Bernina 5 Series Service And Maintenance Manual
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Bernina 5 Series Service And Maintenance Manual

Bernina 5 Series Service And Maintenance Manual

Embroidery module
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Service- and Maintenance Manual
of the 4 and 5 Series (VIO)
BERNINA International AG
Seestrasse 161
CH-8266 Steckborn
Switzerland
Seite 1 von 187

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  • 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 187...

  • Page 2: Table Of Contents

    1.8 Technical specifications of 4 & 5 Series ................14 Chapter 2 – Electronics and Wiring ................17 2.1 BERNINA B 590 (BERNINA Series 4 & 5) Block Diagram ..........17 2.2 PCBA-Power ........................18 2.3 PCBA-CPU-Module (ARM9) General Information ............... 19 2.3.1 PCBA-CPU-Module/ARM9 ........................
  • Page 3 4.3.13.2 Toothed Rack, machines with manual Presser Foot Pressure ..........80 4.3.14.1 Presser foot bar ..........................81 4.3.14.2 Assembly unit BERNINA Dual Feed BDF ..................82 4.3.15.1 Needle-bar support ........................84 4.3.15.2 Needle bar ............................ 85 4.3.16 Needle clamp ........................... 86 4.3.17 Threading Mechanism ........................
  • Page 4 1b Machine firmware data and technical information ................132 1c Machine operating hours data ......................133 1d Stitch counter data ..........................133 1e BSR (BERNINA Stitch Regulator) data ....................133 1f Machine servicing data ......................... 134 1g Saving customer data .......................... 134 1h Customer related data (Customer Information) ...................
  • Page 5 9.5.1 Measures to be taken before the servicing ..................182 9.5.2 Measures to be taken after the service ................... 182 9.5.3 Functional check ..........................183 9.5.4 Maintenance checklist BERNINA Series 4 + 5 VIO ................ 184 9.5.5 Embroidery module ......................... 185 Chapter 10 – Document Revision History ..............186 Chapter 11 –...

  • Page 6: Chapter 1 - General Information

    This service manual is only available in electronic format. It can be downloaded from BERNINA Infogate at http://infogate.bernina.com under ‘Service Manual’ in the ‘Tech. Service’ register. If you don't have access to Infogate, contact your local BERNINA importer. They'll be glad to be of assistance.

  • Page 7: Warning: Dangerous Voltage Levels

    The capacitors require 30 seconds to discharge after the power supply has been switched off. We recommend to wait for the complete discharging of the capacitors before starting any servicing work on the PCBs. BERNINA International AG Seestrasse 161 CH-8266 Steckborn...

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

    5. Treat faulty PCBs in the same manner as new ones to prevent consequential damage or harm For more information (see 2.12 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 8 von 187...

  • Page 9: Tools And Gauges

    1.4 Tools and gauges (commercially available, not available from Bernina): Calliper, multimeter, TORX screwdrivers sizes 6, 8, 10, 10 with 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 10 Common Tool Set for 4 and 5 Series Art.-No.: 034383.70.00 Allgemeines Werkzeug Set 4er und 5er Serie Trousse à outils généralement pour la Série 4 et 5 Name Application Picture Art.-No. Bezeichnung Verwendung Bild Application Image Adjusting needles Needle and hook adjustment...
  • Page 11 Ø1.5, 2.3, 3.2) (Size 3.2) Helpful Tools for BERNINA Sewing and Embroidery Systems Hilfreiche Werkzeuge für BERNINA Näh- und Sticksysteme Trousse à outils secourable pour les maschine à coudre informatisée de BERNINA Spring balance gauge Tension of thread regulator spring 006038.50.00...

  • Page 12: Handling Adjustments

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

  • Page 13: Cleaning

    In the thread-cutting mechanism Drive area: • Drive motor/carbon dust • Toothed-belt discs, and motor pulley • Hook drive Electronics area • All sensors, light barriers, switches, electronic components BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 13 von 187...

  • Page 14: Technical Specifications Of 4 & 5 Series

    1.8 Technical specifications of 4 & 5 Series BERNINA 475 BERNINA BERNINA Features BERNINA 435 B480 B485 Technical 100 - 240 Volt 100 - 240 Volt 100 - 240 Volt 100 - 240 Volt Supply voltage 50-60 Hz 50-60 Hz...
  • Page 15 100 – 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 16 Number of buttonhole types (incl. eyelets) Button sewing-on program Number of utility stitch patterns Number of decorative stitch patterns Embroidery design packages Alphabets Number of embroidery motifs included BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 16 von 187...

  • Page 17: Chapter 2 - Electronics And Wiring

    Chapter 2 – Electronics and Wiring Block diagram and brief descriptions of electronic components 2.1 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...

  • Page 18: 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 18 von 187...

  • Page 19: 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 19 von 187...

  • Page 20: 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...

  • Page 21: 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 21 von 187...

  • Page 22: 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 22 von 187...

  • Page 23: 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 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 23 von 187...

  • Page 24: 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 24 von 187...

  • Page 25: Pcba Embroidery Module Detection

    The infrared (IR) LEDs • The phototransistors Connection • See figure Purpose • Via the sensors, the different presser feet and the signalling of the buttonhole foot are recognised. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 25 von 187...

  • Page 26: 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 27: Chapter 3 - Troubleshooting

    1. FW update via alternative access Does machine start up to (see 8.2) black starting screen with 2. Machine keeps asking for FW update red BERNINA logo? (loop). 3. EEPROM is corrupted or inexistent • Switch machine off. • Remove front cover but don’t disconnect •...

  • Page 28: Operating Voltage Functional Test

    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 28 von 187...
  • Page 29 • Reload firmware via alternative • Check LED 1-2 access • Replace PCBA-Power • 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 29 von 187...

  • Page 30: 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 30 von 187...

  • Page 31: Lower-Thread Sensor

    C signal receiver e) Hook area lighting LED 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...

  • Page 32: Touch Screen Calibration

    3.5 Touch screen calibration Since the 5 Series (VIO) comes with a capacitive touch screen, calibration doesn’t apply. 3.6 EEPROM missing or misprogrammed Issue Machine starts up until briefly before the welcome screen would appear. ‘User update’ mode appears instead of Welcome screen, and asks for an update.

  • Page 33: Update Failed

    Typically occurs with machines from early production, or when several updates have been skipped. 1. Start normal customer updating process. 2. After rebooting, the black screen with the red BERNINA logo stays, or keeps reappearing. 3. Switch machine off. Connect USB stick containing the relevant firmware for machine. Load firmware from...
  • Page 34 After updating it, start machine in Service Program. Carry out the required calibrations: Calibration 5 Series Enter series number as prompted Already done Upper-thread tension unit Presser-foot height light barrier (micro switch) Start/Stop Unit (SSU) Button length measuring system (buttonhole calibration) Electronic balance calibration When using a blank EEPROM, always carry out the calibrations described above.

  • Page 35: 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 35 von 187...
  • Page 36 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 36 von 187...
  • Page 37 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 37 von 187...
  • Page 38 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 38 von 187...

  • Page 39: Personal Notes Regarding Troubleshooting

    ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 39 von 187...

  • Page 40: Chapter 4 - Removal And Refitting Of Components

    (pict 2) • 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) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 40 von 187...

  • Page 41: 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 031935.50.00 Service Info Ref-#: 75475 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 41 von 187...
  • Page 42 Picture 7 - Untighten screw g (T10) next to thread take-up by 2 to 3 rotations • 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 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland...
  • Page 43 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 43 von 187...

  • Page 44: Rear Cover

    Picture 1 - Refit and retighten rear slide-on table • anchoring screw (T15) e • Picture 1 - Retighten screw d • Picture 1 - Refit and retighten screw c incl. washer Service Info Ref-#: 75475 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 44 von 187...

  • Page 45: 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 45 von 187...

  • Page 46: 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 46 von 187...

  • Page 47: 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 48 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 48 von 187...

  • Page 49: Pcba-Cpu-Module (Arm9) General Information

    PCBA-Base for the backlighting is no longer needed. Since PCBA-CPU-Module is the same for B 880, 7 Series, and the 5 Series (VIO), the slot for the small backlighting wire is still there, but not on the PCBA- Base for the 5 Series (VIO) •...

  • Page 50: 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 50 von 187...

  • Page 51: 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 51 von 187...

  • Page 52: 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 52 von 187...

  • Page 53: 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 53 von 187...

  • Page 54: 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...

  • Page 55: 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 55 von 187...

  • Page 56: Pcba-Lower Thread Sensor

    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 56 von 187...

  • Page 57: 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 57 von 187...

  • Page 58: 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 58 von 187...
  • Page 59 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 59 von 187...

  • Page 60: 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 60 von 187...

  • Page 61: Electromechancial/Mechanical Components

    • Picture 4 - Remove hook race cover Remove the screws 1-3 (T20) from the hook race • ring • Carefully remove hook race ring BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 61 von 187...
  • Page 62 • • Remove hook. Then remove circlip 235020.53.++ from hook • Refit hook It is necessary to use the distance gauge 734956.50.00 with the distance 1.025 mm. 734956.50.00 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 62 von 187...
  • Page 63 • Replace hook if it is badly scratched or has broken hook tips • For lubrication of hook refer to lubrication diagram (see BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 63 von 187...

  • Page 64: 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 64 von 187...

  • Page 65: 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 65 von 187...

  • Page 66: Stitch Plate Carrier With Integrated Thread-Cutting Unit

    Picture 5 – Remove the blade screw d (T8, M2.5X3 mm) Move thread catcher slightly to the right • Picture 6 – Pull out the blade slightly to the right and up BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 66 von 187...
  • Page 67 • The blade is a wear part and therefore available as an individual part Blade 033428.51.00 • Use the small red T8-screw driver 030475.51.01, only lightly tighten the screws BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 67 von 187...

  • Page 68: Replacing The Knife Of Integrated Thread-Cutter Unit

    TORX screw driver T8 030475.51.01 • 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 68 von 187...
  • Page 69 Picture 9 – Close bobbin door, and complete test 6e • (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 69 von 187...

  • Page 70: 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 70 von 187...

  • Page 71: Crank Shaft And Stitch Length Stepping Motor

    Picture 1 - Rehook tension springs x, y and z 5.6.3) Main feed • Adjusting the crankshaft (see mechanical balance - basic setting • Refit PCBA-Base. Refit all connectors Service Info Ref-#: 75054 / 75057 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 71 von 187...

  • Page 72: 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 72 von 187...

  • Page 73: Feed-Dog Carrier And Advance Link

    Picture 1 - Rehook tension spring A • 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) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 73 von 187...

  • Page 74: 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 74 von 187...

  • Page 75: 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 75 von 187...
  • Page 76 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 76 von 187...

  • Page 77: 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 77 von 187...

  • Page 78: 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 78 von 187...
  • Page 79 • 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 80: 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 80 von 187...

  • Page 81: 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 81 von 187...

  • Page 82: Assembly Unit Bernina Dual Feed Bdf

    4.3.14.2 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 83 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 83 von 187...

  • Page 84: 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 3.9) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 84 von 187...

  • Page 85: 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 85 von 187...

  • Page 86: Needle Clamp

    036687.50.01 Needle stop pin 036687.50.02 Needle stop pin 036687.50.03 Needle stop pin 036687.50.04 Needle stop pin 036687.50.05 Needle stop pin 036687.50.00 Needle stop pin 036687.50.07 Needle stop pin BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 86 von 187...

  • Page 87: 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 87 von 187...
  • Page 88 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 88 von 187...

  • Page 89: Thread Tension

    Then refit thread tension • Picture 1 - Refit and retighten screw b Picture 5 - Using distance gauge 735386.50.00, • reset to mechanical basic setting BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 89 von 187...

  • Page 90: 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 90 von 187...

  • Page 91: Thread Regulator Spring

    2 (black negative pole '-') Note The positive pole can be identified by the salient 3. • Refit drive belt and impeller. • Adjust belt tension (see 5.1.2) Service Info Ref-#: 75064 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 91 von 187...

  • Page 92: 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 Seite 92 von 187...

  • Page 93: Stitch-Width Stepping Motor

    Machines with presser foot lift by stepping motor: Assemble the support of the presser foot pressure stepping motor (see 4.3.13.1) • Machines with manual presser foot lift: Assemble the support of the presser foot pressure (see 4.3.13.2) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 93 von 187...

  • Page 94: 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 94 von 187...

  • Page 95: Chapter 5 - Adjustments

    5. 0 mm above corner c of frame bar • Untighten screw b (T20). Then use adjusting spanner 733019.70.00 to turn the bearing until the specified tension value has been reached • Retighten screw b BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 95 von 187...

  • Page 96: 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 96 von 187...

  • Page 97: 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 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 97 von 187...

  • Page 98: 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 98 von 187...

  • Page 99: 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 031563.50.00 to bring head- frame plate into position Retighten two screws e • BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 99 von 187...

  • Page 100: 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 100 von 187...

  • Page 101: 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 101 von 187...

  • Page 102: 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 102 von 187...

  • Page 103: Needle Distribution

    • (picture C) • Retighten screw b Adjusting embroidery machines Slightly untighten screw e (T10) • • Set needle to center (picture D) • Retighten screw e 001361.70.00 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 103 von 187...

  • Page 104: 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 104 von 187...

  • Page 105: Hook, Needle Drive And Feed-Dog Movement Timing

    C. Use the adjusting gauge 734258.52.00 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 106: 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 106 von 187...

  • Page 107: Loop Lift

    The two gear wheels must run smoothly (no play, no clamping) • Remove loop lift gauge Retighten second setscrew c2 in direction of rotation • • Check again and repeat setting if required • Recheck loop lift BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 107 von 187...
  • Page 108 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 108 von 187...

  • Page 109: 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 109 von 187...

  • Page 110: Needle Height

    Available sizes of needle stop pins Item no. Height in mm labelled 036687.50.00 n.a. 036687.50.01 n.a. 036687.50.02 n.a. 036687.50.03 n.a. 036687.50.04 n.a. 036687.50.05 n.a. 036687.50.06 n.a. 036687.50.07 n.a. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 110 von 187...

  • Page 111: 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 111 von 187...

  • Page 112: 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 112 von 187...
  • Page 113 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 113 von 187...

  • Page 114: 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 114 von 187...

  • Page 115: 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 115 von 187...

  • Page 116: Upper Feed-Dog (Dual Feed) Mechanical Balance - Basic Setting

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

  • Page 117: Clutch Carriage/Thread Cutter

    Move solenoid casing to right up to stop • Now move solenoid casing ca. 0.3 mm to left Retighten screw a. • • Start machine in Service Program, and run Test 6d 0.3mm BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 117 von 187...

  • Page 118: 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 119: Clutch Carriage Timing

    Use 3. 0 mm pinning tool 007937.50.00 to pin base shaft in loop lift position Untighten clutch-ring setscrew d (T10) • • Position setting gauge 734258.52.00 onto clutch ring • Position clutch ring at base collar • Retighten clutch-ring setscrew d (T10) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 119 von 187...

  • Page 120: 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 120 von 187...

  • Page 121: Hall Position Synchronization

    • Click ‘Checked position reached’ bar. A green check button appears to the right of the bottom bar • Click green check button to exit Service Program BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 121 von 187...

  • Page 122: 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 122 von 187...

  • Page 123: Basting Device (B 590)

    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 123 von 187...

  • Page 124: 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 124 von 187...

  • Page 125: Thread Regulator

    5.11 Thread regulator Checking the tension power: • Thread an approx. 30cm long thread into thread regulator • Attach the two thread ends to the BERNINA tension spring scales 006038 50.00 • Slowly move the scales up. • 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 126: Thread Tension

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

  • Page 127: Lower-Thread Tension (Basic Setting)

    Use a small screwdriver to adjust the lower thread tension by turning the bobbin case spring screw as appropriate • Turn screw counterclockwise (to left) to slacken • Turn screw clockwise (to right) to tighten 398142.03.0+ BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 127 von 187...

  • Page 128: 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 128 von 187...

  • Page 129: 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 129 von 187...

  • Page 130: Chapter 6 - Service Program

    BERNINA Series 4 & 5 1 Servicing Information 2 Touchscreen settings 3 Sensors testing (shows location into machine) 4 Signals 5 Motors 6 Settings 7 EMB settings (all 5 Series machines (VIO) BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 130 von 187...
  • Page 131 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 131 von 187...

  • Page 132: Section 1 - Service Information

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

  • Page 133: 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 134: 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 135: 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 136: Log File

    Blank white LC display (screen 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...

  • Page 137: 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 137 von 187...

  • Page 138: 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 138 von 187...

  • Page 139: 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 139 von 187...

  • Page 140: Presser-Foot Micro Switch

    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 140 von 187...

  • Page 141: 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 141 von 187...

  • Page 142: 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 142 von 187...

  • Page 143: Section 4 - Signalse

    6.4 Section 4 – Signalse 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 144: 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 144 von 187...

  • Page 145: 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 145 von 187...

  • Page 146: 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 147: 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 147 von 187...

  • Page 148: 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 148 von 187...

  • Page 149: 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 149 von 187...

  • Page 150: 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 150 von 187...

  • Page 151: 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 151 von 187...

  • Page 152: 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 152 von 187...

  • Page 153: 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 153 von 187...

  • Page 154: Stitch-Length Stepping Motor

    • Replace PCBA-Base (see 4.2.4). • Replace stitch-length stepping motor (see 4.3.20 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 154 von 187...

  • Page 155: 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 155 von 187...

  • Page 156: Electronic Balance Calibration

    1. Darning Program (not recommended) 2. Number “9” (recommended). 3. Leaf pattern. 1. Darning Program (Stitch counter) It is not recommended to use the Darning Program for balance settings. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 156 von 187...
  • Page 157 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 157 von 187...

  • Page 158: 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 159: 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 159 von 187...

  • Page 160: 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 160 von 187...

  • Page 161: 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 161 von 187...

  • Page 162: 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. BERNINA International AG...

  • Page 163: Automatic Upper-Thread Tension

    Adjustment note • For detailed electronic upper-thread adjustment (see 5.12.1) Gauging thread DMC 50 white can be ordered from BERNINA under item no. 652010.20.++ • • Cotton thread is prone to dry out. Moisture loss reduces tensile strength and gliding properties of thread...

  • Page 164: 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 164 von 187...

  • Page 165: Start-/Stop Slide (Ssu) Calibration

    • Motor speed is displayed in Stitches Per Minute (S.P.M.) on the right • Press Start-/Stop button to stop the machine • To return to section 6, press BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 165 von 187...

  • Page 166: 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 166 von 187...

  • Page 167: Magnetic Position Encoder Calibration

    Customer view embroidery mode Hoop recognition 7n Duration Run Embroidery Motors A detailed description of the Service Program section 7 can be found in the Embroidery Module Service- and Maintenance Manual. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 167 von 187...

  • Page 168: Section 11 - Check-Out Tests

    Buttonhole calibration, test 6c Lubrication and resetting the service stitches, test 1f On completion of the last test and confirmation with , check-out program returns to Service Program main menu. BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 168 von 187...

  • Page 169: 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) 1 drop both both sides sides BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 169 von 187...
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  • Page 174: Lubrication Of Modified Hook Driver When Removed From Machine

    7.1. Lubrication of modified hook driver when removed from machine General information: The hook driver of the new 5 Series has been modified. The modification improves process reliability considerably. The driving part of the hook driver has been made of synthetic material (new), (right part 1 in picture).

  • Page 175: 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: https://infogate.bernina.com...
  • Page 176 USB memory (root USB stick. memory. directory). Defective or incompatible Use a BERNINA USB stick. USB stick. Check functioning of USB stick on a Is the USB stick connected? Connect BERNINA USB Stick with updates and customer data to machine, wait for 10 seconds, then try again.

  • Page 177: Update Alternative Access

    Since the PCBA-CPU modules had been used on other BERNINA products before the launch of the current 5 Series, it can be that the bootloader on the CPU won’t be recognised by the current 5 Series, and consequently the machine won’t be able to load the firmware. However, if the bootloader has been loaded at first attempt, the firmware should load without any difficulty at second attempt.

  • Page 178: 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 179: How Are The Stitches Counted

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

  • Page 180: Wear-And-Tear-Parts Definition

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

  • Page 181: Operating-Time-Related Parts

    (VIO) Art. # Article Maintenance Remarks interval 10 / 19 036726.7X.00 Lower crank shaft asm. 5 Series VIO 036727.7X.00 Lower crank shaft asm. 10 / 19 4 Series VIO 10 / 19 037024.7X.00 Upper crank shaft asm. Dual Feed 035691.5X.0...

  • Page 182: Maintenance Checklist

    Read out the stitch and hour counter and enter on the Service Report Customer data backup in Service Program 1g of the BERNINA Series 4 + 5 VIO. Connect BERNINA USB data stick and select required button. Remove stick after confirmation by the machine.

  • Page 183: Functional Check

    Smooth running of the machine mechanical ease • Needle bar support / needle bar of movement • Swing bearing • Bevel gears • Bobbin case / hook • Drive belt tensions BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 183 von 187...

  • Page 184: 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 185: 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 185 von 187...

  • Page 186: 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 187: Chapter 11 - Appendix - Document List

    4.3.20 Does the drive belt skids off the pulley? 75064 Does the Free Hand System (FHS) work properly? 75074 4.3.6 Can the feed dog be shifted manually? 75057 BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 187 von 187...

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