
Page 122: Stitch-Width Stepping Motor
Machines with presser foot lift by stepping motor: Assemble the support of the presser foot pressure stepping motor (see 4.3.13) • Machines with manual presser foot lift: Assemble the support of the presser foot pressure (see 4.3.13.1) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 122 von 218...
Page 123: Winder Unit
(see 5.13) Machines without BSR Function were equipped with an adapter cable to equalize the production. This cable is of no relevance to the service and can be removed. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 123 von 218...
Page 124: Chapter 5 - Adjustments
• Untighten screw b (T20). Then use adjusting spanner 7330197.0.00 to turn the bearing until the specified tension value has been reached • Retighten screw b BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 124 von 218...
Page 125: Drive Motor Belt Tension
Remove the two motor screws a and b (T20 M4X12 u-washer 4.2x14x1.5) • Turn motor counterclockwise until specified value has been reached. Turn motor clockwise to slacken belt tension • Retighten screws a and b BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 125 von 218...
Page 126: Hook Drive Belt Tension
(picture 1) • Untightening screw d allows for moving the belt tensioner up and down. Moving up slackens the tension, moving down tightens the tension (picture 2) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 126 von 218...
Page 127: Head-Frame Plate Position (Rough Setting)
Raise presser foot ca. 1 mm 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 Switzerland Seite 127 von 218...
Page 128: Position Of Head-Frame Plate/Stitch Plate In X-Direction
Raise presser foot ca. 1 mm from stitch plate • Slightly untighten two screws e (T20 M4x16) • Use setting excenter 0315635.0.00 to bring head- frame plate into position • Retighten two screws e BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 128 von 218...
Page 129: Presser Foot Adjustment
Slide presser foot bar up or down until the distance is 0.5 mm +0.2. Ensure that presser foot and stitch plate are parallel. • Retighten setscrew b 398026131+ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 129 von 218...
Page 130: Embroidery Foot Height (Embroidery Only Machines)
Check the distance (1.2 mm +0.2) with distance gauge 7349565.0.00 (hook driver) and feeler gauge 7349565.0.00 • Ensure that presser foot and stitch plate are parallel Retighten setscrew b BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 130 von 218...
Page 131: Presser Foot Fixation
Sewing-/embroidery machines - Presser-foot sole and stitch plate must be parallel • Embroidery machines - Stitch hole in embroidery foot 26 and stitch hole in stitch plate must be centered BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 131 von 218...
Page 132: Needle Settings
The distance should be ca. 0.4 mm in front of needle 130/705 Nm 100 and ca. 0. 6 mm behind the needle • Retighten lock nut f 0.6 mm 0.4 mm BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 132 von 218...
Page 133: Needle Distribution
Use eccentric key 0013617.0.00 in eccentric mesh to center the needle (picture C) • Retighten screw b Adjusting embroidery machines • Slightly untighten screw e (T10) • Set needle to center (picture D) • Retighten screw e 0013617.0.00 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 133 von 218...
Page 134: Zigzag Stitch Width Limiter
Select test 5a Stitch Width Stepping Motor • Needle bar support mustn't touch the zigzag stitch width limiter a Adjustment • Untighten screw e (T10) • Position limiter a • Retighten screw e BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 134 von 218...
Page 135: Hook, Needle Drive And Feed-Dog Movement Timing
C. Use the adjusting gauge 7342585.2.00 instead. Position the adjusting gauge on the clutch ring (picture D). When the needle bar is in loop lift position, the adjusting gauge must stop at the chassis (see picture D). BERNINA International AG Seestrasse 161 CH-8266 Steckborn...
Page 136: Base Shaft-/Load Lock Screw Distance
Measure distance between base shaft and load lock screw with a feeler gauge • The distance should be 0.15 mm Adjustment • Turn screw f (T10) to set 0.15 mm distance between base shaft and load lock BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 136 von 218...
Page 137: Loop Lift
• Retighten second setscrew c2 in direction of rotation • Check again and repeat setting if required • Recheck loop lift See iPortal info no. 077597 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 137 von 218...
Page 138 Move gauge to right until the needle bar is risen by 2.62 mm (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 Switzerland Seite 138 von 218...
Page 139: Needle-/Hook Distance
Turn eccentric pin b (T6 Torx wrench) to bring stitch plate into specified position • Retighten screw a (T6) We recommend using a magnifying glass to ensure accurate setting BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 139 von 218...
Page 140: Needle Height
Available sizes of needle stop pins Item no. Height in mm labelled 0366875.0.00 n.a. 0366875.0.01 n.a. 0366875.0.02 n.a. 0366875.0.03 n.a. 0366875.0.04 n.a. 0366875.0.05 n.a. 0366875.0.06 n.a. 0366875.0.07 n.a. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 140 von 218...
Page 141: 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 head cover, if appropriate (see 4.1.1) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 141 von 218...
Page 142: Feed Dog Settings
Slightly untighten screw c (T10). The adjusting plate is pressure spring-loaded! • 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 Switzerland Seite 142 von 218...
Page 143 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 Switzerland Seite 143 von 218...
Page 144: Main Feed Mechanical Balance - Basic Setting
Turn balance adjusting cam h with T10 screwdriver in such way that it is pinnable with short pinning tool 001356.50.00 (picture • 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 Switzerland Seite 144 von 218...
Page 145: 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 Switzerland Seite 145 von 218...
Page 146: Upper Feed-Dog (Dual Feed) Mechanical Balance - Basic Setting
Upper feed-dog (Dual Feed) mechanical balance - Basic setting Check • Start machine in Service Program • Carry out test 6b BERNINA Dual Feed Balance Rough-Adjustment • Turn main feed-dog stitch-length crank to maximum stitch length 1.5mm • The distance between crown gear and adjusting hub should be 1.5 mm...
Page 147: Clutch Carriage/Thread Cutter
Setting • Set the distance between the clutch lever and spring to the target dimension 0.1 mm with screwdriver 5 (T8) See iPortal info no. 063984 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 147 von 218...
Page 148: 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 Switzerland...
Page 149: Clutch Carriage Timing
Use 3. 0 mm pinning tool 0079375.0.00 to pin base shaft in loop lift position • Untighten clutch-ring setscrew d (T10) • Position setting gauge 7342585.2.00 onto clutch ring • Position clutch ring at base collar • Retighten clutch-ring setscrew d (T10) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 149 von 218...
Page 150: Thread Cutter
• Hereto, according to picture 2, hold the thread guide plate with slight pressure in arrow direction and tighten the screws d + e. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 150 von 218...
Page 151: 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 Video: Calibration BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 151 von 218...
Page 152: Threader
The threader head can be properly adjusted by moving it up, or down • Retighten needle bar guide adjusting screw s (T8) Refit basting solenoid housing and adjust it (see 5.10) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 152 von 218...
Page 153: Basting Device (Only Machines With Basting Device)
Untighten needle bar guide adjusting screw 2 (T8) • Center needle bar bore within clutch-bolt clearance • Retighten needle bar guide adjusting screw s (T8) Refit basting solenoid housing and adjust it (see 5.10.2) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 153 von 218...
Page 154: Time Of Clutch Release
Functional Check • Presser foot 1d (with sensor) • Run machine at highest speed to test basting solenoid in left and right needle positions BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 154 von 218...
Page 155: 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 0060385.0.00 • Slowly move the scales up. • Picture 1 – On moving the regulator spring, the tension value must be between 14 g and 17g Ensure that the spring scales are gauged.
Page 156: 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 iPortal, Ref: 18249) to thread machine up to and including thread take-up Step 1: • Attach the 30.6-gram gauge 0087097.2.00 to the upper thread (see fig.
Page 157: Lower Thread Tension (Basic Setting, New Tension Gauge)
• 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 CH-8266 Steckborn Switzerland Seite 157 von 218...
Page 158: Lower Thread Tension (Basic Setting, Old Tension Gauge)
5.12.2.1 Lower Thread Tension (basic setting, old tension gauge) 398142.03.0+ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 158 von 218...
Page 159: Winder
Pictures 4 – Turn screw a (T10) in or out as appropriate 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 Switzerland Seite 159 von 218...
Page 160: Lower Thread Sensor Position
Functional check in Service Program section 3 (see Adjustment The position of the lower thread sensor is given and cannot be adjusted • Disassembly and refitting (see 4.2.9) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 160 von 218...
Page 161: 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 Series 4 & 5 1 Servicing Information 2 Touchscreen settings 3 Sensors testing (shows location into machine)
Page 162 Virtual keyboard incl. shift keys for Letters, numbers and symbols special characters depending on display 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 Switzerland Seite 162 von 218...
Page 163: Section 1 - Service Information
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 164: 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 about attached BSR foot Check The BSR foot must be connected so see these informations: • Serial Number •...
Page 165: 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 • BERNINA International AG...
Page 166: 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 167: Log File
1j 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...
Page 168: Section 2 - Screen, Symbols
RGB (Red, Green and Blue) screen Keyboard lights LED sewing light and brightness 2a Touch screen calibration The introduction of capacitive touch screens with the 5 Series (VIO) makes calibration superfluous BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 168 von 218...
Page 169: Lcd (Screen Brightness)
Repair note • 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 Switzerland Seite 169 von 218...
Page 170: 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 Switzerland Seite 170 von 218...
Page 171: Led Sewing Light And Brightness
Check correct positioning of PCBA-Threader. The PCBA Threader is held in position with a pin and 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 Switzerland Seite 171 von 218...
Page 172: Presser-Foot Lifter
Repeat the test using a new bobbin See ESD-related note • 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 Switzerland Seite 172 von 218...
Page 173: Feed-Dog Drop
• To return to section 3, press Repair note See ESD-related 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 Switzerland Seite 173 von 218...
Page 174: Bobbin Winder Micro-Switch
Check cables for deformation and/or wear and tear • 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 Switzerland Seite 174 von 218...
Page 175: Section 4 - Signals
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 176: Functions Of Keys And Buttons On Machine
To return to section 4, press Repair note See ESD-related 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 Switzerland Seite 176 von 218...
Page 177: 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 Switzerland Seite 177 von 218...
Page 178: Bernina Stitch Regulator (Bsr)
4g BERNINA Stitch Regulator (BSR) Is 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 • Move the fabric in different directions •...
Page 179: Speaker
See ESD-related note 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 Switzerland Seite 179 von 218...
Page 180: 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 Switzerland Seite 180 von 218...
Page 181: 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 Switzerland Seite 181 von 218...
Page 182: Section 5 - Locations Of Stepping Motors In The Machine
• Replace PCBA-Base (see 4.2.4). • Replace stitch-width stepping motor (see 4.3.22) Disconnect machine from the power supply. Do not disconnect or reconnect when the machine is powered. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 182 von 218...
Page 183: Presser-Foot Pressure Stepping Motor
‘Running’ appears, and the upper-thread tension unit moves back and forth • Press icon again to stop the stepping motor ‘Successful’ appears • To return to section 5, press BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 183 von 218...
Page 184: All Stepping Motors In Pinning Position
See ESD-related note • Check pinning positions as indicated above. Replace motor(s) according to Service Manual if necessary • Check cables and plugs for deformation and/or wear and tear BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 184 von 218...
Page 185: Winder Motor
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 • Replace PCBA-Base (see 4.2.4) • Replace winder motor BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 185 von 218...
Page 186: Stitch-Length Stepping Motor
• Replace PCBA-Base (see 4.2.4). • Replace stitch-length stepping motor (see 4.3.6 Disconnect machine from the power supply. Do not disconnect or reconnect when the machine is powered. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 186 von 218...
Page 187: Section 6 - Adjustments
Note Ensure to carry out all crucial adjustments and calibrations by following the check list in section 11. Do not run a threaded machine without fabric! BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 187 von 218...
Page 188: Electronic Balance Calibration
• Press to save the settings Fine-Adjustment There are 3 different test patterns available for the fine- adjustment of the stitching: 2. Number “9” (recommended). 3. Leaf pattern. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 188 von 218...
Page 189 • 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 Switzerland Seite 189 von 218...
Page 190: 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 •...
Page 191: 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 Switzerland Seite 191 von 218...
Page 192: Thread Cutter Clamping Mechanism (Solenoid)
To return to section 6, press Repair note See ESD-related 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 Switzerland Seite 192 von 218...
Page 193: 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 Switzerland Seite 193 von 218...
Page 194: Resetting To Factory Settings (Reset All)
If the answer is No, press to leave the sewing settings and return to section 6 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.
Page 195: Automatic Upper-Thread Tension
For detailed electronic upper-thread adjustment (see 5.12.1) • Gauging thread DMC 50 white can be ordered from BERNINA under item no. 6520102.0.++ • Cotton thread is prone to dry out. Moisture loss reduces tensile strength and gliding properties of thread...
Page 196: Test Tie On
Check stitch plate carrier and thread catcher for dirt or dust and check mechanical smooth running • Carry out test 6d. 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 Switzerland Seite 196 von 218...
Page 197: 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 Switzerland Seite 197 von 218...
Page 198: Bsr Sewing Mode
Service Program Repair note See ESD-related 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 Switzerland Seite 198 von 218...
Page 199: Magnetic Position Encoder Calibration
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. Video: Calibration BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 199 von 218...
Page 200: Section 11 - Check-Out Tests
Buttonhole calibration, test Lubrication and resetting the service stitches, test 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 Switzerland Seite 200 von 218...
Page 201: 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) Klübersynth GE 14-151 1600 (036332.70.10) See iPortal info no. 100203 at https://iportal.bernina.com/ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 201 von 218...
Page 202 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 202 von 218...
Page 203 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 203 von 218...
Page 204 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 204 von 218...
Page 205: Lubrication Of Modified Hook Driver When Removed From Machine
Lubrication of modified hook driver when removed from machine Hook driver • Hook drivers with plastic housing are maintenance-free and should not be relubricated BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 205 von 218...
Page 206: Chapter 8 - Firmware Update
If the files are saved in a folder or subfolder on the USB-Stick, the machine will not be able to find them and will consequently not be able to update. Save the update files to a BERNINA USB-Stick (> 512 MB) For BERNINA dealers:...
Page 207: 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 208: 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 209: How Are The Stitches Counted
3,000,000 6,000,000 9,000,000 12,000,000 15,000,000 18,000,000 21,000,000 24,000,000 27,000,000 30,000,000 33,000,000 36,000,000 39,000,000 1000 42,000,000 1077 45,000,000 1154 48,000,000 1231 51,000,000 1308 54,000,000 1385 57,000,000 1462 60,000,000 1538 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 209 von 218...
Page 210: Cleaning- And Service - Stitch Reset
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 (see 9.4.2) once the tenth maintenance interval is...
Page 211: Operating Time Related Parts
0367267.X.00 Lower crank shaft asm. 10 / 19 5 Series VIO 0367277.X.00 Lower crank shaft asm. 10 / 19 4 Series VIO 0370247.X.00 Upper crank shaft asm. 10 / 19 Dual Feed 0356915.X.00 Hook race cover finished part 10 / 19 5.5mm machines...
Page 212: Maintenance Checklist
Read out the stitch and hour counter and enter on the Service Report Customer data backup in Service Program of the BERNINA Series 4 + 5 VIO. Connect BERNINA USB data stick and select required button. Remove stick after confirmation by the machine. •...
Page 213: 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 Switzerland Seite 213 von 218...
Page 214: Maintenance Checklist Bernina Series 4 + 5 Vio
9.5.4 Maintenance checklist BERNINA Series 4 + 5 VIO 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 (see 9.4) Free-arm area...
Page 215: Embroidery Module
Check /calibrate tests in Service Program 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 Switzerland Seite 215 von 218...
Page 216: Chapter 10 - Document Revision History
8.2 Update alternative access 9.2.3 How are the stitches counted? Chapter 9 9.4.2 Operating-time-related parts 9.5.1 Measures to be taken before the servicing 9.5.4 Maintenance checklist BERNINA Series 4 + 5 VIO BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland...
Page 217 3b Presser foot lifter 3c Lower-thread sensor 4a Stitch width and stich lengths knob Chapter 7 Lubrication diagram Chapter 10 Document Revision History Chapter 11 Appendix – Document list BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 217 von 218...
Page 218: Chapter 11 - Appendix - Document List
4.1.4 Freearm cover support angle 080573 4.3.1 Oil depot of machines with BERNINA hook 077667 4.3.1 Introduction of a new hook driver with an optimised 100536 shape of the cams for B4, B5 and B7 Series 4.3.1.2...

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