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BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland of 106

Service - and Maintenance Manual

BERNINA Q20

BERNINA Q24


Contents: Chapter 1 – General Information ..................................................................................................................... 5

1.1 General Regulations and Safety ....................................................................................................... 5 1.2 Warning: Dangerous Voltage Levels! ................................................................................................ 6 1.3 ESD-Related Note: Electrostatic Discharge (ESD) ........................................................................... 7

1.3.1 ESD Setup for Frame Installed Repair Process ........................................................................... 8 1.4 Tools and Gauges ............................................................................................................................. 9 1.5 Handling and Adjustments .............................................................................................................. 11

1.5.1 Main Frame ................................................................................................................................. 11 1.6 Abbreviations / Names used ........................................................................................................... 11 1.7 Cleaning .......................................................................................................................................... 12 1.8 Technical Details by Model ............................................................................................................. 13

Chapter 2 – Electronics and Wiring .............................................................................................................. 14 2.1 BERNINA Q series Block Diagram ................................................................................................. 14 2.2 PCBA Base – General Information ................................................................................................. 15

2.2.1 PCBA-Base ................................................................................................................................. 15 2.3 PCBA CPU Module (ARM9) – General Information ........................................................................ 16

2.3.1 PCBA CPU Module / ARM9 ........................................................................................................ 16 2.4 PCBA Quilt Extension – General Information ................................................................................. 17

2.4.1 PCBA Quilt Extension ................................................................................................................. 17 2.5 PCBA Power Supply ....................................................................................................................... 18 2.6 PCBA Upper Interface ..................................................................................................................... 19 2.7 PCBA Lower Interface ..................................................................................................................... 19 2.8 PCBA Detection .............................................................................................................................. 20

2.8.1 Upper Thread Detection .............................................................................................................. 20 2.8.2 Threader Detection ..................................................................................................................... 20

2.9 PCBA Position ................................................................................................................................. 20 2.10 PCBA Presser Foot Height Sensor ................................................................................................. 21 2.11 Cable Harness ................................................................................................................................. 21

2.11.1 Head Frame Side.................................................................................................................... 22 2.11.2 Main Electronics Side ............................................................................................................. 22

2.12 Handling of Electronic Components ................................................................................................ 23 2.12.1 Returning Defective Electronic Components .......................................................................... 23 2.12.2 Repairs of Electronic Components (PCBA's) ......................................................................... 23

Chapter 3 – Removal and Refitting of Components ................................................................................... 24 3.1 Covers ............................................................................................................................................. 24

3.1.1 Head Covers / Front / Back / Thread Guide and Display ........................................................... 24 3.1.2 Belt Cover ................................................................................................................................... 26 3.1.3 Inside Cover ................................................................................................................................ 27 3.1.4 Hook Cover and Needle Plate Base ........................................................................................... 28

3.2 Electronics and Sensors.................................................................................................................. 29 3.2.1 BERNINA Stitch Regulators (BSR) ............................................................................................. 29 3.2.2 Winder Unit ................................................................................................................................. 30 3.2.3 PCBA Upper Interface ................................................................................................................ 30 3.2.4 PCBA Lower Interface ................................................................................................................ 31 3.2.5 PCBA Position ............................................................................................................................ 31 3.2.6 PCBA Base ................................................................................................................................. 32 3.2.7 PCBA Base / Electronics Frame ................................................................................................. 33 3.2.8 PCBA CPU Module ..................................................................................................................... 36 3.2.9 EEPROM (Electrically Erasable Programmable Read-Only Memory) ....................................... 36 3.2.10 PCBA Quilt Extension ............................................................................................................. 37 3.2.11 PCBA-Power Supply .............................................................................................................. 38 3.2.12 LED Sewing Light Upper Frame ............................................................................................. 39 3.2.13 LED Sewing Light Head Frame .............................................................................................. 39 3.2.14 PCBA Presser Foot Height Sensor ........................................................................................ 40 3.2.15 PCBA Detection – Threader Sensor....................................................................................... 41 3.2.16 PCBA Detection - Upper Thread Observer (UTO) ................................................................. 41 3.2.17 Main Motor .............................................................................................................................. 42 3.2.18 Presser Foot Height / Upper Thread Monitor Sensor Unit ..................................................... 43

3.3 Mechanical Components / Stepper Motors ..................................................................................... 44 3.3.1 Rotary Hook / Hook Gib / Thread Guide Plate / Cutter and Basket ............................................ 44


3.3.2 Thread Tension Stepping Motor ................................................................................................. 47 3.3.3 Thread-Tension and Stepping Motor Unit ................................................................................... 47 3.3.4 Front Hand Wheel Module .......................................................................................................... 49 3.3.5 Regulator Spring ......................................................................................................................... 49 3.3.6 Threader Head ............................................................................................................................ 50 3.3.7 Needle Clamp ............................................................................................................................. 50 3.3.8 Thread Take-Up Lever ................................................................................................................ 51 3.3.9 Presser-Foot Lifter Stepping Motor ............................................................................................. 52 3.3.10 Needle Bar .............................................................................................................................. 54 3.3.11 Replacement of the Lower Thread Cutter .............................................................................. 55 3.3.12 Replacement of the Upper Thread Cutter .............................................................................. 55

3.4 Handles ........................................................................................................................................... 56 Chapter 4 – Settings ....................................................................................................................................... 57

4.1 Basics – General Information .......................................................................................................... 57 4.2 Belt Tensions ................................................................................................................................... 58

4.2.1 Upper / Base Shaft Belt Tension................................................................................................. 58 4.2.2 Take Up Lever Drive Belt Tension .............................................................................................. 58 4.2.3 Drive Motor.................................................................................................................................. 59

4.3 Take Up Lever / Needle Bar Timing ................................................................................................ 60 4.4 Presser-Foot Fixation ...................................................................................................................... 60 4.5 Needle Adjustment .......................................................................................................................... 61

4.5.1 Needle Distribution Left/Right ..................................................................................................... 61 4.5.2 Needle Distribution Front to Back ............................................................................................... 62

4.6 Hook - Needle Drive Synchronization ............................................................................................. 63 4.6.1 Hook / Driver Play ....................................................................................................................... 63 4.6.2 Loop Lift ...................................................................................................................................... 63 4.6.3 Hook/Needle Distance ................................................................................................................ 64 4.6.4 Needle Holder Alignment (Twin Needle) .................................................................................... 64 4.6.5 Needle Height ............................................................................................................................. 65

4.7 Bobbin Case Retainer Stopper ....................................................................................................... 66 4.8 Synchronization Disc ....................................................................................................................... 67 4.9 Presser Foot Height ........................................................................................................................ 68 4.10 Needle Threader ............................................................................................................................. 68 4.11 Thread regulator .............................................................................................................................. 69 4.12 Upper Thread Tension .................................................................................................................... 70 4.13 Lower Thread Tension (Bobbin Case) ............................................................................................ 71 4.14 Winder ............................................................................................................................................. 72

Chapter 5 – Service Program ........................................................................................................................ 73 Menu 1 – Service Information ...................................................................................................................... 75

1a Machine Basic Data ............................................................................................................................ 75 1b Machine Soft- and Firmware Data ...................................................................................................... 75 1c Machine Operating Time Data ............................................................................................................ 76 1d Machine Stitch Counter Data .............................................................................................................. 76 1e BSR (BERNINA Stitch Regulator) Data .............................................................................................. 76 1f Machine Servicing Data ....................................................................................................................... 77 1h Customer Information ......................................................................................................................... 77 1i Dealer Information ................................................................................................................................ 78 1j Log File: ................................................................................................................................................ 78

Menu 2 – Touch and Display........................................................................................................................ 79 2a Touchscreen Calibration ..................................................................................................................... 79 2b LCD Display (Screen) ......................................................................................................................... 80 2c Blank Dark LCD Display (Screen) ....................................................................................................... 80 2d Blank White LCD Display (Screen) ..................................................................................................... 80 2e RGB (Red, Green and Blue) Screen .................................................................................................. 81 2j Display Switch ...................................................................................................................................... 81

Menu 3 – Sensors (Mounting Locations in the Machine) ............................................................................. 82 3a Threader Sensor ................................................................................................................................. 82 3b Overlift Presser Food Switch .............................................................................................................. 82 3f Upper Thread Sensor .......................................................................................................................... 83 3g Bobbin Winder Switch ......................................................................................................................... 83

Menu 4 – Signals .......................................................................................................................................... 84 4b Function of the Handle-Buttons .......................................................................................................... 84


4d Foot Control ........................................................................................................................................ 85 4e Interface Auto Motion .......................................................................................................................... 85 4g BERNINA Stitch Regulators (BSR) ..................................................................................................... 86 4h PCBA-Position .................................................................................................................................... 87 4h Mechanical Fine-Adjustment of Synchronization Disk ........................................................................ 87 4i Speaker ................................................................................................................................................ 88 4j USB Ports ............................................................................................................................................. 88 4m BSR Interface ..................................................................................................................................... 89 4n Channel Lock ...................................................................................................................................... 89 4o Laser Test ........................................................................................................................................... 90

Menu 5 – Stepping Motors (Mounting Locations in the Machine) ................................................................ 91 5b Presser-Foot Pressure Stepping Motor .............................................................................................. 91 5c Upper Thread Tension Stepping Motor ............................................................................................... 91 5f Bobbin Winder Motor ........................................................................................................................... 92

Menu 6 – Adjustments .................................................................................................................................. 92 6g Resetting To Factory Settings (Reset All): .......................................................................................... 92 6j Automatic Upper-Thread Tension ........................................................................................................ 93 6m Main Motor Test ................................................................................................................................. 94

Chapter 6 – Lubrication.................................................................................................................................. 95 6.1 Thread Take Up Lever, Needle Bar Drive ....................................................................................... 95 6.2 Needle Bar, Presser Foot Bar ......................................................................................................... 96 6.3 Hopper Cam .................................................................................................................................... 96 6.4 Presser Foot Bar Guide ................................................................................................................... 97 6.5 Hook, Hook Drive ............................................................................................................................ 97

Chapter 7 – Firmware Update ........................................................................................................................ 98 7.1 Standard Update Procedure............................................................................................................ 98 7.2 Update – Alternative Access ......................................................................................................... 100

Chapter 8 – Maintenance Guidelines .......................................................................................................... 101 8.1 Purpose of the Maintenance Guidelines ....................................................................................... 101 8.2 Explanatory Notes on the Stitch- and Hour Counter ..................................................................... 101

8.2.1 When is a Cleaning Message Displayed? ................................................................................ 101 8.2.2 When is a Maintenance Message Displayed? .......................................................................... 101 8.2.3 Calculation table ....................................................................................................................... 101 8.2.4 Implementation of the Maintenance Intervals ........................................................................... 101

8.3 Maintenance Intervals ................................................................................................................... 102 8.3.1 Cleaning- and Service-Stitch Reset .......................................................................................... 102

8.4 Wear-and-Tear-Parts Definition .................................................................................................... 102 8.4.1 Non-Operating-Related Parts ................................................................................................... 102 8.4.2 Operating Related Parts ........................................................................................................... 103

8.5 Maintenance Checklist .................................................................................................................. 103 8.5.1 Measures to be taken before the Maintenance ........................................................................ 103 8.5.2 Measures to be taken after the Service .................................................................................... 103 8.5.3 Functional Check ...................................................................................................................... 104 8.5.4 Maintenance Checklist BERNINA Q Series .............................................................................. 105

Document Revision History ......................................................................................................................... 106


Chapter 1 – General Information

1.1 General Regulations and Safety Warnings! All electrical and electronic components operate at dangerous voltages. Remove the mains plug before making any adjustments to the machine. Wait about 30 seconds after removing the plug (capacitor discharge). However, servicing-related work can be carried out in Service Program when the machine is powered. When the machine needs to be taken out of the quilt frame to place on a table or work bench for technical services, we recommend strapping the machine tightly to the work table surface. This because the wheels on the machine can make the machine rolling away independently! This service manual is intended to help with minor repairs and adjustments. The instructions do not claim to be complete or comprehensive. The manual does not provide guidance for complete assembly or disassembly. Important: To enable the work described to be performed correctly, the sewing machine must be in good mechanical and electrical condition (running smoothly, properly lubricated and all leads connected)! When adjustments are carried out in the correct order, the machine will function flawlessly. It is important that only devices approved and distributed by BERNINA are connected to the machine ports. When servicing or repairing, always use genuine parts and original accessories, either those delivered with the machine or purchased afterwards.

• Power cable • Foot control unit • Presser foot • Bobbin • Other accessories

The Service Manual and Instructions are protected by copyright laws. It must only be used by authorized people. It is prohibited to disclose the service manual to unauthorized third parties. This Manual is subject to revisions without notice. The recipient is responsible for updating the information provided by BERNINA International AG, Steckborn, Switzerland. This service manual is only available in electronic format. It can be downloaded from BERNINA Infogate at https://infogate.bernina.com. If you don't have access to Infogate, contact your local BERNINA importer. They'll be glad to be of assistance. Author: Hansjörg Herzog (Technical Education Manager, BERNINA of America Inc.) Markus Gretler (Head of After Sales Service, BERNINA International AG)

https://infogate.bernina.com/


1.2 Warning: Dangerous Voltage Levels! Attention! The power connector, the main switch, the PCBA (power) and the power cable all carry dangerous voltages. Therefore always disconnect the machine from the power supply before starting any work on the machine. This applies unless otherwise instructed where required. Note: 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


1.3 ESD-Related Note: Electrostatic Discharge (ESD)

Protection of electrical and electronic components against electrostatic discharges Please note the following points: 1. Always work at a stationary, ESD-compliant workstation equipped with the appropriate ESD protective devices including conductive table and/or floor mat, earth connector box and earthing wristband when doing service work. The cable of the earthing wristband must have a built-in resistance of 1 M ohm to ensure protection. 2. Always put on an earthing wristband before starting to work. Always remove any synthetic parts like plastic bags, covers etc. from your workstation. 3. Only open ESD protective packaging at your ESD-proof workstation while wearing an earthing wristband. Electronic components must only be placed on conductive table mats. Packing is carried out under the same conditions. 4. Only use conductive ESD-capable plastic/foil pouches and ESD transport boxes for dispatching electronic components – even if the components might be faulty. 5. To prevent consequential damage or harm, treat faulty PCBs in the same manner as new ones. .

Electrostatic charges are caused by: a person's walking (influence) friction between and separation of two insulating materials

(triboelectricity) If this static electricity discharges through electronic components, these may be partially or irreparably damaged. Electrostatically charged persons represent the greatest danger for components. This can be dissipated by controlled electrostatic discharge.


1.3.1 ESD Setup for Frame Installed Repair Process To secure a save repair at customer premises, the utilization of a service ESD Kit is required. Make sure, the machine is with an extra wire connected to the ESD mat. Below, a repair situation is shown.

1 Connection to Machine (at any point of solid metallic surface, presser foot bar is recommended)

2 Wrist band 3 ESD Mat (service Kit) 4 Connector to earth


1.4 Tools and Gauges Commercially available (not available from BERNINA): Multimeter, TORX screwdriver no. 6, 8, 10, 15, 20, 20 (200mm blade), 25, 30 and angular TORX nos. 6 and 10, 10mm ring wrench, 6mm flat wrench.

Art.-No. Name

Application

Picture

001356.50.00 002733.50.00 Pinning tool, short or long Pinning positions

031563.50.00 Eccentric key 2.0mm Alignment of head plate to the stitch plate

735209.50.00 Distance gauge Adjusting the needle height

398005.04.0+ Clamping piece Adjusting the loop lift

735136.50.03 Distance gauge 2.4mm Adjusting the loop lift

338109.03.3+ 130/705 H TCN 80

Needle and hook adjustment

Com. available 130/705 H 100 Needle penetration in Y-direction

734101.50.00 Distance gauge Threaded head height

033247.70.00 Adjusting gauge Distance gauge for bobbin case retainer

398026.13.1+ Darning foot height gauge Checking the darning foot level

735261.50.00 Bobbin winder gauge Checking amount of bobbin fill


Art.-No. Name

Application

Picture

035905.70.00 Bobbin tension kit Adjustment of the lower thread tension

008709.72.00 Upper thread adjusting gauge (5-pieces-set)

Weight for setting the upper thread tension

652010.20.++ Gauging thread DMC 50 BLANC (white) Upper- & lower thread-tension

006038.50.00 Spring balance gauge Tension of thread regulator spring

031564.50.01 Tweezers Plugging and unplugging cables

Com. available Watchmaker's magnifier 2.5x (magnification approx. 4x)

Allows for more precise adjustments in the hook-/needle area

398112.03.0+ Spring mounting tool Spring hooking & unhooking aid

033958.50.00 (Size 1.5) 033958.50.01 (Size 2.3) 033958.50.02 (Size 3.2)

C-Clip Holding Assembly C-clips

031935.50.00 Plug mounting tool Mounting aid for plugs and cables

032948.50.00 Chip extraction tool Removal of EEPROM

Com. available Multimeter (digital) Continuity test Ohm measurement Voltage tests


1.5 Handling and Adjustments

1.5.1 Main Frame WARNING: The 8 screws visible on the black vertical front and back panels, 4 screws on each side, MUST NOT be loosened or removed. These screws and the black panels maintain the structural integrity of the entire machine frame. In case the screws were loosened or removed the frame becomes misaligned, the machine must be calibrated at

the manufacturing facility. BERNINA cannot be held liable for any machine damage and expenses occurred by not adhering to this warning. Handling and Adjustments will be explained within the respective items.

1.6 Abbreviations / Names used Throughout the whole manual the following abbreviations have been used. We have reserved the right not to explain individual abbreviations within the text.

Abbreviation: Stands for: BSR BERNINA Stitch Regulator DC Direct Current

EEPROM Electronically Erasable Programmable Read Only Memory

IR Infra red LCD Liquid Crystal Display LED Light Emitting Diode PCBA Printed Circuit Board Assembled TFT Thin Film Technology TT Thread Tension UTO IO UART FC PFP

Upper Thread Observer Input / Output Universal Asynchronous Receiver Transmitter Foot Control Presser Foot Pressure

RGB Red, Green and Blue Screen


1.7 Cleaning Remove the covers and clean. Electrostatic charging may occur during cleaning. To prevent this, use antistatic office-equipment cleaning agents.

Attention! Never use alcohol, petrol, spirits or any corrosive fluids, or abrasive pastes or abrasive cleaners!

Inside parts:

• Dust, lint, thread and fabric remnants can accumulate inside the machine behind the covers and may lead to malfunctions.

Area of the head frame:

• Thread take-up lever (joints), needle bar and needle bar holder. • Between the upper thread tension discs, and in the total thread passage ways and guides.

Area of the free arm and base:

• Bobbin case (under the tension spring.) • Hook

Area of the transmission:

• Main motor (carbon dust). • Toothed belt drive and motor pulley.

Area of electronics:

• All sensors / light barriers / switches / electronic group of parts.


1.8 Technical Details by Model Features Q20 Q24 Technical Line voltage 100 - 240 Volt 50-60 Hz 100 - 240 Volt 50-60 Hz Power input in Watt 100 100 Eco mode (30% reduction) Yes Yes Motor DC / 36 Volt DC / 36 Volt Overall size in mm, L-W-H 802 x 160 (340) x 525 902 x 160 (340) x 525 Weight in kg/pound without accessories 25/55 26/57 Accessories compl., packed 5.1 5.1 Weight in kg, packed ~40 ~42 Free arm space, L x H in mm 510 x 275 610 x 275 Hook system RH M-Class RH M-Class Semi-automatic threading device Yes Yes Automatic upper thread tension Yes Yes Integrated BERNINA Stitch Regulator Yes Yes Upper thread sensors Yes Yes Automatic presser-foot lifter Yes Yes Presser-foot height in mm, normal 7.5 7.5 Presser-foot height in mm, max. extra lift 15 15 Sewing light (sewing area) LED LED Free arm area lighting LED LED TFT color display (Thin Film Transistor) Yes Yes Display size in inch 4.3 4.3 Resolution in pixel 480 x 272 480 x 272 Number of colors 1.67 mio. 1.67 mio. Display backlight in white LED LED User interface Touch Screen Touch Screen Connection Front Side Head rear side

- Handles Yes Yes - Black Light Yes Yes - Laser Yes Yes

Hook right hand side - Aux Future use Future use - FHS Future use Future use - Foot Control Yes Yes

Connection Rear Side

- Display - Laser Yes Yes - Channel locks on frame Yes Yes - Handles Yes Yes - USB Host Yes Yes - Automation Yes Yes

- USB Host & Slave Yes Yes - Ethernet Yes Yes


Chapter 2 – Electronics and Wiring

2.1 BERNINA Q series Block Diagram


2.2 PCBA Base – General Information The PCBA-Base contains:

• EEPROM (storing of machine-specific data, e.g. stitch counter and operating hours counter) • 5-volt and 36-volt voltage control LED’s • PCBA-CPU-module interface • Buzzer • Stepping motors drivers

Internal connectors: • According to table

External connectors: • USB connectors for PC and USB stick • Foot control connector

Caution! When replacing the base PCBA remove the EEPROM from the old PCB and directly fit it on the new PCB. Do not remove or plug in any connectors when the sewing computer is switched on or connected to the power supply.

2.2.1 PCBA-Base The plugs on the PCBA-Base are listed in the table in accordance with their top left to bottom right arrangement on the PCBA. Important: The PCBA Base is the same as used in the B 880, however, with the long arm machines not all plugs are occupied. Those which are NOT occupied are marked with a crossed in the picture below in red.

No. Color Connecting: X17 white PCBA-position X43 black Cable harness yellow X3111 black Cable harness yellow X3112 black Cable harness yellow X28 white PCBA Power Supply X38 black Cable harness yellow X30 black Ribbon cable PCBA Quilt

Extension X101 X39 white Quilt Extension X404 X1 white PCBA CPU Module X502 X12 USB Cable PCBA Quilt

Extension X304 X15 white PCBA Lower Interface X1001 USB Cable PCBA Quilt

Extension X300 X35 PCBA Quilt Extension X401 X100 black PCBA Quilt Extension X402

LED 5 V LED 36 V

EEPROM


2.3 PCBA CPU Module (ARM9) – General Information The PCBA-CPU-module contains:

• Processor (CPU) • Memory • Data

Connectors

• According to picture

2.3.1 PCBA CPU Module / ARM9

TFT screen

PCBA-Base X1

Contacts of PCBA-Base

PCBA-CPU-module sits on PCBA-base. When replacing the PCBA-base, remove the PCBA-CPU-module from the 'old' PCBA and add to the new.


2.4 PCBA Quilt Extension – General Information The PCBA-Quilt Extension contains:

• 3.3 Volt and 1.8 Volt regulator for LCD and USB Hub • LCD switch and serialiser • Touch interface • USB hub • Bobbin winder driver • Channel lock • Laser power supply • Upper thread observer (UTO) adoption

Internal connectors: • According to table

External Connectors: • HDMI for rear LCD • Reset Button • Laser • Channel locks (X and Y direction) • Handles • USB (for Soft Ware updates) • 3 plugs for the auto motion module

2.4.1 PCBA Quilt Extension The plugs on the PCBA-Base are listed in the table in accordance with their top left to bottom right arrangement on the PCBA.

No. Color Connecting: X200 HDMI HDMI Display front X100 White Ribbon cable PCBA CPU

Module X404 White PCBA Base X30 X102 Black LED free arm X103 Black LED free arm X409 Black Cable harness X101 Black PCBA Base X30 X402 Black PCBA Base X100 X400 White PCBA Base X3111 X304 USB PCBA Base X12 X300 USB PCBA Base X1001 X302 USB PCBA lower interface X401 White PCBA Base X35 X403 white PCBA lower interface


2.5 PCBA Power Supply The PCBA Power Supply contains:

• Rectifier • Transformer • Fuse F1 • PCBA-base connector (X28) • Power connector • Dipswitch

Task

• 5 V / DC and 36 V / DC for PCBA base • Voltage control, preventing decrease of voltage output

Note: In the event of malfunction, the F1 (4A primary) fuse protects components against overload. If a fuse blows, this is always for a reason. The cause must be identified and removed. Only a replacement fuse of the correct rating must be used. It is essential to test the functions on replacing the fuse.

Main Motor connection

Power connection

Primary fuse F1

PCBA Base connector X28

Motor break transistor

Temperatur sensor

Secondary fuse F2


2.6 PCBA Upper Interface The upper interface has connectors for: Internal connectors:

• According to table External Connectors:

• Handles • Black Light • Laser

2.7 PCBA Lower Interface The lower interface has connectors for: Internal connectors:

• BSR Sensors External connectors:

• AUX (USB Type, Future use) • FHS (future use) • Foot control

No. Color Connecting: K4 White spare K1 White Cable harness K2 white Bobbin winder

No. Color Connecting: K7 Black BSR left K6 Black BSR right K2 USB Cable harness white

PCBA Quilt Extension X302

K9 Cable harness white PCBA Quilt Extension X403


2.8 PCBA Detection The PCBA-Detection contains:

• 1 Light Barrier • 1 Connector

Task: This PCB is 2 times in the machine, for:

2.8.1 Upper Thread Detection With the threaded machine running, the light barrier open and closes due to movement of the actuator flag connected to the regulator spring.

2.8.2 Threader Detection If the threader handle is pulled down, the light barrier opens and the machine positions the needle bar in height for threading. If the machine is running and the threader handle is accidentally pulled down, the machine stops.

2.9 PCBA Position The PCBA-position contains:

• 3 light barriers • Connector

Connecting

• According to picture Task

• The 3 light barriers detecting the signals from the synch. disk and forward them to the central processor.

• The central processor determines, with the combination of the signals, the angle position of the upper shaft and the speed of the machine.

PCBA Base via harness

Light Barriere

Light barrier 2 A/B Signal

Light barrier 1

Light barrier 3

PCBA Base X17


2.10 PCBA Presser Foot Height Sensor The PCBA-presser-foot height contains:

• Light barrier Connecting

• According to picture Task

• The upper and lower position of the presser foot bar is recognized via light barriers.

2.11 Cable Harness The yellow cable harness inside the upper arm includes:

• 8 connectors at head frame side • 6 connectors at the PCB side • Spiral cable holder.

Task

• The cable harness connects the listed peripheral actuators, sensors and PCBA’s with the main electronics.

Note:

• The cable harness is only available as a complete unit. • The figure gives an approximate picture of the placement in the machine. • Take care not to squash any cables or that individual wires get damaged by movable parts when fitting

the harness.

Light barrier

PCBA Base


2.11.1 Head Frame Side

2.11.2 Main Electronics Side

No. Color Connecting: 1 White Threader sensor 2 White,

black marked

Thread tension motor

3 Black Presser foot motor 4 Black Upper Interface K1 5 White Upper thread Observer 6 White Magnet 7 White Presser foot height

sensor 8 White Sewing light LED

No. Color Connecting: A Black PCBA base X3112 B Black PCBA base X43 C Black PCBA base X3111 D Black PCBA base X38 E Black PCBA quilt extension X409 F White PCBA quilt extension X400


2.12 Handling of Electronic Components Read ESD notes (see 1.3) and observe the guidelines.

2.12.1 Returning Defective Electronic Components For everybody's safety sake, defective electronic components must be treated like new items. Only (original) ESD protective packaging must be used when forwarding components. Check if the EEPROM and the PCBA-CPU module had been removed before forwarding the PCBA-base. Enclose the filled-in repair form in the packaging.

2.12.2 Repairs of Electronic Components (PCBA's) BERNINA International AG offers repaired and tested replacement of almost all electronic components. Replacement electronics can be identified by article number. For example: Article number of repaired PCBA xxxxxx.30.01 / article number of new PCBA xxxxxx.70.01 For product liability and safety reasons it is prohibited to repair electronic components by oneself or to have electronic components repaired by third parties. Electronic components that have been manipulated or repaired by one 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 one or improperly packaged.


Chapter 3 – Removal and Refitting of Components

3.1 Covers

3.1.1 Head Covers / Front / Back / Thread Guide and Display Disassembly:

• Remove the hand wheel by pulling straight outwards. • Remove two screws a (T20) from the left and right hand side of the covers. • Remove the screw with washer b (T20) behind the removed hand wheel. • Loosen the screw with washer c (T20) from the front. • Carefully pull the display screen straight outwards. • Disconnect the HDMI cable 1 from the back of the display screen

o Notice: The position of the ESD conductive sponges 2 • To remove the left and right hand covers, there are a total or 5 snaps two on

the top seam 4, one on the back seam 5 and two snaps each 3 on the bottom of each cover.

• Carefully separate the two covers and remove.

1

2

2

4

c

3 3

a

5

a

b 5


Assembly: • Fit the two covers over the head frame and lock the five snaps in place 3, 4 and 5. • Fasten the screw with washer b (T20) behind the removed hand wheel • Tighten the screw with washer c from the front • Connect the HDMI cable 1 to the back of the display screen • Carefully push the display screen in position • Tighten the two screws a (T20) from the left/right hand side of the covers

and install the thread guide horizontally. • Install the hand wheel

1

2

2

4

a

b 5

a

5

c

3 3


c

c

c

c

c

c

b

c b

4

6

2

3

b

b

1

5

3.1.2 Belt Cover Disassembly:

• Remove the hand wheel by pulling straight outwards and line up the main shaft pin with the slots in the belt cover.

• Remove the 2 screws b (T20) for the on/off switch/power socket • Remove 6 screws c (T25). • Carefully remove the belt cover plate and remove the cover plate for the plugs.

Assembly:

• Line up the cover plate and the plate for the plugs • Install and slightly tighten the 6 screws (T20). • Secure the on/off switch/power socket with the 2 screws b (T20) • Tighten the screws 1 and 2 (T25) completely, then in a criss-cross fashion

tighten the screws 3 to 6 (T25) • Install the hand wheel

Check:

• After the cover is securely installed check the following adjustments: • Needle distribution in needle plate (see 4.5.1)

WARNING: The 8 screws visible on the black vertical front and back panels, 4 screws on each side, MUST NOT be loosened or removed. These screws and the black panels maintain the structural integrity of the entire machine frame. In case the screws were loosened or removed the frame becomes misaligned, the machine must be calibrated at

the manufacturing facility. BERNINA cannot be held liable for any machine damage and expenses occurred by not adhering to this warning.

1


3.1.3 Inside Cover

Disassembly: • Remove 6 screws a (T25). Note: The screw marked with b (T25) is a

shorter screw. • Carefully tilt the inside cover and remove

Assembly:

• Carefully tilt the inside cover and install, making sure the HDMI and the LED light cable are securely situated in the dedicated grove. Pinched wires must be avoided

• Install and slightly tighten the 6 screws (T25). • Tighten the screws 1 and 2 (T20) completely, then in a criss-cross fashion

tighten the screws 3 to 6 (T25) Check:

• After the cover is securely installed check the following adjustments; • Needle distribution in needle plate (see 4.5.1)

WARNING: The 8 screws visible on the black vertical front and back panels, 4 screws on each side, MUST NOT be loosened or removed. These screws and the black panels maintain the structural integrity of the entire machine frame. In case the screws were loosened or removed the frame becomes misaligned, the machine must be calibrated at

the manufacturing facility. BERNINA cannot be held liable for any machine damage and expenses occurred by not adhering to this warning.

b

a

a

a

a

a

3

6

2

1

5

4


3.1.4 Hook Cover and Needle Plate Base Disassembly:

• Remove needle plate • Remove the 2 needle plate base screws a (T20) • Using a small screw driver separating the two prongs 1

and remove the hook cover. • Remove hook cover base screws with washers b (T20), • Unplug the two BERNINA stitch regulators plugs 2 from

the circuit board and remove the needle plate base. Assembly:

• Plug in the two BERNINA stitch regulators plugs 2 into the circuit board

• Install the hook cover base 2 screws with washer b (T20) • Note: Ensure that the BSR cables are not being pinched

between the cover and the base. • Install the 2 needle plate base screws a (T20). • Note: Prior to installing the cover plate make sure the

bobbin case retainer finger is engaged in the bobbin basket.

• Insert stitch plate. • Note: After handling, make sure to clean the lenses of the

BSR units.

a a

1 1

b b

2 2


3.2 Electronics and Sensors

3.2.1 BERNINA Stitch Regulators (BSR) Disassembly:

• Remove the needle plate base screws, hook cover and base (see 3.1.4).

• Unplug the two BERNINA stitch regulators plugs from the circuit board

• Remove four screws b (T20) and remove the BSR units. Assembly:

• With the needle plate installed aligned the BERNINA stitch regulators units. • Install the four screws b (T20) • Line up the BERNINA stitch regulators lenses equally within the needle plate openings. • Tighten the four screws b (T20) • Plug in the two BERNINA stitch regulators plugs. • Note: Make sure the bobbin basket is secured by the retainer stopper on the needle plate base when

installing the plate. • Install the needle plate base and hook cover (see 3.1.4).

b

b b

b


3.2.2 Winder Unit

Disassembly: • Remove the right hand head covers and slightly pull out the display

screen (see 3.1) • Unhook the upper two cables 1 tide. • Disconnect winder plug from PCBA-Upper interface 2. • Remove 2 screws with washers a (T20). • Carefully remove the winder unit with harness.

Assembly:

• Install the winder unit with harness. • Tighten the 2 screws with washers a (T20) • Guide the wire harness around the wire tree and connect the winder plug into

the PCBA-Upper interface 2. • Secure the cables with a 2 cable tide 1. • Refit the right head cover (see 3.1).

3.2.3 PCBA Upper Interface

Disassembly: • Remove back and front head covers (see 3.1). • Unplug the bobbin winder 1 and the 18 pin connector 2

from the PCBA Upper interface • Remove the two screws a (T20) • Remove PCBA

Assembly:

• Install the PCBA Upper interface • Tighten the two screws a (T20) • Plug in the bobbin winder 1 and the 18 pin connector 2 to the PCBA-Upper interface

1

2

a

a

1

1

2

a

a


1

a

a

1

3.2.4 PCBA Lower Interface

Disassembly: • Remove the hook and base covers (see 3.1.4) • Unplug the two BSR connectors 1, Micro USB 2 and

the 9 pole white 3 from the PCBA lower interface • Remove the two screws a (T20) and the spacers

behind the PCBA. • Remove the PCBA

Assembly:

• Install the PCBA and the spacers. • Tighten the two screws a (T20). • Plug in Micro USB 2, the two BSR connectors 1 and the 9 pole white 3 into the PCBA lower interface • Refit the hook covers and base (see 3.1.4).

Note: Make sure the bobbin basket is held by the bobbin case retainer stopper located on the needle plate base.

3.2.5 PCBA Position

Disassembly:

• Remove upper access cover by slightly lifting up the cover on the hand wheel side, slide the cover towards the hand wheel and remove.

• Disconnect plug 1. • Remove the 2 screws a (T20). • Take out the PCBA

Assembly:

• Install the PCBA position. o Warning: Make sure the PCBA position is

aligned with the synchronization disks! • Tighten the 2 screws a (T20). • Connect the plug 1. • Install the upper access cover into the groove.

a

a

1

3

2

1


3.2.6 PCBA Base When replacing the PCBA base, remove the EEPROM from the “old” PCBA and immediately install it on the “new” PCBA. The EEPROM contains imported machine-related data. For disassembly and assembly (see 3.2.9)

PCBA-Base connectors: The top-bottom listing of the connectors in the table corresponds to their top left to bottom right arrangement on the PCBA.

No. Color Connecting: X17 white PCBA position X43 black Cable harness X3111 black Cable harness X3112 black Cable harness X28 white PCBA Power Supply X38 black Cable harness X30 black Ribbon Cable PCBA Quilt Extension X101 X39 white Quilt Extension X404 X1 white PCBA CPU Module X502 X12 USB Cable PCBA Quilt Extension X304 X15 white PCBA Lower Interface X1001 USB Cable PCBA Quilt Extension X300 X35 PCBA Quilt Extension X401 X100 black PCBA Quilt Extension X402


3.2.7 PCBA Base / Electronics Frame

Disassembly: • Remove the belt- and the inside-cover (see 3.1.2 and 3.1.3) • Loosen the securing screw a (T20) from the electronics frame (left hand side). • From the hand wheel side disconnect the white plug 1 and motor cable 2 (red/black).

• Warning: Place a cloth of muslin between the lower/upper and the Electronics Frame for scratch protection.

• Carefully slide the entire Electronics Frame about 3 inches (7.5cm) to the left hand side, making sure not to scratch the upper/lower arm of the machine or pinching any wires.

• Disconnect the USB plug 3 , white plug 4 and the HDMI plug 5

1

2

3

4

5

a


9

7

6 8

10

6

9

7

6 8

10

6

a

a

a

• Gradually move the entire module to the left hand side, while

disconnecting the two light wire plugs 6, plug 7 upper left hand side.

• Upper left white plug with 4 yellow wires 8, black plug single wire 9

• White plug with yellow wires 10 • Remove the 3 screws a (T20) holding the PCBA Base in

place. Note: One of the 3 screws is under the ribbon cable and not visible in this photograph.

Assembly:

• Refit the PCBA Base to the frame with the 3 screws a. • Do not forget to refit the PCBA CPU Module • Line up the module with the tracks of the machine housing and

slightly insert the unit, making sure the wires are in the appropriate position and not getting pinched.

• Gradually move the entire module to the right hand side, while connecting the two light wire plugs 6, plug 7 upper left hand side.

• Connect the white plug with 4 yellow wires 8, black plug single wire 9

• White plug with yellow wires 10


• Be careful when sliding in the module into the machine not to

pinch wires or inadvertently disconnect plugs/flat band cables etc.

• Connect the USB plug 3 and white plug 4 • Carefully slide the entire module into the machine

• Line up the module screw with the previous screw imprint and tighten the board securing screw a (T20) • From the hand wheel side connect the white plug 1, motor cable 2 (red/black) • Install the belt and the inside cover (see 3.1.2 and 3.1.3)

a

3

4

5

1

2


3.2.8 PCBA CPU Module

Disassembly • Remove the belt and the inside cover (see 3.1.2 and 3.1.3) • Remove the Electronics Frame (see 3.2.7) • Disconnect the two cables 1 and 2. • Remove the screw a (T20). • Twist the cap 3. • Spread the two locking levers 4. • Tilt the PCBA on the top and remove.

Assembly • Insert the PCBA and push it all the way down • Securely lock in the board using the two locking levers 4 • Twist the cap 3 and lock in the board • Tighten screw a (T20) • Connect the two cables 1 and 2

Warning!

The current state of the firmware must be checked after assembly of the new PCBA-CPU-module. If it is not the latest version, the firmware must be updated (via updating procedure).

3.2.9 EEPROM (Electrically Erasable Programmable Read-Only Memory) When replacing the PCBA-Base, remove the EEPROM from the old PCBA and directly fit it on the new PCBA.

Disassembly: • Remove the belt and the inside cover

(see 3.1.2 and 3.1.3) • Remove the Electronic Frame (see 3.2.7) • Use IC extracting tool (032948.50.00) to remove

EEPROM a Assembly:

• Attach EEPROM 2 to base. • Careful fitting the EEPROM in the correct position

(markings must match) and avoid bending the contacts. • Install the belt and the inside cover

(see 3.1.2 and 3.1.3) • Install the Electronic Frame (see 3.2.7)

3

4 a

1

2

a

EEPROM marking positions

must match

http://de.wikipedia.org/wiki/EPROM


3.2.10 PCBA Quilt Extension


(see 3.1.2 and 3.1.3) • Remove the Electronic Frame (see 3.2.7) • Remove the 3 screws a (T20) • Unplug the plug 1 • Unplug the flat band cable 2 and 3 • Unplug plug 4 • Unplug plug the plug 5

Assembly:

• Plug in the plug 1 • Connect plug 5 • Plug in the 4 • Connect the flat band cable 2 and 3 • Tighten the 3 screws a (T20) • Install the belt and the inside cover (see 3.1.2 and 3.1.3) • Install the Electronic Frame (see 3.2.7)

1

a

5

a

3

a

2

4


a 3

2

a

1

3.2.11 PCBA-Power Supply Remove power plug to disconnect machine from power supply!


(see 3.1.2 and 3.1.3) • Remove the CPU module (see 3.2.7) • Unclip the white power board cover • Remove two screws a (T10) • Unplug the power supply plug 1 • Disconnect plug 2 and 3 • Pull out the board

Assembly:

• Install the board • Attach the board with two screws a (T10) • Connect plug 2 and 3 • Connect the three plugs 1, 2 and 3 • Install the white power board cover • Install the belt and the inside cover (see 3.1.2 and 3.1.3) • Install the CPU module (see 3.2.7)

Warning High

Voltage


3.2.12 LED Sewing Light Upper Frame


(see 3.1.2 and 3.1.3) • Partially remove the CPU module (see 3.2.7) • Disconnect the plugs at the PCBA quilt extension • Remove the 3 screws a (T20) • Remove the 3 screw bases from the upper frame • Guide the cables out of the channel and remove

LED sewing light Assembly:

• Carefully and without pinching the cables, guide the cables into the channel.

• Install the 3 screw bases and secure the cables • Install the LED sewing light approximately 3 inches or 75mm from the right inside cover. • Tighten the 3 screws a (T20) Note: the cables must lie loosely in the cable channel to prevent pinching. • Connect the plug into the PCBA quilt extension • Carefully slide the PCBA-CPU-Module (see 3.2.7) • Install the belt and the inside cover (see 3.1.2 and 3.1.3)

3.2.13 LED Sewing Light Head Frame

Disassembly: • Remove head covers (see 3.1). • Disconnect the sewing light 1. • Un-snap the two snaps from the inside of the white cover. • Tilt the U-shaped LED light bar down and carefully unhook it from the left

hand side. Assembly:

• Snap in the LCD lights and secure it with the two snaps a inside of the white cover.

• Connect the plug to the sewing light 1 • Install back and front head covers (see 3.1).

a a a

a

a 1


3.2.14 PCBA Presser Foot Height Sensor

Disassembly: • Remove right head covers (see 3.1). • For more working space remove the hand wheel module first (see

3.3.4). • Unplug the cable 1 • Remove screw a (T10) with washer • Remove the PCBA presser foot height sensor by carefully tilting

the top of the sensor out of the machine before removing. Assembly:

• Install the PCBA presser foot height sensor making sure the base for the board is clipped in place in the metal support in the bottom.

• Manually move the presser foot up/down to check if the flag on the presser foot bar clears the presser foot height sensor.

• Make sure the flag of the presser foot bar does not touch the light barrier

• Install washer and screw, tighten the screw a (T10) • Plug in the cable 1 • Install the hand wheel module (see 3.3.4). • Install the right head cover (see 3.1).

a

1

a

1


3 a

3.2.15 PCBA Detection – Threader Sensor

Disassembly: • Remove the left head cover (see 3.1). • Unplug the plug 1 • Remove screw a (T20) • Remove the PCBA Detection - Threader Sensor

Assembly:

• Install the PCBA Detection - Threader Sensor, making sure the needle threader flag is centered inside the sensor.

• Tighten the screw a (T20) • Plug in the plug 1 • Install the left head cover (see 3.1).

3.2.16 PCBA Detection - Upper Thread Observer (UTO)

Disassembly:

• Remove right hand wheel cover (see 3.1) • Remove the upper thread clamp module (see 3.3.5) • Disconnect plug 2 • Remove the screw b (T20) • Take out the PCBA Detection – Upper Thread Observer

Assembly:

• Install the PCBA Detection – Upper Thread Observer • Tighten the screw b (T20) • Connect the plug 2 • Install the upper thread clamp module (see 3.3.5) • Install right hand wheel cover (see 3.1)

a

1

b 2


b b

c

a

a

1

3.2.17 Main Motor Disassembly:

• Remove belt and the board covers (see 3.1). • Pull the motor fan straight outward. • Disconnect motor plug 1 • From the hand wheel side remove two screws a (T20) from the motor

bracket • Remove two screws b (T20) from the motor bracket and the screw

base c (Open end wrench 8 mm) on the needle side. • Remove the motor bracket with motor.

Assembly:

• Slide-in the motor • Without tightening install the two screws b (T20) to the motor bracket

and the screw base c to the machine frame as well as the 2 screws a (T20).

• Adjust the motor belt tension (see 4.2.3) • Install the motor fan • Connect motor plug 1 • Warning: The belt must run in the middle of the main shaft and motor

pulley.


b

b

3

1

2

3.2.18 Presser Foot Height / Upper Thread Monitor Sensor Unit Disassembly:

• Remove two screws b (T10) • Swing out the presser foot height and upper therad monitor sensor as one

single unit 3 Assembly:

• With the presser foot at its highest position align the flag 1 on the presser foot height clamp and flag 2 on the upper thread monitor sensor with the height sensor unit.

• Install two screws b (T10) and hold the height sensor unit. • Slide the sensor from left to right stop, middle the position between the

flag 1 and the presser foot height sensor. • Tighten the two screws b (T10). • Warning: The presser foot height flag must be in the middle of the

height sensor flag 1. Carefully push the presser foot bar up and make sure the presser foot height flag 1 is not interfering with the sensor.

• Move the check spring and make sure the upper thread monitor flag 2 is moving within the sensor.


b

b

b

b

1

c

c

c

2

3

3.3 Mechanical Components / Stepper Motors

3.3.1 Rotary Hook / Hook Gib / Thread Guide Plate / Cutter and Basket Note: the Cutter is not implemented yet. Subject to future change Disassembly:

• Remove needle plate, presser foot and needle. • Remove needle plate base 2 screws a (T20). • With the BERNINA stitch regulator cables still attached let

the plate rest in the front of the hook. • Remove bobbin case.

Thread Guide Plate / Cutter

• Note: When removing or installing the screws c a quality screw driver has to be used (tip must be able to hold the screws c by a press fit, it is not advisable magnetizing the screw driver tip)

• Hold the screws with at press fit. • Remove 4 screws (slotted) b from the thread guide plate • Remove the thread guide plate 1

Hook Gib / Bobbin Basket

• Remove 3 screws (slotted) c • Remove the hook gib 2 • Rotate hook tip to 8:30 o clock and bobbin basket cutout

to the 12:00 position. • Remove the basket 3 by tilting and removing it.

a a


c

c c

5

6

Remove Hook Body

• Loosen 3 screws d (T15) two complete revolutions • Remove the entire hook body 4

Assembly: Install the Hook

• Rough adjustment: With the needle on its lowest point install the hook with the hook tip pointing at 2:00 o clock.

• Install a new needle. • With the loop lift of 2.4mm line up the hook tip with the left

hand side of the needle (see 4.5.3) • Adjust the hook needle clearance of 0.01 to 0.05 mm (see

4.6.3) • Tighten the 3 screws d (T15)

Hook Gib / Bobbin Basket

• Note: When removing or installing the screws c a quality screw driver has to be used (tip must be able to hold the screws by a press fit, it is not advisable magnetizing the screw driver tip)

• Rotate hook tip to 8:30 o clock and bobbin basket cutout to the 12:00 position

• Insert the basket 5 by tilting the basket at 4:00 clock position.

• Install the hook gib 6 • Tighten 3 screws (slotted) c

d

d

d

d

d

d

4


b

b b

b 1

Thread Guide Plate

• Note: When removing or installing the screws b a quality screw driver has to be used (tip must be able to hold the screws by a press fit, it is not advisable magnetizing the screw driver tip)

• Line up and press the thread guide plate 1 against the hook body.

• First install all 4 screws (slotted) b then tighten the 4 screws.

Needle plate base

• Install bobbin case, presser foot • Note: Prior to installing the plate base make sure the

bobbin case retainer finger is engaged in the bobbin basket.

• Tighten 2 screws a (T20) on free needle plate base. • Install needle plate, presser foot and needle. • For the final bobbin case retainer adjustments (see 4.7)

Note regarding servicing:

• Use a polishing disk to remove scratch marks on the hook body, thread guide plate, bobbin basket etc. Badly scratched or broken hook tips and thread guide plates must be replaced.

• For lubrication of hook refer to lubrication diagram (see 6.5).

a a


a

a

1

2

b b

1

2 3 4 5 6 7 8 9 10 11

3.3.2 Thread Tension Stepping Motor Disassembly:

• Remove the right head cover (see 3.1). • Remove two screws a (T20) and the two distance sleeves behind

the unit (Note: The longer sleeve is in the top left position) • Disconnect plug 1 • Open the wire harness • Unhook the wires and remove the stepping motor

Assembly:

• Unload spring pressure by rotating the white thread tension gear 2 counter clockwise.

• Guide the wires through the wire harness and secure the wires • Connect plug 1 • Install the stepping motor with screws a (T20) and distance

sleeves (Notice: the longer sleeve is in the top left position) • Tighten the two screws a (T20), making sure there is no bind or

excessive play between the drive gears and the top tension gear. • Install the right head cover (see 3.1).

Important: The calibration of the tension unit must be carried out using the Service Program (see 6j).

3.3.3 Thread-Tension and Stepping Motor Unit Disassembly:

• Remove the right head cover (see 3.1). • Using an extra-long (T20x200mm) from the top or an L-shaped T20

wrench, remove two screws a (T20) in the back of the hand wheel unit.

• Disconnect plug 1 and open the wire harness • Remove the entire top tension unit with stepping motor

Tension Unit Disassembly:

• Remove thread tension stepping motor (see 3.3.2) • Remove c-clip 2 from pin. • Remove clutch gear wheel 3 from pin. • Remove washer 4. • Remove thread-tension nut 5. • Remove slotted shim 6. • Remove tension spring7. • Remove slotted plastic pressing disc 8 • Remove right thread-tension disc 9, tension shim 10 and left thread-tension disc 11.


b b

1

Assembly: • Refit left thread-tension disc 11, tension shim 10 and right thread-tension disc 9, taking care to position

them correctly on the thread-tension shaft. • Refit slotted plastic pressing disc 8 onto thread-tension shaft. • Refit tension spring 7 onto thread-tension shaft. • Refit slotted shim 6 onto thread-tension shaft. • Screw thread-tension nut 5 onto thread-tension shaft. • Refit washer 4 onto thread-tension shaft. • Refit clutch gear wheel 3 onto thread-tension shaft, taking care that the claws and thread-tension nut

mesh correctly. • Refit circlip 2. • Install thread tension stepping motor (see 3.3.2) • Install the right head cover (see 3.1).

Assembly:

• Using an extra-long (T20x200mm) from the top or an L-shaped (T20) a secure the entire top tension with stepping motor.

• Tighten the two screws b (T20), making sure the tension discs are perpendicular to the machine frame.

Important: The calibration of the tension unit must be carried out using the Service Program (see 6j).


a a

2

a a

2 1

3.3.4 Front Hand Wheel Module Disassembly:

• Remove the right head cover (see 3.1). • With a short L-shaped T20 remove two screws a (T20) • Note: If there is no room to remove the screws then remove the

entire top tension unit. (see 3.3.3) • Take out the hand wheel module 2

Assembly:

• Install the hand wheel module 2 • Pull the module away from the white gear inside the machine • Tighten two screws a (T20). • Install the right head cover (see 3.1). • Note: Make sure the hand wheel gear is clearing the internal bevel

gear when the machine is in operation. • Install the right head cover (see 3.1).

3.3.5 Regulator Spring Disassembly:

• Open the front cover • Remove 2 screws a (T20) • Disconnect the cable1 from the solenoid • Remove the thread clamp module 2

Assembly:

• Install the thread clamp module • Connect the cable to the solenoid • Tighten 2 screws a (T20) • Close the front cover

a a

2 1


4

3

3.3.6 Threader Head Disassembly:

• Set needle bar to its top position. • Remove the needle. • Move needle threader holder a little downwards. • Holding on to the black shaft 3, pull threader head 4 off

threader bar. Assembly:

• Push up the threader head 4 and snap in position. • Insert needle. • Perform a needle threading function check • Adjust threader if necessary (see 4.9).

3.3.7 Needle Clamp Disassembly:

• Remove the needle with screw a (T6) • Raise the presser foot • Lower the needle bar • Remove the screw b (T8) • Remove needle clamp and thread guide

Assembly:

• Insert the needle clamp and thread guide • Fasten the screw a (T8) • Insert needle and secure with screw (T6)

b

a


1

b b

3.3.8 Thread Take-Up Lever Disassembly:

• Open the light cover • Remove 3 screws a (T20) • Carefully remove the entire take up lever assembly.

Assembly:

• Connect and line up the take up lever assembly. • Install the three washers behind the take up lever base • Install the 3 screws a (T20) • Gradually tighten the screws while rotate the hand wheel. By

doing so the parts will find their perfect position. Warning: By not adhering to this process, damage to the take up lever components might occur!

Disassembly:

• Loosen 2 screws b (T8) • Pull the shaft 1 • Please notice the 2 washers 2 on each side of the upper take up lever

linkage. Also notice the 2 washer’s 3 on the inside of the lower take up lever linkage.

Assembly:

• Install small washers e on each side of the take up lever 4 • Install the linkages 5 on each side of the take up lever 4 • At the upper linkage first install the larger washer 2 then the first part of

the upper linkage 5 • Gradually insert the shaft 1 as the parts are being assembled making

sure the washers 2 are installed on each side of the linkages 5 • Push the shaft 1 all the way through • Rotate the shaft 1 until the flat spot points straight at the screw b T8 • Middle the shaft 1 and tight the screw b (T8) on the location flat of the

shaft 1 • Tighten the second screw b (T8)

Note: Check for smooth rotation and apply lubrication (see 6.2) to the components.

a a

a

3 3

4

5 5

1 2


a a

b

b

1

Inside right hand view

3.3.9 Presser-Foot Lifter Stepping Motor Disassembly:

• Remove covers (see 3.1). • Unplug the sewing light (see 3.2.13) • Remove two screws a (T20) and sewing light • Remove two screws b (T10) • Swing out the presser foot height and upper thread monitor sensor as one

single unit. (see 3.2.18)

• Remove two screws c (T10) from stepping motor

• Loosen two screws d (T20) from presser foot height clamp 1. • Remove the presser foot and lower the presser foot bar by pulling down the

bar. • Note: Be aware of the presser foot guide piece 2 and the fitting into the slot in

the frame. • From the right hand side pull up the presser foot height clamp 1 and unhook

it from the presser foot bar. • Unplug the stepping motor 3. • Remove the stepping motor 4.

c

c

d

d

2

1

3

4


a a

b

b

Assembly:

• Install the stepping motor 4 • Tighten two screws a (T10), making sure to align the motor gears with the

presser foot lifter gears for no play and no binds • Plug in the stepping motor 1

• Install the presser height clamp 1 with presser foot bar. • For a rough adjustment push the bar up so that the presser foot shaft is about

1mm above the presser height clamp 1 • Note: Make sure the white presser foot guide piece 3 is in the correct position,

guiding the pin.

• Install the presser foot. • Adjust presser foot height (see 4.9). • Install the presser foot height and upper thread monitor (see 3.2.18) • Install two screws a (T20) and sewing light. • Plug in the sewing light (see 3.2.13) • Install covers (see 3.1).

c c

4

1

2

1

1mm


2

1

3.3.10 Needle Bar Disassembly

• Remove the covers (see 3.1). • Remove the needle, needle clamp and thread guide (T8/T6) (see 3.3.7) • Swing out the presser foot height and upper thread monitor sensor as

one single unit. (see 3.2.18) • Move the needle bar to the highest position to access the needle threader

height adjusting block

• Loosen screw b (T8. • Loosen the needle bar height adjusting screw c (T8). • Rotate the hand wheel slightly. • Note: The threader height adjusting block remains inside the machine. • Push the needle bar straight up and remove.

Assembly:

• Install the needle bar together with the needle threader height adjusting block making sure the block is guided by the threader shaft.

• Note: Slightly tighten the screw c; the screw on the threader height block b must remain loose.

• Install the needle clamp and the thread guide and secure with screw b (T8) (see 3.3.7)

• Install the needle height gauge 1 • Pin the take up lever pinning position 2

• Lower the needle bar/gauge to the top of the hook body • Using a straight edge hold it against the gauge and line up

the edge with the groove of the arm by twisting the needle bar.

• Tighten needle bar height adjusting screw c (T8). • Warning: As a rough adjustment for the needle threader

height adjusting block bring the needle to the highest position, lift up the block and tighten the screw b (T8) though the opening in the frame.

• Rotate the hand wheel making sure the block does not interfere with the internal parts.

• Finally adjust the needle threader height (see 4.10)

b

c


4

3

3.3.11 Replacement of the Lower Thread Cutter Disassembly:

• Open the bobbin door • Warning: The knife of the cutter is very sharp take cautions. • At point 1 and point 2 pull the thread cutter straight out.

Assembly:

• Line up the cutter and push it in as far as it will go. • Close the bobbin door

3.3.12 Replacement of the Upper Thread Cutter Disassembly:

• Place the finger under the thread cutter at about 5 o’clock 3 and give a smooth push until you feel the cutter is released

• Pull out the cutter with at least 2 fingers. Assembly:

• Position the cutter so that the end of the arrow is at 2 o’clock 4 • Insert it carefully until the 2 holding fingers are properly in position • Prove if the cutter holds in position

1

2


3.4 Handles Remove Handles from the machine:

• Disconnect plug 1 • Loosen the two screws a (T20) and remove the entire handles from the machine

Disassembly: Front handles:

• Open the clamp 2 and carefully pull the front handle, disconnect the plugs 3 and 4 • Peel back the foam handhold and remove screw b (T10) and pull out end cap with switch 5

Handle harness: • Remove screw c (T20) • Remove screw d (T6), open the clamp 6 and carefully pull out the right hand handle • Do the same on the other side • Open the pull relief 7 carefully. It will be damaged and need to be replaced • Pull out the cable harness and refit the new one

Assembly: Front handles:

• Install the end cap with switch 5, peel back the foam handhold and insert screw b (T10) • Line up the switch in the operation position. Do not tighten screw d (T10) to let the end cap being

adjustable • Connect the plugs 3 and 4, open the clamp 2 and carefully insert the front handle. • Open the right hand handle clamp 6 • Carefully install the right handle and tighten screw c (T20) • Tighten screw d (T6) very carefully • Install the entire handles on the machine, tighten the two screws a (T20) • Connect plug 1

d a

c

a

d

6

5

3

4

2

1

b

c

d 7


Chapter 4 – Settings

4.1 Basics – General Information To enable the settings and adjustments described to be performed correctly, the machine must be in good mechanical and electrical condition. (Running smoothly, properly oiled and all leads connected) Important: Unless otherwise specified, always use a needle size «Nm 80» when adjusting and setting the machine, Always start with a new needle before carrying out adjustments on the machine! The needle must be absolutely straight (130/705 H TCN). For servicing, we recommend to always use the accessories included with the machine or purchased specifically for it. These are the following: power cable, foot control, and other accessories. For maintaining and adjusting the machine we recommend to only use the BERNINA specific adjusting tools and gauges, drivers for Torx, regular screws, hexagon nuts and screws must be metric and of professional grade.


4.2 Belt Tensions

4.2.1 Upper / Base Shaft Belt Tension Check:

• Too tightly tensioned belts might cause binds and overheating of the bearings.

• Too loose tensioned belts may cause slippage and rattling sounds Adjustment:

• Loosen two screws a (T20) • The compression spring 1 will apply the correct amount of pressure to the

idler pulley/thus belts. • Slowly rock the hand wheel forwards and backwards while tightening the

two screws a (T20)

4.2.2 Take Up Lever Drive Belt Tension Check:

• With a pressure of approx. 500gr. the center of the belt 2, the belt must move 5mm +/-1mm.

Adjustment:

• Remove the covers (see 3.1). • Loosen the nut c (10mm) and move the idler pulley b to the

desired position.

a

a

1

c

2

b


a

a

c

1

4.2.3 Drive Motor Check:

• Remove the belt- and the inside-cover (see 3.1.2 and 3.1.3) • With a pressure of approx. 500gr. at the belt in the center 1, the

belt must move 8mm +/-1mm. Adjustment:

• Loose two screws a (T20) of motor bracket on the hand wheel side • Loosen screw base b (open end wrench 8 mm) from the needle

side • Slide motor up or down until the specification is met. • Retighten screws a (T20). • Tighten the screw base b (open end wrench 8 mm) from the needle

side • For a fine adjustment the rotate the screw c (T20) that also serves

as a physical stop for the motor bracket. • Install the belt and the inside cover (see 3.1.2 and 3.1.3)

Note: Make sure the when running the machine that the motor belt is running in the middle of the hand wheel and motor pulley.

b


4.3 Take Up Lever / Needle Bar Timing Check:

• Remove the covers (see 3.1). • Precisely move needle bar to its very lowest stroke. • The take up lever 1 must be in the pinning position.

Adjustment:

• Loosen two screws a (T10) • Pin the take up lever 1 • Pull the needle bar down by hand while rocking the counter weight 2

find the absolute lowest stroke of the needle bar. • Tighten the two screws a (T10) • Install the covers (see 3.1).

4.4 Presser-Foot Fixation Check:

• Use the standard machine foot to check if the clamping lever a meshes with the clamping bar b by a third to a half of its travel

• The presser foot sole opening must be equally distributed in respect to the needle.

Adjustment:

• From the right hand side loosen screw c (T20) on clamp d. • Adjust clamp height until correct clamping position is reached (1/3 of

clamping range). • Ensure that presser foot sole is properly aligned in the needle plate • Tighten screw c (T20) on clamp d

c

a

b

d

1

a

a

2


4.5 Needle Adjustment

4.5.1 Needle Distribution Left/Right Check:

• Use a new 130/705H TCN size 80Nm needle. • Move the needle to its lowest position. • Needle must be equally distributed in the center of the stitch hole.

Adjustment:

• Remove the covers (see 3.1). • Move the needle out of the stitch hole. • Very slightly loosen 4 screws a (T20) on the head frame

plate • Move the needle to its lowest position. • Carefully pivot the entire head frame left/right until the

needle is in the center of the stitch hole • Tighten the 4 screws a (T20) • Install the covers (see 3.1).

Warning: This adjustment must only be carried out with the belt and the inside covers securely installed. (see 3.1.2 and 3.1.3)

a

a a

a


4.5.2 Needle Distribution Front to Back Check:

• Use a new 130/705H TCN size 80Nm needle. • Move the needle to its lowest position. • From front to back the needle must be equally distributed in the center of the

stitch hole. Adjustment:

• Remove the covers (see 3.1). • Bring the needle out of the stitch hole. • Very slightly loosen 3 screws a (T30) on the head frame plate. • Move the needle to its lowest position. • Using an L shaped eccentric tool 031563.50.00 in position 1 move

the entire head frame front/back until the needle is in the center of the stitch hole.

• Tighten the 3 screws a (T30) • Install the covers (see 3.1).

Warning: After performing this adjustment the distance between the hook and the needle must be checked (see 4.6.3)

a

1

a

a

031563.50.00


4

5

b

b

b

4.6 Hook - Needle Drive Synchronization

4.6.1 Hook / Driver Play Check:

• Rotate the hook and check in 90 degree increments for hook gear play • A small amount of play should be detected at one single spot during the

testing. Adjustment:

• Remove the needle base (see 4.1.4). • Loosen the screw a (T10). • Rotate the large white eccentric 1 until the correct hook gear play is achieved. • Tighten carefully the screw a (T10). The eccenter part is plastic! • Re check the for adequate hook gear play. • Install the needle base (see 4.1.4)

4.6.2 Loop Lift Check:

• Open the front cover • Pin the take up lever with the needle at its lowest point (see 5.3). • Install the loop lift clamp 3 on the needle bar and adjust a distance of 2.4mm 2. • Remove the pin from the take up lever (see 5.3). • Remove the 2.4mm distance gauge 2. • Rotate the hand wheel in sewing directions until the clamp 3 is against the

bottom of the machine housing. • The hook tip must be flush with left needle edge.

Adjustment:

• Loosen the three screws b (T15) on the hook body. • Manually rotate the hook body until the hook tip 4 is flush with the

left hand side of the needle 5. • At the same time adjust the distance of 0.01 – 0.05mm between the

hook tip 4 and the needle 5 • Note: A Jewelry loupe might be helpful in the aligning process. • Tighten the three screws a (T15) on the hook body tight.

Warning: After performing this adjustment the distance between the bobbin basket and the retainer stopper must be checked. (see 5.7)

3

2

a 1

4

5


a

b

4.6.3 Hook/Needle Distance Check:

• Remove stitch plate and presser foot. • Use new needle 130/705H Nm 80. • Move the needle to the lowest position and keep moving until the needle tip is

flush with the left hand side of the needle. • Push with the finger against the needle towards the hook tip and check the

amount of needle deflection against the hook tip. • The distance between the needle scarf and the hook tip should be 0.01 –

0.05mm. Note: We recommend using a Jewelers loupe to ensure accurate setting. Adjustment: (see 4.6.2)

Warning: After performing this adjustment the distance between the bobbin basket and the retainer stopper must be checked. (see 4.7)

4.6.4 Needle Holder Alignment (Twin Needle) Check:

• Remove the needle plate • Remove the needle and install the needle height gauge 1 • Using a straight edge, hold it against the gauge and line

up the edge with the groove of the arm by twisting the needle bar.

Adjustment:

• Turn the hand wheel until the needle bar is on top position • Loosen the screw a (T8) • Loosen the screw b (T8) on the threader height adjusting block and keep the

screwdriver inserted • Using a straight edge, hold it against the gauge and line up the edge with the

groove of the arm by twisting the needle bar. • Tighten the screw b (T8) on the threader head height adjusting block • Adjust the needle bar height (see 4.6.5) • Prove/adjust the needle threader height (see 4.10)


4.6.5 Needle Height Check:

• Remove the needle plate • Remove the needle and install the needle height gauge 1 • Pin the take up lever 2 (lower dead end) • The gauge should be flush with the top of the hook body

Adjustment:

• Loosen the screw a (T8) at the needle bar holder • Lower the needle bar/gauge to the top of the hook body • Tighten needle bar height adjusting screw a (T8).

Note: Finally check/adjust the needle threader height (see 4.10)

1

a

2


4.7 Bobbin Case Retainer Stopper Note: This adjustment must only be carried out with the needle plate base securely fastened. Check

• The distance 1 between the bobbin case retainer 2 and the retainer stopper 3 must be 0.6 mm.

• Use the special gauge 033247.70.00. • The 0.55mm side must fit loosely; the 0.7mm side must not

fit in the space 1. Adjustment:

• Loosen screw d (T20) underneath the needle plate. • Move the retainer stopper to the desired position. • Tighten screw d (T20) underneath the needle plate

Note: Any wrongly adjusted distance between the basket and the retainer stopper can result in tension issues, thread breakage and or noises.

1

3

2

d


Position: 0

Signal 1

Signal 2

4.8 Synchronization Disc Note: The machine must be in the Service Program (see Chapter 5) Check:

• Open the front cover • Pin thread take up lever a • Select test 4h. • Signal 1 and 2 are not active, the position 0°.

Adjustment:

• Remove pin at the thread take up lever a • Remove the cover over the synch disk (see 3.2.5) • Rotate the hand wheel until the set screw b is visible • Loosen screw b (T8) of synchronization 1 disk just enough so that

the synchronization disk is not completely loose but dragging on the shaft.

• Pin the threader take up lever. • Carefully rotate the synchronization disk in sewing direction until

0° is visible on the screen (test 4h) and the two signals are not active.

• Take the pin out of the threader take up lever • Rotate the hand wheel until the set screw b of the synchronization

disk 1 is visible. • CAREFULLY and lightly tighten the set screw b • Install the cover over the synch disk (see 3.2.5)

Warning: Tightening the synchronization disk screw a too tight might result in synchronization disk breakage. The consequence is, having to replace the upper shaft, main shaft bushing and synchronization disk, which is on single piece!

a

b

1


1

2

4.9 Presser Foot Height Check:

• Open the front cover • Pin thread take up lever a • The distance between the bottom of the sole 1 and the needle

plate 2 must be 0.5mm Adjustment:

• Remove the covers (see 3.1). • Pin the take up lever a. • Rotate the white gear 3 and bring the presser foot to the lowest position. • Loosen two screws b (T20) from presser foot height clamp. • Raise or lower the disconnected presser foot bar. • Generate a gap of 0.5mm between the presser foot sole and the top of the

needle plate. • Note: The presser foot spring should not be compressed. • Line up the presser foot with the needle/needle plate. • Tighten two screws b (T20) from presser foot height clamp. • Install the covers (see 3.1).

4.10 Needle Threader Check:

• Remove needle and insert threader gauge 734101.50.00 • Set needle bar to top dead center. • Push threader handle downward until the threader head slides underneath

the gauge. No play between gauge and threader head

a

3

b

b


b

Adjustment: • Open the front door • Loosen the screw b (T8) on the threader height adjusting block and keep

the screwdriver inserted • Move the block accordingly so ensure a proper needle threader height • Tighten the screw b (T8) on the threader height adjusting block

4.11 Thread regulator Check:

• Note: Make sure the BERNINA tension spring scale (00603850.00) reads zero when the tip of the gauge points straight down, calibrate accordingly

• Pull 30cm or 1 ½ foot of thread from the spool and loop it vertical around check spring.

• Attach the two thread ends to the BERNINA tension spring gauge • Vertically pull the gauge up until he check spring just starts to move

upwards. • The spring is supposed to move when the gauge indicates 23 gr.

Adjustment:

• Slightly loosen screw a (T10). • Turning the thumb wheel 1 will tighten or slacken the

tension. • Retighten screw a (T10).

Check:

• When the thread regulator spring 2 rests on the black regulator spring stop 3.

• The distance between the spring 2 and the check spring guide 3 should be a distance of 1.7mm (+/-0.3mm).

Correcting the position:

• Slightly loosen the screw c (T10). • Rotate the black regulator spring stop 3. • Retighten screw c.

a

1

2

c

e

3


1

2

1

4.12 Upper Thread Tension Note: The machine must be in the Service Program (see Chapter 5) Note: With all BERNINA sewing computers that are utilizing an automatic top tension system we established two specific tension calibration points. They must be most accurate to set the baseline for various automatic tension settings. Note: Use a DMC 50 BLANC cotton thread specified by BERNINA. Check:

• Select test 6j for thread tension adjustment. • Then select the icon in the screen. • Thread the machine to the left side of the take up lever. • Select DMC 50, 100% Cotton Color BLANC (white). • With the take up lever at the highest point attach the 30.6-gram

gauge 1 to the upper thread on the left side of the take up lever. • The thread must not release from the spool (NO-GO). • Add a 5 gr. magnet 2 the thread must slowly coming off the spool

(GO). Adjustment:

• Select “UP” or “DOWN” until the (NO-GO/GO) statements are fulfilled. • Once fulfilled select


3

2

1

2

Check: • Attach the 50-gram gauge 2 to the weight base 1 • The thread must not release from the spool (NO-GO) • Add a 2 x 5 gr. magnet 3, the thread must slowly coming off

the spool.(GO) Adjustment:

• Select “UP” or “DOWN” until the (NO-GO/GO) statements are fulfilled. Once fulfilled select the setting and automatically advances to the exit of the test

• Touch to save the settings. • A 'Successful' message along with the tension settings (in increments) will appear.

4.13 Lower Thread Tension (Bobbin Case) Check:

• Use a DMC 50 BLANC cotton thread specified by BERNINA.

• Use special gauge No. 035.905.70.00 to test and calibrate the bobbin case tension.

• Insert the bobbin with the bobbin thread threaded only through the spring bobbin case tension spring.

• Insert the bobbin case into the gauge. • Guide the thread around the rollers and pull

on the thread. • The gauge should read 22 gr. +- 2 gr.

(actually display 220 +- 20mN) Adjustment:

• Using a small screwdriver adjust the lower thread tension screw 4 a as appropriate. • Turn screw counterclockwise (to left) to slacken. • Turn screw clockwise (to right) to tighten.

4


b

4.14 Winder Check: Bobbin filling amount

• The thread should be evenly wound, and the bobbin should be correctly filled.

• Attach the gauge 035.905.70.00 to the bobbin spindle with the flat surface facing the winder lever

• With the machine in the off position engage the winder lever, the lever should stay.

• Rotate the gauge on the spindle the winder lever should snap back. Adjustment:

• Rotate the screw b (T10) until the proper filling amount is achieved Check: Even bobbin filling

• Wind a bobbin • The bobbin should be filled correctly

Adjustment:

• Loosen the screw c (T8) • Move the pretensioner sleeve slightly in or out • Tighten the screw c (T8)

c


Chapter 5 – Service Program Entering:

• Switch machine on ("1"), if not already on

• Click the Home button

• Following by • The machine is now in the basic position for servicing - first level.

Exiting the test program:

• Click on to go to the set up menu or to go into the sewing menu

Basic position: Menus 1 to 6 are selected in the service program basic menu.

1 = Service Info Menu 2 = Screen Menu

3 = Sensors Menu 4 = Signals Menu

5 = Motors Menu 6 = Settings Menu

Menus:

• The various tests – menus 1 to 6 – are selected in the basic service program.

• Press to return to basic service program without saving the settings. Tests:

• The testing level contains the active part of the program.

• Press to return to respective menu with saving the settings.


Virtual keyboard The following tests require data entering:

• Test 1a (purchase date) • Test 1f (reset service stitches) • Test 1h (customer information) • Test 1i (dealer information)

1 Data entry line touch to delete completely 2 CLR button () touch to delete individual characters 3 Virtual keyboard including shift key for

special characters letters, numbers and other characters

4 Selecting a keyboard a: Upper case letters b: Lower case letters c: Numbers, special characters and punctuation marks d: Special marks

PIN keyboard Some tests and calibrations require a PIN code, so that unauthorized access can be avoid. The PIN code is 8266 (ZIP Code of Steckborn, Switzerland)


Menu 1 – Service Information • The tests/submenus are selected by touching the

appropriate button. • Information on configuration, machine status and user /

dealer data. • Data is displayed by the page, with the page reference as a

title. • Explanations of data and how to change and save data are

given below.

1a Machine Basic Data

What to test: • Language • Purchase Date (MMDDYYYY)

MM = Month DD = Day YYYY = Year

1b Machine Soft- and Firmware Data

What to test: • Software version: (application and data) • Boot loader version. • Memory and flash capacity. • Application versions for both BSR sensors

What to test:

• Touch the right pointing symbol to go to the next pages. • Technical data (1 – 10).

Note: • Using the virtual keyboard, technical data can be entered in

the page. • The entered data gives the technician information on

already made improvements.


1c Machine Operating Time Data

What to test: • Total Time Power On • Time Standby • Time Working • Time Manual Sewing (with and without BSR) • Time Automated Sewing

1d Machine Stitch Counter Data

What to test: • Total number of stitches • Total number of manual sewn stitches (incl. BSR) • Total number of automated sewn stitches • Stitches since last lubrication • Stitches since last service

1e BSR (BERNINA Stitch Regulator) Data

What to test:

• The BSR sensors are connected. (Default) Product Numbers

• Serial Numbers • Production Dates • Hardware Revisions • Boot Loader Versions • BSR Application Versions • Sensors Resolution X • Sensors Resolution Y

Note: Information will only be displayed if the BSR sensor(s) are connected to the machine. (Connected by default). On the left-hand side of the slash (/), the information of the left connected BSR is shown.


1f Machine Servicing Data

What to test: • Stitches since last lubrication = Time for cleaning / lubrication (appears after 500’000 stitches). • Reset lubrication stitches = Resetting cleaning / lubrication interval to 0 stitches • Stitches since last service = Time for servicing (appears after 30’000’000 stitches) • Reset service stitches = Resetting servicing interval to 0 stitches. PIN code protected

Cleaning interval • The stitch counter triggers a reminder after 500’000

stitches (intended for the customer to carry out): Please clean and oil the machine.

Important: • Remember to always reset the counter (cleaning interval)

after servicing or repairing. Service interval

• The stitch counter triggers a reminder after 30’000’000 stitches: Please contact your BERNINA dealer for servicing your machine.

Important: • Remember to always reset the counter (cleaning interval) after servicing or repairing as follows:

o Click on the yellow bar “Reset Service Stitches”, the PIN code keyboard show up o Enter PIN Code (8266), the keyboard to enter the Service and Repair Data. o Entering Service And Repair Data

Touch the left- or right-pointing symbol to go to the previous or next page. There are 5 entry lines available. The sixth entry will overwrite the first entry. Maintained by…on = entered by (technician's name) on (date) Note:

• When resetting the servicing stitches the virtual keyboard opens.

• Repairing data must now be entered first. Otherwise the stitch counter won't reset to zero.

1h Customer Information

What to do: • Enter Customer First Name • Enter Customer Last Name • Enter Customer Telephone Number • Enter Customer E-Mail Address

Note: • The virtual keyboard opens on selecting a field. • Customer data can now be entered. • 'Reset Language: English':

Touch the button to reset the language to 'undefined'. The language can be selected again after re-starting the machine.


1i Dealer Information

What to do: • Enter Dealer name • Enter Dealer address • Enter Dealer telephone number • Enter Dealer Internet/E-Mail address

Note: • The virtual keyboard opens on selecting a button. • Dealer data can now be entered. • Dealer data can also be read and entered in .txt format from a BERNINA USB memory stick.

Important: The file must be named "dealerdata.txt" (see example below). • The dealer-related data will automatically appear on the screen when a maintenance reminder is

triggered. For example:

BERNINA International AG 8266 Steckborn 0521234567 www.bernina.com

1j Log File:

What to test: • External saving of internal processes (log book) on a

BERNINA USB memory stick. • The log file contains processes and configuration data.

Note: • If software problems occur, the read data (log files) should

be sent to the respective importer / distributor by email with a detailed description of the symptom(s).


Menu 2 – Touch and Display What to test:

• The tests are selected by pressing the appropriate button. • Information on touchscreen, LCD, defective pixels, *RGB

colors, buttons, clock settings and LED settings. * = Red, Green and Blue

2a Touchscreen Calibration

What to test: • Touch 'Calibrate' to start the test. • To calibrate the touchscreen, use the BERNINA stylus to

touch the 3 crosses as required • Touch to save and return. • Touch to close without saving.

Note: • If the touchscreen’s calibration is misadjusted in such way that the function can no longer be selected in

the service or setup program, an alternative access is provided. Alternative access for the front connected LCD:

• Switch off the machine • Switch on the machine while the touch screen is pressed with the finger in any position. • The touch screen can now be calibrated as per instructions above.

Repair notes: • Check touch screen connector cables (HDMI). Check cables for deformation and or wear and tear. • Replace touch screen.


2b LCD Display (Screen)

What to adjust: • Use “+” and “-“ buttons or stitch width button to adjust the

brightness. • Select 'Default' to reset to the default settings. • To save and return. • to return without saving

2c Blank Dark LCD Display (Screen)

What to test: • Blank dark screen to find any pixel errors. • To return to menu 2, touch .

Repair notes: • Check cables and plugs for deformation and/or wear and

tear. • Replace the LCD display if pixel errors occur. (see 3.1.1)

2d Blank White LCD Display (Screen)

What to test: • White blank screen to find dirt or stains. • To return to menu 2, touch .

Repair notes: • Clean LCD and touch screen.

Attention! Never use alcohol, petrol, spirits or any corrosive fluids, or abrasive pastes or abrasive cleaners!


2e RGB (Red, Green and Blue) Screen

What to test: • The color screen is built up from the basic colors RGB.

All other colors are merely a mixture of these 3 colors. The screen will detect if any color faults occur.

• The colored bar graphs run from right to left. • The color should be a true color at the right side, running

through to black resp. white at the left side • If any color defects occur, it will show within the bar graphs • To return to menu 2, touch

Repair notes: • Check cables for deformation and/or wear and tear. Check if ribbon cables are properly plugged. • Replace the LCD if any color defects occur. (see 3.1.1)

2j Display Switch

What to test:

• Switch between the displays front and rear to carry out the tests from menu 2

The 1. Picture on the right hand side shows the situation if only the front display is connected, while the lower picture shows 2 LCD’s connected, front and rear.


Menu 3 – Sensors (Mounting Locations in the Machine) What to test: These sensors can be tested: a) Threader sensor b) Over lift presser foot switch f) Upper thread sensor g) Bobbin Winder Switch

3a Threader Sensor

What to test:

• Select test 3a. A bar will appear. • Pull threader unit down. • The signal in the bar will change from "0" to "1" • When releasing the threader, the signal will change from

“1” to “0” again • Press to return to menu 3.

Repair notes:

• Check that the threader lever moves freely and that the spring pulls the threader all the way to the top position.

• Check cables for deformation and/or wear and tear. • Check correct positioning of PCBA Threader. The PCBA Threader is held in position and fastening with

a screw (T20) in the needle bar support. • Clean the PCBA Threader • If the sensor doesn't respond, replace the PCBA Detection - Threader Sensor (see 3.2.15).

3b Overlift Presser Food Switch

What to test: • Select test 3b. • Press the presser-foot button to lift the presser foot. • Press the presser foot bar manually up to the stop position • The Signal changes from “0” to “1”. • When releasing the presser foot bar, the signal changes

from “1” to “0” again “1” represents the foot is in the over lift position “0” represents the foot is out of the over lift position

• Press to return to menu 3. Repair notes: Signal doesn't respond:

• Check cables for deformation and/or wear and tear. • Clean PCBA Presser Foot Height Sensor • Replace PCBA Presser Foot Height Sensor (see 3.2.14).


3f Upper Thread Sensor

What to test:

• Insert a thread loop around the thread-regulator spring. • Move thread-regulator spring with thread loop up and

down. • The bar flashes green when the sensor is active. Thread is

pulled up. Repair notes:

• Check adjustment values of the thread-regulator spring mechanics and adjust if necessary.(see 4.11) • Check light barrier for dust or dirt. • Check whether the switching flag is displayed from the thread-regulator spring. • Check cable to PCBA Detection – Upper Thread Observer (see 3.2.16). • Exchange PCBA Detection – Upper Thread Observer (see 3.2.16). • Exchange PCBA Base (see 3.2.6).

3g Bobbin Winder Switch

What to test: • The tripping lever is in the upper position; the situation is

shown as of the upper picture. The winder motor does not run

• When moving the tripping lever down, the micro switch is activated. The indication turns to green, as of the lower picture. The winder motor runs

Repair notes:

• Check cables for deformation and/or wear and tear. • Replace bobbin winder (see 3.2.2) • Replace PCBA Upper Interface (see 3.2.3) • Replace PCBA Base (see 3.2.6).


Menu 4 – Signals What to test: These signals can be selected and tested: b) Functions of the handle-buttons d) Foot control e) Interface auto motion g) BERNINA Stitch Regulator sensors (BSR) h) PCBA-Position i) Speaker j) USB ports m) BSR interface n) Channel Lock o) Laser Test

4b Function of the Handle-Buttons

General explanation: On the left side of the display in Service Program 4b, the front side connected handles are shown, while the right side of the display shows the test results for the rear side connected handles There are 2 different handle sets available. One with the flat control panels (only optional) has on both sides red safety buttons (Left Picture, red button on the right side). The standard handles with the round handhold do not have safety buttons. The safety circuits are internally short cut on will light up green permanently.

What to test:

• Select test 4b. • If a handle set is connected, the indication is shown on top • Press the key of the function to be tested. The respective symbol will light up in the display. • Press to return to menu 4.

Repair notes: • Check the handles on the rear side of the machine.

o If still not working, the problem is within the handles o If the handles do work on the rear side of the machine, the issue is with the machine

Issue within the handles • Check the mechanical functioning of the key if the function doesn't light up. • Check the inside cables for deformation and/or wear and tear.

Issue at the machine • If the handles do not work connected at the head side

o Check cable connection to the PCBA Upper Interface to PCBA Quilt Extension X400 o Replace PCBA Upper Interface o Replace PCBA Quilt Extension

• If the handles do not work connected at the rear side o Replace PCBA Quilt Extension


4d Foot Control What to test:

• Select test 4d. • Slowly press foot control down as far as stop. The bar will

fill accordingly. • Heel kicking the foot control will light up the needle stop

down button in the display. • Press to return to menu 4.

Repair notes: • Check foot control cable for deformation, damage and

loose contacts. • Check foot control ceramic plate and spring-mounted carbon pin holder for correct fitting and

functioning. • Check lower cable harness for squeezed wires • Replace PCBA Lower Interface • Replace PCBA Base (see 3.2.6).

4e Interface Auto Motion

The optional auto motion module was not available at the editorial deadline What to test:

• Select test 4e • The status of the physical interfaces (UART, IO and FC)

between the Q20/Q24 and the auto motion module will be shown

• Press to return to menu 4. Repair notes:

• Not available at the editorial deadline Physical Interfaces:

• UART = Universal Asynchronous Receiver Transmitter (physical interface module) • IO = Input/Output (information processing) • FC = Foot Control (simulated speed regulation of the machine from the auto motion module


4g BERNINA Stitch Regulators (BSR)

What to test: Individual sensor test

• Select test 4g. • Select the sensor to be tested. Sensor left or sensor right. • Press the BSR icon to start the test. • Move fabric in different directions over the selected BSR. • The directions of the movement will be displayed in the

screen. • The covered distances X and Y will be displayed, value in mm. • Press to return to menu 4.

Comparison test

• Prepare a piece of fabric and draw a straight line of 200 mm on it

• Select Test 4g. • Position the fabric or machine at start of the defined line

and start the test by pressing the BSR icon. • Move fabric or machine along the line and stop at the end. • The display shows the numbers of mm of the movement for

each BSR sensor, about 200 = 200 mm • The difference between the 2 values should be less 5% • The measurement can be reset by clicking on the BSR button in the display

Repair notes: Individual sensor test

• Check cables for deformation and/or wear and tear. • Check BSR sensors for dust or stains. • Check BSR plug and PCBA Lower Interface (see 3.2.4) • Unplug one after the other to see if one fails • Replug over cross to see if a sensor or the PCB is defective • Replace PCBA Lower Interface (see 3.2.4). • Replace BSR sensor.

Comparison test If the comparison test shows a repetitive difference of more than 5%:

• Clean the BSR windows • Replace the BSR sensor which show more difference to the nominal value


b

1

4h PCBA-Position What to test:

• Select test 4h. • Set needle bar to bottom dead center (= 0°, pinning

position at thread take up lever). (see 4.3) • Remove the pin and slowly turn hand wheel in rotating

direction. The signal 1 and 2 bars turn green. • To the right of the signal bars, the position is displayed

in degrees. • Press to return to menu 4.

Note:

• Bottom dead center of needle bar is 0°.

• Upper dead center of needle bar is 180°.

• Loop lift Position at 27.5° • Resolution of this system is +/- 2.5°

Repair notes:

• If the degrees appear in the correct order but at the wrong time, check the position of the synchronization disc (see 4.8).

• If the degrees appear in the wrong order or if no signal appears, replace the PCBA-Position. • Clean PCBA-Position light barriers. • Check cables for deformation and/or wear and tear. • Check correct position of PCBA-Position. • If no signal appear, replace the PCBA-Position.(see 3.2.5)

4h Mechanical Fine-Adjustment of Synchronization Disk

What to test: • Pin thread take up lever (see 4.3) • Select test 4h. • Signal 1 and 2 blank, angle position 0° as described above.

What to adjust:

• Remove pin at the thread take up lever a • Remove the cover over the synch disk (see 3.2.5) • Rotate the hand wheel until the set screw b is visible • Loosen screw b (T8) of synchronization 1 disk just enough so that the

synchronization disk is not completely loose but dragging on the shaft. • Pin the threader take up lever. • Carefully rotate the synchronization disk in sewing direction until 0° is visible on the screen (test 4h) and

the two signals are not active. • Take the pin out of the threader take up lever • Rotate the hand wheel until the set screw b of the synchronization

disk 1 is visible. • CAREFULLY and lightly tighten the set screw b • Install the cover over the synch disk (see 3.2.5)

Caution:

Tightening the synchronization disk screw a too tight might result in synchronization disk breakage. The consequence is, having to replace the upper shaft, main shaft bushing and

synchronization disk that is only available as single assembly!

Hand wheel position in degrees: Signal 1 Signal 2 0° X X 25° X 115°

202.5° (position at start, needle up)

215° X

277.5° X X


4i Speaker What to test:

• Select test 4i. • Press the 'Start Speaker Test' bar to start the test. • A few beep sounds can be heard. • Press bar again to finish the test. • Press to return to menu 4.

Repair notes: • Replace PCBA-Base (see 3.2.6).

4j USB Ports

What to test: • Select test 4j. • Connect a USB cable from the USB host to a USB

slave . Recommended: Use a cable with included LED's at the two ends.

• If an end-lit cable is used, the LED’s will automatically light up = Host / Slave OK

• If a standard USB cable is used, the icon on the screen must be pressed to start the test. • Click on the yellow icon to start the test • A 'successful' or 'Test Failed' message will appear. • Press to return to menu 4.

Repair notes: If 'Test Failed' message appears:

• Repeat the test using another USB cable. • Check the slave and host ports on the machine. • Replace PCBA Base (see 3.2.7) • Replace PCBA Quilt Extension. (see 3.2.10)


4m BSR Interface

What to test: • Select test 4m. • The color of the bar is green and appears if the

interfaces of the BSR sensors are working • Press to return to menu 4.

Repair notes: • Check BSR plugs and connectors. • Check cables for deformation and/or wear and tear. • Replace BSR sensor. (see 3.2.1). • Replace PCBA Lower Interface (see 3.2.4).

4n Channel Lock

The optional auto channel locks were not available at the editorial deadline What to test:

• Select Test 4n • Click on the left yellow icon to test the channel lock in x direction. The machine

carriage must not move anymore in direction left or right • Click on the right yellow icon to test the channel lock in y direction.

The machine carriage must not move anymore back or forth Repair notes:

• If one of the tests should fail, prove cable and connection first. If it does not resolve, o Unplug both channel locks and re-plug the working one to the not working

connector. o Start the test on the connected function. Verify the icon on the display with the

one at the rear side connector. If it is still not working, replace the PCBA Quilt Extension (see 3.2.10)

o If it is working, replace the channel lock which is unplugged • If both channel locks do not work, replace the PCB Quilt Extension (see 3.2.10)


4o Laser Test

What to test:

• Select test 4o • The Laser must be active

Repair notes: • If laser does not light up check the cabling and test with a

different laser. • Replace the PCB Quilt Extension (see 3.2.10)

Warning: Caution when operating the laser.


Menu 5 – Stepping Motors (Mounting Locations in the Machine) What to test: b) PFP= Presser-Foot Pressure c) TT = Upper Thread Tension f) Bobbin Winder Motor

5b Presser-Foot Pressure Stepping Motor

What to test: • Select test 5b. • Press the button to start the test. • The presser foot bar will move up and down. • The word 'Running' appears and the icon changes to

turquoise. • To stop the test/stepping motor, press the button again. • A 'Successful' message will appear. • Press to return to menu 5.

Repair notes: • If the stepping motor doesn’t move, the fault might be with the motor itself (see 3.3.9) • Check the wiring or the PCBA-Base or replace the PCBA-Base (see 3.2.3) • Check plugs and cables for deformation and/or wear and tear.

Caution! Disconnect from the power supply. Do not disconnect or reconnect when the machine is powered.

5c Upper Thread Tension Stepping Motor

What to test: • Select test 5c. • Press the button to start the test. • The upper thread tension stepping motor moves back

and forth. • The word 'Running' appears and the icon changes to

turquoise. • To stop the test/stepping motor, press the button again. • A 'Successful' message will appear. • Press to return to menu 5.

Repair notes: • If the stepping motor doesn’t move, the fault might be with the motor itself (see 3.3.3) • Check the wiring or the PCBA-Base or replace the PCBA-Base (see 3.2.3) • Check plugs and cables for deformation and/or wear and tear.

Caution! Disconnect from the power supply.

Do not disconnect or reconnect when the machine is powered.


5f Bobbin Winder Motor

What to test: • Select test 5f. • Press the button to start the winder motor/test. • The word 'Running' appears and the icon changes to

turquoise. • To stop the test/winder motor, press the button again. • A 'Successful' message will appear. • Press to return to menu 5.

Repair notes: • Check plugs and cables for deformation and/or wear and tear. • Replace the bobbin winder unit (see 3.2.2). • Replace PCBA Upper Interface (see 3.2.3).

Menu 6 – Adjustments What to test: g) Reset to factory settings j) Automatic upper-thread tension m) Main motor test

6g Resetting To Factory Settings (Reset All):

What to test: • Select test 6g. • The prompting 'To Reset Sewing Settings Press OK'

appears. • To continue, press . • The query 'Do you really want to reset?' appears. • If the answer is Yes, press to reset the sewing settings

to factory settings and to return to menu 6. • If 'No', press to return to menu 6. The sewing settings

remain unchanged.


6j Automatic Upper-Thread Tension

IMPORTANT! This sub menu is PIN protected. The PIN code: 8266

What to test: (see 4.12.4)

• Select test 6j. • Confirm and enter the PIN code • Press the button to start the test. (see 4.12.4)


6m Main Motor Test

What to test:

• Select Test 4m • Start the test with either the foot control or the associated

handle button. • The main motor will run with maximum the adjusted

speed. The max. Speed can be altered, sliding with the finger in the blue bar. • Press to return to menu

Repair notes:

• Check belt and belt tension (see 4.2.3) • Check the wiring of the motor or replace the motor (see 3.2.17) • Replace the PCBA Power Supply (see 3.2.12) • Replace the PCBA Base (see 3.2.3)


Chapter 6 – Lubrication Klüber OY 100 (007779.70.01)

Velocite 6 (033567.50.01) Klübersynth UH1 14-1600 (002779.72.02)

6.1 Thread Take Up Lever, Needle Bar Drive


6.2 Needle Bar, Presser Foot Bar

6.3 Hopper Cam


6.4 Presser Foot Bar Guide

6.5 Hook, Hook Drive


Chapter 7 – Firmware Update

7.1 Standard Update Procedure Note:

• The BERNINA Q 20 and Q 24 do have the same firmware (FW) • Update files are available for downloading from Infogate. • The update files can be downloaded to one BERNINA USB stick (FAT 32 formatted) but must be saved

on the first level of the memory directory (root directory). Note: If the files are saved in a folder or subfolder, the machine will not be able to find them and will consequently not be able to update.

1. Save the update files to a BERNINA USB stick (at least 512 MB).

For BERNINA dealers: For BERNINA end users:

2. Connect BERNINA USB stick to machine and switch main switch ON.

3. Enter the Setup Program, and then press the Update button.

4. The Update window opens. Press 'Update'. The updating process starts. 5. The update files will be checked, data and settings saved to the USB stick and a reset triggered. 6. On resetting the update will be carried out and the machine will start and run in update mode

automatically. 7. The saved settings and data are copied back from the USB stick to the sewing machine and the

application changes to normal mode. 8. Now the machine is ready for normal usage with the new version. 9. If the update cannot be started or in the event of problems occurring while updating, one of the error

messages below may appear:

http://infogate.bernina.com

www.bernina.com/downloads

http://infogate.bernina.com/

http://infogate.bernina.com/

http://www.bernina.com/downloads


Error message Possible cause Possible solution

No valid Updates on USB Stick

Files not complete or faulty. Save the proper update files to the USB stick (again).

Update files were not saved to the first level of the USB memory.

Move the update files to the first level of the USB memory (root directory).

Defective or incompatible USB stick.

Use a BERNINA USB stick. Check functioning of USB stick on a pc.

Restore of customer data failed

USB stick not recognized.

Is the USB stick connected? Connect BERNINA USB Stick with updates and customer data to machine, wait for 10 seconds, and then try again. Switch the machine with the USB stick connected, off and on again. Check functioning of USB stick on a pc.

Saved settings / personal data missing.

Repeat update procedure. Load the saved settings / personal data again via the service program (1g – load the customer settings)

Update failed Updating of machine with new application failed.

Switch the machine off and wait for 30 sec. Then switch on and run the update process again. Save the proper update files to the USB stick (again). Then repeat the updating. Try alternative access.

Replace PCBA-Module.


7.2 Update – Alternative Access Note: If the update cannot be carried out in Setup, or if the machine fails to reboot, an alternative access is provided.

Important: Avoid Loss of Data! If the sewing/embroidery system fails to reboot (e.g. due to not recognizing the firmware), the data saved by the customer will not be saved any more. However, the machine-related data in EEPROM (e.g. hours and stitch counter, calibration settings) remain saved.

Attach the USB stick to the machine at position . Keep the reset buttons pressed and switch the machine on. After the machine has started, the display asks to confirm the firmware update. Therefore release the reset button and press it again. The update process will start and check the data on the USB stick.

Rear side connectors of the Q series machines Note: On completion of the manual update procedure, the machine must be started manually.


Chapter 8 – Maintenance Guidelines

8.1 Purpose of the Maintenance Guidelines • The technician is given guidelines for carrying out the service. • This improves service- and repair quality. • The dealer or service technician can calculate the expected maintenance costs for the user

transparency. • Calculable maintenance costs offer the opportunity for Maintenance contracts. These result in additional

business, and a degree of customer retention that should not be underestimated. • Same service quality worldwide. • The wear-and-tear-parts definition helps to identify (unjustified) warranty claims by the customer, mainly

in the case of intensive use. • Defined wear-and-tear parts are subject to a charge; exempt are the parts declared in the spare-parts-

warranty extension (BERNINA warranty provision). • Compliance with Maintenance intervals allows system functioning to be ensured and increases the

service life of the sewing and embroidery machines. • Should the customer not comply with the Maintenance intervals, the guarantee may be limited. The

Maintenance guidelines consist of the following: • The wear-and-tear-parts definition. • The service checks to be carried out during a Maintenance Service.

8.2 Explanatory Notes on the Stitch- and Hour Counter Every sewing stitch is counted, but because of the low mechanical load, only every second embroidery stitch is counted.

8.2.1 When is a Cleaning Message Displayed? On reaching 500'000 stitches a cleaning reminder appears. Cleaning can be carried out by the customer. The stitch counter can be found under Information in the Setup Program.

8.2.2 When is a Maintenance Message Displayed? On reaching 30'000'000 stitches maintenance/servicing reminder appears.

8.2.3 Calculation table This table is meant to show how many hours are required for a Maintenance message to be displayed as a function of the SPM (stitches per minute) speed. Example: Sewing time total (hours)

Sewing time total (minutes)

Average SPM (Stitches/min)

Total Stitches

500 30’000 1000 30’000’000

8.2.4 Implementation of the Maintenance Intervals At every interval, the Maintenance message is displayed each time the machine is switched on. The message only disappears after resetting to zero by the technician making a service entry in the Service Program.


8.3 Maintenance Intervals To calculate the Maintenance intervals, an average quilting speed of about 1000 S.P.M. is assumed. Maintenance Interval

Stitch Counter Time Counter (hours)

1 30’000’000 500 2 60’000’000 1’000 3 90’000’000 1’500 4 120’000’000 2’000 5 150’000’000 2’500 6 180’000’000 3’000 7 210’000’000 3’500 8 240’000’000 4’000 9 270’000’000 4’500 10 300’000’000 5’000

8.3.1 Cleaning- and Service-Stitch Reset • Service entries must be made by the technician in the Service Program after a service or repair –

otherwise, the service stitches are not reset to zero. • The same holds true for the cleaning-stitch reset.

8.4 Wear-and-Tear-Parts Definition Explanations:

• The service life of the machine was defined for “standard” quilting use. • In the case of intensive use for which the machine was not designed, increased wear-and-tear of parts

cannot be ruled out. • In order to ensure continuously defect-free operation of the machine, BERNINA recommends replacing

the parts according to the table (Item 8.4.2), once the Maintenance interval is reached. • The customer has a right to the replaced parts, with the exception of replaced electronic components,

should these be repaired by BERNINA. • The defined wear-and-tear parts are subject to charge and are NOT subject to general warranty. • The Maintenance work to be carried out is listed on the Maintenance checklist.

8.4.1 Non-Operating-Related Parts Depending upon purpose, handling, climatic conditions and use, the following parts cannot be defined in time terms, and are therefore to be individually assessed or replaced when signs of wear and tear appear and/or functionality is impaired:

• Sensors and actuators. • Electronic components. • Display / touch screen. • Sewing light / back lighting. • Thread sensors. • Regulator spring. • Stitch plate (scratch marks of needle around stitch hole). • Foot control cable and cable plate. • Cables and wires in general (squashed, interrupted etc.). • Covers, casings (cracked/worn threaded holes, tears, scratch marks and signs of wear and tear). • Presser feet (scratch marks, wear). • Components of semi-automatic threading process.


8.4.2 Operating Related Parts The parts below listed have to be carefully checked for proper functionality and wear and tear. At the Maintenance Intervals, it is technically foreseen to replace the parts. Anyway if the parts are judged as good, replacement can be postponed until the next Maintenance Interval for a new evaluation. Article No Article Name At Maintenance Interval Remarks 034519.50.00 Glider (Presser foot bar)

1, 2, 3, 4, 5, 6, 7, 8, 9, 10 …….

Radial play of presser foot

032265.70.00 Thread Cutter (upper thread) Cutting test 034567.70.00 Thread Cutter (lower thread) Cutting test 034415.70.00 Hook M-Class cpl

2, 4, 6, 8, 10 ……

Excess noise, bobbin basket play and wear and tear of the hook tip

034872.70.00 Bobbin Case Tension spring, break spring

034409.50.00 Retainer stopper 034474.70.00 Take up lever assy

3, 6, 9, 12 …….

Play, availability of ceramic eyelet

034528.50.00 Tooth belt (take up lever) Need expansion of Service Manual

030955.50.04 Tooth belt (main motor) Wear and tear 030955.50.05 Tooth belt (synch.) Wear and tear 034485.70.00 Main Motor Smooth running -- Needle Drive System Play

8.5 Maintenance Checklist The Maintenance Checklist explains what work is to be carried out on appearance of maintenance messages. Note: The Maintenance Checklist refers to maintenance work only (cleaning, lubrication, visual and functional checks) and not to repairs (excluded owing to their complexity). The parts whose replacement is recommended after the display of the tenth maintenance interval are listed in the Wear-and-Tear-Parts Definition (see 8.4). The Service and Maintenance Manual and the service and technical information notices serve as a basis for the service work to be carried out. The service works listed in the Maintenance Checklist must be carried out in the order listed, at each maintenance interval.

8.5.1 Measures to be taken before the Maintenance Note: The machine must be switched on in order to use the Service Program. Refer to the safety instructions please.

• Update the machine to the latest firmware. • Read out the stitch and hour counter and enter on the Service Report.

8.5.2 Measures to be taken after the Service Maintenance- and cleaning-stitches reset, service entry in the Service Program.

Recommended: Create a Service Report and save in a customer database, or file a copy. Furthermore, the following data should be noted in the Service Report. Customer and machine data, standard accessories (supplied with the machine), stitch and hour counter, report number, maintenance interval, complaint, work carried out, time and material input, date when next maintenance is due, name of technician.


8.5.3 Functional Check Consider customer complaints, if any, when carrying out functional checks. The resulting diagnosis must be taken into account in addition to the normal maintenance check. What to check What to check for specifically

1. Visual check: Covers, LCD / touch screen, Spool pin

• Scratch marks and signs of having dropped the machine • Tears and cracks • Clearance/gap widths

2. Feature • Main switch

3. Needle

• Properly attached • Bent • Blunt • low quality • wrong system

4. Power cable Foot control cable

• Damaged insulation • Loose contacts / interruptions • Squashed cables • Connectors

5. Switch machine on and let it run • Listen for unusual noises and noise level • Foot control test

6. Functions to test with machine switched on

• Stepping motors • Sewing light • Touchscreen • Screen / LCD • Threading process • Handles for frame version

7. Functioning of connectors

• Automation • Foot control • USB data stick • Channel lock • Laser

8. (Remove covers) Ribbon cable Single-strand cable

• Damaged insulation • Loose contacts / interruptions • Squashed cables • Connectors

9. Rough visual check of settings • Needle height • Needle position in needle plate • Needle-/hook distance • Main shaft-/base shaft synchronization

10. Drive motor • Bearing play • Mechanical ease of movement (smooth running) • Drive belt

11. Smooth running of the machine – mechanical ease of movement

• Shaft and cam play • Main and base shaft • Thread take-up lever • Needle bar • Bobbin carrier / hook • Drive belt tensions


8.5.4 Maintenance Checklist BERNINA Q Series

1. Covers to be removed Head covers Hook casing Belt Cover (rear side)

2. Parts that must be removed

Needle Stitch plate Hook Recommended parts according to Tear-and-Wear Parts Definition

3. These areas must be cleaned

Free-arm area Needle bar Thread take-up lever Upper thread tension disks Complete drive unit including motor Sensors / light barriers

4. Check these parts for scratch marks, deformations, exceptional wear and/or oxidation and polish or replace if required

Thread redirecting guides Thread regulator spring / upper thread indicator actuating lug Needle holder thread guide / thread redirections Hook Stitch plate Presser feet

5. Assembly: of the removed and replaced parts

6.

Oiling / lubrication according to lubrication diagram in Service Manual

Needle bar Presser foot bar Thread take lever assembly Hopper mechanism Hook drive shaft and hook drive eccentric Hook Shafts / axes Eccentric / cams

7.

Check / adjust settings according to Service Manual (Use a new needle 130/705H 80 TCN)

all drive belts (3 items) Position of head plate in y- and x-direction Darning foot height Presser foot fixation Hook and needle drive synchronization Loop lift Needle-/hook distance Needle penetration in Y direction Needle height (Automatic thread cutter) Synchronization disk Threader mechanism Thread tensions, upper and lower Winder

8. Fitting Covers (ensure correct placement of cables and connectors)

9. Check /calibrate tests in Service Program Cleaning- and maintenance-counters reset Enter service/maintenance date etc.

10. Sewing-off According to Sewing-Off Guideline (not ready at the editorial deadline)

11. Cleaning Covers 12. Final check Does the machine run, are the accessories complete?

Check using Service Program

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland from 106

Document Revision History Date Version Description Author October 2014

1.0 First release in English Hansjörg Herzog Markus Gretler

December 2014

1.1 - Chapter 1.3.1: change of set up - Chapter 1.5.1 added - Pictures replaced in chapters: 3.3.2 / 4.12 / 4.14 - Chapter 3.3.11 and 3.3.12 added - Chapter 6.1: added needle bar drive for lubrication - Chapter 4.6.4 added Needle Holder Alignment - previous Chapter 4.6.4 becomes 4.6.5 - Chapter 8.2.2 and 8.2.4: Text corrections

Hansjörg Herzog Markus Gretler

service and maintenance manual - bernina · service - and maintenance manual bernina q20 bernina...

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